1997-2001 Honda CR250 – Top End Service – Part 4: Exhaust Valve Removal

How To Remove The Exhaust Valve On Your 1997 – 2001 Honda CR250.

1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Featured

The Tools You Will Need Are:

  • 4mm Hex Wrench
  • Needle Nose Pliers
  • Snap Ring Pliers

Start by removing the right crankcase cover.

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Exhaust Valve Removal

(Click To Start Slide Show)
Remove the pinion shaft and bushing from the top of the crankcase, and remove the governor assembly.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Pinion Shaft And Bushing1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Governor Assembly
On the cylinder, disconnect the valve link from the right side sub-exhaust valve.
Insert a drift in the hole left of the link, and remove the mounting bolt from the valve.
1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Valve Link Bolt
Back out the valve stopper bolt, and remove the bearing, exhaust valve, the valve shaft, and flap valve shaft.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Stopper Bolt1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Bearing Valve and Shaft
Remove the left valve cap from the left side of the cylinder.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Left Valve Cover
Remove snap ring, and remove bearing and valve.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Snap Ring1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Bearings and Valve
Remove the flap valve from the cylinder

  • 1997-1998 models – through the exhaust port
  • 1999-2001 through cylinder
1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Flap Valve
Remove the drive shaft clip from exhaust valve linkage.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Loosen Shaft Linkage
Pull the drive shaft and bushing from the bottom of the cylinder, and remove the linkage.1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Drive Shaft1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Linkage
Part 3: Piston RemovalPart 5: Piston Inspection
1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal1997 - 2001 Honda CR250 - Top End Service - Part 5 - Piston Inspection

 

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