250SX rear brake upgrade,disc brake!!!!

[atc500x]

Ok,it was the last time I have problem with the brake on my SX,everytime I ride in mud or cross river,I have to clean brake,change brake,seal.....time was come for a little upgrade,with the disc brake,no more problem!!! I will convert the front with a 200x for the disc brake too.

hummmmm....I can attach picture,Did there is a problem with picture upload on the furom or it's my computer?

[three_wheelin45]

I hate drum brakes with a passion, there lil bitches!!

[atc500x]

http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6910.jpg (http://www.servimg.com/image_preview.php?i=14&u=16184596)

http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6911.jpg (http://www.servimg.com/image_preview.php?i=15&u=16184596)

http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6912.jpg (http://www.servimg.com/image_preview.php?i=16&u=16184596)

[aldochina]

cool stuff man! is that something you made?? the piece that attatches to the hub?? could be a demand for such a conversion!! i am def interested in some details!!

[Xpress]

I hate drum brakes with a passion, there lil bitches!!

x2. And when they wear out they SQUEAL!!!!!

[dcreel]

Very nice work.. Definitely one of the better upgrades..

[atc500x]

cool stuff man! is that something you made?? the piece that attatches to the hub?? could be a demand for such a conversion!! i am def interested in some details!!

Yes I built all parts,easy to do when you find the right parts like the hub and disc.The caliper is a twin piston from a yamaha yz125.I have check to use a caliper from a 200x to keep the park brake(most original as possible),but the double piston will be better when I tow a trailer.
You need a old backing plate to keep only the bearing holder,cut all around the holder to remove the plate(thanks to my new milling),install longer stud and youre done.

I have now only to install the master cylinder,probably this weekend and will take more pictures!

[dougspcs]

Yes I built all parts,easy to do when you find the right parts like the hub and disc.The caliper is a twin piston from a yamaha yz125.I have check to use a caliper from a 200x to keep the park brake(most original as possible),but the double piston will be better when I tow a trailer.
You need a old backing plate to keep only the bearing holder,cut all around the holder to remove the plate(thanks to my new milling),install longer stud and youre done.

I have now only to install the master cylinder,probably this weekend and will take more pictures!

Damn 'ATC500x' you got skills..really nice job.

I guess I'm going to be the contrary here cause I prefer my drum brakes!! I mean the discs are great an all, love them on my 350x, but being as all the parts are exposed they get trashed when riding on the really muddy trails. I ripped up a brand new set of rear pads a couple of months ago in about 3-4 hours heavy riding in the really thick stuff..

At least the drums keeps most of the crap out..I tear down the brakes at the end of ever season, clean, lube and deglaze the drums.

I love my BRs and SX when I am going for a serious mud bath..the shaft drive and drum brakes ensure that all I will have to do when I get back is give them a really good cleaning when I'm done..not tear it down and rebuild stuff.

[three_wheelin45]

Damn 'ATC500x' you got skills..really nice job.

I guess I'm going to be the contrary here cause I prefer my drum brakes!! I mean the discs are great an all, love them on my 350x, but being as all the parts are exposed they get trashed when riding on the really muddy trails. I ripped up a brand new set of rear pads a couple of months ago in about 3-4 hours heavy riding in the really thick stuff..

At least the drums keeps most of the crap out..I tear down the brakes at the end of ever season, clean, lube and deglaze the drums.

I love my BRs and SX when I am going for a serious mud bath..the shaft drive and drum brakes ensure that all I will have to do when I get back is give them a really good cleaning when I'm done..not tear it down and rebuild stuff.

Well you have a point, thats how I lost my front brakes on my 200x. Mud gummed them all up and ate my pads to shiet!! but all in all I love disc brakes alot more.

[fabiodriven]

Damn 'ATC500x' you got skills..really nice job.



Look up some of his other threads. This guy is one of my favorite fabricators on this site. He pulls off some amazing shnit.

[Thorpe]

OOOHHH... I got a chubby!! Please tell me you are gonna start selling these in a kit form!! I have an ES and SX that could you one of these systems! Very nice work!

[hillbilly 200x]

^^ I would be in for one to!!

[Thorpe]

I keep coming back to look at those pics! Man, thats cool!

[hillbilly 200x]

This really sweet it would also allow you to use a diffenert rim to?

[atc500x]

This really sweet it would also allow you to use a diffenert rim to?

For now my SX is on 9 inch ES wheel,I will check but I'm pretty sure the 200x wheel will fit

Thanks for the comment,I will complete the setup tomorrow and test it.

