[450R brake conversion] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs

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450R brake conversion
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Posted by: Rich250RRacer

This are pics of my rear brake conversion on one of my 250R's. It was a very easy switch and much cheaper than replacing a stock 250R caliper, if they're still available. I will list the part numbers so anyone who is interested can price it out on Service Honda's site. At Honda retail it would cost about $200, but should be about $150-160 through Service. If you want to use an anti-fade, figure in the cost of a 450R unit. I had one on the quad with the original stock brake set-up, but it will not work with the 450 system. For the time being, I'll run a stock nut, but a 450R anti-fade is on the way. You will need a caliper sub-assembly, caliper stay (plate caliper mounts on), rear disc, disc hub, and rear brake pads. I was going to hold off on this until I purchased an anti-fade, but when I ordered the rear disc, it came with the stock hub. This is the first one I've seen come this way, I've replaced three rear discs on my 450 and none of them came with the hub. The only problem I ran into was the depth at which the 450 brake hub sat in the 250R carrier. Apparently 450 bearings are set deeper into the carrier. This required 2 8mm spacer washers between the caliper stay and the caliper. Be sure to have a micrometer handy to measure the thickness of these washers, since I just used some bulk washers I had in stock. Thickness isn't very critical, just as long as both washers are within a thousandth or two of each other. If your washers are different thicknesses (and I've noticed as much as .020") the pads will wear unevenly. Anything between .055 and .070 will work and this will put the disc in the center of the caliper bracket. I plan on doing the front conversion also. When I do, I will post pics, a parts list and any problems I encountered.

43150-HP1-006 caliper sub-assembly
43220-HP1-000 caliper stay
43251-HP1-003 rear disc with hub
Pads of your choice.

http://www.imagestation.com/picture/sraid164/peaebb649043e084c683b035088940ea0/f4869427.jpg
http://www.imagestation.com/picture/sraid164/pe4320a03dfbb27c814ef56a1c244b9d2/f4869428.jpg
http://www.imagestation.com/picture/sraid164/p574d8874db49db9a435e3810d9970504/f486942b.jpg

Posted by: zedicus00

heres the list for a 450r front end on a 250r not counting brake pads an sum lil misc stuf... this is a very nice upgrade

51210-HP1-000 - KNUCKLE, R. FR. - $65.66 - 1
51260-HP1-000 - KNUCKLE, L. FR. - $65.66 - 1
45150-HP1-006 - CALIPER SUB-ASSY. L - $40.31 - 1
45250-HP1-006 - CALIPER SUB-ASSY. R - $40.31 - 1
44311-HN6-000 - COLLAR, WHEEL SIDE - $3.96 - 2 - $7.92
44313-HN1-000 - COLLAR, WHEEL SIDE - $3.49 - 2 - $6.98
44615-HP1-000 - HUB SUB-ASSY., FR. - $146.21 - 2 - $292.42
90102-KV3-700 - BOLT, FLANGE (8X28) - $1.81 - 4 - $7.24
90105-MBB-000 - BOLT (8X24) (Brake rotor bolts) - $3.11 - 6 - $18.66

Total $545.16

-use 400ex or 450r rotor bolts
-400ex/250r hubs dont work
-250r tie rods can be used but will be adjusted way out
-ball joints all did fine.
i picked up a good condition complet setup used for 250$

Posted by: zedicus00

does anyone make aftermarket front 450R hubs??

Posted by: JTRtrx250r

Killer post Rich!!

and zed!

Posted by: zedicus00

yup, you guys ever notice how nuthing out of the 250r part of this forum ever gets stickied or put in the FAQ thing? this is another one of thouse posts that should b there.

Posted by: Rich250RRacer

One other thing I forgot to mention. I run a 88-89 length swing arm with a braided line, and it looks like the line may be a little tight if the chain is adjusted all the way out. I did not try it to see how it would end up, but an 86-87 length line would take care of this problem.

Posted by: JTRtrx250r

quote:
Originally posted by zedicus00
yup, you guys ever notice how nuthing out of the 250r part of this forum ever gets stickied or put in the FAQ thing? this is another one of thouse posts that should b there.

sure do! Think we need a legit R mod for this forum

At least it would help w/ the same questions asked everyday...

Posted by: Vtr_Racing

Great thread. Did you guys notice a big difference in braking? Or was it just that the parts were a little cheaper from the 450r than the 250r?

