How To Install The Cylinder On Your 1997 – 2001 Honda CR250.
The 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 To Start Slide Show)|
|Double check the cylinder bore and mating surfaces for cleanliness.|
Apply lithium grease to the exhaust valve pinion joint.
|Install NEW alignment dowels on the left side of the crankcase.|
|Install your new gasket.|
|Place your piston holder, and rotate the crankshaft so the piston skirt is resting against the holder.|
|Double check the piston rings are seated against the locating pins, and position your cylinder.|
|Hold the cylinder as lever as you can with the piston, and compress the top ring against the alignment pin.|
|The cylinder should slide right over the ring. |
Repeat with the second ring.
|It Is Extremely Important That You Do NOT Rotate The Cylinder!|
|Remove the holder, and align the exhaust valve drive shaft.|
The drive shaft opening should face the rear of your bike.
|Lower the cylinder onto the studs.|
|Thread the cylinder mounting nuts finger tight.|
|Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve buy pulling and pushing on the governor.|
|Begin torquing the nuts in the same pattern as removal.|
|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.
|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.|
|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.
|Install the right cylinder cover with a new gasket.|
|Torque the valve stopper bolt to 141 in-lbs.|
|Torque the left exhaust valve cap to 115 in-lbs.|
|Torque check the head studs, and install the right crankcase cover.|
|Cylinder Mounting Nuts||29 ft-lbs.|
|Pinion Bolt||48 in-lbs.|
|Valve Stopper Bolt||141 in-lbs.|
|Left Exhaust Valve Cap||115 in-lbs.|
|Part 11: Piston Installation||Part 13: Cylinder Head 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