1997-2001 Honda CR250 Transmission & Internal Shift Mechanism Specifications

Transmission & Internal Shift Mechanism Specifications For Your 1997-2001 Honda CR250 Dirt Bike.

1997 -2001 Honda CR250 - Transmission And Internal Shift Mechanism Specifications - FeaturedIf you need parts and tools make sure to buy them here!

Related: ’97-’01 Honda CR250 Transmission Service

General Transmission Specifications:

Service Limit mm (in.)
Transmission 5 – Speed Constant Mesh
Primary Reduction Type Gear
Ratio 3 (63/21)
Final Reduction Ratio
– 1997 3.769 (49/13)
– 1998 – 2001 3.846 (50/13)
Gear Ratios
– First Gear 1.800 (27/15)
– Second Gear 1.470 (25/17)
– Third Gear 1.210 (23/19)
– Fourth Gear 1.000 (21/21)
– Fifth Gear 0.869 (20/23)

 

Transmission Service Specifications:

New – mm Service Limit – mm
Mainshaft Assembly
Mainshaft O.D. @ 5th Gear 24.959 – 24.980 24.94
4th Gear I.D. 28.007 – 28.028 28.05
4th Gear Bushing O.D. 27.959 – 27.980 27.94
4th Gear To Bushing Clearance 0.027 – 0.069 .11
5th Gear I.D. 25.020 – 25.041 25.07
5th Gear To Shaft Clearance 0.040 – 0.082 0.13
Countershaft Assembly
Countershaft
Countershaft O.D. @ 1st Gear Bushing 18.959 – 18.980 18.94
Countershaft O.D. @ 2nd Bushing 24.959 – 24.979 24.96
Countershaft O.D. @ 3rd Gear 24.959 – 24.980 24.94
1st Gear
1st Gear I.D. 22.020 – 22.041 22.07
1st Gear Bushing O.D. 21.979 – 22.000 27.95
1st Gear Bushing I.D. 19.000 – 19.021 19.04
1st Gear To Bushing Clearance 0.020 – 0.062 0.12
1st Gear Bushing To Shaft Clearance 0.020 – 0.062 0.12
2nd Gear
2nd Gear I.D.  30.020 – 30.041 30.07
2nd Gear Bushing O.D. 29.979 – 30.000 29.95
2nd Gear Bushing I.D. 27.000 – 27.021 27.04
2nd Gear To Bushing Clearance 0.020 – 0.062 0.12
2nd Gear Bushing To Shaft Clearance 0.020 – 0.062 0.12
3rd Gear
3rd Gear I.D. 25.020 – 25.041 25.07
3rd Gear To Shaft Clearance 0.041 – 0.082 0.11
Internal Shift Mechanism
Shift Fork Shaft O.D.
Center Fork 10.983 – 10.994 10.97
Right & Left Forks 11.966 – 11.984 11.95
Shift Fork I.D.
Center Fork 11.003 – 11.024 11.04
Right & Left Forks 12.035 – 12.056 12.07
Shift Fork Claw Thickness 4.93 – 5.0 4.8

 

Keep Your ’97-’01 CR250 Running Right!

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