Cr 500 brake upgrades

This guy from the UK makes oversized rotors for all the Honda 125, 250 & 500’s from 1987-2001, you can also use modern CRF front caliper and master cylinders that are far better than what the hondas used in the 80’s and 90’s.

Guys got a CR500 wants brakes !! Rockets don’t have brakes? 😝

JMX247's suggestion is spot on : in terms of a bigger disc. I think a 95 has the 6 bolt disc, like my 2001 / 02 CRE,  though.

A starting point should be the fact that you are dealing with, probably, 28 year old  brake components.

Hoses, seals, pistons and their bores, in both the MC and Caliper, have all copped a hiding over the years.

Things like the caliper pins, and the respective 'bores' they slide in, are almost certainly not healthy. Just cleaning and lubing those, and all seal rebuilds can produce a marked improvement. As well as a new hose. Though, that can add up to a bit of coin. However, there's never a guarantee later model components you buy will Not need a rebuild.....

Big disc kit and new pads : a good idea.

My old Teddy Bear of a bike, when I fitted WPccs to it, they came with a full front Brembo system, that I did a service / rebuild on. Combined with a 270mm floating disc, well, the brake works as well, or better than,  any modern bike.

The rear : I've run a LHRB for many years now. Even with first a Hayes MTB MC, but with a longer lever I machined up, I could easily lock up the rear wheel on tar, with a sticky Michelin Trials tyre. I eventually fitted a brand new Brembo Clutch MC I got for free , and, later, a 240 rear disc (From 2000/2001 CR250??), basically because I got an aluminium disc guard / caliper carrier that required a 240. All that was required to fit it was a Top Hat spacer I machined up to reduce the 25mm axle hole to the 20mm of the 500. The 'Top Hat' part of the spacer was to increase the width of the carrier, to that of the std one.  The 240 was really not needed, but has made it easier to use both the brake lever, and clutch lever at the same time. It's a one finger brake, as is the front. Though, I do have bloody big hands, compared to most people.....

Bear, a 97 thru 99 CR250 rear brake bracket is set up for 240mm and uses proper size axle hole. The rub is that the SA on the CR5 won't like that bracket with out some love mods which IMHO are worth the rub.

Cheers mate.

Sean

Regarding the front wheel, 95 and newer hubs are the same bolt pattern. You just need the proper bracket to match your fork lugs. So if you were running new AF forks get that bracket, same wheels fits, if your running stock forks (ick) get that bracket.

Run a 2008 or newer CRF master and if you can find a bracket that fits the latest offset caliper, which used 27mm and 30mm pistons (with new forks this is easy) that's the best honda stuff available. OF course the bracket needs to fit the rotor diameter..... Which should be dictated by stopping power needs and terrain. I run 280mm for mx and if I were running nasty  rock beds I'd run 240mm. Most people would want 260, 270 or 280.

Hi Sean!

This is the bloke (well, I think it is)  I got the Scotts 240 Carrier AND my Swingarm,  Subframe and Airbox from to do my PDS Conversion (without my having to harm my original parts) on my CRE500.

A Good Man, and a tremendous source of info, and, perhaps parts, for CR500s.

Hi, yeah it's me. I could retire early if I still had the CR500 parts I sold off over the years, stuff has gone bloody mad prices. I still have some bits but finding a bike to hack up these days is purdy tough.

I,m searching for the cr mc upgrade & can’t find it. But I found this post.  It may hv been the crf 07 but not sure. 

I have a KTM brembo master cylinder that would certainly be an upgrade for you. lines should mate up without a problem.

In my '98 (kyb forks,100mm between caliper holes, 6 bolt disc) I use a KX450f '09 complete front brake system (master cylinder, hose and caliper) with a 240 NG oem replica rotor plus nissin pads.

Bolts directly, and improves braking a lot.

Cheers.