One of the
problems we have with Honda ATVs are the front brakes. Only
now have they started putting disk brakes on the newer bike.
The old ones still have the old style drum brake. Sure they
have changed them to a triple seal bla bla bla but they
still leak. They might not on the first couple of rides but
trust me, if you ride in the mud or water they will.
To solve this
problem you can pull off your stock drum brakes and bolt on
a set of disk brakes. In my opinion, Xtreme products ( http://www.xpatv.com/
) has the best conversion kits on the market today. I
have installed many different kits and this is by far the
We called up
Joe at Xtreme Products and ordered their conversion kit. In
a couple of days the kit was ready to be installed. The kit
came with all the hardware and directions needed for the
After lifting the
bike in the air and pulling the tires off we were ready to
The drums were the
first to come off. As you can see, the stock drums had
started leaking and mud had started to cake onto the brake
The axle nut was then
removed so we could remove the hub
The four inner bolts
were then removed holding the drum brake assembly onto the
spindle. The backing plate was then moved to the side
leaving the brake line connected to the plate. This is to
prevent excess air from getting into the brake lines
The new disk brake
backing plate was then bolted up to the spindle. This will
be the backbone to all the new parts we will add later.
With the hub removed,
we needed to remove the stock studs. This is needed because
they are too short. You can press these out using a press or
vise or you can do it the wrong way by beating them out with
a big hammer. We went the cheap way because we did not have
a press or a vise. With a big socket placed under the back
side of the stud we hit the front end squarely on the tip.
After a couple of hits the studs popped out. If you beat on
your studs like we did there is a chance of bending the
studs. Once bent it is going to be very hard to remove. This
is your call. I'm just showing you the cheapest way.
With the stock studs
out we could assemble the disk brakes. The new studs attach
the rotor, bolt spacers, hub, and wheel spacers all
The hub is then
reinstalled back on the bike
The caliper is then
bolted to the backing plate
These calipers are
floating calipers. This means that if the hub flexes in any
way, due to wheel Barings going bad or the rotor warping,
the caliper will follow the rotor. This is the same
technology in all auto disk brakes. On other kits the
calipers are not floating and when Barings go bad the brake
pads will wear very fast.
Once the caliper was
bolted up we could connect the brake line. Acting fast we
unbolted the line from the stock backing plate and bolted it
to the caliper using the provided new crush washers. These
washers keep the line from leaking and are very important to
your brake system.
The stock backing
plate could then be removed from the bike by clipping the
factory vent line. This will not be needed on the disk
With the line tight
we could start bleeding all the air out of the lines. There
is a couple of ways you can do this. The directions
recommends the gravity method. Remove the top of the master
cylinder reservoir so that you can check the fluid levels
during the process. With everything tight, pump the brakes a
couple of times to increase the line pressure going to the
new calipers. Loosen one of the calipers bleeder screws to
allow the unwanted air to come out. Leave the screw loose
for a few seconds to allow the fluid to leak out. DO NOT
PUMP ON THE BRAKES WHILE THE BLEEDER SCREW IS LOOSE. Fill
the reservoir back full and do the same process on the other
side. We did this a couple of times to be sure all the air
was clear from the lines. The brakes should now be working.
Place the lid back on the reservoir being sure not to damage
the heads of the screws.
Last we reattached
the brake lines to the A-Arms using the provided brackets.
We did have to modify the lower bracket to clear the stock
rims. All we did was drill a hole in the center of the
provided plate. This gave us enough room to clear. After
market rims are going to have more clearance.
To check your
clearance, turn your wheels all the way and see if the rim
rubs the brake line.
Now we have better
brakes and we don't have to clean the drums after every
other ride. We love them and have installed them on 2 other
MUDandDIRT Hondas. They are the best aftermarket brakes out.