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Husqvarna WR 250/2003 Instruction manual

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Variante al mauale di officina N°800097300
Variant to the workshop manual N°800097300
Variante au manuel d’atelier N°800097300
Variante zum werkstatthandbuch N°800097300
Variante al maual de taller N°800097300
WR 250/2003
CR 250/2003
Part. N. 8000A1732
COPERTINA 9-06-2003 12:38 Pagina 1
La MV Agusta Motorcycles S.P.A. - Varese declina qualsiasi responsabilità per eventuali
errori in cui può essere incorsa nella compilazione del presente manuale e si riserva il diritto di
apportare qualsiasi modifica richiesta dallo sviluppo evoluto dei propri prodotti. Le illustrazioni
riportate sono indicative e potrebbero non corrispondere esatamente al particolare trattato. É
vietata la riproduzione anche parziale della presente pubblicazione senza autorizzazione
scritta. I motocicli partecipanti a competizioni di qualunque genere sono esclusi da ogni
garanzia, in tutte le le loro parti.
1a Edizione (03-03)
To the best knowledge of MV Agusta Motorcycles S.p.A. - Varese, Inc. the material
contained herein is accurate as of the date this pubblication was approved for printing. Cagiva
Motor S.p.a. - Varese, Inc. reserves the right to change specifications, equipment, or designs
at any time without notice and without incurring obligation. Illustrations in this manual are
merely for demonstration purposes and could not exactly match the detail described.No part of
this manual can de reproduced without permission in writing of the copyright holder. All the
motorcycles and their detailed parts taking part in copetitions of any type are excluded
from the guarantee.
1st Edition (03-03)
MV Agusta Motorcycles S.p.A. - Varese décline toute résponsabilitépour erreurs évuntuelles
commises pendant la rédaction du manuel et question et se réserve le droit d’apporter tous les
perfectionnements nécessaires sans avis préalable. Les illustrations gravées dans ce manuel
ne sont qu’à titre idicatif et pourraient ne pas correspondre au détail traité. Le copiage partiel ou
totale de ce manuel sans autorisation écrite est strictement interdit. Les motocycles et leur
détails participant à des compétitions sont exclu de toute garantie.
1ére édition (03-03)
Die MV Agusta Motorcycles S.p.A. - Varese lehnt jegliche Verantwortung für eventuelle
Fehler ab, welche bei der Zusammenstellung dieses Handbuches entstanden sein können und
behält sich ferner das Recht vor, alles, was sich an Änderungen durch die Weiterentwicklung
ihrer Produkte ergeben sollte, in diesem Hendbuch anzuführen. Die wiedergegebenen
Darstellungen sind indikativ und Könnten nicht genau dem betreffenden Teil entsprechen. Die
Reproduktion, auch teilweise, der vorliegenden Harausgabe ohne vorheriger schriftlicher
Genehmigung ist untersagt. Die an den Wettrennen jeder Art teilnehmenden Motorräder
sind in allen deren Teilen von jeglicher Garantie ausgeschlossen.
1. Auflage (03-03)
MV Agusta Motorcycles S.p.A. - Varese no se responsabiliza por los errores debidos a la
compilación del presente manual y se reserva el derecho de aportar toda modificación
necesaria para el desarrollo evolutivo de sus productos. Las ilustraciones presentadas son
indicativas y pueden no corresponderse exactamente con la pieza tratada. Se prohibe la
reproducción, también parciel, de la presente publicación sin autorización por escrito. Las
motocicletas que participan en competiciones de cualquier clase están excluidas de
cualquier garantia, en todas sus partes.
1°Ediciòn (03-03)
COPERTINA 9-06-2003 12:38 Pagina 2
N° 8000A1732 (03-03) 1
Variante al mauale di officina N°800097300
Variant to the workshop manual N°800097300
Variante au manuel d’atelier N°800097300
Variante zum werkstatthandbuch N°800097300
Variante al maual de taller N°800097300
WR 250/2003
CR 250/2003
Copyright by
MV Agusta Motorcycles S.p.A.
