1997-2001 Honda CR250 – Front Caliper Service

How To Service The Front Brake Caliper On Your 1997 – 2001 Honda CR250

1997 - 2001 Honda CR250 - How To Change Front Wheel Bearings FeaThe Tools You Will Need Are:

  • 12mm Socket
  • Torque Wrench
  • 6mm Hex Wrench
  • Small Pick
  • A Stiff Brush
  • Calipers
  • Gloves
  • Shop Towels
  • Safety Glasses

The Parts You Will Need To Service Your Front Caliper:

  • Front Caliper Rebuild Kit
  • Rubber Grease
  • DOT 4 Brake Fluid

If you don’t have your rebuild kit yet, you can get the one I am using HERE (link to RockymountainATVMC.com).

This rebuild should cost no more than $25, and should take around 1 hour.

Cost & Difficulty Dial - 1997-2001 Honda CR250 - Brakes - Rear CaliperBrake fluid will damage almost everything, so make sure you have plenty of shop towels and a catch pan before you start!

Click Here To Open Brake Specs In A New Window

Front Caliper Removal:

Remove the brake pads, but do not remove the caliper.1997-2001 Honda CR250 - Front Caliper - Removal - Remove Brake Pads
If you take your caliper off the fork to pump the pistons out off the body, they may not extend evenly, and you will play whack-a-piston the whole time. So leave the caliper mounted, and use the  the brake disk as a backstop to make sure the pistons are pumped out evenly.1997-2001 Honda CR250 - Front Caliper - Removal - Whack A Piston1997-2001 Honda CR250 - Front Caliper - Removal - Even Pistons
When the pistons have reached the brake disk, Loosen the banjo bolt while the caliper is mounted, then remove the caliper, then the banjo bolt.
Make sure to wrap the end of your brake line with a paper towel.

Front Caliper Disassembly:

Unlike the rear caliper, the pistons have the openings facing in, so they usually won’t unseat themselves.1997-2001 Honda CR250 - Front Caliper - Disassemble - Pull Pistons
They can be tough to remove, so if you use a pair of pliers, make sure to wrap them in electrical tape do avoid damaging the pistons.Be Careful!
Remove the bleeder valve, and all the rubber components from the caliper, taking extra care when removing the piston seals.1997-2001 Honda CR250 - Front Caliper - Disassemble - Pull Piston Seals 1997-2001 Honda CR250 - Front Caliper - Disassemble - Pull Bleeder Valve
Clean Your Caliper:
Clean every part of the assembly with fresh brake fluid and a stiff brush. 1997-2001 Honda CR250 - Front Caliper - Clean - Scrub 1997-2001 Honda CR250 - Front Caliper - Clean - Dry
This caliper was extremely dirty, so I had to go at it with carb cleaner, and then a dremel, to remove all the corrosion on the body, pins, and bore. After all that, I cleaned it again with fresh brake fluid. 1997-2001 Honda CR250 - Front Caliper - Clean - Dremel
Caliper Inspection:
Measure the inside diameter of the piston bore, and the outside diameter of the piston.1997-2001 Honda CR250 - Front Caliper - Measure - Pistons
The piston bore should be no Greater than 27.06mm and the piston should be no LESS than 26.89mm on the 97-2000 model, and 26.85mm on the 2001 model.1997-2001 Honda CR250 - Front Caliper - Measure - Caliper Bore
Why the cylinder service limits changed and not the bore, is something you’d have to ask Honda.Be Careful!
New Parts:
Before assembly, take stock of your new parts.
I am installing an All Balls rebuild kit that includes a new pad pin, slider boots, bleeder cap cover, banjo seal washers, and piston seals.1997-2001 Honda CR250 - Front Caliper - New Parts
Make sure to match the old parts with the new ones so you don’t throw away something you need.
Soak your new rubber parts in fresh brake fluid for 15 minutes before assembly. 1997-2001 Honda CR250 - Front Caliper - Assemble - Soak New Rubber

Front Caliper Assembly:

Give the caliper bore one last wipe just to be safe, then add a final coat of brake fluid for lubrication.
Install the piston seals, immediately followed by the pistons.1997-2001 Honda CR250 - Front Caliper - Assemble - Pston Seals
Make sure your pistons are aligned as flat as possible, then install them in a twisting motion.1997-2001 Honda CR250 - Front Caliper - Assemble - Install Pistons
Install the bleeder valve cover, then the bleeder valve.1997-2001 Honda CR250 - Front Caliper - Assemble - Install Bleeder Valve
Grease and install the slide pin boots.1997-2001 Honda CR250 - Front Caliper - Assemble - Grease Boot Holes
The short boot goes on the bracket, and the long boot goes on the body.1997-2001 Honda CR250 - Front Caliper - Assemble - Install Bracket Boot1997-2001 Honda CR250 - Front Caliper - Assemble - Install Caliper Boot
Assemble the bracket and body, then give the bracket a few pumps to evacuate any trapped air in the boots.1997-2001 Honda CR250 - Front Caliper - Assemble - Pump Bracket And Caliper
Front Caliper Installation:
Install your banjo bolt with the new seal washers hand tight.1997-2001 Honda CR250 - Front Caliper - Install - Mount Caliper
Mount the caliper, then torque the banjo bolt to 25 foot pounds, and the mounting bolts to 22 foot pounds 1997-2001 Honda CR250 - Front Caliper - Install - Torque Banjo Bolt1997-2001 Honda CR250 - Front Caliper - Install - Torque Mounting Bolt
Front Caliper Torque Specs:
Banjo Bolt25 ft-lbs
Mounting Bolts22 ft-lbs
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