Transmission & Internal Shift Mechanism Specifications For Your 1997-2001 Honda CR250 Dirt Bike
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General Transmission Specifications
| Service Limit mm (in.) | |
| Transmission | 5 – Speed Constant Mesh |
| Primary Reduction Type | Gear |
| Ratio | 3 (63/21) |
| Final Reduction Ratio | |
| – 1997 | 3.769 (49/13) |
| – 1998 – 2001 | 3.846 (50/13) |
| Gear Ratios | |
| – First Gear | 1.800 (27/15) |
| – Second Gear | 1.470 (25/17) |
| – Third Gear | 1.210 (23/19) |
| – Fourth Gear | 1.000 (21/21) |
| – Fifth Gear | 0.869 (20/23) |
Transmission Service Specifications
| New – mm | Service Limit – mm | |
Mainshaft Assembly | ||
| Mainshaft O.D. @ 5th Gear | 24.959 – 24.980 | 24.94 |
| 4th Gear I.D. | 28.007 – 28.028 | 28.05 |
| 4th Gear Bushing O.D. | 27.959 – 27.980 | 27.94 |
| 4th Gear To Bushing Clearance | 0.027 – 0.069 | .11 |
| 5th Gear I.D. | 25.020 – 25.041 | 25.07 |
| 5th Gear To Shaft Clearance | 0.040 – 0.082 | 0.13 |
Countershaft Assembly | ||
| Countershaft | ||
| Countershaft O.D. @ 1st Gear Bushing | 18.959 – 18.980 | 18.94 |
| Countershaft O.D. @ 2nd Bushing | 24.959 – 24.979 | 24.96 |
| Countershaft O.D. @ 3rd Gear | 24.959 – 24.980 | 24.94 |
| 1st Gear | ||
| 1st Gear I.D. | 22.020 – 22.041 | 22.07 |
| 1st Gear Bushing O.D. | 21.979 – 22.000 | 27.95 |
| 1st Gear Bushing I.D. | 19.000 – 19.021 | 19.04 |
| 1st Gear To Bushing Clearance | 0.020 – 0.062 | 0.12 |
| 1st Gear Bushing To Shaft Clearance | 0.020 – 0.062 | 0.12 |
| 2nd Gear | ||
| 2nd Gear I.D. | 30.020 – 30.041 | 30.07 |
| 2nd Gear Bushing O.D. | 29.979 – 30.000 | 29.95 |
| 2nd Gear Bushing I.D. | 27.000 – 27.021 | 27.04 |
| 2nd Gear To Bushing Clearance | 0.020 – 0.062 | 0.12 |
| 2nd Gear Bushing To Shaft Clearance | 0.020 – 0.062 | 0.12 |
| 3rd Gear | ||
| 3rd Gear I.D. | 25.020 – 25.041 | 25.07 |
| 3rd Gear To Shaft Clearance | 0.041 – 0.082 | 0.11 |
Internal Shift Mechanism | ||
| Shift Fork Shaft O.D. | ||
| Center Fork | 10.983 – 10.994 | 10.97 |
| Right & Left Forks | 11.966 – 11.984 | 11.95 |
| Shift Fork I.D. | ||
| Center Fork | 11.003 – 11.024 | 11.04 |
| Right & Left Forks | 12.035 – 12.056 | 12.07 |
| Shift Fork Claw Thickness | 4.93 – 5.0 | 4.8 |
Back To 1997-2001 Honda CR250 Master Repair Index
