1997-2001 Honda CR250 – Top End Service – Part 12: Cylinder Installation

How To Install The Cylinder On Your 1997 – 2001 Honda CR250.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder InstallationThe Tools You Will Need Are:

  • Piston Holder
  • Motion Pro Torque Wrench Adapter
  • Foot Pound Torque Wrench
  • Inch Pound Torque Wrench
  • 4mm Hex Socket
  • 17mm Socket
  • 14mm Socket
  • 12mm Socket
  • 8mm Socket
  • Lithium Grease
  • Shop Towels

If you don’t have your Motion Pro Torque Wrench Adapter yet, you can get your HERE for $13.

The Parts You Will Need Are:

  • New Cylinder Base Gasket
  • New Right Cylinder Cover Gasket
  • New Alignment Dowels

You can get your new gasket set HERE for $24. (Link To RockMountainATVMC.com)

Click Here To Open The Top End Specifications Table In A New Window

Cylinder Installation

(Click To Start Slide Show)
Double check the cylinder bore and mating surfaces for cleanliness.

Apply lithium grease to the exhaust valve pinion joint.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Check Mating Surface
Install NEW alignment dowels on the left side of the crankcase.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Install Alignment Dowels
Install your new gasket.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Install New Gasket
Place your piston holder, and rotate the crankshaft so the piston skirt is resting against the holder.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Place Piston Holder
Double check the piston rings are seated against the locating pins, and position your cylinder.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Double Check Piston Rings
Hold the cylinder as lever as you can with the piston, and compress the top ring against the alignment pin.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Position Cylinder And Compress Top Ring
The cylinder should slide right over the ring.

Repeat with the second ring.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Slide Cylinder Onto Piston
It Is Extremely Important That You Do NOT Rotate The Cylinder!Be Careful!
Remove the holder, and align the exhaust valve drive shaft.

The drive shaft opening should face the rear of your bike.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Align Exhaust Valve Drive Shaft With Pinion
Lower the cylinder onto the studs.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Lower Cylinder Onto Studs
Thread the cylinder mounting nuts finger tight.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Thread Base Nuts
Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve buy pulling and pushing on the governor.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Check Exhasut Vavle Connection1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Check Exhasut Valve Operation
Begin torquing the nuts in the same pattern as removal.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Tighten Base Nuts
Turn the nuts a ¼ turn at a time, taking as many passes as you need to reach torque.

Torque the cylinder mounting nuts to 29 ft-lbs.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Torque Base Nuts
Remember, when using the torque adapter, you will NOT need to compensate for length if the adapter remains at a right angle to your torque wrench.Be Careful!
Loosen the exhaust linkage pinion bolt, turn the valve all the way counterclockwise, and check that the flap valve is open.

Torque the pinion bolt to 48 in-lbs.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Torque Exhaust Valve Linkage Hex Bolt
Install the right cylinder cover with a new gasket.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Install Right Cylinder Cover
Torque the valve stopper bolt to 141 in-lbs.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Torque Valve Stopper Bolt
Torque the left exhaust valve cap to 115 in-lbs.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Torque Left Valve Cap
Torque check the head studs, and install the right crankcase cover.1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Torque Head Studs

Torque Specifications

Cylinder Mounting Nuts29 ft-lbs.
Pinion Bolt48 in-lbs.
Valve Stopper Bolt141 in-lbs.
Left Exhaust Valve Cap115 in-lbs.
Part 11: Piston InstallationPart 13: Cylinder Head Installation
1997 - 2001 Honda CR250 - Top End Service - Part 11 - Piston Installation1997 - 2001 Honda CR250 - Top End Service - Part 13 - Cylinder Head Installation

Keep Your ’99-’01 CR250 Running Right!

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