Servizio Assistenza Tecnica
Via Nino Bixio, 8
21024 Cassinetta di Biandronno (VA) - Italy
Telefono ++39-0332-254111
Telefax ++39-0332-756509
www.husqvarna.it
USA MODEL
Cagiva U.S.A.
2300 MARYLAND ROAD
WILLOW GROVE, PA 19090-4193
215-830-3300
1° Edizione - 1st Edition - 1ère édition - 1. Auflage - 1° Edición
Stampato in Italia - Printed in Italy - Imprimé en Italie - In Italien gedruckt - Impreso en Italia
Stampato N°- Print No. - Imprimé N. - Druckschriff Nr. - Impreso N. 8000A1732
VALIDITÀ(dalla matricola) - VALIDITY (from vehicle identification number) - VALIDITE (du matricule) - GÜLTIGKEIT
(von der Kennummer) - VALIDEZ (desde la matrícula)
WR 250: ZCG3H00AB3V002200
CR 250: ZCG3H00AB3V051000
COPERTINA 9-06-2003 12:38 Pagina 3
IMPORTANTE: Tutte le moto partecipanti a gare o competizioni di
qualunque genere, sono escluse da ogni garanzia in tutte le loro parti.
●Le indicazioni di destra e sinistra si riferiscono ai due lati del motociclo
rispetto al senso di marcia.
●
Z: n° denti
●
A: Austria
AUS: Australia
B: Belgio
BR: Brasile
CDN: Canada
CH: Svizzera
D: Germania
E: Spagna
F: Francia
FIN: Finlandia
GB: Gran Bretagna
I: Italia
J: Giappone,
USA: Stati Uniti d’America
●
Dove non diversamente specificato, i dati e le prescrizioni si
riferiscono a tutte le Nazioni.
IMPORTANT: All the motorcycles (and their parts) entering
competitions of any kind are excluded from the guarantee.
●References to the “left”or “right”of the motorcycle are in the sense of a
person facing forwards.
●
Z: number of teeth
●
A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
●
Where not specified, alla the data and the instructions are referred to
any and all countries.
IMPORTANT: La garantie tombe pour les motos participant à
compétitions de tout genre. Il en est de même pour leur parties.
●
Les indications “droite”et “gauche”se refèrent aux deux côtés du
motocycle par rapport au sens de marche.
●
Z: numéro dents
●
A: Autriche
AUS: Australie
B: Belgique,
BR: Brasile
CDN: Canada,
CH: Suisse
D: Allemagne
E: Espagne
F: France
FIN: Finlande
GB: Grand Bretagne
I: Italie
J: Japon
USA: Etas Units d’Amerique
●
Si non différemment spécifié, les données et les instructions sont
valables pour tous les pays.
WICHTIG: Alle an Sportrennen jeder Art teilnehmenden Motorräder
sind von jeder Garantie für alle Teile ausgeschlossen.
●
Die Angaben, rechts und links, beziehen sich auf die beiden
Motorradseiten in Bezug auf die Fahrtrichtung.
●
Z: Zähne nummer
●
A: Österreich
AUS: Australien
B: Belgien
BR: Brasilien
CDN: Kanada
CH: Schweize
D: Deutschland
E: Spanien
F: Frankreich
FIN: Finnland
GB: Groos Britan
I: Itelien
J: Japan
USA: Vereinigte Staten von
Amerika,
●
Wenn nicht anders angegeben, beziehen sich die Daten und
Vorschriften auf alle Länder.
IMPORTANTE: Todas las motocicletas que participan a carreras o
bien a competiciones de cualquier tipo, son excludidas de todas
garantias en todas cuantas sus partes.
●
Las indicaciones de la derecha y la izquierda hacen referencia a los dos
lados de la moto con respecto al sentido de marcha..
●
Z: nùmero dientes
●
A: Austria
AUS: Australia
B: Bélgica
BR: Brasil
CDN: Canadà
CH: Suiza
D: Alemania
E: España
F: Francia
FIN: Finlandia
GB: Gran Bretaña
I: Italia
J: Japòn
USA: Estados Unidos
●
A falta de indicaciones específicas, los datos y las instrucciones se
refieren a todos los Países.
