How To Remove And Install The External Exhaust System On Your 1997 – 2001 Honda CR250.
The Tools You Will Need Are:
- Exhaust Spring Hook
- Various Sockets
- Shop Towels
The Parts You May Need Are:
- Expansion Chamber O-rings
- Exhaust Port Seal Washer
Start with your bike on a stand, with the seat and right body plastic removed.
Exhaust System Removal:
|(Click To Enlarge)|
|Remove the bolts mounting the silencer to the subframe.|
|Rotate the silencer away from the body, then pull the silencer backward.|
|If the silencer is seized to the expansion chamber, this slight rotation should break it free.||This bike is missing the rubber that seals the connection between the expansion chamber and the silencer. While this connection is not critical, I would still recommend having one.|
|Remove the two springs holding the pipe to the cylinder.|
|Remove the two mounting bolts, and pull the expansion chamber away from the cylinder head.|
|Don’t forget to grab the seal washer.|
|And Just to be safe, plug the exhaust port with a clean shop towel.|
Clean & Inspect Exhaust System:
|Check the o-rings on the expansion chamber, if they look worn out, make sure to replace them. These are worn out, so they will need to be replaced.|
The OEM O-Ring part number is:
|I am installing a new FMF Gnarly pipe, and this new pipe comes with new o-rings installed.|
|Wipe down and inspect the seal washer for warping or cracks.
The OEM washer part number is:
|Finally, wipe down the exhaust port, and check for any visible signs of wear.|
Exhaust System Installation:
|Install the washer, followed by the expansion chamber, and attach the mounting springs.|
|If you are installing a new pipe, you may need to adjust the mounts.|
|Install and tighten the two mounting bolts.|
|Feel around the cylinder head to make sure the pipe mounted properly, and the o-rings didn’t roll out of their grooves.|
|Connect the silencer to the expansion chamber with the silencer away from your bike.|
|Push the silencer onto the expansion chamber as you rotate the silencer toward your bike.|
|Install the two silencer mounting bolts.|
Exhaust System Torque Specs:
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Keep Your ’97-’01 CR250 Running Right!