Fork Swap Help - 2004 CRF450 onto 1996 CR250

Tenacious P
Posts
325
Joined
9/1/2016
Location
SoCal, CA US
Hi guys,
I picked up a set of '04 CRF450R forks for my 1996 CR250R. They should shim in nicely with coke cans.

I guess Honda changed brake calipers in 2004, so my 1996 front brake won't work.
1. Is there a cheap/simple way to make the existing 96 brake caliper work like a bracket?
2. Can I just buy the front caliper and use my existing master cylinder (is the leverage ratio the same on 96 master and 04 master)?
3. Just buy a 2004+ front brake caliper/hose/lever setup for $50 on eBay

Brake rotors are 240mm for both years, so the existing rotor should be fine.
What else do I need to buy?
1. 2004 axle + nut
2. 2004 wheel spacer
3. ???

Thanks!
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Tracktor
Posts
2343
Joined
8/17/2006
Location
The RTF/Amboy, WA US
8/10/2020 2:32pm
Same year(design) axle & spacers. You can either buy the correct caliper bracket for the forks you are running or upgrade. If upgrading I would go to the new 2007+ style MC as it makes a big difference. Your MC/caliper etc will work with just correct bracket however. You don't need a new caliper........
Tenacious P
Posts
325
Joined
9/1/2016
Location
SoCal, CA US
8/12/2020 9:44pm
Tracktor wrote:
Same year(design) axle & spacers. You can either buy the correct caliper bracket for the forks you are running or upgrade. If upgrading I would go...
Same year(design) axle & spacers. You can either buy the correct caliper bracket for the forks you are running or upgrade. If upgrading I would go to the new 2007+ style MC as it makes a big difference. Your MC/caliper etc will work with just correct bracket however. You don't need a new caliper........
Thanks Tracktor, I was able to get all of the above for about $80, including a full brake setup. I’ll letcha know how it works. Appreciate your help!

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