N°8000A1732 (03-03)
2
COPERTINA 9-06-2003 12:38 Pagina 4
C.12 N°8000A1732 (03-03) 7
CR 250
Ove non diversamente specificato i dati e le prescrizioni si intendono validi per tutti i modelli.
Unless otherwise specified, data and figures refer to all models.
Si rien n'est spécifié, les données et les prescriptions se réfèrent àtous les modèles.
Falls nicht anders angegeben sind die technischen Daten und Anweisungen für sämtliche Modelle gültig.
Si no se especifica de otra manera, los datos y las prescripciones son válidos para todos los modelos.
WR 250
COPERTINA 9-06-2003 12:38 Pagina 5
N°8000A1732 (03-03)
Sommario
Sezione
Generalità............................................................A
Manutenzione ......................................................B
Inconvenienti e rimedi............................................C
Registrazioni e regolazioni ....................................D
Operazioni generali ..............................................E
Scomposizione motore ..........................................F
Revisione motore ..................................................G
Ricomposizione motore..........................................H
Telaio, sospensioni e ruote ......................................I
Freni ....................................................................L
Impianto elettrico ..................................................M
Raffreddamento motore ........................................N
Valvola di scarico H.T.S.........................................O
Attrezzatura specifica ..........................................W
Coppie di serraggio ..............................................X
Note per modelli USA............................................Z
Summary
Section
General................................................................A
Torque wrench settings ..........................................B
Maintenace ..........................................................C
Adjustment............................................................D
General operations ................................................E
Engine disassembly................................................F
Engine overhauling ..............................................G
Engine reassembly ................................................H
Frame, suspensions and wheels................................I
Brakes ..................................................................L
Electric system ......................................................M
Engine cooling system ..........................................N
Troubles and remedies............................................P
Specific tools........................................................W
Torque wrench settings ..........................................X
Notes for USA models............................................Z
Index
Section
Notes générales ....................................................A
Couples de serrage................................................B
Entretien ..............................................................C
Réglages et calages ..............................................D
Opérations générales ............................................E
Décomposition moteur............................................F
Révision moteur ....................................................G
Récomposition moteur............................................H
Chassis, suspensions et rous ....................................I
Freins ....................................................................L
Installation électrique ............................................M
Refroidissement moteur..........................................N
Inconvénients et remèdes ........................................P
Outillage spécial..................................................W
Note pour les modèles USA....................................Z
Indice
Sección
Generalidades ......................................................A
Pares de torsion ....................................................B
Mantenimiento ......................................................C
Ajustes y regulaciones ..........................................D
Operaciones generales ..........................................E
Desmontaje motor..................................................F
Revision motor......................................................G
Inhaltsverzeichnis
Sektion
Allgemeines..........................................................A
Anziehmoment ......................................................B
Wartung ..............................................................C
Einstellungen ........................................................D
Allgemeine arbeiten ..............................................E
Motorausbau ........................................................F
Motorueberholung ................................................G
Wiederzusammenbau des motors ..........................H
Rahmen, Anfhaengung end raeder ..........................I
Bremsen ................................................................L
Elektrische anlage ................................................M
Motorkühlung ......................................................N
Störungen und Behebung........................................P
Spezifische Ausrustung ........................................W
Anmerkung für Modell USA....................................Z
8
Recomposicion motor ............................................H
Bastidor, suspension y ruedas ..................................I
Frenos ..................................................................L
Sistema eléctrico ..................................................M
Sistema de refrigeración del motor ........................N
Inconvenientes y remedios ......................................P
Herramental especifico ........................................W
Note por los modelos USA ....................................Z
COPERTINA 9-06-2003 12:38 Pagina 6
N° 8000A1732 (03-03)
MOTORE
Monocilindrico 2 tempi con aspirazione lamellare e valvola
H.T.S. a comando meccanico sullo scarico.
