How To Install The Exhaust Valve On Your 1997 – 2001 Honda CR250.
- 4mm Hex Wrench
- Needle Nose Pliers
- 2-Stroke Oil
- Molybdenum Grease (Amazon)
- Inch Pound Torque Wrench
- Rubber Gloves
The Parts You Will Need Are:
- Left Valve Cap O-ring – Part Number: 91302-001-020
If you don’t have your parts yet, you can get them from RockyMountianATVMC.com
Exhaust Valve Linkage Assembly
|(Click To Start Slide Show)|
|Start by assembling the linkage.|
|Apply grease to the drive shaft bushing and driveshaft.|
Fit the bushing on drive shaft, and Install drive shaft part way into the cylinder
|Align the link assembly, and finish installing the drive shaft.|
|Clip the driveshaft into the linkage.|
Exhaust Valve Governor Install
|Apply grease to the pinion shaft and bushing.|
Seat bushing in the crankcase.
|Assemble the governor washers and engage the rack. |
Install the governor in the crankcase
|Install pinion shaft with the opening facing in.|
Double check the rack and pinion operation.
Flap Valve Assembly
|Apply grease to the flap valve shaft, and partially install it into the cylinder.|
|Install the flap valve with the projections facing up.|
Align and install the flap valve.
Right Sub-Exhaust Valve Install
|Apply grease to the exhaust valve shaft, and connect it to the valve.|
|Align the valve shaft with the flap valve, and place the sub-exhaust valve on it’s bore.|
Apply 2-stroke oil to the valve, then press the valve into the cylinder.
|Turn the valve until the cutout is facing up, and install the stopper bolt hand tight.|
|Install bearings with the manufacturer’s marks facing out.|
Connect Valve Linkage
|Seat the valve link against the end of the valve so the tab sits in the cutout.|
Rotate the valve counter clockwise, and insert a drift into the hole.
|Install the hex bolt, and torque to 48 in-lb.|
Left Sub-Exhaust Valve Install
|Lubricate the left Sub-Exhaust valve with 2-stroke oil.|
Align the valve with the valve shaft, and press it into the bore.
|Lubricate and install the bearings with the markings facing out.|
|Install the collar with the stepped side facing in, followed by the snap ring.|
|Lubricate a new o-ring, and install it on the valve cap.|
|Apply grease to the valve cap threads, and install the cap hand tight.|
Test Power Valve Operation
|Tighten the hex bolt on the pinion holder temporarily, and test the operation of the exhaust valve system.|
|Loosen the pinion bolt, as you will need to adjust the system after the cylinder is installed.|
Exhaust Valve Torque Specifications
|Linkage Hex Bolt||48 in-lb.|
|Pinion Hex Bolt||48 in-lb.|
|Part 9: Clearance Calculations||Part 11: Piston Installation|
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