1997-2001 Honda CR250 – Remove & Install External Exhaust System

How To Remove And Install The External Exhaust System On Your 1997 – 2001 Honda CR250.

1997 - 2001 Honda CR250 - External Exhaust SystemThe Tools You Will Need Are:

  • Exhaust Spring Hook
  • Various Sockets
  • Shop Towels

The Parts You May Need Are:

  • Expansion Chamber O-rings
  • Exhaust Port Seal Washer

Start with your bike on a stand, with the seat and right body plastic removed.

Related: 1997-2001 Honda CR250 Engine Top End Specifications

Exhaust System Removal:

(Click To Enlarge)
Remove the bolts mounting the silencer to the subframe.1997 - 2001 Honda CR250 - External Exhaust - Remove Silencer Bolts
Rotate the silencer away from the body, then pull the silencer backward.1997 - 2001 Honda CR250 - External Exhaust - Rotate Silencer
If the silencer is seized to the expansion chamber, this slight rotation should break it free.This bike is missing the rubber that seals the connection between the expansion chamber and the silencer.  While this connection is not critical, I would still recommend having one.
Remove the two springs holding the pipe to the cylinder.1997 - 2001 Honda CR250 - External Exhaust - Remove Expansion Chamber Springs
Remove the two mounting bolts, and pull the expansion chamber away from the cylinder head.1997 - 2001 Honda CR250 - External Exhaust - Remove Expansion Chamber Bolts
Don’t forget to grab the seal washer.1997 - 2001 Honda CR250 - External Exhaust - Remvoe Seal Washer
And Just to be safe, plug the exhaust port with a clean shop towel.1997 - 2001 Honda CR250 - External Exhaust - Plug Exhaust Port

Clean & Inspect Exhaust System:

Check the o-rings on the expansion chamber, if they look worn out, make sure to replace them. These are worn out, so they will need to be replaced.

The OEM O-Ring part number is:

91304-KZ3-890

1997 - 2001 Honda CR250 - External Exhaust - Inspect O-rings
I am installing a new FMF Gnarly pipe, and this new pipe comes with new o-rings installed.1997 - 2001 Honda CR250 - External Exhaust - New FMF Gnarly Pipe
Wipe down and inspect the seal washer for warping or cracks.

The OEM washer part number is:

18309-KZ3-600

1997 - 2001 Honda CR250 - External Exhaust - Inspect Seal Washer
Finally, wipe down the exhaust port, and check for any visible signs of wear.1997 - 2001 Honda CR250 - External Exhaust - Clean Exhaust Port
Exhaust System Installation:
Install the washer, followed by the expansion chamber, and attach the mounting springs.1997 - 2001 Honda CR250 - External Exhaust - Install Washer1997 - 2001 Honda CR250 - External Exhaust - Attach Mounting Springs
If you are installing a new pipe, you may need to adjust the mounts.
Install and tighten the two mounting bolts.1997 - 2001 Honda CR250 - External Exhaust - Install Expansion Chamber Mounting Bolts
Feel around the cylinder head to make sure the pipe mounted properly, and the o-rings didn’t roll out of their grooves.
Connect the silencer to the expansion chamber with the silencer away from your bike.1997 - 2001 Honda CR250 - External Exhaust - Connect Silencer
Push the silencer onto the expansion chamber as you rotate the silencer toward your bike.1997 - 2001 Honda CR250 - External Exhaust - Rotate Adn Push Silencer
Install the two silencer mounting bolts.1997 - 2001 Honda CR250 - External Exhaust - Install Silencer Mounting Bolts
Exhaust System Torque Specs:
1998-1999106 in-lb
200110 ft-lb

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