brake caliper swaps for 83-85 200x's

[jason85atc250r]

i bought a nice 85 200x off ebay for $300 that runs great but had no rear caliper and the front was bleed rite and held the bike when pushing on it in the garage. but i found out on the test drive that it di not stop the trike when riding it. piston was partually sticking and i almost hit a tree.:lol:

i have piles off 200x parts and all the rear caliper i have the pistons are stcuk bad. so i was searching on ebay for calipers and found out that CR 80 front caliper are close to the same for the back of a 200x. they bolt the exact same to the 200x bracket you attach to the swingarm. the rotors to big for the cr 80 bracket. i got one from a 2006 cr80 that was being parted out for $22. back into the 80's even the cr80 uses the exact same caliper

after finding that out i went searching under every type of dirt bike caliper to see what would fit since on the front of a 200x since the slider and pin are switched. walla a 2000 kx 80 rear caliper bolts rite up to the front mounting bracket that attaches to the fork. i chanced it and bid on it and won it for the starting bid of $5. not sure what other years are the same.

just letting you know to help out some fellow 200x owners out.

[jason85atc250r]

here is some pics of the front caliper swap i did. the 1st picture is a side by side with the right one being the 2000 kx80 caliper on 200x bracket. it bolts rite up

[jason85atc250r]

heres a picture of the rear caliper swap. it's a 2006 cr80 caliper on a 200x bracket. it bolts rite up also the caliper only sold for $26

the second is a master cylinder from a 2002 cr80. i got the whole front brake setup for $23.

[oldskool83]

jason,

a member ask me this info and i found the right years that fit for the KX80 calipers:

"ok man heres your info on the KX80 rear calipers. the caliper is the same from 1987-2007 but changes part numbers per each year it was restyled.

heres the breakdown.

KX80 1987-1997 (bikebandits part number for the caliper assy) 591700-001
KX80 1998-2000 (bikebandits part number for the caliper assy) 591608-001
KX85 2001-2003 (bikebandits part number for the caliper assy) 1480316-001
KX85 2004-2007 (bikebandits part number for the caliper assy) 1822434-001

i belive the manufactures are doing now days is every times somthing is restyled some what they give the parts a new part number so there is no confustion on what year parts fit. alot of times these parts are 100% the same as other parts reason i say so is because my wifes 89 cr80 was running a 02 cluch cover under a dif part number then 89 but it was 100% the same, just not painted black.

there were may style changes in the kx80 line up from 87-97 but parts didnt change, in 98 the style changed, it was gas tank, front number plate and number plates, thats reall it! in 01 it just got 5cc more to make it a 85, nothing else changes really. in 04 is of a left radiator shroud and thats about it, style has been the same since 98.

hope that helps. this sould be posted in jasons atc200x thread also. maybe ill do that too."

aaron

the cr80 front calipers are the same from 1986-2002 after that cr85 2003-07 is a dif part number. the CRF150R may use the same front and rear calipers the old CR85did. hope this helps everyone.

[jason85atc250r]

actually i seen no difference in the 2002 cr80 caliper i have laying on the shelf from the 2006 cr85 one i used on my 200x.

[Nick_R_23]

they bolt the exact same to the 200x bracket you attach to the swingarm. the rotors to big for the cr 80 bracket

So does the cr80 caliper bolt right on, or what do you have to do to make it fit? Did you just use the 200x bracket instead of the cr80 bracket?

-Nick :TrikesOwn

[84honda200s]

also do we need a smaller roder ? or can we use the stock x one ?

[jason85atc250r]

all i did was use the 200x bracket and just bolted the cr80 caliper to it. it fits rite on

i used the 200x rotor when i installed it like mentioned above

it's been working awesome the last couple times i rode

[Nick_R_23]

Thanks man that cleared things up. :beer

-Nick :TrikesOwn

[maggiesboy]

bump to a very good thread

[gizmo_22]

any chance of maybe a sticky on this one guys? Its good info for a common problem.

[jason85atc250r]

bringing this one to the top to get noticed to help people out

NOTICE:lol: i just found out also the this swap will work on a trx250x or 300ex quad also. a 350x will work also.

[aonick]

i have my rear brake is out my 85 200x... so what works!

[WIkid500]

Thank you Jason for the great info here. I installed a 2003 CR85 front caliper on the rear of my 85 200X. It was as simple as switching the mount plate for the caliper, bolt it up and bleed out the air. Now I'm rockin with a NEW caliper and one that doesn't have all the extra crap for the parking brake.

