1997-2001 Honda CR250 – Rear Caliper Service

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

1997 - 2001 Honda CR250 - Brakes - Rear Caliper ServiceThe Tools You Will Need Are:

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

The Parts You Will Need To Service Your Rear Caliper:

  • Rear Caliper Rebuild Kit
  • New Brake Pads
  • Rubber Grease
  • DOT 4 Brake Fluid

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

Related: 1997-2001 Honda CR250 – Reed Valve Service

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

Rear Caliper Removal:

Start by removing the brake pad pin and brake pads while your caliper is still on your bike. 1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Remove Brake Pads
Remove the caliper guard, then separate the caliper from the caliper bracket.1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Seperate Caliper And Bracket
Pump the brake pedal to build pressure in the brake line, which will push the piston out of the caliper body.1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Remove Piston From Caliper1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Pump Piston From Caliper 11997 - 2001 Honda Cr250 - Rear Caliper - Removal - Pump Piston From Caliper 2
If your piston will not unseat itself, pump it out of the body as far as you can, then remove the piston by hand, with a twisting motion.Be Careful!
Reassemble the caliper and caliper bracket, re-mount the assembly, and loosen the banjo bolt.1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Reassemble Caliper1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Loosen Banjo Bolt
Remove the assembly then remove the banjo bolt and seal washers.1997 - 2001 Honda Cr250 - Rear Caliper - Removal - Remove Banjo Bolt

Clean & Inspect:

Clean every part of the assembly with fresh brake fluid and a stiff bristle brush.1997 - 2001 Honda Cr250 - Rear Caliper - Clean Caliper Components
As you can see here, I had to take extra steps to completely clean this rear caliper. So after I scrub, grind and sand, I will have to go back through with brake cleaner for the final clean.Be Careful!
Measure the outside diameter of the piston, and the inside diameter of the piston bore.1997 - 2001 Honda Cr250 - Rear Caliper - Measure Caliper Piston
The piston should be no less than 26.89mm, and the piston bore should be no More than 27.06mm.1997 - 2001 Honda Cr250 - Rear Caliper - Measure Caliper Piston Bore

New Rear Caliper Parts:

Before assembly, take stock of your new parts, so you don’t accidentally throw away something you need.Be Careful!
I am installing an All Balls rebuild kit that includes a new set of banjo bolt seal washers, dust seal, piston seal, pad pin, bleeder cap cover, and new boots. (Get Yours HERE)1997 - 2001 Honda Cr250 - Rear Caliper - Caliper Rebuild Kit Parts


Rear Caliper Assembly:
Soak your new dust seal and piston seal in fresh stop juice for about 15 minutes before install.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Soak New Seals In Fresh Brake Fluid
Start by installing your new piston seal and dust seal.    1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Install Piston Seals
Install the new boots.  The long boot goes on the caliper, and the short boot goes on the bracket.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Install Caliper Side Slider Boot1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Install Bracket Side Slider Boot
Install the new bleeder valve cap, then install the bleeder valve.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Install Bleeder Valve Cap And Bleeder Valve
Coat the piston in brake fluid, then install the piston with the open end facing OUT.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Coat Piston With Fresh Brake Fluid1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Install Piston With Open End Facing OUT!
Make sure to wipe off any remaining brake fluid.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Wipe Off Excess Brake Fluid
Use your new pad pin to grease the insides of the boots.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Grease Bracket Boot1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Grease Caliper Slider Boot
Add a layer of grease to the caliper sliders, and assemble the caliper and the mount.1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Grease Slider Pins1997 - 2001 Honda Cr250 - Rear Caliper - Assembly - Caliper
Rear Caliper Install:
Install the banjo bolt with new seal washers.1997 - 2001 Honda Cr250 - Rear Caliper - Install - Install Banjo Bolt With New Seal Washers
Hold the bracket to the swingarm, and torque the banjo bolt to 25 foot pounds.1997 - 2001 Honda Cr250 - Rear Caliper - Install - Torque Banjo Bolt To 25 ft-lbs
Install the rear wheel, and install the brake pads.1997 - 2001 Honda Cr250 - Rear Caliper - Install - Install New Brake Pads
Torque the brake pad pin to 13 foot pounds.1997 - 2001 Honda Cr250 - Rear Caliper - Install - Torque Brake Pad Pin To 13 ft-lbs
Torque Specs:
Banjo Bolt25 ft-lbs
Brake Pad Pin13 ft-lbs
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