1997-2001 Honda CR250 – Remove & Install External Exhaust System

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1997 -2001 Honda CR250 - External Exhaust System Featured Image

How To Remove And Install The External Exhaust System On Your 97-01 Honda CR250

1997 - 2001 Honda CR250 - External Exhaust SystemThe Tools You Will Need

  • Exhaust Spring Hook
  • Various Sockets
  • Shop Towels

The Parts You May Need

  • Expansion Chamber O-rings
  • Exhaust Port Seal Washer

Pre-Service Notes

  • Start with your bike on a stand, with the seat and right body plastic removed.
  • 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 System Removal

  1. Remove the bolts mounting the silencer to the subframe.
  2. Rotate the silencer away from the body, then pull the silencer backward.
  3. If the silencer is seized to the expansion chamber, this slight rotation should break it free.
    1. This bike is missing the rubber that seals the connection between the expansion chamber and the silencer.  While this connection is not critical, I would still recommend having one.
  4. Remove the two springs holding the pipe to the cylinder.
  5. Remove the two mounting bolts, and pull the expansion chamber away from the cylinder head.
  6. Don’t forget to grab the seal washer.
  7. And Just to be safe, plug the exhaust port with a clean shop towel.
1 - Remove The Silencer Bolts
1 – Remove The Silencer Bolts
2 - Rotate The Silencer
2 – Rotate The Silencer
3 - Remove The Expansion Chamber Springs
3 – Remove The Expansion Chamber Springs
4 - Remove The Expansion Chamber Bolts
4 – Remove The Expansion Chamber Bolts
5 - Remove The Seal Washer
5 – Remove The Seal Washer
6 - Plug The Exhaust Port
6 – Plug The Exhaust Port

Clean & Inspect Exhaust System

  1. Check the o-rings on the expansion chamber, if they look worn out, make sure to replace them. These are worn out, so they will need to be replaced.
    1. The OEM O-Ring part number is: 91304-KZ3-890
  2. I am installing a new FMF Gnarly pipe, and this new pipe comes with new o-rings installed.
  3. Wipe down and inspect the seal washer for warping or cracks.
    1. The OEM washer part number is: 18309-KZ3-600
  4. Finally, wipe down the exhaust port, and check for any visible signs of wear.
7 - Inspect The O-rings
7 – Inspect The O-rings
New FMF Gnarly Pipe
New FMF Gnarly Pipe
8 - Inspect The Seal Washer
8 – Inspect The Seal Washer
9 - CleanThe Exhaust Port
9 – CleanThe Exhaust Port

Exhaust System Installation

  1. Install the washer, followed by the expansion chamber, and attach the mounting springs.
  2. If you are installing a new pipe, you may need to adjust the mounts.
  3. Install and tighten the two mounting bolts.
  4. Feel around the cylinder head to make sure the pipe mounted properly, and the o-rings didn’t roll out of their grooves.
  5. Connect the silencer to the expansion chamber with the silencer away from your bike.
  6. Push the silencer onto the expansion chamber as you rotate the silencer toward your bike.
  7. Install the two silencer mounting bolts.
10 - Install The Washer
10 – Install The Washer
11 - Attach The Expansion Chamber Mounting Springs
11 – Attach The Expansion Chamber Mounting Springs
12 – Install The Expansion Chamber Mounting Bolts
13 - Connect The Silencer
13 – Connect The Silencer
14 - Rotate And Push Silencer Onto The Expansion Chamber
14 – Rotate And Push Silencer Onto The Expansion Chamber
15 - Install The Silencer Mounting Bolts
15 – Install The Silencer Mounting Bolts

Exhaust System Torque Specs

  • 1998-1999 – 106 in-lb
  • 2001 – 10 ft-lb

If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!

Keep Your ’97-’01 CR250 Running Right!

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