1997-2001 Honda CR250 External Shift Linkage Maintenance Part 2: Inspection

This is PART 2 of the full step-by-step external shift linkage inspection for your 1997-2001 Honda CR250 Dirt Bike.

You can find Part 1: Removal here, and Part 3: Installation here.

Remember, if you need parts and tools you can get them HERE.

You can follow long with the video below!

Honda CR250 External Shift Linkage Inspection

Click The Pictures To Start Slideshow!

Step 9: Inspect the shift shaft:

  • Check the shaft for bend or uneven wear
  • Check the shift lever splines for pits or cracks
  • If the spring and snap ring are tight leave them
    on the shaft, if they are loose, replace them
 Step 9: Inspect Shift ShaftStep 9.1: Inspect Shift Shaft Step 9.2: Inspect Shift Shaft
Step 10: Inspect the stopper assembly components:

  • Check the stopper arm for bends or cracks
  • Test the stopper wheel for smooth operation
  • Check the stopper spring for tension, fractures
    or uneven wear
  • Ensure the washer is still flat and smooth
Step 10: Inspect Stopper Arm AssemblyStep 10.1: Inspect Stopper Arm Assembly Step 10.2: Inspect Stopper Arm Assembly
Step 11: Inspect the shifter drum and center pin.

  • Check the center pin for bends and the threads for
    stripping
  • Check the drum for signs of excessive wear.  If any
    parts of the drum are worn it will not operate properly
Step 11: Inspect Pin & Drum CenterStep 11.1: Inspect Pin & Drum Center




Step 12: Inspect the guide plate and drum shifter
components:

  • Check the pawls, springs, plungers and drum shifter
    body for wear. If these components are worn in any
    way they will need to be replaced.
  • Check the guide plate for warping, cracks, or any
    signs of fatigue
 Step 12: Inspect Drum Shifter ComponentsStep 12.1: Inspect Drum Shifter Components Step 12.2: Inspect Drum Shifter Components Step 12.3: Inspect Drum Shifter Components Step 12.4: Inspect Drum Shifter Components
Step 13: Assemble the drum shifter:

  • Install the plunger and spring into drum shifter body
  • Install the pawl with the round end in the drum
    shifter body, make sure the groove pushes against the plunger
  • Repeat on the opposite side
  • Install the drum shifter into the guide plate, the
    drum shifter assembly should not move with the pawls extended.
Step 13: Assemble Drum ShifterStep 13.1: Assemble Drum Shifter Step 13.2: Assemble Drum Shifter Step 13.3: Assemble Drum Shifter Step 13.4: Assemble Drum Shifter

If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!

 97-01 Honda CR250 External Shift Linkage Part 3: Installation →

Keep Your ’99-’01 CR250 Running Right!

Fix Your Dirt Bike Logo