1997-2001 Honda CR250 – Water Pump Service And Repair

How To Service The Water Pump On Your 1997-2001 Honda CR250

1997 - 2001 Honda CR250 - Cooling System - Water Pump Service And Repair - Featured

What Are The Signs Of A Bad Water Pump?

Your water pump is located at the front of your crankcase on the right side. Right next to the oil level plug is a tiny opening. 

The other side of this opening sits between the impeller shaft oil and coolant seals. If you can see oil, coolant, or both coming out of that opening, your water pump is no longer sealed and needs to be repaired.

You can change the gasket on your water pump without removing the right crankcase cover. But if you need to change the seals, bearing, or impeller, your right crankcase cover must be removed.

1 - Water Pump Location

2 - Water Pump Weep Hole
Water Pump Weep Hole. Keep This Opening Clean So You Can See If Your Cooling System Is Compromised.

The Tools You Will Need Are:

  • 8mm socket
  • Socket Wrench
  • Inch-Pound Torque Wrench
  • Blind Bearing Puller
  • Socket For  Oil Seal
  • Socket For Water Seal
  • Flat Head Screwdriver
  • Lithium Grease
  • Scraper
  • Dremel
  • Parts Cleaner
  • Shop Towels
  • Safety Glasses
  • Mallet
  • Small Pick

Pre-Service Notes:

Water Pump Removal

  1. Start by draining your coolant and oil.
  2. I recommend removing the water pump cover while it is still mounted because it might put up a fight.
  3. A few taps with a mallet should release the gasket but DO NOT hit it very hard, or in the same spot repeatedly.
  4. Remove the right crankcase cover, and keep the bolts organized because length and placement are critical.
  5. Make sure to remove the shaft side washer from the case, and make sure the exhaust valve governor washer stayed in place.
3 - Drain The Coolant
Start by draining your coolant and oil.
4 - Remove The Water Pump Cover While It Is Still Mounted
I recommend removing the water pump cover while it is still mounted because it might put up a fight.
5 - Inside Of The Water Pump
Inside Of The Water Pump
6 - Remove Case Side Impeller Shaft Washer
Make sure to remove the shaft side washer from the case, and make sure the exhaust valve governor washer stayed in place.
7 - Make Sure Exhaust Valve Governor Washer Is Still There
Make Sure Exhaust Valve Governor Washer Is Still There

Clean And Inspect

Thoroughly clean the mating surfaces and housing first, for two reasons.

  • One, cleaning first will save you time and money in the long run if you find damage and need to replace or fix the housing.
  • Two, you can see if anything was damaged during service.

Related: When was the last time you serviced your external shift linkage?

Water Pump Disassembly

  1. Hold the impeller shaft with a box wrench, and loosen the impaler with an 8mm socket.
  2. The impeller looks like it is secured with a hex nut, but the impeller is all one piece.
  3. Remove the impeller and copper washer, followed by the impeller shaft.
  4. Remove the coolant side seal with a flat screwdriver and a towel to protect the housing.
  5. The oil side seal is behind the impeller shaft bearing, and the bearing needs to be pulled with a blind bearing puller.
  6. Now, you could, theoretically, punch the bearing out from outside the cover with a drift, but I am NOT TELLING YOU TO DO THAT.
  7. Fortunately, the impeller bearing is not an interference fit and can be removed and installed easily.
  8. Remove the oil side seal with a flat head screwdriver and a towel.
  9. Thoroughly clean the seal bores, and the bearing bore.
8 - Loosen And Remove The Impeller
Remove the impeller and copper washer, followed by the impeller shaft.
9 - Remove The impeller Shaft
Remove The impeller Shaft
10 - Remove Old Coolant Seal With Screwdriver And Towel
Remove the coolant side seal with a flat screwdriver and a towel to protect the housing.
11 - The Oil Seal Is Behind The Bearing
The oil side seal is behind the impeller shaft bearing, and the bearing needs to be pulled with a blind bearing puller.
12 - Remove The Bearing With A Blind Bearing Puller
Remove The Bearing With A Blind Bearing Puller
13 - Remove The Oil Seal With A Screwdriver And Towel
Remove the oil side seal with a flat head screwdriver and a towel.

