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:

  • New ’97-’01 Honda CR250 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 Parts And Tools Through Our Partner Links HERE!

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.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.Removal - Remove Piston From CaliperRemoval - Pump Piston From Caliper 1Removal - 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.Removal - Reassemble CaliperRemoval - Loosen Banjo Bolt
Remove the assembly then remove the banjo bolt and seal washers.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.Measure Caliper Piston
The piston should be no less than 26.89mm, and the piston bore should be no More than 27.06mm.Measure Caliper Piston Bore

New 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
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.    Assembly - Install Piston Seals
Install the new boots.  The long boot goes on the caliper, and the short boot goes on the bracket.Assembly - Install Caliper Side Slider BootAssembly - Install Bracket Side Slider Boot
Install the new bleeder valve cap, then install the bleeder valve.Assembly - Install Bleeder Valve Cap And Bleeder Valve
Coat the piston in brake fluid, then install the piston with the open end facing OUT.Assembly - Coat Piston With Fresh Brake FluidAssembly - Install Piston With Open End Facing OUT!
Make sure to wipe off any remaining brake fluid.Assembly - Wipe Off Excess Brake Fluid
Use your new pad pin to grease the insides of the boots.Assembly - Grease Bracket BootAssembly - Grease Caliper Slider Boot
Add a layer of grease to the caliper sliders, and assemble the caliper and the mount.Assembly - Grease Slider PinsAssembly - Caliper
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.Install - Torque Banjo Bolt To 25 ft-lbs
Install the rear wheel, and install the brake pads.Install - Install New Brake Pads
Torque the brake pad pin to 13 foot-pounds.Install - Torque Brake Pad Pin To 13 ft-lbs
Torque Specs:
Banjo Bolt25 ft-lbs
Brake Pad Pin13 ft-lbs
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Keep Your ’97-’01 CR250 Running Right!

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