1997-2001 Honda CR250 External Shift Linkage Maintenance Part 1: Removal

Oct 26, 2015

168

This is PART 1 of the full step-by-step external shift linkage inspection for your 1997-2001 Honda CR250 Dirt Bike.

You can find Part 2: Inspection and Part 3: Installation.

When did you last perform a full external shift linkage inspection on your motocross or trail Honda CR250?

Your External Shift Linkage might be bad, and you don’t even know it, which could damage other internal parts. A common Honda CR250 external shift linkage problem is having problems getting your bike into gear. This problem has no definite cause, so you must inspect every part of the linkage.

The Tools You Will Need Are

8mm socket
10mm box wrench
2 Pry bars

Pre-Service Notes

To access the shift linkage, you will need to remove the right crankcase cover and clutch assembly. The Clutch Inspection Walkthrough explains how to do this.
I highly recommend using OE parts. Although aftermarket parts may be cheaper, they may not be of the same quality as the original Honda parts.
I recommend opening the Service & Torque Specs table in a new tab for easy reference.
If you need parts and tools, make sure to buy them here! → https://amzn.to/4h4lDKq
Put a box or tray under your bike to catch falling parts.
- The external shift linkage has many tiny components, so keep everything in a Ziploc bag!
Pictures with captions are after the steps below.
Honda OEM part numbers are listed at the bottom of the page.
If you need any help, don’t hesitate to ask!

External Shift Linkage Removal

Step 1: Remove the shift lever.
Step 2: Pull the shift shaft from the crankcase. The washer may be stuck to the crankcase.
Step 3: Remove the guide collar.
Step 4: Remove the guide plate.
Step 5: Remove the shifter drum center pin.
Step 6: Pry back the stopper arm and remove the shifter drum.
Step 7: Remove the stopper arm.