Alternative Rear brake Caliper??

[trx250scar]

looking at this, there is an adapter plate, showing there should be another mounting hole up closer near the bleeder valve (beige circled area), compared to the mounting holes referenced by the red circles. hopefully the other caliper bracket works for you! let us know!

When used this caliper on y sons r we ended using a stock steel stay and welded flat metal onto the OEM stay so it was bigger then drilled holes were they needed to be. Really was a hassle. We were riding next day and the r caliper was toast so had to make it work. Wouldn't go that route again.

[Langbolt]

Ok, the Caliper Arrived today....this is what it looks like bolted up to our stock 250R caliper mount. As you can see....the front hole is off just a bit....now I want to mock it up on an R to see where the best place is to adjust to make the best fit. Stay tuned.....

Part# 45150-KZ4-J31 - 2001-2003 CR125R, CR250R Front Caliper & Bracket

Part# 45190-KZ4-J21 - Bracket "ONLY" is used on front brakes from 2000 to 2014 on XR650, CR125, CR250R, CRF150F, CRF230F

Part# 45150-KZ4-J21 - Bracket & Caliper is used on front brakes from 2000 to 2014 on XR650, CR125, CR250R, CRF150F, CRF230F

So What I plan to Fabricate is a Support for the 45190-KZ4-J21 Bracket to make this a BOLT ON Caliper assembly.

I Also plan to Fabricate a Bracket for VROOMY so he & others that have the Part# 45150-MEN-006 Bracket from the CR450R, will be able to BOLT ON that assembly.

[rk88r]

That's about how far mine was off before oblonging the hole. For clarity you should give us the year and part numbers again.

Sweet!

[Langbolt]

Or look here:

http://www.partzilla.com/parts/detail/honda/HP-45150-KZ4-J21.html

[Langbolt]

Ok Who wants to cut them ?

Should we use Steel or Aluminum ?

[Langbolt]

OK...So it's mounted up....had to elongate the holes to accept the smaller center to center bolt pattern.....and also had to remove material from the bracket itself to allow the caliper to align correctly.....So my plan now is to take this piece....design a replica and have it CNC'd out of billet Aluminum....with the STOCK Honda bolt spacing.....this way it will make this Caliper a BOLT ON! And will be a perfect replacement for our stock 250R Caliper.....Keepin' the 250R alive!

[Langbolt]

Here's a clear pic showing how much material was removed.

[Langbolt]

Bracket Complete


Just need to make the spacer to move the rotor out from the Swingarm.....or machine the CRF Bracket to get it to fit.

I'm thinking the SPACER would be easier and I could weld it to the bracket to make it one piece.

Stay tuned

[spintly]

That is awesome!  Thanks for doing this.  When the final product is ready, PM me with a price please.

[bnau267]

good progress....

[Uns]

Bracket Complete


Just need to make the spacer to move the rotor out from the Swingarm.....or machine the CRF Bracket to get it to fit.

I'm thinking the SPACER would be easier and I could weld it to the bracket to make it one piece.

Stay tuned

I ordered the partzilla part in the post above, HP-45150-KZ4-J21, but I'm running into an issue with the thickness of the "bracket sub assembly" part where it still rubs against the rotor's mount bolts after filing down the bracket's mount points.

Your bracket above looks at least a quarter inch thinner than mine, with tons of daylight between the rotor bolts and the new bracket.  Did you file down the face of the rotor side of that bracket for clearance?

[Langbolt]

Yes! Look at the pic and compare it to your bracket.....where the "Bracket Sub Assembly" touches the mounting bracket...that surface of the "Bracket Sub Assembly" has to be machined down to enable the caliper to align with the rotor properly.

Looking at the pic for direction....I filed down the LEFT side of the bracket.....not the right (rotor side)

Let me know if you need a better Pic

[Uns]

Yes! Look at the pic and compare it to your bracket.....where the "Bracket Sub Assembly" touches the mounting bracket...that surface of the "Bracket Sub Assembly" has to be machined down to enable the caliper to align with the rotor properly.

Looking at the pic for direction....I filed down the LEFT side of the bracket.....not the right (rotor side)

Let me know if you need a better Pic

It's not a big deal, but it is weird.  I filed down the left side some, but only until it looked like the rotor was centered on the rotor notch of the caliper.  The right(rotor) side is on the same plane as the left-most side of the rotor notch, and my rotor bolts stick out a good bit.  This basically means that I have to file down the right(rotor) side of the bracket.  

I don't see any way that all the material you removed was from the left side, and not from the right.  This is all mostly for clarity for others, as I'm clunking through it slowly myself, but see the pic below to see what I'm talking about.

[Langbolt]

Yes it is weird as I see your Brake rotor hub is closer to the Bearing carrier than mine....Do you have single row bearings in a Double row carrier ? I'll get a measurement from the Carrier to the rotor surface for comparison.

[Uns]

Everything on the rear but the swinger is straight from LSR last year.  I had my stock brake caliper on there for a while, so it can't be too far off.

Really, the moral of the story is go slow and test fit often!