1. 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
    WR = 2st Enduro & CR = 2st Cross

250-500cc 08 Wr250 Leaking Kick Start

Discussion in '2 Stroke' started by David_D., Feb 14, 2018.

  1. David_D. Husqvarna
    AA Class

    Location:
    Idaho, USA
    Husqvarna Motorcycle:
    2008 WR250
    Other Motorcycles:
    Hondas: XR200, XR100, CRF100
    Hey everyone, my engine is leaking oil from the kick start shaft. I’ve looked at several schematics and I can’t tell if there is a seal in there. Can anyone point me in the correct direction to get this fixed?

    Thanks
  2. taps Husqvarna
    AA Class

    Location:
    TX
    Husqvarna Motorcycle:
    '94 WXC360
    Other Motorcycles:
    '15 RMZ450, '08 RM250, & '74 MX360
    I think it is #21. Part number 800048209 - says it is 20*28*6 which seems about right. I'm sure someone will come along and confirm or correct.

    image.gif
  3. shawbagga Husqvarna
    Pro Class

    Location:
    Eaton, Western Australia
    Husqvarna Motorcycle:
    None
    Other Motorcycles:
    2018 Gasgas XC250
    Dunno but I'm interested in this too as mine has developed a leak the past few months. Not much but noticeable when dusty
  4. Hurky Husqvarna
    AA Class

    Location:
    Spain
    Husqvarna Motorcycle:
    WR300 2010
    Other Motorcycles:
    Yamaha WR480F 2008
    taps is right, it is a 20 x 28 x 6 seal :

    [IMG]

    I've got mine from a bearing shop real cheap. The OEM is a single lip seal that I replaced with a double lip NBR seal, as these are better to keep moisture out (pressure washer ..)

    Cheers !
    NCSteve and taps like this.
  5. shawbagga Husqvarna
    Pro Class

    Location:
    Eaton, Western Australia
    Husqvarna Motorcycle:
    None
    Other Motorcycles:
    2018 Gasgas XC250
    How do you change them? Pick old one out & push new one in!
    taps likes this.
  6. PaulD Husqvarna
    AA Class

    Location:
    Little Egg Harbor N.J.
    Husqvarna Motorcycle:
    2010 wr250( sold)
    Other Motorcycles:
    Triumph Sprint RS. Honda TRX300EX Be
    Hey Hurky where did you get that nifty clutch lever extension?
  7. David_D. Husqvarna
    AA Class

    Location:
    Idaho, USA
    Husqvarna Motorcycle:
    2008 WR250
    Other Motorcycles:
    Hondas: XR200, XR100, CRF100
    Awesome! Thanks for the info.

    Same question...Where did you get that clutch lever extension? Can you shoot a photo of that for me?
  8. David_D. Husqvarna
    AA Class

    Location:
    Idaho, USA
    Husqvarna Motorcycle:
    2008 WR250
    Other Motorcycles:
    Hondas: XR200, XR100, CRF100
    With regards to removing the seal, I used a paint can opener and very carefully pried it out. This did destroy the seal, but there aren’t a lot of options for removal.

    Now, on to the clutch lever extension. I decided to make my own clutch lever extension. You will notice that I offset the hole where the cable will attach as I didn’t have much play at all and with the hole further away, the cable wouldn’t reach. I have not actually installed this yet as I have to get some bolts and lock nuts, but I think it will work. If I have to make an adjustment to the hole locations, I’ll weld up the mount hole and re-drill it.
    98E36D00-0C59-4192-893E-44A57DF08FB2.jpeg 6A71B455-5C9A-4381-A8F5-4DD899CFBCD8.jpeg 4E1B2B02-0DDB-4D27-BDB2-19D5057A9E75.jpeg A1093423-0DA5-4E94-954D-1BD0DE392317.jpeg
    NCSteve and taps like this.
  9. NCSteve Husqvarna
    Pro Class

    Location:
    Appalachia
    Husqvarna Motorcycle:
    12 WR300 13 WR165
    Other Motorcycles:
    02 XR250R 00 XR100R
    Somewhere in this 2T forum is a discussion about clutch extension with a couple different versions. Maybe it was the 300 love thread :cheers:
  10. Hurky Husqvarna
    AA Class

    Location:
    Spain
    Husqvarna Motorcycle:
    WR300 2010
    Other Motorcycles:
    Yamaha WR480F 2008
    I build that extension myself some time ago, It's made out of a 2mm thick steel plate:
    [IMG]
    [IMG]
    [IMG]

    It make quite a big difference in clutch pull but there is a downside: You need more clutch lever travel for the same clutch pull, I mean, you will have less movement on the clutch plates for the same amount of clutch lever movement.
    In my case I separated the two holes too much and needed to pre-tension the clutch cable quite a lot to still being able to disengage the plates without having too much drag. Later I filed the left hole to reduce this problem.
    Now the clutch is still softer but I can disengage the plates fully without having to pre-tension the cable that much.

    It's a cheap and easy to do part.

    As of removing the old seal, In my case I did change it along with my transmission so the casings were separated, but using some tools like a screwdriver with a folded tip is also an option, you just need to make sure to not scratch the aluminum or you will probably have leaks.

    Cheers.
    mr_manny likes this.
  11. Hurky Husqvarna
    AA Class

    Location:
    Spain
    Husqvarna Motorcycle:
    WR300 2010
    Other Motorcycles:
    Yamaha WR480F 2008
    I would say that I even like the feel of a well lubricated clutch cable over the hydraulic stuff I tried (on other bikes)... But I do clean and lubricate the cable often.
    rancher1 likes this.
  12. 2premo Husqvarna
    Pro Class

    Location:
    Northern NV
    Husqvarna Motorcycle:
    98 WR360, 1987 WR430, 1988 XC430
    Other Motorcycles:
    Sherco 300, 2002 KTM 380EXC
    I have two Husky 360's with cables and a 2002 KTM 380 with hydraulic, the cable is smoother the hydraulic is more consistent
    and I have a 2016 Sherco 300 that has a more modern hydraulic, it is sweet, so newer might just be "gooder"
  13. 2premo Husqvarna
    Pro Class

    Location:
    Northern NV
    Husqvarna Motorcycle:
    98 WR360, 1987 WR430, 1988 XC430
    Other Motorcycles:
    Sherco 300, 2002 KTM 380EXC
    and seal removal, a drywall screw and a pair of pliers works well
    taps likes this.