1997-2001 Honda CR250 – Top End Service – Part 4: Exhaust Valve Removal

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1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Featured

How To Remove The Exhaust Valve On Your 97-01 Honda CR250

1997 - 2001 Honda CR250 - Top End Service - Part 4 - Exhaust Valve Removal - Featured

The Tools You Will Need

  • 4mm Hex Wrench
  • Needle-Nose Pliers
  • Snap Ring Pliers

Pre-Service Notes

  • Start by removing the right crankcase cover.
  • 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 here!
  • Pictures with captions are after the steps below.
  • If you need any help don’t hesitate to ask!

Exhaust Valve Removal

  1. Remove the pinion shaft and bushing from the top of the crankcase, and remove the governor assembly.
  2. On the cylinder, disconnect the valve link from the right side sub-exhaust valve.
    Insert a drift in the hole left of the link, and remove the mounting bolt from the valve.
  3. Back out the valve stopper bolt, and remove the bearing, exhaust valve, the valve shaft, and flap valve shaft.
  4. Remove the left valve cap from the left side of the cylinder.
  5. Remove snap ring, and remove bearing and valve.
  6. Remove the flap valve from the cylinder. – 1997-1998 – through the exhaust port, 1999-2001 – through the cylinder
  7. Remove the driveshaft clip from exhaust valve linkage.
  8. Pull the driveshaft and bushing from the bottom of the cylinder, and remove the linkage.
Remove the pinion shaft and bushing from the top of the crankcase, and remove the governor assembly.
Remove the pinion shaft and bushing from the top of the crankcase, and remove the governor assembly.
On the cylinder, disconnect the valve link from the right side sub-exhaust valve. Insert a drift in the hole left of the link, and remove the mounting bolt from the valve.
On the cylinder, disconnect the valve link from the right side sub-exhaust valve. Insert a drift in the hole left of the link, and remove the mounting bolt from the valve.

Removal - Governor Assembly

Back out the valve stopper bolt, and remove the bearing, exhaust valve, the valve shaft, and flap valve shaft.
Back out the valve stopper bolt, and remove the bearing, exhaust valve, the valve shaft, and flap valve shaft.
Remove the left valve cap from the left side of the cylinder.
Remove the left valve cap from the left side of the cylinder.
Remove snap ring, and remove bearing and valve.
Remove snap ring, and remove bearing and valve.

Removal - Bearing Valve and ShaftRemoval - Bearings and Valve

Remove the flap valve from the cylinder. - 1997-1998 - through the exhaust port, 1999-2001 - through the cylinder
Remove the flap valve from the cylinder. – 1997-1998 – through the exhaust port, 1999-2001 – through the cylinder
Remove the driveshaft clip from exhaust valve linkage.
Remove the driveshaft clip from exhaust valve linkage.
Pull the driveshaft and bushing from the bottom of the cylinder, and remove the linkage.
Pull the driveshaft and bushing from the bottom of the cylinder, and remove the linkage.

Removal - Linkage
← Part 3: Piston Removal

Part 5: Piston Inspection →

Keep Your ’97-’01 CR250 Running Right!