1997-2001 Honda CR250 Kickstarter Maintenance Part 3: Installation

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This is Part 3 of the step-by-step Kickstarter maintenance for your 1997-2001 Honda CR250 Dirt Bike.

You can find Part 1: Removal here, and Part 2: Inspection here.

You Can Get Parts And Tools Through Our Partner Links HERE!

1997-2001 Honda CR250 Kickstarter Installation

  • Step 24: Install the idle gear with the smooth side out. Install the Kickstarter bushing with the shoulder on the inside of the idle gear.
  • Step 25: Install the Kickstarter assembly. Make sure the ratchet stopper arm rests behind the ratchet stopper.
  • Step 26: Install the return spring into the crankshaft.
  • Step 27: Install a new crankcase cover gasket.
  • Step 28: Install the crankcase cover. You will need to rotate the water pump fins to lineup the water pump gear teeth with the primary gear teeth.
  • Step 29: Install the water pump with a new gasket.
  • Step 30: Bolt down the crankcase cover.
  • Step 31: Install the clutch cover.
  • Step 32: Install the kickstarter lever.
  • Step 33: Torque the kickstarter bolt.
    • 1997-2000: 20 ft.lb
    • 2001 : 28 ft.lb
  • Step 34: Reconnect the coolant line.
Step 24: Install the idle gear with the smooth side out. Install the Kickstarter bushing with the shoulder on the inside of the idle gear.
Step 24: Install the idle gear with the smooth side out.
Step 24.1: Install the Kickstarter bushing with the shoulder on the inside of the idle gear.
Step 24.1: Install the Kickstarter bushing with the shoulder on the inside of the idle gear.
Step 25: Install the Kickstarter assembly. Make sure the ratchet stopper arm rests behind the ratchet stopper.
Step 25: Install the Kickstarter assembly. Make sure the ratchet stopper arm rests behind the ratchet stopper.
Step 26: Install the return spring into the crankshaft.
Step 26: Install the return spring into the crankshaft.
Step 27: Install a new crankcase cover gasket.
Step 27: Install a new crankcase cover gasket.
Step 28: Install the crankcase cover.  You will need to rotate the water pump fins to lineup the water pump gear teeth with the primary gear teeth.
Step 28: Install the crankcase cover. You will need to rotate the water pump fins to lineup the water pump gear teeth with the primary gear teeth.
Step 29: Install the water pump with a new gasket.
Step 29: Install the water pump with a new gasket.
Step 29.1: Install water pump cover
Step 29.1: Install water pump cover
Step 30: Bolt down the crankcase cover.
Step 30: Bolt down the crankcase cover.
Step 31: Install the clutch cover.
Step 31: Install the clutch cover.
Step 32: Install the kickstarter lever.
Step 32: Install the kickstarter lever.
Step 33: Torque the kickstarter bolt. 1997-2000: 20 ft.lb 2001 : 28 ft.lb
Step 33: Torque the kickstarter bolt. 1997-2000: 20 ft.lb | 2001 : 28 ft.lb
Step 34: Reconnect the coolant line.
Step 34: Reconnect the coolant line.

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

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