1997-2001 Honda CR250 – Top End Rebuild – Part 3: Piston Removal

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1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal

How To Remove The Piston On Your 97 -01 Honda CR250

1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal

The Tools You Will Need

  • Wrist Pin Removal Tool
  • Small Pick
  • Shop Towel
  • (Master Tools & Parts List Below)

Pre-Service Notes

  • Start with the piston rotated to top dead center.
  • I recommend opening the Service & Torque Specs in a new tab for easy reference.
  • If you need parts and tools, make sure to buy them on Amazon!
  • Pictures with captions are after the steps below.
  • If you need any help don’t hesitate to ask!

Check Piston Connection

  1. Before removing the piston, test the condition of the connecting rod opening, needle bearing, and wrist pin.
  2. Grip the connecting rod with one hand, and try to rock, not slide, the piston side to side.
  3. If there is any play in the piston connection, you already know something is out of spec.
  4. Remove the pin clips with a pick and safety glasses, because they might go flying.
  5. Assemble your wrist pin removal tool, and press the pin from of the cylinder.
  6. Remove the needle bearing, and wrap your connecting rod with a clean shop towel.
Grip the connecting rod with one hand, and try to rock, not slide, the piston side to side.
Grip the connecting rod with one hand, and try to rock, not slide, the piston side to side.
If there is any play in the piston connection, you already know something is out of spec.
If there is any play in the piston connection, you already know something is out of spec.
Remove the pin clips with a pick and safety glasses, because they might go flying.
Remove the pin clips with a pick and safety glasses, because they might go flying.
Assemble your wrist pin removal tool, and press the pin out of the cylinder.
Assemble your wrist pin removal tool, and press the pin out of the cylinder.

1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal - Press Pin1997 - 2001 Honda CR250 - Top End Service - Part 3 - Piston Removal - Pin Removed

Remove the needle bearing, and wrap your connecting rod with a clean shop towel.
Remove the needle bearing, and wrap your connecting rod with a clean shop towel.

Top End Service - Part 3 - Piston Removal - Wrap Conecting Rod← Part 2: Cylinder Removal

Part 4: Exhaust Valve Removal →

Top End Rebuild Tools List: (Links to Amazon)

  • Piston Pin Puller
  • Piston Holder
  • Machinists Straight Edge
  • Feeler Gauges
  • Telescoping Bore Gauges
  • Digital Calipers
  • Plastic Scraper
  • Spark Plug Thread Follower
  • Motion Pro Torque Wrench Adapter
  • Molybdenum Grease
  • Lithium Grease

Top End Rebuild Parts List: (Links to Amazon)

  • Top End Gasket Set
  • Cylinder Alignment Dowels
  • Exhaust Valve Cap O-Ring

Keep Your ’97-’01 CR250 Running Right!

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