Cutting your bars on the Honda CRF-250X and the
"brake master cylinder" modification.

The Honda CRF250X comes with 32 inch Renthal handlebars. If you plan to cut them narrower, please READ below before you cut.

Next! See Tom's cool TOURATECH IMO 100R300 Speedo/Odo motorcycle computer on CRF-250X!


carb_bowl_hex.jpg

CRF-250X, with one inch trimmed from bar,
Brake Master cyl does not fit well.

If the 32 inch bars are cut down to 30 inches, the brake lever angle on the CRF-250X cannot be adjusted.

The only position available for the brake levers is horizontal to the ground.

To adjust your brake levers downward, please see the photos below.

carb_bowl_hex.jpg

If I had a second chance I would leave part of the lower nub.......

Remove the "upper" nub.The lower nub prevents the banjo fitting from rotating counterclockwise thus loosening in this critical brake line fitting.

Leaving part of the lower nub remaining makes this modification more difficult, but it's worth it.

Be sure to protect the sealing surface for the Banjo bolt, don't make any scratches on the sealeing surface or your brakes will leak, and the only solution is to replace the master cylinder.

carb_bowl_hex.jpg

Ready for re-installation. Filed surface "facet" is required for clearance with Renthal crossbar clamp.

carb_bowl_hex.jpg

TWO THINGS I WOULD DO DIFFERENTLY (if I had seen this website first, for example!)

1) I removed both nubs, but after fitting, discovered that part of the lower nub can remain (for safety).

2) The facet could be done at a better angle.


Leaving part of the lower nub retains a level of safety by preventing the banjo fitting from loosening thus causing loss of hydraulic brakes.

This is not a trivial issue. A crash, a branch, or pulling the bike out of the bushes, or any action that rotates the banjo downward, could loosen the banjo fitting. And every time you place your "tiedowns" on the bar, you have to check that the hook is not bothering the banjo fitting.

If your desired position of the brake lever results in the "nub" being narrower than it's height, it would be a good idea to reduce the height to just taller than half the tubing thickness (such that it still prevents rotation but is not likely to break off).


Back to Trail Tips or see TM's CRF-250X page, Rick Ramsey's CRF-250X page
See CycoActive Motorcycle Products or CycoActive GPS page.

This page and images are ©2004 by CycoActive. All rights reserved.
(02/21/2004)
Any suggestions, comments or links?
Please contact CycoActive e-mail moto@cycoactive.com
This page has been accessed times