1997-2001 Honda CR250 – Top End Service – Part 2: Cylinder Removal

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

1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal

The Tools You Will Need Are:

  • Motion Pro Torque Wrench Adapter
  • 3/8″ Socket Wrench
  • 17mm Socket
  • 14mm Socket
  • 8mm Socket
  • Mallet or Dead Blow
  • Sharpie Marker
  • Shop Towel

You can get your Torque Wrench Adapter at RockyMountainATVMC.com

Start your removal by turning the piston to bottom dead center.

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

Cylinder Removal

(Click To Start Slide Show)
Remove the right cylinder cover, and loosen the left valve cover while the cylinder is still mounted.1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Right Cover
Mark the 4 cylinder base nuts 1 through 4 to follow a consistent pattern.1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Mark Nuts 1 and 3 1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Mark Nuts 2 and 4
Loosen the cylinder base nuts ¼ turn at a time to avoid binding, take as many passes as you need.

Tap the cylinder with mallet in multiple locations.

1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Loosen Mounting Nuts 1 1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Loosen Base Nuts 21997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Loosen Base Nuts 31997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Loosen Base Nuts 4
While standing on the left side of your bike, slowly raise the cylinder up to expose the alignment dowels, and stuff a clean shop cloth into the crankcase opening.1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Raise Cylinder1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Stuff Shop Towel Into Opening

DO NOT TWIST THE CYLINDER!Be Careful!

If your dowels are seated on the studs, remove the cylinder.

If the dowels are in the cylinder, make sure they don’t fall into the crankcase!

1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Lift culinder Off Studs
You may experience binding on the left side of the cylinder due to seized alignment dowels.

If your cylinder is seized to the stud, use PB blaster and patience.

1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - PB Blast Stud Dowel
Remove the alignment dowels, and any loose gasket material immediately following cylinder removal.1997 - 2001 Honda CR250 - Top End Service - Part 2 - Cylinder Removal - Remove Gasket
Part 1: Cylinder Head RemovalPart 3: Piston Removal
1997 - 2001 Honda CR250 - Top End Service - Part 1 - Cylinder Head Removal1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal

Keep Your ’99-’01 CR250 Running Right!

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