[hillbilly 200x]

For now my SX is on 9 inch ES wheel,I will check but I'm pretty sure the 200x wheel will fit

Thanks for the comment,I will complete the setup tomorrow and test it. the 200x rim will probably fit with your disk brakes now. I tryed my 200x rim on mine today didn't fit around the brake drum. lol

[Thorpe]

^^ 400ex 9" wheels will not fit over the drum either, without a spacer (fwiw)

[atc500x]

the 200x rim will probably fit with your disk brakes now. I tryed my 200x rim on mine today didn't fit around the brake drum. lol

83-85 200x wheel will not fit,bolt pattern is correct,but the diameter of inside the rim doesn't clear the diameter of the SX hub.I have 4 1/4 of offset clearance

[atc500x]

It work!!! Some picture of it.The SX wheel and the ES wheel fit perfect.Since I removed the park brake system I will remove the handle and cable,and install a XR decompressor lever just for the reverse system

http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6913.jpg (http://www.servimg.com/image_preview.php?i=17&u=16184596)
http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6914.jpg (http://www.servimg.com/image_preview.php?i=18&u=16184596)
http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6915.jpg (http://www.servimg.com/image_preview.php?i=19&u=16184596)
http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6916.jpg (http://www.servimg.com/image_preview.php?i=20&u=16184596)
http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6917.jpg (http://www.servimg.com/image_preview.php?i=21&u=16184596)
http://i48.servimg.com/u/f48/16/18/45/96/th/dscf6918.jpg (http://www.servimg.com/image_preview.php?i=22&u=16184596)

[Thorpe]

SO SICK!! I love it!

[nstyle73]

Very Awesome. I'm still a little fuzzy on the details of the swap, but I think if I looked at the 250sx I'd be fully capable of replicating this sweet innovation. Thanks for sharing your work.

[atc500x]

Just back from first test,unbelievable,best brake I ever seen on a SX,3/4 inch play to the pedal and the wheel lock so easily....
The XR decomp lever used for the reverse is a direct fit,the cable fit right in the handle,no cable adjustement needed.No more problem with cable!!!!!
This week I will built the front!

[atc350xer]

Fantastic idea! I hate the way the reverse setup is on the SX/BR... I may just do the decomp lever mod by itself!

[dougspcs]

'ATC500x', love the work you've done..1st rate. But I'll think I leave my 250SX with it's stock drums..it's my heavy mud machine.

You should consider makeing conversion kits for some of these creative ideas you have. I know there are buyers for your stuff here!!

[big specht]

So have you got to ride it much more to see how it will hold up ??? it looks like there would be alot of leaverage on the disk adapter. I wounder if there would be alot of differance in the stoping power if it were a single piston caliper ??? I would like to keep my parking brake

[atc500x]

I have ride it a lot,normal riding and deep mud.Always perfect,powerfull in any condition.I have also fit a front disc brake too.
I'm pretty sure a single piston caliper will do the job,but for the difference of work,I would stay with the dual piston,but using a newer atv rear caliper with the park brake system is a good option if you want to keep the park brake.I have use the parts available in stock.

[big specht]

Do you have a better pic of the adapter I would like to really do this to our big reds

[Thorpe]

Thinking of building a kit? I have a ES and a SX patiently waiting....

[Jason125m]

I would buy these kits!!!!!!!!

[atc500x]

I don't know If I will built a kit and sell it.I kept all the pattern of parts I built.But for the moment,I just don't have time to do anything.Just find time to sleep is a job....to much work,too much idea!!!!!!

[Stonewall]

What did that disc and caliper origionally belong to? I may try this on my 250ES.

[atc500x]

the disc is from a yamaha kodiak 450 2009

[big specht]

Any better pic ???

[atc500x]

No for the moment,all picture I have are on the forum,for the moment my 250sx need a good clean up after a SERIOUS mud bath (over the rack).If I remove the wheel for any reason I will take better picture

[Stonewall]

Cool, any chance you could put up some pictrues of the front disc setup?

[schneed]

I posted these pics on another thread (http://www.3wheelerworld.com/showthread.php/136295-Cheap-and-easy-mods-to-a-Big-Red?p=1060228#post1060228), but here is a pic of the rear discs brakes my buddies and I all have.

133781

We did a different design, than atc500x did, but similar in the end.

Depending on interest, could sell some kind of kit!

We went to the local atv salvage yard and just picked whatever we could find for disc brakes and levers on old 4 wheelers (prices vary on condition).

[big specht]

Why on the other side??? and hoo does it stop with the single piston caliper??

[atctim]

Outstanding Idea. I know it has been talked about several times in my group of 3 wheeling buddies to do this mod, but this is the first I've seen it. Way to think outside of the box. My issue was alway, how do I mount the disc to the axle. Your idea of back extending the hub for the mount is MINT!!!!! Kudos. I may have to do this on my rider 250ES. Again - Outstanding work / idea. You da man!

[atc350xer]

Outstanding Idea. I know it has been talked about several times in my group of 3 wheeling buddies to do this mod, but this is the first I've seen it. Way to think outside of the box. My issue was alway, how do I mount the disc to the axle. Your idea of back extending the hub for the mount is MINT!!!!! Kudos. I may have to do this on my rider 250ES. Again - Outstanding work / idea. You da man!
If you're considering making the parts, Tim - if you make a coupla extra, I'll buy 'em!

[schneed]

Why on the other side??? and how does it stop with the single piston caliper??

Well, I put the disc brake on the opposite side of the drum brake, b/c on my '86 BR, the drum brake is sealed around the axle and tough to just remove (unlike the '85 BRs).

It seem to stop just fine with the single piston.

Some said that they like the drum brakes better for mud, but we ride in as much mud and swamps as possible and the disc brakes are far superior to the drum. I would say that until you have tried both, you don't know what you are missing!

