1997-2001 Honda CR250 Clutch Maintenance Part 1: Removal

This is PART 1 of the full step-by-step 1997-2001 Honda CR250 clutch maintenance guide.

You can find Part 2: Inspection here, and Part 3: Installation here.

When was the last time you performed a full clutch inspection on your motocross or trail Honda CR250?

Your Clutch might be bad and you don’t even know it, and that could damage other internal parts. If your clutch does not fully disengage, drags or slips you may need to install a replacement clutch pack.

Clutch problems can range from using the wrong oil to a damaged clutch basket.  The only way to check for problems is to fully inspect the clutch on your CR250.

Before you begin your clutch inspection you will need these tools/supplies:

  • Philips head screwdriver
  • 8mm socket
  • 10mm socket
  • 17mm socket
  • 22mm socket
  • Pry bar
  • Flywheel puller
  • Micrometer
  • Foot pound torque wrench
  • Inch pound torque wrench
  • Pro honda HP trans oil or pro honda GN4 4-stroke 10w-40 SF/SG engine oil or equivalent

If you need tools you can get them HERE

If you are replacing your clutch you will need the following parts:

  • Clutch Kit with springs
  • Crank case cover gasket
  • Water pump gasket
  • Clutch cover O-ring

I found the best price for good quality replacement clutch on Amazon.com

I highly recommend using OE parts and gaskets.  Aftermarket parts may be cheaper but they may not be the same quality as original Honda parts. (However, since the clutch is a wearable part I wanted to go with a cheaper aftermarket kit.)

Here are the OE Honda part numbers:

Parts:

  • Pressure Plate – 22351-KZ3-860
  • Lifter Needle Bearing – 91001-147-003
  • Center Nut – 90235-KA4-000
  • Lock Washer – 90461-MAC-741
  • Outside Thrust Washer – 90501-ML3-910
  • Clutch Inner  – 22120-MEN-A00
  • Inside thrust washer WASHER, THRUST (23X48)
  • Clutch Outer – 22100-KSK-670
  • Outer Guide Needle Bearing – 91021-ML3-003
  • Clutch Outer Guide – 22106-KS7-000
  • Lifter Lever – 22810-KS7-000

Gaskets & O-rings:

  • Right Crank Case Cover Gasket – 11395-KZ3-880
  • Water Pump Gasket Separator – 19222-KZ3-860
  • Water Pump Gasket – 19229-KZ3-880
  • Clutch Cover O-ring – 91211-KS7-701

RockyMountainATVMC.com has the best prices on OE parts that I have foundCLICK HERE

First things first, put your bike on a sturdy stand and drain oil and coolant.  I recommend opening the Service & Torque Specs table in a new tab for easy reference.

Also, make sure to keep track of every bolt and nut, there will be a lot!

Watch the video below to get an idea of how this 1997-2001 Honda CR250 clutch routine inspection will go.

1997-2001 Honda CR250 Clutch Removal

Click Pictures To Start Slideshow!

Step 1: Remove outer clutch coverStep 1: Remove Clutch Cover
Step 2: Remove the spring bolts.  The clutch will spin
freely when in neutral. Put your bike in a high gear and
secure the rear brake pedal with a ratchet strap.
Step 2: Remove Spring Bolts
Step 3: Remove the pressure plate and springs.Step 3: Remove Presure Plate & Springs
Step 4: Remove the clutch packStep 4: Remove Clutch Pack
Step 5: Remove the lifter and lifter rod.  The lifter
and the rod are not connected.  If the lifter comes
off of the rod you can pull it out with a pair of needle
nose pliers.
Step 5: Remove Lifter & Rod
Step 6: Pry the lock washer tab off of the center nut.
Use whatever you need to, the washer will be discarded.
Step 6: Pry Back Lock Washer
Step 7:  The center bolt is torqued on enough that
attempting to loosen it with a socket will turn the rear
wheel, even with the break applied.  Either have
someone hold the back wheel, or use an impact
wrench.
Step 7: Remove Center Bolt
DO NOT WEDGE THE WHEEL SPOKES!
Step 8: Remove and discard the lock washer.
Note: If you want to reuse the lock washer make
sure to cut off the bent tab and file down the edge.
Step 8: Discard Old Lock Washer
Step 9: Pull the clutch inner and thrust washer.  If
the washer is not on the shaft, it may be stuck
to the back of the clutch outer.
 Step 9: Pull Clutch Inner & WasherStep 9.1 Pull Clutch Inner & Washer
Step 10: Disconnect the coolant line. Step 10: Remove Coolant Line
Step 11: Remove the water pump cover. Step 11: Remove Water Pump & CoverStep 11.1 Remove Water Pump cover
Step 12:  Remove the kickstarter lever. Step 12: Remove Kickstarter Lever




Step 13: Remove the crank cover bolts.

Keep track of what bolt goes where!

 Step 13: Remove Crank Case Cover Bolts
Step 14: Pull the crank case cover. Step 14: Remove Crank Case Cover
Step 15: Discard the old crank cover gasket. Step 15: Discard Old Gasket
Step 16: Pull the clutch outer. Step 16: Pull Clutch Outer
Step 17: Pull the clutch outer guide and needle
bearing.  The needle bearing is fragile so keep
the two parts together.
 Step 17: Oull Outer Guide & Needle Bearing
Step 18: In order to remove the lifter lever you
will have to remove the flywheel and stator.
 Step 18: Remove Flywheel cover
Step 19: Remove flywheel bolt and washer
and install the flywheel puller.
 Step 19.1: Remove Flywheel Bolt & WasherStep 19: Remove Flywheel Bolt & Washer
Step 20: Pull the flywheel.  The flywheel is
magnetized so give it a good pull to remove it.
 Step 20: Pull Flywheel
Step 21: Remove the stator and lay it to the
side, there is no need to disconnect it completely.
 Step 21: Remove Stator
Step 22: Disconnect the clutch cable. Step 22: Disconnect Clutch Cable
Step 23: Pull the lifter lever. Step 23: Pull Lifter Lever

1997-2001 Honda CR250 Part 2: Clutch Inspection

Large-Final

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