A recent inquiry to Dirt Wheels highlights a common problem for owners of older ATVs: expensive or unavailable replacement parts. Cliff and Danny Moore from Gray, KY, reached out regarding their son's 2007 Can-Am DS250. Neglected maintenance led to a destroyed rear brake caliper, and the replacement cost from Can-Am was quoted at a staggering $500, without even including new brake pads.
The Moores asked Dirt Wheels for advice on finding a more affordable solution. According to the response from Dirt Wheels, direct aftermarket replacements for the DS250 rear caliper are not readily available. Used parts might surface on eBay, but their condition and price can be unpredictable.
However, Dirt Wheels offered a clever workaround involving a Caltric CR157 rear brake caliper, originally designed for 2006-2012 Can-Am Outlander models. This caliper, available from Caltric for around $28 at the time of the article, can be adapted to fit the DS250 with a minor modification.
The Modification:
- Align one of the Caltric CR157 caliper's mounting holes with the DS250's bracket.
- Mark the location of the second hole on the bracket.
- Drill a 17/64-inch hole at the marked location.
- Tap the newly drilled hole with an 8mm x 1.25mm tap. Dirt Wheels recommends using a thread gauge on the original caliper bolts to confirm the correct thread pitch before tapping.
Dirt Wheels suggests that any competent shop familiar with metric bolts and foreign machines should be able to perform the drilling and tapping if the owner isn't comfortable doing it themselves.
Additional Considerations:
- Brake Disc Condition: The original inquiry mentioned salvaging the brake disc. Dirt Wheels noted that EBC offers a replacement disc (P/N MD6282D), but it costs over $130.
- Maintenance: The incident underscores the importance of regular maintenance. Neglecting brake pads can lead to damage to the caliper and potentially the disc, resulting in costly repairs.
This resourceful solution demonstrates that with a bit of ingenuity and mechanical skill, owners of older ATVs can overcome parts availability challenges and keep their machines running without breaking the bank. Always consult a qualified mechanic if you are unsure about performing any modifications.