[jason85atc250r]

Thank you Jason for the great info here. I installed a 2003 CR85 front caliper on the rear of my 85 200X. It was as simple as switching the mount plate for the caliper, bolt it up and bleed out the air. Now I'm rockin with a NEW caliper and one that doesn't have all the extra crap for the parking brake.

no problem glad to see it worked out good for you. It;s a lot less of a pain then rebiulding your old crusty original one

one of the ones i bought was from a 2002 cr80 and the sliders were stuck already.:mad: i just used it on a 1993 300ex a have thats getting a 350x motor in it.

[WIkid500]

The one I got off of the 2003 was like new. It was almost too easy lol. One bolt to switch the back plate and you are in business. Knowing what I know now I would never rebuild an old caliper when these are very available and cheap. Oh Jason do you need that braided steel brake cable, it's way to long to put on my 200x.

[Brad200X]

Anybody know about the rear master from other bikes working on the '85 200X's?

[351ranger]

i would like to know this as well. mine is poop.

[jason85atc250r]

The one I got off of the 2003 was like new. It was almost too easy lol. One bolt to switch the back plate and you are in business. Knowing what I know now I would never rebuild an old caliper when these are very available and cheap. Oh Jason do you need that braided steel brake cable, it's way to long to put on my 200x.

how much do you want for the line?

i never had to swap out a rear master yet. i heard the a trx450r is close to a 350x trike. just have to drill out the master cylinder bolt holes. the quad is threaded on the master and a trike is on the frame.

[WIkid500]

how much do you want for the line?

i never had to swap out a rear master yet. i heard the a trx450r is close to a 350x trike. just have to drill out the master cylinder bolt holes. the quad is threaded on the master and a trike is on the frame.


Pay the shipping and it's yours. I have no use for it. I won't be home again for 2 and a half weeks when the semester is over. If you want it let me know, we can work something out when I get home. I don't want to sit on your money for a few weeks and not be able to ship it out.

[ironchop]

on the rear masters....

I took the rear master from an 06 Cr 80 and drilled out the bolt holes...they are tapped as opposed to thru holes on the stock X masters...the bolt pattern angle was the same as the stocker...the rod lined right up pretty close with stock 83-85 brake lever linkage also

the only differences are that the line mounts at the top instead of on the inside...the intake from the resevoir tube is in front instead of in back on the stock master

I got pics....hang on

[ironchop]

forgot to add that I machined some spacers to go between the new master and the X frame...they are about .375 ...this is needed to clear the frame

I also used the CR reservoir with a .750 alum spacer to clear the frame up top...I payed about $15 bux for this stuff...and updates my cresty res and my trashed stock master

let me know if these pics show up

http://i7.photobucket.com/albums/y265/southernfriedchoppers/DSC05695.jpg

http://i7.photobucket.com/albums/y265/southernfriedchoppers/DSC05696.jpg

http://i7.photobucket.com/albums/y265/southernfriedchoppers/DSC05701.jpg

http://i7.photobucket.com/albums/y265/southernfriedchoppers/DSC05700.jpg

[ironchop]

the res looks tiny but it`s capacity is about the same as the old box top stocker...since the inlet from the res is on the front of the master, you`ll need a little longer supply hose and carefully route it away from the exhuast

the stock X pedal linkage sticks out a little from the frame lug...I will probably shave the front side and turn a new bushing with built-in spacer to line up the intermediate linkage with the master`s centerline

I`ll have all new and updated full brake system for my X`s for less than $80 each trike to refit these machines using easily found dirtbike stuff...this makes for good sense if one plans on driving 200 miles from home to go ride for a weekend...try finding 85X stuff in a distant town in a local dealership to salvage your weekend ride...but walk in for, say 2000-up dirbike stuff and chances are...it`s on the shelf

Thanks for this thread, gentlemen

[Billy Golightly]

Thats a SWEET little mod there. Thanks for sharing!

[ugly200x]

sorry for bringing an old thread back but does anyone know any other front calipers that can bolt on as the 200xs rearr? I did the kx80 rear caliper on the front and it did mount up perfect. Thanks!

[jason85atc250r]

do the cr80 one like listed earilier it just bolts rite up like the kx80 one you did.

maybe type in cr85 and or crf150 to find ones on ebay from really new dirt bikes.

[ugly200x]

crf150 is the same? is that all of the calipers thatll work?

[fire1]

Hey Jason do CR85 front calipers work on the 300ex i just got a 300ex axle setup with brake hub that im going to use in the 350x and the cr85 calipers are cheaper than the 300ex .thanks for the info

[jason85atc250r]

just reuse your 350x trike brake hub,rotor and caliper on the 300ex axle. that is what i did with my 350x when the axle was junk. i got a used +4 Lonestar 300ex axle and reused my trike brake stuff

if your caliper is junk the cr swap will work for a 350x or 300ex quad also.

