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

How To Install The Cylinder On Your 1997 – 2001 Honda CR250.

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

  • 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 Are:

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

You can get your new gasket set HERE.

Related: 1997-2001 Honda CR250 – Brake Pad Service

Click Here To Open The Top End Specifications Table In A New Window

Cylinder Installation

(Click To Start Slide Show)
Double check the cylinder bore and mating surfaces for cleanliness.

Apply lithium grease to the exhaust valve pinion joint.

1997 - 2001 Honda CR250 - Top End Service - Part 12 - Cylinder Installation - Check Mating Surface
Install NEW alignment dowels on the left side of the crankcase.Installation - Install Alignment Dowels
Install your new gasket.Installation - Install New Gasket
Place your piston holder, and rotate the crankshaft, so the piston skirt is resting against the holder.Installation - Place Piston Holder
Double check the piston rings are seated against the locating pins and position your cylinder.Installation - Double Check Piston Rings
Hold the cylinder as level as you can with the piston, and compress the top ring against the alignment pin.Installation - Position Cylinder And Compress Top Ring
The cylinder should slide right over the ring.

Repeat with the second ring.

Installation - Slide Cylinder Onto Piston
It Is Extremely Important That You Do NOT Rotate The Cylinder!Be Careful!
Remove the holder, and align the exhaust valve drive shaft.

The drive shaft opening should face the rear of your bike.

Installation - Align Exhaust Valve Drive Shaft With Pinion
Lower the cylinder onto the studs.Installation - Lower Cylinder Onto Studs
Thread the cylinder mounting nuts finger tight.Installation - Thread Base Nuts
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 Vavle ConnectionInstallation - Check Exhasut Valve Operation
Begin torquing the nuts in the same pattern as removal.Installation - Tighten Base Nuts
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.

Installation - Torque Base Nuts
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.Be Careful!
Loosen the exhaust linkage pinion bolt, turn the valve all the way counterclockwise, and check that the flap valve is open.

Torque the pinion bolt to 48 in-lbs.

Installation - Torque Exhaust Valve Linkage Hex Bolt
Install the right cylinder cover with a new gasket.Installation - Install Right Cylinder Cover
Torque the valve stopper bolt to 141 in-lbs.Installation - Torque Valve Stopper Bolt
Torque the left exhaust valve cap to 115 in-lbs.Installation - Torque Left Valve Cap
Torque check the head studs and install the right crankcase cover.Installation - Torque Head Studs

Torque Specifications

Cylinder Mounting Nuts29 ft-lbs.
Pinion Bolt48 in-lbs.
Valve Stopper Bolt141 in-lbs.
Left Exhaust Valve Cap115 in-lbs.
Part 11: Piston InstallationPart 13: Cylinder Head Installation
1997 - 2001 Honda CR250 - Top End Service - Part 11 - Piston Installation1997 - 2001 Honda CR250 - Top End Service - Part 13 - Cylinder Head Installation


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