Alesaggio .............................................................66,4 mm
Corsa ......................................................................72 mm
Cilindrata ..........................................................249,3 cm3
Rapp. di compressione (a luci chiuse) ................................8,4:1
ALIMENTAZIONE
Aspirazione regolata da valvola a lamelle.
DIAGRAMMA DISTRIBUZIONE
TRAVASO: ...............................................................116°
SCARICO: ...............................................................184°
Carburatore ................................................................Mikuni TMX 38
LUBRIFICAZIONE
MOTORE
Miscela benzina/olio: al 3% (durante il rodaggio); al 2%
NON MENO, a rodaggio effettuato.
CAMBIO e TRASMISSIONE PRIMARIA: Mediante l'olio conte-
nuto nel basamento.
RAFFREDDAMENTO
A liquido con circolazione mediante pompa. Due radiatori, sul-
la parte anteriore del gruppo termico.
ACCENSIONE
Elettronica, a scarica capacitativa con anticipo variabile.
Marca ...............................................................KOKUSAN
Anticipo accensione
(corsa del pistone prima del P.M.S.):.....................0,5 mm (8°)
Candela marca e tipo:...................................“NGK” BR8 EG
Distanza elettrodi ...............................................0,6÷0,7 mm
AVVIAMENTO
A pedale.
TRASMISSIONE
Cambio in cascata con ingranaggi sempre in presa.
Rapporto primaria ..................................Z 27/69= 1:2,555
Rapporti cambio
CR 250 WR 250
1ª....Z 14/30=1:2,142 Z 14/30=1:2,142
2ª....Z 16/28=1:1,750 Z 17/27=1:1,588
3ª....Z 16/23=1:1,437 Z 19/24=1:1,263
4ª....Z 19/23=1:1,210 Z 21/22=1:1,047
5ª....Z 19/20=1:1,053 Z 24/20=1:0,833
Rapporto secondaria ................................Z13/48= 1:3,692
Catena di trasmissione ..........................(CR) REGINA 135 RX
oppure D.I.D. 520-DS, 5/8”x1/4”;
(WR) REGINA 135 ORN-A oppure D.I.D. 520-V6 (OR), 5/8”x1/4”
Rapporti totali
CR 250 WR 250
1ª ....20,220 20,220
2ª ....16,513 14,986
3ª ....13,564 11,919
4ª ....11,422 9,885
5ª ......9,932 7,863
Frizione .................................a dischi multipli in bagno d'olio
FRENI
Anteriore
A disco fisso forato con comando idraulico e pinza flottante.
Diametro disco........................................................260 mm
Pinza freno............................................................BREMBO
Area pastiglie........................................................33,4 cm2
Posteriore
A disco fisso forato con comando idraulico e pinza flottante.
Diametro disco........................................................220 mm
Pinza freno............................................................BREMBO
Area pastiglie........................................................29,5 cm2
TELAIO
Monotrave con doppia culla chiusa in tubi di acciaio ad alta
resistenza; telaietto posteriore removibile in alluminio.
Angolo di sterzata............................................45° per parte
Angolo asse di sterzo .....................................................26°
Avancorsa.......................................................111 mm (CR)
114 mm (WR)
SOSPENSIONI
Anteriore
Forcella teleidraulica a steli rovesciati e perno avanzato regola-
bile in compressione ed estensione.
Marca ............................................................MARZOCCHI
Diametro steli............................................................45 mm
Escursione ruota anteriore (sull’asse scorrevole) ...........300 mm
Posteriore
Forcellone oscillante in lega leggera con sospensioni a leverag-
gi progressivi (sistema SOFT DAMP) e mono-ammortizzatore
idraulico con molla elicoidale. Possibilità di regolazione del fre-
no idraulico in compressione (doppia), in estensione e del pre-
carico della molla.
Marca ammortizzatore ..............................................SACHS
Escursione verticale ruota posteriore...........................320 mm
RUOTE
Cerchio anteriore in lega leggera.
Marca e tipo.............................................TAKASAGO Excel
Dimensioni..........................................................1,60"x21"
Cerchio posteriore in lega leggera.