[fire1]

just reuse your 350x trike brake hub,rotor and caliper on the 300ex axle. that is what i did with my 350x when the axle was junk. i got a used +4 Lonestar 300ex axle and reused my trike brake stuff

if your caliper is junk the cr swap will work for a 350x or 300ex quad also.

hey thanks my caliper is junk that was the reason i was making sure before i ordered the cr caliper

[n10sivern]

read through this and have been looking on ebay. i'm looking at replacing the front and rear brakes on my 200x that i'm building. unless i read wrong, i need a cr80 front caliper for the rear brakes on the 200x and i need a rear kx80 or kx85 caliper for the front of the 200x. other than new brake lines, do i need to replace anything else? can i still use the 200x cylinders or do i need to swap them out as well?

[SWIGIN]

the master cly will be ok but the newer front master cly work better

[ironchop]

I agree with Swigin....the parts will work together but imagine this for a moment

yer out 300 miles from the house riding trails with a group of buds when you blow a seal on the only old part left of your brake system...there`s a cycle shop in town 20 miles away from the trails but they only have newer dirt bike stuff on the shelf...and you are left wishing you had put a CR85 master on yer ride


keep in mind that I just got this swap done on one of my trikes....but when you mount your X mounting plates to these new calipers, I would suggest using the newer posts/studs on your mounting bracket...the newer studs are grooved to retain grease on the big stud ( the allen head stud)....the brackets for the KX and CR calipers came with them when I bought them so I took them apart and compared them...the newer studs are WAY BETTER

I have a pile of 3 or 4 old X calipers....funny thing is they were locked up NOT because the puck was siezed in the caliper pot, but because those mounting studs were never serviced or lubed and it was the big stud the caliper slides laterally on that was stuck tight and locking up the caliper on EVERY one

the calipers would have been salvageable had they been lubed once in awhile...which seems to be oft overlooked when servicing your machine

you fellas with old trike calipers that sill work should look into at least updating those studs and/or lube-ing your old one REGULARLY....newer style has a steel sleeve inside the slider hole so it`s steel on steel...the older Honda units have a steel stud sliding in a bare aluminum hole which is prone to shrink up and sieze...it is possible to press out a siezed stud out of the caliper, however in some cases it will destroy that aluminum bore making for a sloppy fit and greater chance of dirt to get inside and create more damage


I did Jason`s swap and he is correct.....as long as you use the X mounting plates, they bolt right the heck up with no issues whatsoever

[n10sivern]

well, i am the new owner of kx85 rear brake assembly and cr85 front brake assembly. both include the master cylinders. anything else that i'll need for this swap other than new pads and probably new brake lines?

[jason85atc250r]

well, i am the new owner of kx85 rear brake assembly and cr85 front brake assembly. both include the master cylinders. anything else that i'll need for this swap other than new pads and probably new brake lines?

you can just reuse your original brake lines/hoses the ends were they attach to the caliper are the same. the kx and cr pads are exactly the same as the 200x caliper used. So if you already bought 200x pads they will fit no problem

[n10sivern]

sweet, cant wait on them to get in even though i can't even install them for about another month until i get my frame stripped and painted.

[adamd]

ok just to check and make sure does the 05 cr85 front caliper fit the 200x?

[jason85atc250r]

ok just to check and make sure does the 05 cr85 front caliper fit the 200x?
yes it will work perfectly.

[jason85atc250r]

back to the top for more people to notice it and help them out.

[jason85atc250r]

back to the top for more people to notice it and help them out.

same as above.

[69HemiGTX]

Thanks for the insight and clarification, y'all! :beer I saved every pic and made plenty of notes for my 200X build. I'll get to it eventually. The good news is that my son is only five months old, so I have plenty of time. :lol:

[ctk]

Bringing this back up.
I just installed a cr 85 1998 year front caliper on the rear of my 84 200x.
All is needed is to swap the mount of the cr 80/85 with the original off the 200x caliper.
thanks for the research jason

[Doppler]

I just put an 03 CR85 rear caliper on my 85 350x. Works perfect! Thank you for the idea Jason85atc250R

[f4istunna]

will this work on the 86 350x? i know the 85 and 86 rear calipers mount differently. If someone could tell me calipers that will bolt on the 86 350x id appreciate it. Only calipers i have laying around were z400 fronts the mounting holes actually line right up w/ rear brake stay holes, but the brake line and banjo wont let it sit right when you try and mount it on the bike.

