How to Do a Top End on a Honda CR250


Based on your use of your CR250, you should rebuild the top end after every 40 to 100 hours of use. You will notice a loss in power or a weak idle when your top end needs to be rebuilt. It is a basic job that can be done at home. When replacing your piston, you should always replace your C-clips and wrist pins. Ensure that you purchase your replacement piston from a reputable manufacturer.

Things You'll Need

  • Socket Set
  • Screwdriver
  • Spring puller
  • New piston
  • 2 new C-clips
  • New wrist pin
  • Needle nose pliers
  • Remove the gas tank by removing the bolts that secure it.

  • Remove the rear portion of the frame by removing the bolts that secure it.

  • Drain the coolant from your motorcycle by removing the drain plug at the bottom of the engine.

  • Use a tusk spring puller to remove the springs that secure the exhaust pipe. Remove the pipe.

  • Remove the top motor mount head stay by removing the bolts that secure it.

  • Remove the spark plug by unscrewing it.

  • Remove the radiator hoses by unscrewing the clamps that secure them.

  • Remove the engine head by removing the six bolts that secure it.

  • Remove the head gasket by pulling it out of its socket.

  • Pull out the two centering dowels.

  • Remove the power valve cover by removing the bolts that secure it.

  • Remove the linkage bolt using a socket wrench.

  • Loosen the cylinder bolts and remove the cylinder.

  • Pull the C-clip out of the groove in the cylinder using a small flat head screwdriver.

  • Slide out the wrist pin. The piston is now disconnected from the connecting rod. Remove the old piston

  • Slide the new piston onto the connecting rod.

  • Install the new C-clip by pressing it into the groove on the cylinder.

  • Slide the new wrist pin into its slot.

  • Slide on the second C-clip using needle nose pliers.

  • Slide the cylinder back onto the bike and tighten it back into place. Tighten the bolts in a crisscross pattern for even tightening.

  • Reassemble the rest of your bike in the exact opposite order that you disassembled it.

Related Searches


  • "Honda Cr250/500R Owners Workshop Manual"; Alan Ahlstrand and John Harold Haynes; 1998
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