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Question on front brake assembly

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Dear fellow enthusiasts,

Over production years, have there been changes to front brake calipers and the forks?

I have a pair of forks and original front brake calipers that don't seem to fit by about half a centimeter length wise. If the top fixating hole of the caliper braket is aligned with its respective match on the fork, then the bottom holes don't connect because the calipers are resting on the disk brake.

I'm wondering, what's my best solution.. which year fork / brake caliper should I proceed to procure?

According to this description, these calipers should fit all production year XR600's: LINK to EBAY       Is that legit at all? Price is good :)

Can anyone share their knowledge in this regard?
I cannot safely say which years either of these components are, as I am going through a difficult restoration. Pictures are attached :)

cheers!



 

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You are not measuring center to center. You are measuring inside to inside. The calipers are also resting on the threads in the bracket. That is why the way you are measuring is inaccurate. Maybe a picture of you trying to mount it may help.

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Make sure to start both bolts by hand, before touching them with a wench.

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Thank you all for the answers!
Sorry for posting wrong measurments, it seems I do indeed need 104mm calipers.
 

I hope these pictures help...

I deserve that "start bolts with a wench" comment, considering my measuring fail! Haha
I promise I won't ruin this bike, I am careful taking my time to do a good job. You should have seen it when I bought what was left of it, scraps of rust in sad ruins of neglect. I have successfully not broken any screw filaments so far and will take care not to do so in future. Especially when parts are aluminium or magnesium, I pay particular attention :)

Anyways, I have still not managed to fit the calipers, and somehow their measurment of 102.5mm confuses me!!? As I understood it should be either 78mm or 104mm ?! :D

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Edited by pssg
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Odd problem.  Did you get it figured out?  I'm interested to hear if the legs were the issue or the caliper mount.  

It's easy to miss the measurements when guessing at the centers.  The most accurate way is to insert the bolts, measure outside to outside, or inside to inside, then add or subtract the outer diameter of one bolt.  This will get you exact (or as exact you can be with those calipers).  

Obviously the actual measurement of the two sets of bolt holes are important but I wouldn't worry too much about what size the brake caliper is called.  It's like a lot of things, call sizes aren't always measurable on the part.  It's just a name.

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This info may help you.

I compiled this info while searching for a 320mm kit for my 01 XR650L with 03 CR125R forks.
All interchange was using EBC part #s and Rocky Mountain ATV site, This may not be a complete list just what I found while searching. I searched for 280mm kit because the applications covered a wider range of bikes, then did a search for a 320mm kit that would fit my needs.

Application #1
EBC #132523002 280mm Kit (rotor & re-location bracket) fits the following bikes
(Rotor 4 bolts with holes 135mm center to center + or - Caliper mounting bracket bolt holes 103mm + or - center to center)
92-94 CR125R
03-09 CRF150F
03-09 CRF230F
2012 CRF230F
08-09 CRF230L
2009 CRF230M
92-94 CR250R
93-96 XR250L
91-04 XR250R
96-04 XR400R
92-94 CR500R
91-00 XR600R
00-07 XR650R
93-10 XR650L

Application #2
EBC #104479001 280mm kit (rotor & re-location bracket) This application worked for me because I'm also running a CRF hub.
(6 bolt rotor 3 sets of 2, Caliper mounting bracket bolt holes 103mm + or - center to center)
95-03 CR125R
95-03 CR250R
02-03 CRF450R
95-01 CR500R


Application #3
(Uses the same 6 bolt rotor as Application #2 but the caliper mounting bracket bolt holes are 78mm + or - center to center)
Part #1325230005 (rotor & re-location bracket)
EBC Oversized Contour Brake Rotor, Front
04-11 CRF450R

Warp 9s Honda SM wheels use CRF rotors front and rear

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On 8/13/2017 at 1:39 PM, Jonny Enduro said:

This info may help you.

I compiled this info while searching for a 320mm kit for my 01 XR650L with 03 CR125R forks.
All interchange was using EBC part #s and Rocky Mountain ATV site, This may not be a complete list just what I found while searching. I searched for 280mm kit because the applications covered a wider range of bikes, then did a search for a 320mm kit that would fit my needs.

Application #1
EBC #132523002 280mm Kit (rotor & re-location bracket) fits the following bikes
(Rotor 4 bolts with holes 135mm center to center + or - Caliper mounting bracket bolt holes 103mm + or - center to center)
92-94 CR125R
03-09 CRF150F
03-09 CRF230F
2012 CRF230F
08-09 CRF230L
2009 CRF230M
92-94 CR250R
93-96 XR250L
91-04 XR250R
96-04 XR400R
92-94 CR500R
91-00 XR600R
00-07 XR650R
93-10 XR650L

Application #2
EBC #104479001 280mm kit (rotor & re-location bracket) This application worked for me because I'm also running a CRF hub.
(6 bolt rotor 3 sets of 2, Caliper mounting bracket bolt holes 103mm + or - center to center)
95-03 CR125R
95-03 CR250R
02-03 CRF450R
95-01 CR500R


Application #3
(Uses the same 6 bolt rotor as Application #2 but the caliper mounting bracket bolt holes are 78mm + or - center to center)
Part #1325230005 (rotor & re-location bracket)
EBC Oversized Contour Brake Rotor, Front
04-11 CRF450R

Warp 9s Honda SM wheels use CRF rotors front and rear

 

Hi I know this is an old thread but I have a related question...

I put XR650R forks on my WR450.  Yes you read that correctly, it is not written backwards...   lol

After 15 years of impossible to tune USD forks and seals leaking oil all over the brakes I gave up and went "old school"

 

Anyway.   The brakes are an issue.   Stock Yamaha WR450 front rotor is 250mm.   The XR650R is 240mm.   My Nissin caliper bolts up just fine, but the sweep of the rotor is 10mm off.

The issue is the caliper lugs on the XR forks are shorter than those on the Yamaha forks.

I had a 270mm Tusk rotor on the WR before the fork swap and the caliper bolts up but hits the rotor.   I changed the rotor back to stock 250mm using the caliper bracket from the 270mm kit temporarily to clear the 250mm rotor.  The caliper sits 10mm too high with this combo.  Not ideal, but at least usable.

I did similar research with EBC parts to what you did here, and found an irreconcilable anomaly.  

The EBC 280mm kit for the XR650R uses the same caliper relocation bracket as the EBC 280mm kit for the WR450.     In theory, this suggests that the solution for my clearance problems is simple...  Get the EBC 280mm caliper bracket, and use it with the 270mm rotor.  Easy!  BUT...  The fact that EBC claims the same caliper bracket goes for XR and WR is a conflict I cannot resolve because it just isn't possible due to the different fork lugs.

Either EBC is lying about the size of the rotor on one of these applications, or they are selling kits that DO NOT FIT properly for the Honda.  The sweep of the rotor would be 10mm too high.   If it is wrong for the Yamaha, it is 10mm too low and the caliper hits the rotor.   Either way, something ain't right...

 

Anyone have any insight here?    Anyone try the EBC 280mm kit on a XR?   Is the rotor *really* 280mm?   What was the part number stamped on the caliper bracket they supplied?

 

Thanks!
 

 

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