Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.


SuperATV Foreman Rear Disk Conversion

Recommended Posts

This is part number: RDBK-H.


TRX300 2x4 1988-2000

TRX300 4x4 1988-2000

TRX350 RANCHER 2x4 2000-2006

TRX350 RANCHER 4x4 2000-2006

TRX400AT RANCHER 400 2004-2007

TRX420 RANCHER 4x2 2007-NEWER (with Solid Rear AXLE, not IRS MODELS)

TRX420 RANCHER 4x4 2007-NEWER (with Solid Rear AXLE, not IRS MODELS)

TRX400 FOREMAN 4x4 1995-2003



So we start it off, everything was packaged nicely.


Full color instructions....nice touch:


Disc looks sturdy:


Share this post

Link to post
Share on other sites

This is the new bearing part number, already assembled:


For those not that familiar with the outboard drum setup on the 500 foreman, this it.


A little closer pic:


You'll notice from this pic I had to cut a stud off so I could get a wrench on the castle nut. It would not budge otherwise as I didn't have the correct sized socket. This was stock as assembled by Honda and 8 years old.


You can see the dust cover seal has already taken some punishment, and would be a high failure point due to constant clay mud and water intrusion.


Share this post

Link to post
Share on other sites

This smelled like straight cow manure. Apparently it had been hiding in there for some time:


And this is the drum, besides being wet, overall in good shape (750 miles)


What hides beneath is a mess. There is stuff growing in there.....absolutely due to owner neglect.


With the pads moved out of the way:


Dis-assembly complete. Now its time to install the new stuff.


Share this post

Link to post
Share on other sites

The o-ring that seals your bearing plate to your axle tube is plain not gonna stay in place without some help. The bearing needs to be lightly tapped on the axle, so apply some rtv of choice just to hold it in place while you position your bearing.


Here is the bearing plate, caliper bracket, and line bracket mocked up:


Here's another issue with this kit. The turn cam that drives the caliper closed is dry, I think it needs grease. Rotate it out of the caliper, add the grease/lube of your choice and re-insert. Also, the long bracket needs two things done, remove the powder coat out of the hex hole at the bottom, and two: remove the powder coat out of the slots, otherwise this will not go together. Hey at least the tolerances are nice and tight.


Threw the disc and caliper rear bracket on after the touches: Another issue, focus on the castle nut. They supply you a very thin washer, well its not thick enough. You will need to add 1/4" minimum in washer thickness or the disc will slight left and right because the castle nut runs out of threads before its tight. I put their wider washer first, then my thicker one next, then the castle and it worked perfect.


And this is fully assembled and adjusted. Huge improvement.


My driving impressions were: Good stopping power. If this was your only brake on the machine you could get by easily. I'd say it stops as good as a perfectly functioning drum setup, the difference is, this wont hold water and stop working. Should be easier/cheaper maintenance and upkeep also. Win/win.


EDIT: Added hydraulic to it.

I started by buying the generic 68" ATV brake cable off ebay. It was about $20. Anything longer then that and price goes up quite a bit and is hard to find. Turns out the stock brake line is about 80". So yeah, it didn't work. Here's what I had going for me: $24 generic driver side master, revised bracket, new caliper/pads: IMG_20141217_134649_273_zpsd3211834.jpgIMG_20141213_111138_887_zps29f4c12b.jpg

Came up slightly short: IMG_20141217_142538_283_zps576bf55a.jpg

Turns out for "scooters" there is a longer cable for about $30. Well before I knew about that I bought an AN line from Russel. I converted the brake fittings to AN, used straight couplers, and a prefit, pre-made brake line so it was all plug and play. Perfect fit, and remember I have the 2.5" longer 450 swingarm. I bought solid washers also instead of the oring stuff that SuperATV provided. IMG_20141226_122645_526_zps200f2b4f.jpg


I was even able to keep my winch control on the drivers side: IMG_20141226_143113_912_zps071cd796.jpg

Impressions: Stops incredible after about 3 pumps. I think the master is not strong enough to make this caliper do the full amount of work its capable of. On the first pump its a decent braking amount but not enough for an emergency move...by the third pump, its got impressive stopping power. I may change to a name brand master and see if that makes it better.

