SuperATV Disc Brake Conversion

Looks like the old buckboard will be stopping on a dime

Additional information and precautions for anyone wanting to do this brake conversion.

Everything went well as far as the "form, fit and function" of the kit installation itself. The trouble became apparent when trying to put the wheels back on the bike. The 12" Honda Rubicon 500 alum. wheels are slightly smaller inside I.D. then Honda steel wheels. So this let the backside of the caliper rub the inside of the wheel and both corners of the "black" metal caliper mounting bracket also gouge the inside of the wheel.



After snugging up the lug nuts it took both hands with some force to turn the tire, not good. I took some pictures and sent them to SuperATV and their going to try to re-assembly a kit on a newer style Honda Rubicon with aluminum wheels also. After several phone calls, looking and figuring it seemed that everything had enough clearance on the inside of the hub assembly but just needed tweaked inward about an 1/8" inch to clear and rotate smoothly. With (2) two new "gold" knuckle mounting brackets in hand, they were milled to a larger 1/8" slot opening and re-installed.



Then with my "newly purchased" angle grinder I rounded off both top and bottom corners of the "black" caliper mounting bracket an extra 1/8" inch for extra clearance.



So, a final after thought would have been to try on one of the wheels for fit-up before fully installing both sides of the kit.

Now everything seems to be right with universe and GiddyUpGirl's Honda can live on.

Very nice.
Did this change the width of the bike at all?

Tumbleweed wrote:

Very nice.
Did this change the width of the bike at all?

Thanks TW

The overall width of the bike in the front increased by 1" inch.
A black 1/2" wheel spacer is included for each side and are threaded
to hold the rotor, spacers and hub together using the through bolts.

Very neat design and similar to the kit that HighLifter sells also.

The only other thing that takes a little time to adjust is the brake line
re-location mounting bracket and trying to make sure the line doesn't
get hit/pinched at full steering lock by the wheel/tire in either direction.

Glad you got it all figured out

So now that you are Wacker master mechanic..and not Wacker master...something else... What plans do you have for your next project? A V-8 in the razr? A 1200 vtwin for the Grizz???? theres bound to be an adapter kit thats caught your eye

Here are links to V8 ATV's


https://www.youtube.com/watch?v=l0iFxQEE17c

http://www.google.com/#sclient=psy&hl=en&q=V-8+ATV&aq=0sx&aqi=g-sx1&aql=&oq=&pbx=1&bav=on.2,or.r_gc.r_pw.&fp=a50d8bbb4089c98a

You sure have been a wrenchin of late. Nice job with the pictures and write up. Atleast you had a good excuse to have to buy some new tools.

Diddo on the pictures & write up, I have been closely watching the rebuild of Gug's machine. I still have my Rubicon & this will be a great guide if I have to rebuild mine.

Keep up the good work, this is like reading Mechanics Illustrated or watching
Shadetree Mechanic on TV

Thanks Grizz

Honda Rubicon's are tough for sure.

If it helps down the road it's even better.

Pictures are always a big help for me...