250-500cc 1996 WR or WXE 250 Manual

[joffco]

Hi all
I just bought what I think is a 1996 WR or WXE 250 in boxes. I have started assembling the bike but I am stranded on several fronts. One of them is the owners or shop manual. I have done a search online but have been unable to locate one. Does anyone in here have one available in a pdf format?
Thanks,
Jon

 

[joffco]

Here is the unfinished project. I am missing several parts so if anyone here has a parts bike and willing to sell, I am all esrs.

 

[2premo]

what are you missing?
looks like a couple of plastic pieces

 

[brian bush]

I have a number of engine parts from a 2000 WR 250. The prior owner installed a rebuilt 360 in the bike and I came away with the leftover 250 parts. I have sold some of the parts - cylinder, kickstart lever, V-Force reed valve but I still have a lot of the parts if you think any of them would work on yours. I think Husqvarna carried a lot of the parts over from year-to-year on these bikes but I am no expert on what parts fit what years unfortunately. I'd be happy to help if I can though.

I still have a perfectly clean bottom-end that I would eat off of, clutch plates/pressure plates/basket, clutch cover, water pump cover, power valve cover, flywheel cover, rubber intake where the reeds are located, cylinder head (with 0.8mm squish mod - more low-end power), FMF Burly Pipe and various other pieces 0 feel free to ask. Let me know if you're interested in any of it and I can post pics..

You can also find many parts on Ebaymotors.com

Good luck with your project!

 

[joffco]

what are you missing?
looks like a couple of plastic pieces

Hi 2premo
Yes, I am missing the side panels, kickstand, chain guide (the one in the pic is worn completely through)and probably a few other things as I continue assembling.

 

[joffco]

I have a number of engine parts from a 2000 WR 250. The prior owner installed a rebuilt 360 in the bike and I came away with the leftover 250 parts. I have sold some of the parts - cylinder, kickstart lever, V-Force reed valve but I still have a lot of the parts if you think any of them would work on yours. I think Husqvarna carried a lot of the parts over from year-to-year on these bikes but I am no expert on what parts fit what years unfortunately. I'd be happy to help if I can though.

I still have a perfectly clean bottom-end that I would eat off of, clutch plates/pressure plates/basket, clutch cover, water pump cover, power valve cover, flywheel cover, rubber intake where the reeds are located, cylinder head (with 0.8mm squish mod - more low-end power), FMF Burly Pipe and various other pieces 0 feel free to ask. Let me know if you're interested in any of it and I can post pics..

You can also find many parts on Ebaymotors.com

Good luck with your project!

Hi Brian
I at least need the outer clutch basket (notched) and water pump gear (mine is missing one tooth). The head sounds interesting. I will go through the partslist and compare mine to the 2000 and let you know what fits.
Thanks,
Jon

 

[joffco]

Hi Brian
I compared the parts between the 1996 and the 2000 WR:

Clutch Basket and primary sprocket set
1996 WR/WXE
- 8000 64450 (250)
- 8000 63389 (360)
2000 WR
- 8000 86860 (250)
- 8000 63389 (360)

Water pump gear
1996 WR/WXE
- 8000 59843 (250 & 360)
2000 WR
- 8000 59843 (250 & 360)

Cylinder head

1996 WR/WXE
- 8000 68704
2000 WR
- 8000 86823
iT
It seems that the only sure thing is the water pump gear. The other parts might fit but it is a gamble.
Please provide pricing for these items if you are willing to part with them : )
Thanks,
Jon

I

 

[joffco]

Update: Things are happening

 

[brian bush]

Hi Joffco, I am out of town right now. I sold a few of the 250 parts on Ebay since I last posted but I think I still have all of the items you listed. I will get you some photos and info just as soon as I can.

 

[brian bush]

I think this is the part you're looking for. $10 plus shipping in you want it..

 

[joffco]

Sold. I will send you my details via pm.

 

[brian bush]

I don't see anything in my PM. You can e-mail me at bbqkidd@yahoo.com That may be easier.. Thanks!

 

[brian bush]

Hey Joffco,

Here are some pics of the head you asked about. It has squish cut to 1.8mm (.063"). Boosts low-end power and makes jetting easier. Likes quality gas.

 

[brian bush]

one more..

 

[2premo]

how far have you gotten with this??

 

[Andy butler]

Hi Brian.
I'm also doing and engine rebuild on a WR250. you wouldn't happen to have a crank primary gear in your spare 250 parts. 27 tooth.
Cheers Andy

 

[joffco]

Hi all.
Finally sat down to update this thread. Bike is up and running, have put 13 hrs on it already.
Work done:
New top end installed
All oil seals and several gaskets replaced
CR500 Keihin carb installed and jetted
Clutch basket notches repaired
Clutch arm lengthened
CDI bracket fabricated and welded to frame
Complete 2002 WR 250 electrical system installed
Complete suspension rebuild, fwd and aft
Shock spring powdercoated
Retro fork boots installed
Wheels rebuilt as required, spokes and bearings
New brake pads fwd and back
Front brake hose fabricated
All frame bearings lubricated, steering, swingarm and linkage
New handlebar bumpers, bar and grips
LED bulbs in headlight
Sidestand bracket fabricated and welded to frame
Silencer core and packing replaced
Chain guide repaired
New chain and fwd sprocket, 13T for lower gearing
New airfilter and cage
New sidepanels
Love the bike, nice torque and low end, light and agile, rear suspension great.
Only problem is a midstroke harshness in the forks, still working on that

 

[joffco]

More pics

 

[wrx]

bike looks sweet. good luck with it.

 

[Mbcoulter]

Wow, fantastic pics and riding location!