Posted by: zedicus00

450r front brakes are equall too or only slightly better then the 250R brakes. i did the conversion originally for the aluminum spindles and the brakes went along for the ride.

Posted by: quadboy38

i have a crf front brake with 400ex caliper mount on the rear of my R. this setup has worked awesome for me.

Posted by: zedicus00

honestly the 250r caliper itself, front and rear. is one of the best brake setups on a quad, i wouldnt just change out the brakes on my r just to do it, as theres no reason. like the first guy said though cost is a good reason. or like on the front end, newer design pluss less unsprung wieght. the calipers are pretty much the same style and design.

Posted by: cisco

I've done the full conversion on the front I went with the 05 setup it was much cheaper than the R stuff and it work"s killer.Seem"S to handle slightly better inthe turns but I also went +3 a-arms instead of +2 at the same time I did the conversion.

Posted by: 250R-Dee

Pappy came through for us! I requested that this thread be stickied because I have had to use it to answer members questions several times!! Good info!!

I wish people wouldn't price gouge soo much on the 250R parts. Once they see people are using NEW 400EX and 450R parts instead of over-prced 250R parts some of the goobers might lower their prices.

Thanks Pappy!!!

Posted by: rustyATV

Two questions about this conversion:

First, have you (or anyone) noticed any problems with the rear caliper hitting the silencer when the suspension bottoms out like the stock 250R setup can do?

Second, was a 450R rear master cylinder used, or is there plans to use it?

Posted by: Rich250RRacer

quote:
Originally posted by rustyATV
Two questions about this conversion:

First, have you (or anyone) noticed any problems with the rear caliper hitting the silencer when the suspension bottoms out like the stock 250R setup can do?

Second, was a 450R rear master cylinder used, or is there plans to use it?

It just barely scrapes, but it does leave a mark on the silencer. You can try spacing out the silencer just a little bit. I used the 250R master cylinder, but I'm looking to convert that too.

Posted by: cincy250R

this part number is discontinued

43220-HP1-000 caliper stay

Posted by: loboboy

quote:
[i]

-use 400ex or 450r rotor bolts
-400ex/250r hubs dont work
-250r tie rods can be used but will be adjusted way out
-ball joints all did fine.
i picked up a good condition complet setup used for 250$ [/B]

I have heard that the 2006 Honda Spindles are the same as the 400EX so I am hoping that my RPM hubs will work with the new 450R spindles(2006).

I run a Lonestar Outlaw Banshee and all of my 250R stuff is getting worn a little.

Posted by: peeping TOM

a little easy upgrade on the front is a brand new nifin master cylinder and lever , got mine for $32 of ebay ..money well spent !!!!!!!

Posted by: Meat

quote:
I have heard that the 2006 Honda Spindles are the same as the 400EX

Can anyone confirm this ?? 400ex hubs fitting on 2006 450r spindles.

Posted by: QuadRacer041

quote:
Originally posted by Meat
Can anyone confirm this ?? 400ex hubs fitting on 2006 450r spindles.

i think they will fit on but the offset at which the rotors sit is differnt so they wont line up in the calipers. im not 100% sure though.

Posted by: QuadRacer041

[QUOTE]Originally posted by Rich250RRacer
[B]This are pics of my rear brake conversion on one of my 250R's. It was a very easy switch and much cheaper than replacing a stock 250R caliper, if they're still available. I will list the part numbers so anyone who is interested can price it out on Service Honda's site. At Honda retail it would cost about $200, but should be about $150-160 through Service. If you want to use an anti-fade, figure in the cost of a 450R unit. I had one on the quad with the original stock brake set-up, but it will not work with the 450 system. For the time being, I'll run a stock nut, but a 450R anti-fade is on the way. You will need a caliper sub-assembly, caliper stay (plate caliper mounts on), rear disc, disc hub, and rear brake pads. I was going to hold off on this until I purchased an anti-fade, but when I ordered the rear disc, it came with the stock hub. This is the first one I've seen come this way, I've replaced three rear discs on my 450 and none of them came with the hub. The only problem I ran into was the depth at which the 450 brake hub sat in the 250R carrier. Apparently 450 bearings are set deeper into the carrier. This required 2 8mm spacer washers between the caliper stay and the caliper. Be sure to have a micrometer handy to measure the thickness of these washers, since I just used some bulk washers I had in stock. Thickness isn't very critical, just as long as both washers are within a thousandth or two of each other. If your washers are different thicknesses (and I've noticed as much as .020") the pads will wear unevenly. Anything between .055 and .070 will work and this will put the disc in the center of the caliper bracket. I plan on doing the front conversion also. When I do, I will post pics, a parts list and any problems I encountered.