[Mondexbrute]

atc500x I need this set up so bad for my Big Red! Please find the time to build a few kits, I will pay top dollar for this setup!

[schneed]

atc500x I need this set up so bad for my Big Red! Please find the time to build a few kits, I will pay top dollar for this setup!

Mondexbrute, I thought you sold your Big Red?

[big specht]

Who ever makes a kit will be able to sell them.

[atc500x]

The problem is also a price
example,if I bought all parts,used to built a kit,including price of shipping of these parts to my house + the labor at 30$ /hour on my working hour since it's my job,

rear hub with disc 90$
master cylinder + hose and caliper 150$
used backplate 40$
labor 8 @ 30$/hour 240$

total 520$
+ shipping

Now sure every body will buy a kit for 520$ + shipping.......

Wasn't a problem for me,all parts was stock when I built it,but now all parts need to be ordered

[schneed]

I agree with atc500x...the cost gets kinda high, but...

I think we paid around $120 for caliper, disc, handle lever and reservoir and line off of any random atv we could find at the salvage yard.

The other parts we used were laying around the shop:

approx 4" dia pipe, 1/4" thick used to weld to the axle/hub that the disc was welded too
random angle iron for custom brackets

So maybe $150-200 parts and about 3-4 hours in labor, but most of that labor was installing, so labor hours wouldn't be high.

Thing is, I doubt any of us what to go back the salvage yard anytime soon, as its not close and it's getting cold here in MN!

Maybe next spring! Or I can put up some detailed photos of the build (post installation of course).

[Stonewall]

Could you post up some pics of your front disc setup?

[big specht]

I agree with atc500x...the cost gets kinda high, but...

I think we paid around $120 for caliper, disc, handle lever and reservoir and line off of any random atv we could find at the salvage yard.

The other parts we used were laying around the shop:

approx 4" dia pipe, 1/4" thick used to weld to the axle/hub that the disc was welded too
random angle iron for custom brackets

So maybe $150-200 parts and about 3-4 hours in labor, but most of that labor was installing, so labor hours wouldn't be high.

Thing is, I doubt any of us what to go back the salvage yard anytime soon, as its not close and it's getting cold here in MN!

Maybe next spring! Or I can put up some detailed photos of the build (post installation of course).

Yea we need some pics

[atc500x]

Yes I will took some picture of the front setup

Don't forget you need an old backing plate that need some work on the milling to fit the bearing and cler the disc.
With my experience in this built,if you don't have access to a machine shop with a lathe and milling,to built good parts,the cost of labor will be very high.

Locally the cost of used parts are expensive.But it's approx the same as ordering a part on ebay + shipping
My hub with the disc cost me 75$ locally,the price was 45 on ebay + shipping,approx 25$.

Will check for more picture and will post.

[sweetip2000]

Looks like you have some customers in line already. LoL.
Nice work.

[schneed]

Yea we need some pics

Last night I put new wheels on my BR and had the opportunity to snap a few pics of my rear disc brake set-up.

The first pic shows the wielded tube (the ID of the tube is slightly great than the OD of the axle housing). It is about 3" long.
136351

First we wielded the tube to the hub and then wielded the disc to the tube as straight as possible. You can also see we made custom brackets to mount the caliper to the axle housing using angle iron and a lot of grinding, :-)
136352

Here is the bracket for the caliper on the front side of the axle housing.
136353

Another shot of the tube, disc and caliper.
136354

[JasonB]

nice upgrade, i freaking HATEd my old drum brakes on my 85 and my girlfriends new 87 hasnt been checked out yet. drums are ancient technology :*(

[big specht]

Ok I'm digging this old thread up. Me and my brother and kizer and big daddy tri-z where out riding big reds sunday and we were playing in the mud and none of bikes brakes worked very good after that so we need to dig this thread back up and get this figured out. Ok I was thinking for the people the like to use there hand rear brake and foot brake, do they make a brake system that can have two masters hooked to one caliper?? Like have the hand brake master cylinder line piggy backed on top of the foot brake master line??? And is there any calipers that work better than others ????

[atc300r]

This is a good conversion.But I like the drum brake on my 250r.Id like to figure out how to make it a hydraulic drum setup. Iv checked some brake systems on a couple utility quads it look posible. I read an article in Dirt Wheels years ago where the guys put disc brakes on a trx 2 wheeldrive.They used all oem honda parts.

[the great gazoo]

I'm pretty sure there's a rear disc brake conversion kit for the TRX300 util quad available,which would work on the ES or SX but it's really expensive................

[big specht]

Ok do you have a link to the REAR disc brake conversion?? I've been all over the web and can find it all I can find is the front kit

[atc500x]

pretty sure they exist only for the front.The front are expensive,I'm doing a front kit setup on my trx300 now with a trx250r setup,easy to do....

[threewheelin-feelin]

ever get any pics of the front setup??

[Dirtcrasher]

I didn't read all this but front is cake if you simply slide in 200X forks.

You can use SX forks with a creative bracket though....

[atc500x]

It's exaclty what I did,250sx stock clam and 200x shock