[jason85atc250r]

To do this swap you have to reuse the caliper mounting bracket and just cwap the CR caliper over to it. It'll work on your 86 350x

[f4istunna]

ok thanks. means im gonna have to get the bracket this trike didnt come with caliper bracket just the stay that mounts to swingarm.

[ironchop]

bump for a good tech thread

[kasey200x]

bumb.. just got my cr85 caliper in. What plate is it that i have to swap with the 200x? I'm guessing it's the mounting plate between the caliper and the swinger? If so, where in the world can i find this??
thanks

[dcreel]

I'd make a classified ad for the part here on the site. I wouldn't think it would cost you too much for the 200x caliper mount. If the cr caliper you got has its mount someone here said you can make it work.

[kasey200x]

okay, sounds good dc. I do alot of fabrication and to make this work, i'm either going to have to make a completely new plate, or drill a whole on my swinger where it mounts. thanks again.

[pcs]

another bump, im going to redo the front brake set up on my new (old) 84 200x, this helps a lot

[ironchop]

bumpity for the new dudes

[turbowrenchhead]

Are the pads the same for the cr80? I have a set of new pads however when I took the caliper off the pad pins busted right off in the caliper.

[ironchop]

same pads....no difference

[rdlsz24]

After my rear brakes locked up and I still had to ride home, I figured to be on the safe side I was going to replace everything. I just put a CR85 rear master cylinder (rebuilt with new seals), rear brake line and front caliper on the rear of my 200x to build a complete system. I was going to post pics but they would look about the same as what ironchop posted a couple pages back. For the line from the reservoir down to the master I used rubber gas line. I figured if it can withstand gas it will work for brake fluid also. Is this ok?

Rob

[ironchop]

most of the newer masters I use had rubber supply hoses.....I actually used a stainless braided supply line mad for a icemaker fridge supply and cut the ends off and cut to length...made from same plastic mtl as the hoses in the brake bleeder set and I also let them sit in fluid for a couple weeks to check for erosion or adverse softening of the hoses and they were good....looks trick too.

Beware using the gas comparison, Rob.....gas won`t remove hardened enamel paint on autos but brake fluid will eat the paint right off in a matter of minutes so you can see where this might bite you

[ctbale]

Bump

This 200x had bad brakes when I got it, the front master looked like it was off a CB750, tall round plastic res, with a alum cap. All the brakes were trash. Front master is a 02 YZ250F, front caliper is a KX85, rear master and res is the same KX85 and the rear caliper is the honda cr85. I want to thank you guys for the great mods!! Now I just need to find a 30" braided line for my front. I will check the classifieds forum

[ctbale]

One more thing, there was some discussion about finding the original plate for the rear to mount the CR80/85 caliper on. If you mount the KX80/85 on the front, your extra orig honda front caliper plate will work for the rear mod, just have to flip the post over. And after research you need a special kind of hose for the brake fluid res for the rear, its EPDM. Mine needed 15" Got 18" for $9.99 delivered off ebay. My vinyl will sweat thru dot3 and 4. VW Volkswagen Blue Braid Brake Fluid Reservoir Hose 7mm http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=150585363230&viewitem=&sspagename=STRK%3AMEWNX%3AIT

[jb2wheels]

Thanks for the auction link - I need some for my projects!

Did you have any problems bleeding the front caliper with the bleed nipple on the down side like that? I am curious because that was the reason I did not buy the KX caliper for my X. I was concerned so I just bought a complete new caliper.

I have CR calipers on the back of my 200x and my 350x. Great solution.

[ctbale]

yea, it was a total pain in the ars. I ended up pulling off the caliper with the hose hooked up, and sticking a piece of metal to simulate the disk/rotor, then zip tied the caliper to a plastic garbage can handle (garbage can had gravel in it) with the bleeder pointed up. the caliper was almost the level with the bars. piece of cake after that. It still is spongy, I can see the orig brake line expanding, so I might get a ss braided line. I see used lines for honda cr125/250/450s on ebay for $15 total, might just do that if I can figure out the length, I need a 28" to 30" line.

[pcs]

added info, i swapped out my rear caliper with had new pads and the were the same as the 2000 cr 80, the cr bracket did not work and when i put the cr caliper on the 200x bracket it bolted up but the small notch on the bracket would rub with the cr caliper, then i swapped back the 200x caliper and it would not??? i ended up just shimming the bracket withe cr caliper to give the notch some clearance and it works well now.