1997-2001 Honda CR250 External Shift Linkage Maintenance Part 3: Installation

This is PART 3 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 2: Inspection here.

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

Related: Better Grip Strength Means More Control Of Your Dirt Bike

You can follow along with the video below!

Honda CR250 External Shift Linkage Installation

Click The Pictures To Start Slideshow!

Step 14: Install the drum alignment pinStep 14: Install Alignment Pin
Step 15: Install the stopper arm assembly.  Make sure the spring is hooked around the stopper arm, and the other end rests against the crankcase. Step 15: Install Stopper ArmStep 15.1: Install Stopper Arm
Step 16: Torque the stopper arm. (106 in.lb)Step 16: Torque Stopper Arm
Step 17: Install the shift drum:

  • The notch on the back of the drum needs to line up with the alignment pin
  • Pry back the stopper arm
  • Install the shift drum
Step 17: Install Shift DrumStep 17.1: Install Shift DrumStep 17.2: Install Shift DrumStep 17.3: Install Shift Drum
Step 18: Install and torque the center pin. (16 ft.lb) Step 18: Install & Torque Center PinStep 18.1: Install & Torque Center Pin


Step 19: Carefully install the guide plate and drum shifter assembly. Hold the guide plate in place as you thread the retaining bolts. Torque the guide plate retaining bolts (88in.lb)Step 19: Install Guide PlateStep 19.1: Install Guide Plate Step 19.2: Install Guide Plate
Step 20: Install the guide plate collar.Step 20: Install Collar
Step 21: Install the washer in the shift shaft then install the shift shaft into the crank case.Step 21: Install Shift ShaftStep 21.1: Install Shift Shaft
Step 22: Install a stopper bar to keep the shift shaft in place.  I used an 8mm wrench.Step 22: Install Stopper Bar
Step 23: Install and bolt down the shift leverStep 23: Install Shift Lever
Step 24: Test the shift linkage – Rotate the main shaft with your hand as you run through the gears.Step 24: Test Shifter Operation

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

Keep Your ’97-’01 CR250 Running Right!

Fix Your Dirt Bike Logo

 

This site uses Akismet to reduce spam. Learn how your comment data is processed.