43150-HP1-006 caliper sub-assembly
43220-HP1-000 caliper stay
43251-HP1-003 rear disc with hub
Pads of your choice.

hey rich,
i just ordered the parts needed to do this conversion and dont have the 450 stuff yet but it looks like the 450 caliper stay is a little thicker then the 250r stay. did you have to machine the 450 stay dow any?
again im just going by the way it looks.

Posted by: Meat

quote:
Originally posted by QuadRacer041
i think they will fit on but the offset at which the rotors sit is differnt so they wont line up in the calipers. im not 100% sure though.

Could a spacer setup of some kind be made to shim the caliper ? Or grind something ?? Or a better question is.... can the offset rotor issue be engineered (rigged) up with common sense.... in my garage?

Posted by: QuadRacer041

quote:
Originally posted by Meat
Could a spacer setup of some kind be made to shim the caliper ? Or grind something ?? Or a better question is.... can the offset rotor issue be engineered (rigged) up with common sense.... in my garage?

i dont remember if the rotor will be too far in or out. if the caliper moves out it might hit the rim, youd have to get all the parts and see where evrything sits.

Posted by: Meat

Three (dumb) questions for Rich250RRacer....

Are you using a 250r axle ? I know you didnt mention needing a 450r axle, but I just want to be 100% sure, cause I just bought a sweet RPM 250r axle. Im thinkin' there might be an issue with the axle splines not matching up with the disc hub.

Is that a 250r axle nut your using ??

Did ya do the 450r rear master cylinder swap yet ??

Posted by: ninis470

quote:
Originally posted by QuadRacer041
i dont remember if the rotor will be too far in or out. if the caliper moves out it might hit the rim, youd have to get all the parts and see where evrything sits.

hey dud can i ask you why you have a lynk of my photo album in your descrption area??? just askin???

Posted by: Rich250RRacer

quote:
Originally posted by Meat
Three (dumb) questions for Rich250RRacer....

Are you using a 250r axle ? I know you didnt mention needing a 450r axle, but I just want to be 100% sure, cause I just bought a sweet RPM 250r axle. Im thinkin' there might be an issue with the axle splines not matching up with the disc hub.

Is that a 250r axle nut your using ??

Did ya do the 450r rear master cylinder swap yet ??

It's a 250R axle. Splines are the same, easiest way to tell this is the stock threaded collar and axle locknut for a 450 and a 250 are the same. I didn't use a 450 master cylinder, the 250R M/C works fine.

Posted by: QuadRacer041

quote:
Originally posted by ninis470
hey dud can i ask you why you have a lynk of my photo album in your descrption area??? just askin???

cause i like you.....

Posted by: jason86PRP250r

heres a picture of my rear brake conversion. i used a 2000 yz426 front caliper on the rear with the stock 250r mount that goes on the housing.

it spaced perfect from rite to left and i had to egg out the one hole a 1/8 inch

Posted by: ninis470

quote:
Originally posted by QuadRacer041
cause i like you.....

kewl just thought i'd ask...

Posted by: ninis470

quote:
Originally posted by QuadRacer041
cause i like you.....

kewl just thought i'd ask...

Posted by: Meat

quote:
The only problem I ran into was the depth at which the 450 brake hub sat in the 250R carrier.

How bout using the 450r axle carrier ? Im in the middle of this brake conversion and have most of the parts, but I don't have an axle carrier yet. I was wonderin if 450r carriers are swappable with 250r carrriers ???

Posted by: gregw338

Will the 450r rear brake caliper work with the 250r setup? All I am needing is a new rear brake caliper. Will I need anything else to make this work?

Posted by: QuadRacer041

quote:
Originally posted by gregw338
Will the 450r rear brake caliper work with the 250r setup? All I am needing is a new rear brake caliper. Will I need anything else to make this work?

your kidding right??????? isnt that what this whole thread is about? go back and read, if you dont know how to read there is even pictures.....and if you still cant figure it out the parts #'s are even there...o wait you might not be able to read....looks like your screwed!

Posted by: brandonpeake

why aern't the pics still there Id like to see an illustration