1997-2001 Honda CR250 – Top End Service – Part 12: Cylinder Installation

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1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation

How To Install The Cylinder On Your 97-01 Honda CR250

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder InstallationThe Tools You Will Need

  • Piston Holder
  • Motion Pro Torque Wrench Adapter
  • Foot-Pound Torque Wrench
  • Inch-Pound Torque Wrench
  • 4mm Hex Socket
  • 17mm Socket
  • 14mm Socket
  • 12mm Socket
  • 8mm Socket
  • Lithium Grease
  • Shop Towels

If you don’t have your Motion Pro Torque Wrench Adapter yet, you can get yours HERE.

The Parts You Will Need

  • New ’97-’01 Honda CR250 Cylinder Base Gasket
  • New Right Cylinder Cover Gasket
  • New Alignment Dowels

Pre-Service Notes

Cylinder Installation

  1. Double-check the cylinder bore and mating surfaces for cleanliness.
  2. Apply lithium grease to the exhaust valve pinion joint.
  3. Install NEW alignment dowels on the left side of the crankcase.
  4. Install your new gasket.
  5. Place your piston holder, and rotate the crankshaft, so the piston skirt is resting against the holder.
  6. Doublecheck the piston rings are seated against the locating pins and position your cylinder.
  7. Hold the cylinder as level as you can with the piston, and compress the top ring against the alignment pin.
  8. The cylinder should slide right over the ring.
  9. Repeat with the second ring.
  10. It Is Extremely Important That You Do NOT Rotate The Cylinder!
  11. Remove the holder, and align the exhaust valve drive shaft.
  12. The drive shaft opening should face the rear of your bike.
  13. Lower the cylinder onto the studs.
  14. Thread the cylinder mounting nuts finger tight.
  15. Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve by pulling and pushing on the governor.
  16. Begin torquing the nuts in the same pattern as removal.
  17. Turn the nuts a ¼ turn at a time, taking as many passes as you need to reach torque.
  18. Torque the cylinder mounting nuts to 29 ft-lbs.
  19. Remember, when using the torque adapter, you will NOT need to compensate for length if the adapter remains at a right angle to your torque wrench.
  20. Loosen the exhaust linkage pinion bolt, turn the valve all the way counter-clockwise, and check that the flap valve is open.
  21. Torque the pinion bolt to 48 in-lbs.
  22. Install the right cylinder cover with a new gasket.
  23. Torque the valve stopper bolt to 141 in-lbs.
  24. Torque the left exhaust valve cap to 115 in-lbs.
  25. Torque check the head studs and install the right crankcase cover.
Double-check the cylinder bore and mating surfaces for cleanliness.
Double-check the cylinder bore and mating surfaces for cleanliness.
Install NEW alignment dowels on the left side of the crankcase.
Install NEW alignment dowels on the left side of the crankcase.
Install your new gasket.
Install your new gasket.
Place your piston holder, and rotate the crankshaft, so the piston skirt is resting against the holder.
Place your piston holder, and rotate the crankshaft, so the piston skirt is resting against the holder.
Doublecheck the piston rings are seated against the locating pins and position your cylinder.
Doublecheck the piston rings are seated against the locating pins and position your cylinder.
Hold the cylinder as level as you can with the piston, and compress the top ring against the alignment pin.
Hold the cylinder as level as you can with the piston, and compress the top ring against the alignment pin.
The cylinder should slide right over the ring.
The cylinder should slide right over the ring.
It Is Extremely Important That You Do NOT Rotate The Cylinder!
It Is Extremely Important That You Do NOT Rotate The Cylinder!
Lower the cylinder onto the studs.
Lower the cylinder onto the studs.
Thread the cylinder mounting nuts finger tight.
Thread the cylinder mounting nuts finger tight.
Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve by pulling and pushing on the governor.
Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve by pulling and pushing on the governor.

Installation - Check Exhasut Valve Operation

Turn the nuts a ¼ turn at a time, taking as many passes as you need to reach torque.
Turn the nuts a ¼ turn at a time, taking as many passes as you need to reach torque.
Torque the cylinder mounting nuts to 29 ft-lbs.
Torque the cylinder mounting nuts to 29 ft-lbs.
Torque the pinion bolt to 48 in-lbs.
Torque the pinion bolt to 48 in-lbs.
Install the right cylinder cover with a new gasket.
Install the right cylinder cover with a new gasket.
Torque the valve stopper bolt to 141 in-lbs.
Torque the valve stopper bolt to 141 in-lbs.
Torque the left exhaust valve cap to 115 in-lbs.
Torque the left exhaust valve cap to 115 in-lbs.
Torque check the head studs and install the right crankcase cover.
Torque check the head studs and install the right crankcase cover.

Torque Specifications

  • Cylinder Mounting Nuts 29 ft-lbs.
  • Pinion Bolt 48 in-lbs.
  • Valve Stopper Bolt 141 in-lbs.
  • Left Exhaust Valve Cap 115 in-lbs.

← Part 11: Piston Installation

Part 13: Cylinder Head Installation →

Keep Your ’97-’01 CR250 Running Right!

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