Edited by SSreda4

Share this post

Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Admin
      Looking for Yamaha ATV VIN (Vehicle Identification Number) Number Decoders? Once you find your ATV VIN number off the tag on your Yamaha ATV, you can go to all kinds of websites that have VIN Decoders available. The best ones are backed by the Yamaha ATV manufacturer, however there are plenty of aftermarket Yamaha ATV VIN Decoder websites on the web. This topic will stay pinned and if you find any to add, please do it with a reply. 
      The following Yamaha ATV VIN Decoder websites are available where you can just enter your VIN number and it will shows you some of your ATV model details:
      KBB.com https://www.kbb.com/vehicle-history-report/ 
      CARFAX https://www.carfax.com
      autoDNA https://www.autodna.com
      VinAudit http://www.vinaudit.com/
      decodeTHIS https://www.decodethis.com
      VINCario https://vindecoder.eu/
      NICB Theft Check https://www.nicb.org/theft_and_fraud_awareness/vincheck 
    • By Jim Hoffman
      Hi,  I'm looking for a repair manual for a 2011 Honda Rancher 420 ES.  I've been looking on here and have only seen manuals for the 420 AT.  Does anyone have a PDF that would be willing to share?  
      Thanks in advance.
    • By Randel1
      I am trying to put a 1994 Suzuki 250 quadrunner back into service. I have it up and running like new but need to replace the plastics as they are brittle and crumbling due to age and sun exposure. I would like to purchase new parts either OEM or aftermarket but have had little luck in finding them. I would even consider used or salvaged parts in serviceable condition. Any help in locating these parts would be greatly appreciated. Thanks in advance.
    • By northernmi
      View File ETON Multiple Models ATV Service Manuals
      Shop manuals from various ETON ATV models. Includes the following service manuals:
      ETON 2004 VIPER 50-90R & RXL50-70-90
      ETON 2009 VIPER & YUKON YXL-CXL-RXL150cc
      ETON 2011 VIPER SILVER 90R
      ETON 2009 VIPER SILVER 70
      ETON 2009 VECTOR VXL250
      ETON 2000 SIERRA DXL90 
      ETON 2000 LIGHTING 50 & THUNDER 90 
      ETON 2005 VIPER & RX4 4-CYCLE 
      Submitter northernmi Submitted 01/27/2020 Category Other ATV  
    • By quadcrazy
      View File 1985 - 1995 Polaris ATV Service Manual (All Models)
      1985 - 1995 Polaris ATV Service Manual (All Models) 
      Covers the following models:
      1985   Scrambler Trail Boss
      1986   Scrambler
      1986   Trail Boss
      1986   Scrambler
      1986   Trail Boss
      1987   Trail Boss
      1987   Cyclone
      1987   Trail Boss 4x4
      1987   Trail Boss 4x4
      1987   Trail Boss 4x4
      1988   Trail Boss 2x4
      1988   Trail Boss 4x4
      1988   Trail Boss 250 RIES
      1988   Trail Boss 250 RIES
      1989   Trail Boss
      1989   Trail Boss 2x4
      1989   Trail Boss 4x4
      1989   Big Boss 4x6
      1989   Big Boss 4x6
      1990   Trail Blazer
      1990   Trail Boss 250
      1990   Trail Boss 2x4
      1990   Trail Boss 2x4 350L
      1990   Trail Boss 4x4
      1990   Trail Boss 4x4 350L
      1990   Big Boss 4x6
      1991   Trail Blazer
      1991   Trail Boss 250
      1991   Trail Boss 2x4
      1991   Trail Boss 2x4 350L
      1991   Trail Boss 4x4
      1991   Trail Boss 4x4 350L
      1991   Big Boss 4x6
      1991   Big Boss 6x6
      1992   Trail Blazer
      1992   Trail Boss 250
      1992   Trail Boss 2x4
      1992   Trail Boss 2x4 350L
      1992   Trail Boss 4x4
      1992   Trail Boss 4x4 350L
      1992   Big Boss 4x6
      1992   Big Boss 6x6
      1993   2502x4
      1993   3502x4
      1993   2504x4
      1993   3504x4
      1993   Sportsman
      1993   2506x6
      1993   3506x6
      1993   Trail Boss
      1993   Trail Blazer
      1994   3002x4
      1994   4002x4
      1994   3004x4
      1994   4004x4
      1994   3006x6
      1994   4006x6
      1994   Trail Boss 2W
      1994   Trail Blazer 2W
      1994   Sportsman 4x4
      1994   Sport
      1995   3002x4
      1995   4002x4
      1995   3004x4
      1995   Xplorer4x4
      1995   4006x6
      1995   Trail Boss
      1995   Trail Blazer
      1995   Sportsman 4x4
      1995   Scrambler
      1995   Magnum 2x4
      1995   Magnum 4x4
      1995   Sport
      This is an external source from https://thequadconnection.com
      Submitter quadcrazy Submitted 05/24/2018 Category Polaris ATV  
  • Similar Tagged Content

  • Recently Browsing   0 members

    No registered users viewing this page.

  • Create New...