Wednesday, March 2, 2011

Honda ATV Front Disc Brake Conversion Kit

Honda ATV Front Disc Brake Kit
Installation Instructions
Part #: DBK-H
Honda Fourtrax 300: 1992 - 1999
Honda Rancher 350: All  Years
Honda Foreman 400: All Years
Honda Foreman 450: All Years
Honda Rubicon 500: All Years
Honda Rincon 650: All Years
(Any Honda ATV with 12" wheels and front drum brakes)

Honda ATV Front Disc Brake Kit

  1. First, raise the front of the ATV and secure it on jack stands. Then remove the front wheels.
  2. Remove the cotter pin and castle nut from the end of the axle and set aside.
  3. Next, remove the brake drum.  This may take a little force depending on  how old the brakes are.  If so, use a dead blow hammer and pry bar if you are not able to remove them by hand.
  4. Now, remove the two bolts that secure the hub to the drum.  Then remove the studs from the hub.  (NOTE: A hydraulic press is preferred but a hammer will work if a press is not available.)
  5. Remove the brake line. Secure it out of the way at a high level to prevent brake fluid from draining.
  6. Remove the four bolts securing the backing plate to the steering knuckle and move the backing plate out of the way.
  7. Clean the hub assembly with a wire brush and rage to remove all debris.
  8. Install the Caliper Mounting Bracket on the knuckle and secure with the provided counter sink Allen Head Bolts.  See Fig.1 & Fig.2.  (NOTE: a hydraulic press is preferred but a hammer will work if a press is not available.)
  9. Once the mounting plates are installed, you can now assemble the Rotor assembly.  First, install the M10 x 65mm Lg bolts into the Rotor. See Fig.3.  Then place the 3/4" Tube Spacers onto the bolts.  See Fig.4.  Next, slide the Hub onto the bolts with spacers.  See Fig.5.  Finally, slide the 1/2" Wheel  spacer into place (Fig.6.) and tighten the bolts securely (Fig.7).
  10. Next, place the assembled Hub onto the axle and install the Castle Nut and new Cotter Pin to secure the Castle nut.  See Fig.8.
  11. After the Hub is in place, you will be installing the Brake Calipers.  The calipers are marked up with "LH" for Left Hand (driver's side), and "RH" for Right Hand (passenger's side).  Place the caliper onto the rotor with the bleeder up.  This is another way to tell if you have the correct caliper or not.  To mount, line up the mounting holes on the Mounting Bracket with the Caliper holes.  See Fig.9, and secure using the M8 x 16mm Hex Head bolts and Lock Washers provided.  (Caliper is mounted toward the rear).
  12. On some models the brake hose will need to be rerouted using the relocation brackets.  Disconnect the stock brake hose at teh outer mounting bracket.  The Relocation Bracket mounts using the factory hardware at the bottom and the 6mm Hex Head Bolts and Nylon nuts at the top.  The hose in its final position should be crossing over the tie rod end and attaching to the caliper.  If everything is clear, take them back off to complete any unfinished work.  The hose must not bind or r ub while turning the wheels or rotating the tires.  See Fig.10 for details.
  13. Next, you will need to bleed the brake system and seat the pads.  First bleed the lines of any air.  After they're bled, you will need to seat the pads.  Test drive and make several hard stops, then allow the pads to cool while riding.  Once the pads have cooled off, make a couple more hard stops.  If the brakes begin to feel spongy or weak during this time, you may need to bleed them again.
Honda Foreman ATV Front Disc Brake KitHonda Rancher ATV Front Disc Brake Kit
Honda Recon ATV Front Disc Brake KitHonda Rincon ATV Front Disc Brake Kit
Honda Rubicon ATV Front Disc Brake KitHonda Foreman ATV Front Disc Brake Conversion Kit
Honda Recon ATV Front Disc Brake Conversion KitHonda Rancher ATV Front Disc Brake Conversion Kit
Honda Rincon ATV Front Disc Brake Conversion KitHonda Rubicon ATV Front Disc Brake Conversion Kit
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