Question about 2002 Honda CR 250 R

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I need too replace my main sail need diagram - 2002 Honda CR 250 R

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This is not as hard as it sounds. First drain the radiator fluid from the bike at the pump screw. (The one thats a phillips head screw)
it will come out quick so be ready to catch the fluid in a clean container so you can reuse it if you wish to. Then replace the screw. Lay the bike down on its left side. Remove the exuast pipe.
Remove the kick start lever. Remove the foot brake lever. Remove the coolant hose from the right side case. Remove the side case cover, you can leave the clutch cover on. Once open, the clutch basket can be removed and the water pump drive gear as well. These bolts are standard right hand threads and may require an impact tool to remove as things do tend to turn when you try to remove them.This will expose the seal you need to change. Remove the bushing inside the seal, this can be stuborn but should just slip stright out. Now using a seal removing tool, (or a good firm hook type tool) pull out the seal. No mater what, throw away this seal and replace with a new one as you will damage the seal getting it out. A new seal is about $15 at the dealer. The new seal has some grease on it but add a little more to make things easier. Press the new seal in carefully as to not damage it. Tap on the seal with a rubber mallet back and forth around the seal until it is fully seated in place. Thats it. Replace the gear, clutch basket, etc.... in the reverse order that they were removed. When fully assembled, stand the bike back up and refill the radiator with coolant. You're done. Go ride.

Posted on Feb 18, 2010

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For an exploded diagram of your engine, go to

Posted on Feb 03, 2010


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