How To Install The Cylinder On Your 97-01 Honda CR250
The Tools You Will Need
- Piston Holder
- Motion Pro Torque Wrench Adapter → https://amzn.to/4g2Moy8
- Foot-Pound Torque Wrench → https://amzn.to/3DOqm4B
- Inch-Pound Torque Wrench → https://amzn.to/4j9LDpC
- 4mm Hex Socket
- 17mm Socket
- 14mm Socket
- 12mm Socket
- 8mm Socket
- Lithium Grease → https://amzn.to/3ChhKTB
- Shop Towels
- Safety Glasses → https://bulltru.com
The Parts You Will Need
- New ’97-’01 Honda CR250 Bottom End Gasket Set → https://amzn.to/42jJKkd
- New Right Cylinder Cover Gasket → See Above
- New Cylinder Alignment Dowels → https://amzn.to/3DVxPPm
Pre-Service Notes
- 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 below after step b.
- If you need any help don’t hesitate to ask!
Cylinder Installation
- Double-check the cylinder bore and mating surfaces for cleanliness.
- Apply lithium grease to the exhaust valve pinion joint.
- Install NEW alignment dowels on the left side of the crankcase.
- Install your new gasket.
- Place your piston holder, and rotate the crankshaft so the piston skirt rests against the holder.
- Double-check the piston rings are seated against the locating pins and position your cylinder.
- Hold the cylinder as level as possible with the piston and compress the top ring against the alignment pin.
- The cylinder should slide right over the ring.
- Repeat with the second ring.
- It Is Extremely Important That You Do NOT Rotate The Cylinder!
- Remove the holder and align the exhaust valve drive shaft.
- The drive shaft opening should face the rear of your bike.
- Lower the cylinder onto the studs.
- Thread the cylinder mounting nuts finger tight.
- Tighten the exhaust linkage pinion bolt hand tight and check the exhaust valve’s operation by pulling and pushing on the governor.
- Begin torquing the nuts in the same pattern as removal.
- Turn the nuts ¼ turns at a time, making as many passes as necessary to reach torque.
- Torque the cylinder mounting nuts to 29 ft-lbs.
- Remember, when using the torque adapter, you will NOT need to compensate for length if the adapter remains at a right angle to your torque wrench.
- Loosen the exhaust linkage pinion bolt, turn the valve all the way counter-clockwise, and check that the flap valve is open.
- Torque the pinion bolt to 48 in-lbs.
- Install the right cylinder cover with a new gasket.
- Torque the valve stopper bolt to 141 in-lbs.
- Torque the left exhaust valve cap to 115 in-lbs.
- Torque-check the head studs and install the right crankcase cover.
![Double-check the cylinder bore and mating surfaces for cleanliness.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Check-Mating-Surface.jpg)
![Install NEW alignment dowels on the left side of the crankcase.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Install-Alignment-Dowels.jpg)
![Install your new gasket.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Install-New-Gasket.jpg)
![Place your piston holder, and rotate the crankshaft, so the piston skirt is resting against the holder.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Place-Piston-Holder.jpg)
![Doublecheck the piston rings are seated against the locating pins and position your cylinder.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Double-Check-Piston-Rings.jpg)
![Hold the cylinder as level as you can with the piston, and compress the top ring against the alignment pin.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Position-Cylinder-And-Compress-Top-Ring.jpg)
![The cylinder should slide right over the ring.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Slide-Cylinder-Onto-Piston.jpg)
![It Is Extremely Important That You Do NOT Rotate The Cylinder!](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Align-Exhaust-Valve-Drive-Shaft-With-Pinion-.jpg)
![Lower the cylinder onto the studs.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Lower-Cylinder-Onto-Studs.jpg)
![Thread the cylinder mounting nuts finger tight.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Thread-Base-Nuts.jpg)
![Tighten the exhaust linkage pinion bolt hand tight and check the operation of the exhaust valve by pulling and pushing on the governor.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Check-Exhasut-Vavle-Connection.jpg)
![Turn the nuts a ¼ turn at a time, taking as many passes as you need to reach torque.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Tighten-Base-Nuts.jpg)
![Torque the cylinder mounting nuts to 29 ft-lbs.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Torque-Base-Nuts.jpg)
![Torque the pinion bolt to 48 in-lbs.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Torque-Exhaust-Valve-Linkage-Hex-Bolt.jpg)
![Install the right cylinder cover with a new gasket.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Install-Right-Cylinder-Cover.jpg)
![Torque the valve stopper bolt to 141 in-lbs.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Torque-Valve-Stopper-Bolt.jpg)
![Torque the left exhaust valve cap to 115 in-lbs.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Torque-Left-Valve-Cap.jpg)
![Torque check the head studs and install the right crankcase cover.](https://www.fixyourdirtbike.com/wp-content/uploads/2018/08/1997-2001-Honda-CR250-Top-End-Service-Part-12-Cylinder-Installation-Torque-Head-Studs.jpg)
Torque Specifications
- Cylinder Mounting Nuts 29 ft-lbs.
- Pinion Bolt 48 in-lbs.
- Valve Stopper Bolt 141 in-lbs.
- Left Exhaust Valve Cap 115 in-lbs.
← Part 11: Piston Installation
Part 13: Cylinder Head Installation →
Keep Your ’97-’01 CR250 Running Right!