How To Service The Front Brake Caliper On Your 97-01 Honda CR250
The Tools You Will Need
- 12mm Socket
- Torque Wrench
- 6mm Hex Wrench
- Small Pick
- A Stiff Brush
- Shop Towels
- Safety Glasses
The Parts You Will Need
- New ‘97-’01 Honda CR250 Front Caliper Rebuild Kit (Amazon)
- Brake Pads (Amazon)
- Rubber Grease
- DOT 4 Brake Fluid
This rebuild should cost no more than $25 and should take around 1 hour.
- 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 on Amazon!
- Brake fluid damages everything, so keep your towels handy!
- Pictures with captions are after the steps below.
- If you need any help don’t hesitate to ask!
Front Caliper Removal
- Remove the brake pads, but do not remove the caliper.
- If you take your caliper off the fork to pump the pistons out of 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 brake disk as a backstop to make sure the pistons are pumped out evenly.
- 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.
- They can be tough to remove, so if you use a pair of pliers, make sure to wrap them in electrical tape to avoid damaging the pistons.
- Remove the bleeder valve, and all the rubber components from the caliper, taking extra care when removing the piston seals.
- Clean every part of the assembly with fresh brake fluid and a stiff brush.
- 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.
- Measure the inside diameter of the piston bore and the outside diameter of the piston.
- 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.
- Why the cylinder service limits changed and not the bore, is something you’d have to ask Honda.
New Brake 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.
- 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.
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.
- Make sure your pistons are aligned as flat as possible, then install them in a twisting motion.
- Install the bleeder valve cover, then the bleeder valve.
- Grease and install the slide pin boots.
- The short boot goes on the bracket, and the long boot goes on the body.
- Assemble the bracket and body, then give the bracket a few pumps to evacuate any trapped air in the boots.
- Install your banjo bolt with the new seal washers hand tight.
- Mount the caliper, then torque the banjo bolt to 25-foot-pounds and the mounting bolts to 22-foot-pounds.
- Banjo Bolt 25 ft-lbs
- Mounting Bolts 22 ft-lbs
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Keep Your ’97-’01 CR250 Running Right!
- Service Specification
- Clutch Replacement
- Carburetor Service
- Engine Top End
- Engine Bottom End
- Front Suspension
- Rear Suspension
- Wheels & Tires
- Kickstarter Inspection
- External Shift Linkage