Marca e tipo.............................................TAKASAGO Excel
Dimensioni ........................2,15"x19" (CR); 2,15”x18” (WR)
PNEUMATICI
Anteriore
Marca ...................... “Pirelli” (CR); “Michelin” o “Pirelli” (WR)
Tipo.........................................................51R-MT 32A (CR);
Enduro Competition 3 oppure MT 71A (WR)
Dimensioni ..................... 80/100-21” (CR); 90/90-21” (WR)
Pressione di gonfiaggio a freddo:
..0,9÷1,0 Kg/cm2(12,8÷14,2 psi)
Posteriore
Marca e tipo ............ “Pirelli” (CR); “Michelin” o “Pirelli” (WR)
Tipo .................................................NHS (62) - MT 32 (CR);
Enduro Competition 3 oppure MT 81 (WR)
Dimensioni ....................110/90-19” (CR); 140/80-18” (WR)
Pressione di gonfiaggio a freddo:
..0,8÷0,9 Kg/cm2(11,4÷12,8 psi)
GENERALITÀ
A.4 N° 8000A1732 (03-03)
RIFORNIMENTI TIPO QUANTITÀ
(litri)
Serbatoio carburante Benzina senza piombo (98 ottani) 8,5 (CR); 11,2 (WR)
Riserva (comando manuale) 1,8 (CR); 2,2 (WR)
Olio per miscela carburante AGIP RACING 2T —
Olio cambio e trasmissione primaria AGIP CITY 4T 0,8
Olio per forcella anteriore AGIP FORK 7,5
(SAE 7,5 per climi particolarmente rigidi SAE 5)
Livello olio 80 mm
Olio per ammortizzatore posteriore AGIP FORK 2,5 (SAE 2,5) —
Olio per impianto di raffeddamento AGIP COOL 1,1÷1,3
Fluido freni idraulici AGIP BRAKE 4 (DOT 4) —
Lubrificazione catena di trasmissione AGIP CHAIN LUBE —
Trasmissioni flessibili AGIP BIKE GREASE —
Protettivo contatti elettrici AGIP CONTACT CLEANER —
Turafalle per radiatori AREXONS LIQUIDO —
IMPORTANTE - Non è ammesso l'uso di additivi nel carburante o nei lubrificanti.
GENERALITÀ
INGOMBRI mm (in.)/PESI
WR 250
Kg. 108,3
Lb 238.7
CR 250
Kg. 101,5
Lb 223.8
IMPIANTO ELETTRICO
Impianto di accensione composto da:
CR WR
Generatore Generatore 12V-110W
Bobina elettronica Bobina/Centralina elettronica
Centralina elettronica Regolatore di tensione
Candela accensione Candela accensione
L'impianto elettrico consta dei seguenti elementi principali (WR):
- Faro anteriore con lampade biluce da 12V-55/60W e lampada
luce di posizione 12V-5W;
- Cruscotto con lampade stumenti da 12V-2W e spie da 12V-
1,2W;
- Indicatori di direzione con lampada 12V-10W;
- Fanale posteriore con lampada segnalazione arresto 12V-21W
e lampada luce di posizione 12V-5W.
*: larghezza max.
N° 8000A1732 (03-03) A.5
ENGINE
Single-cylinder, two-stroke engine, with lamellar suction and
mechanical control H.T.S. valve on the exhaust system.
Bore........................................................66,4 mm/2.61 in.
Stroke.........................................................72 mm/2,83 in.
Capacity .............................................
249,3 cm3/15.21 cu.in.
Compression ratio (with closed ports)
..............................8,4:1
FUEL FEEDING
Intake setting by lamellar valve.
PORT TIMING
TRANSFER: ................................................................116°
EXHAUST: .................................................................184°
Carburetor: ...........................................................Mikuni TMX 38
LUBRICATION
ENGINE
3% of oil-gasoline mix (during running) NOT LESS than 2%
when running is over.
SHIFTING and MAIN TRANSMISSION: Through the oil contai-
ned in the engine block.
COOLING
With liquid circulation through a pump. Two radiators are pro-
vided in the thermal assembly front.
