You will need to reference the Service & Torque Specs table for the installation process.
Watch the video below to get an idea of how your Honda CR250 Clutch Install will go.
1997-2001 Honda CR250 Clutch Install
Click The Pictures To Start Slideshow
|Step 33: Install the clutch lifer lever.|
|Step 34: Connect the clutch cable.|
|Step 35: Install the stator.|
|Step 36: Install the clutch outer guide and needle bearing.|
|Step 37: Install the clutch outer basket.|
You will need to line up the clutch inner gear teeth with the idle gear, and the outer teeth with the primary drive gear.
|Step 38: Install the inner thrust washer.|
|Step 39: Install the clutch inner.|
|Step 40: Install the outer thrust washer and lock washer.|
|Step 41: Install the center bolt.|
|Step 42: Bolt the clutch holder tool to the clutch inner using the clutch spring bolts.|
(You can build your own clutch holder tool for under $3, click here for instructions.)
|Step 43: Torque the center nut (59 ft.lb) and remove the holder tool.|
|Step 44: Fold the small edge of the lock washer up against the side of the center nut. Get the tab as flat as possible.|
|New Clutch: The clutch discs and springs in this 1997 Honda CR250 were out of spec, so we will be installing a new Tusk heavy duty clutch kit. |
|Step 45: Install the clutch plates and friction discs.|
|Step 46: Install the lifter and lifter rod.|
|Step 47: Install the pressure plate and springs.|
|Step 48: Tighten the clutch spring bolts in a crossing pattern to ensure even pressure.|
|49: Torque the clutch spring bolts (88 in.lb) using the same crossing pattern.|
|Step 50: Test the clutch lifter and spring operation.|
|Step 51: Install the flywheel.|
NOTE: Be extremely careful when jamming the primary drive gear. Make sure the screwdriver is flat on the teeth. If you have a flywheel holder, use it!
|Step 52: Install a new crank cover gasket.|
|Step 53: Install the crank case cover.|
|Step 54: Install new gaskets on the water pump cover.|
|Step 55: Install the water pump cover.|
|Step 56: Bolt down the crank case cover.|
This is where knowing what bolt goes where comes in very handy!
|Step 57: Install a new O-ring and install the clutch cover.|
|Step 58: Install the kickstarter lever.|
|Step 59: Torque the kickstarter lever bolt.|
|Step 60: Connect the coolant line.|
Remember to refill the
Coolant and Oil!
If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!
Keep Your ’99-’01 CR250 Running Right!
- Service Specification
- Clutch Replacement
- Carburetor Service
- Engine Top End
- Front Fork Maintenance
- Rear Shock Rebuild
- Wheels & Tires
- Kickstarter Inspection
- External Shift Linkage