1988 WR250 revival 2016

case porting and gasket matching are a very real improvement

I have an 88wr250 looking for all bearings and seals, gaskets would be nice as well. I am not sure what the piston looks like atm. Will tear down as soon as i can find parts. Please Help!!

Yep, same here. I've always done it the same way much to my wife's disgust when many years ago her oven smelled like burnt oil for a few days!

I hope I can make mine half as tidy as that!

Chris, all of your bearings and seals are available from any reputable bearing shop, Phil at Husqvarna parts can supply a complete gasket set. Make sure to specify '87-88 only as the centre case gasket and possibly the head gasket will differ from all other models.
Tony.

Thank you Very much for the Info!

Hey Guys,
on the 1988 250wr.. which crank seals can be replaced without splitting case? I have an air leak i think that is causing it to revv out as soon as i start it.

Thanks!

Don't forget to check your inlet manifold, Reed gaskets and base gasket.
Tony.

Thanks!! It was the first thing check and the reeds were worn and the rubber intake manifold was shot. Currently I have a new rubber intake boot, new reed valves, new gaskets and it still revs out immediately after start up. the only thing i can think of would be the crank seals. I ordered the crank seals and hoping they are the correct ones.
3 seals with the kit. 1 Large ( ID:28.33 ID:30mm) OD:52.25mm <<////// 2 Same size smaller seals (ID:24.68 ID24.06mm <<////// OD:35.38mm

As we move closer.......

Sadly, I must concede defeat in having the 250 ready for the first Vinduro event of the year at Canowindra NSW, still too much to do and I would be better served running it in and sorting any issues rather than rushing it and breaking down, only to give Huskies a bad name.
I had really hoped to have this bike ready but "life" got in the way.
The Yass Vinduro is in early May which gives me some breathing space, where my son will be participating in either the 250 or the 400, looking forward to that!

there cant be more than 6 bolts left to do up??? whats going on

An expansion chamber in three pieces

aaahhh...the old 3 speed pipe holding you up.

did it come in 3 pieces or are you rebuilding it?

It was flattened badly, I cut it up to panel beat it, but it may be too far gone. I may have to put up with the 400.

Update: First start up after rebuild was very satisfying, after 4 hearty kicks it fired up and ran well...... until it started smoking like a steam kettle!
So after shutting it down and wondering if I went a little overboard on the assembly oil, I started it again.....worse this time. It's sucking gearbox oil into the lower crankcase.

You know that sinking feeling when shit like this happens?

Seventeen minutes later a 250 engine was sitting on my garage floor once again, about another 30-40 minutes and the cases were split again.
Upon inspection, the centre case gasket was perfect, that only left the crank seal on the clutch side.

Thinking it must have ruined the seal, I discovered that the seal that was fitted was incorrect, I can't believe I didn't slide it onto the crank as always but I must have been distracted or something, maybe those little green bottles? The seal was 32 x 52 x 7 instead of 30 x 52 x 7!

New seal fitted, engine assembled again and fitted into the frame it had it's first ride.

It runs great! I rode it very carefully for about 15 minutes and no issues this time, it has good low end, a very strong mid range and I can't try the top end until I get some more time on it.

More updates and pics to come in the near future!
Tony.

Nice determination ripping it back apart immediately to get it done.