IGNITION
Capacity discharge electronic start with variable advance.
Manufacturer .....................................................KOKUSAN
Ignition advance
(piston stroke before T.D.C.) ...............0,5 mm/0.0197 in. (8°)
Spark plug make and type: ..................“NGK” BR8 EG (250);
Electrode gap.......................0,6÷0,7 mm/0.0236÷0.0275 in.
STARTING
Kick-start.
TRANSMISSION
Cluster constant-mesh gears.
Primary ratio ...........................................Z 27/69= 1:2,555
Gear ratios
CR 250 WR 250
1st Z 14/30=1:2,142 Z 14/30=1:2,142
2nd Z 16/28=1:1,750 Z 17/27=1:1,588
3rd Z 16/23=1:1,437 Z 19/24=1:1,263
4th Z 19/23=1:1,210 Z 21/22=1:1,047
5th Z 19/20=1:1,053 Z 24/20=1:0,833
Final drive ratio ........................................Z13/48= 1:3,692
Gearing chain ....................................(CR) REGINA 135 RX
or D.I.D. 520-DS, 5/8”x1/4”;
(WR) REGINA 135 ORN-A or D.I.D. 520-V6(OR), 5/8”x1/4”
Total ratios
CR 250 WR 250
1st..............20,220 20,220
2nd.............16,513 14,986
3rd ............13,564 11,919
4th..............11,422 9,885
5th..............9,932 7,863
Oil-bath multi-disc clutch type.
BRAKES
Front brake
Perforated fixed hydraulic control and floating caliper.
Disc diameter ..........................................260 mm/10.23 in.
Brake caliper .........................................................BREMBO
Pad area............................................33,4 cm2/5.18 sq.in.
Rear brake
Perforated fixed disc hydraulic control and floating caliper.
Disc diameter ..........................................220 mm/8.661 in.
Brake caliper .........................................................BREMBO
Pad area............................................29,5 cm2/4.57 sq.in.
FRAME
Double cradle; rear frame. Made up of rectangular and square
high tensile steel tubes.
Steering angle .......................................................45° each
Steering axis angle.........................................................26°
Front fork caster ..................................111 mm/4.37 in. (CR)
114 mm/4.49 in. (WR)
SUSPENSIONS
Front suspension
Telescopic-hydraulic up-side down fork with led pin, adjustable
in compression and rebound.
Manufacturer...................................................MARZOCCHI
Legs diameter ..............................................45 mm/1.77 in.
Front wheel stroke(on the sliding axis) ...........300 mm/11.8 in.
Rear suspension
Light alloy swinging fork with progressive leverage suspensions
(SOFT DAMP system) and hydraulic single-damper with helical
spring. The hydraulic brake compression (double), extension,
and the spring preload can be adjusted.
Damper make .........................................................SACHS
Rear wheel vertical travel ............................320 mm/12.6 in.
WHEELS
Light alloy front rim.
Manufacturer and type ...............................TAKASAGO Excel
Dimensions .........................................................1,60"x21"
Light alloy rear rim.
Manufacturer and type ...............................TAKASAGO Excel
Dimensions ........................2,15"x19" (CR); 2,15”x18” (WR)
TYRES
Front
Make ......................“Pirelli” (CR); “Michelin” or “Pirelli” (WR)
Type ........................................................51R-MT 32A (CR);
Enduro Competition 3 or MT 71A (WR)
Dimensions .....................80/100-21” (CR); 90/90-21” (WR)
Inflation pressure (cold):...........0,9÷1,0 Kg/cm2(12,8÷14,2 psi)
Rear
Make ..................... “Pirelli” (CR); “Michelin” or “Pirelli” (WR)
Type ................................................NHS (62) - MT 32 (CR);
Enduro Competition 3 or MT 81 (WR)
Dimensions ...................110/90-19” (CR); 140/80-18” (WR)
Inflation pressure (cold):...........0,8÷0,9 Kg/cm2(11,4÷12,8 psi)
GENERAL
A.6 N° 8000A1732 (03-03)