How To Remove And Install The External Exhaust System On Your 97-01 Honda CR250
The Tools You Will Need
- Exhaust Spring Hook → https://amzn.to/40HUrMt
- Various Sockets
- Shop Towels
The Parts You May Need
- Expansion Chamber O-rings → https://amzn.to/40juTDR
- Exhaust Port Seal Washer → https://amzn.to/40juTDR
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! → https://amzn.to/4h4lDKq
- Pictures with captions are after the steps below.
- If you need any help, don’t hesitate to ask!
Exhaust System Removal
- Remove the bolts mounting the silencer to the subframe.
- Rotate the silencer away from the body, then pull the silencer backward.
- This slight rotation should break it free if the silencer is seized to the expansion chamber.
- 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.
- Remove the two springs holding the pipe to the cylinder.
- Remove the two mounting bolts and pull the expansion chamber away from the cylinder head.
- Don’t forget to grab the seal washer.
- And Just to be safe, plug the exhaust port with a clean shop towel.
Clean & Inspect Exhaust System
- Check the o-rings on the expansion chamber. If they look worn out, make sure to replace them.
- The OEM O-Ring part number is 91304-KZ3-890
- I am installing a new FMF Gnarly pipe with new o-rings installed.
- Wipe down and inspect the seal washer for warping or cracks.
- The OEM washer part number is 18309-KZ3-600
- Finally, wipe down the exhaust port and check for any visible signs of wear.
Exhaust System Installation
- Install the washer, followed by the expansion chamber, and attach the mounting springs.
- If installing a new pipe, you may need to adjust the mounts.
- Install and tighten the two mounting bolts.
- Feel around the cylinder head to ensure the pipe is mounted correctly and the o-rings don’t roll out of their grooves.
- Connect the silencer to the expansion chamber with the silencer away from your bike.
- Push the silencer onto the expansion chamber as you rotate the silencer toward your bike.
- Install the two silencer mounting bolts.
Exhaust System Torque Specs
- 1998-1999 – 106 in-lb
- 2001 – 10 ft-lb
If you have any questions or comments, please leave them in the comments or on our Facebook page!
Keep Your ’97-’01 CR250 Running Right!
