How To Service The Rear Brake Caliper On Your 97-01 Honda CR250
The Tools You Will Need
- 12mm Socket
- 12mm Box Wrench
- Torque Wrench
- 6mm Hex Socket
- 6mm Hex Wrench
- A Stiff Brush
- Shop Towels
- Safety Glasses
The Parts You Will Need
- New ’97-’01 Honda CR250 Rear Caliper Rebuild Kit
- New Brake Pads
- 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 here!
- 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!
Rear Caliper Removal
- Start by removing the brake pad pin and brake pads while your caliper is still on your bike.
- Remove the caliper guard, then separate the caliper from the caliper bracket.
- Pump the brake pedal to build pressure in the brake line, which will push the piston out of the caliper body.
- 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.
- Reassemble the caliper and caliper bracket, re-mount the assembly, and loosen the banjo bolt.
- Remove the assembly then remove the banjo bolt and seal washers.
Clean & Inspect
- Clean every part of the assembly with fresh brake fluid and a stiff bristle brush.
- 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.
Measure the outside diameter of the piston, and the inside diameter of the piston bore.
- The piston should be no less than 26.89mm, and the piston bore should be no More than 27.06mm.
New Brake Parts
- Before assembly, take stock of your new parts, so you don’t accidentally throw away something you need.
- 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)
Rear Caliper Assembly
- Soak your new dust seal and piston seal in fresh stop juice for about 15 minutes before the install.
- Start by installing your new piston seal and dust seal.
- Install the new boots. The long boot goes on the caliper, and the short boot goes on the bracket.
- Install the new bleeder valve cap, then install the bleeder valve.
- Coat the piston in brake fluid, then install the piston with the open end facing OUT.
- Make sure to wipe off any remaining brake fluid.
- Use your new pad pin to grease the insides of the boots.
- Add a layer of grease to the caliper sliders, and assemble the caliper and the mount.
- Install the banjo bolt with new seal washers.
- Hold the bracket to the swingarm, and torque the banjo bolt to 25-foot-pounds.
- Install the rear wheel, and install the brake pads.
- Torque the brake pad pin to 13 foot-pounds.
- Banjo Bolt 25 ft-lbs
- Brake Pad Pin 13 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