Assembly

  1. Pack your new oil seal with lithium grease and install it with the open side facing up.
  2. Use a socket of matching size, and drive the seal into the bore.
  3. Place your new bearing squarely over the bore, and drive it into place with a socket that matches the OUTSIDE bearing race.
  4. Drive your bearing until it bottoms out.
  5. Pack the coolant side seal with lithium grease, and install it with the open side facing up. 
  6. The coolant seal is a different size, so you will need to use a different matching socket to drive the seal into the bore.
  7. Apply grease to the impeller shaft, and carefully install it into the case in a twisting motion.
  8. Install a NEW copper washer, followed by your impeller.
  9. Hold the impeller shaft with a box wrench and torque to 106-inch pounds.
14 - Greas The Lip Of The Oil Seal With Lithium Grease
Pack your new oil seal with lithium grease and install it with the open side facing up.
15 - Install The Oil Seal With The Open Side Facing UP
Use a socket of matching size, and drive the seal into the bore.
16 - Place The Bearing Squarely Over The Bore
Place your new bearing squarely over the bore, and drive it into place with a socket that matches the OUTSIDE bearing race.
17 - Drive The Bearing With A Socket That Matches The OUTSIDE Bearing Race
Drive your bearing until it bottoms out.
18 - Grease And Install The Coolant Seal With The Opening Facing UP
Pack the coolant side seal with lithium grease, and install it with the open side facing up.
19 - Drive The Seal With A Matching Socket
The coolant seal is a different size, so you will need to use a different matching socket to drive the seal into the bore.
20 - Grease The Impeller Shaft
Apply grease to the impeller shaft, and carefully install it into the case in a twisting motion.
21 - Install The Impeller Shaft In A Twisting Motion
Install The Impeller Shaft In A Twisting Motion
22 - Install A NEW Copper Washer
Install a NEW copper washer, followed by your impeller.
23 - Install The Impeller
Install The Impeller
24 - Torque The Impeller To 106 Inch Pounds
Hold the impeller shaft with a box wrench and torque to 106-inch pounds.

Water Pump Installation

  1. Place your new dowels in the case.
  2. Place your inner gasket, followed by the flow plate, followed by the outer gasket.
  3. Place your water pump cover and press it firmly into place.
  4. Install the case side impeller shaft washer and make sure the exhaust valve governor washer is still in place.
  5. Install a fresh gasket on your crankcase and install the right crankcase cover.
  6. Place your bolts that you definitely kept organized and tighten them hand tight.
  7. The right crankcase bolts do not have a torque specification, but the water pump cover does at 106-inch pounds.
  8. However, I DO NOT recommend torquing these bolts to 106-inch pounds, as I have had several bolts break on me in the past.
  9. I recommend tightening the right crankcase cover bolts no tighter than what a small 1/4in ratchet will achieve.
25 - Install New Alignment Dowels
Place your new dowels in the case.
26 - Install Inner Gasket
Place your inner gasket, followed by the flow plate, followed by the outer gasket.
27 - Install Flow Plate
Install Flow Plate
28 - Install Outer Gasket
Install Outer Gasket
Place your water pump cover and press it firmly into place.
Place your water pump cover and press it firmly into place.
30 - Install Case Side Impeller Shaft Washer
Install the case side impeller shaft washer and make sure the exhaust valve governor washer is still in place.
31 - Double Check The Exhaust Valve Governor Washer
Double Check The Exhaust Valve Governor Washer
32 - Install A New Crankcase Cover Gasket
Install a fresh gasket on your crankcase and install the right crankcase cover.
33 - Install The Crankcase Cover
The right crankcase bolts do not have a torque specification, but the water pump cover does at 106-inch pounds.

If you need any help with your 1997-2001 Honda CR250 water pump service, please let me know in the comments or on social!

Keep Your ’97-’01 CR250 Running Right!

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