FL400 Front Disc Brake Conversion - Full Kit
Upgrade your FL4000 with better stopping power with a front disc brake conversion. The stock drum brakes are notoriously weak and can be a substantial safety risk when riding in situations where the ability to stop is critical. Our disc brake conversion kit comes with everything needed to swap out those old style drum brakes to disc brakes. Includes the brackets, calipers, brake pads and disc. This is one of the best upgrades you can make to your FL400 to make it safer to ride.
Note 1: See Installation Notes below for what is necessary to install on a Pilot!
Note 2: This kit will NOT work with stock wheels. You will need to upgrade to modern wheels for the conversion to fit properly.
Note 3: Modification of the spindle assembly is required with one tab needing to be removed. See pictures for detials.
Note 4: Wheel bearings will need to be replaced due to differences in the inner and out diameters.
Note 5: Item is generally stocked but if not in stock, Made to Order ~2 to ~4 weeks for production.
Note 6: To bleed the brakes, you must do so with them off the mounting bracket and turned upside down. Call for details if in question.
For a video showing the installation process, use this link here. Note... this video is for the FL350R but it should also generally apply for the FL400R.
Installation Notes
Parts Needed:
- FL400 Front Disc Brake Conversion Full Kit (1)
- Inner Dust Seals (2): 30x42x6 double lip – easy to find
- Inner Bearings (2): 22x42x12 – custom size, hard to find in the states. Purchase available from international suppliers.
- Bearing Spacer: Can use the stock spacer but must be cut down to 19.80mm long
- Outer Bearings (2): 20x42x12 – can use OEM, abundant & easy to find
- Outer Dust Seal (2): 28x42x8 double lip- can use OEM
Installation Instructions:
The installation process is very similar to the FL350, with only three modifications required to use the OEM spindle:
Mounting Plate Adjustment:
For the FL400 kit, two of the holes on the mounting plate will need to be filed out slightly to ensure a proper fit. This modification does not require much material to be removed but is necessary for the mounting plate to align correctly with the spindle.
Spindle Modification:
The upper rear ear/mounting holes on both the left and right spindles need to be ground off. A small hand-held die grinder is recommended for precision. This modification is quick and should take approximately 15 minutes for both spindles, ensuring the cuts are symmetrical across both.
Bearing Spacer Modification:
The OEM bearing spacer needs to be precisely cut down to 19.80mm. Alternatively, this spacer can be crafted from a 1 1/8” OD X .125” Aluminum round tube, a readily available material, providing a perfect fit as OEM bearing spacers are no longer available.
By following these instructions, the FL400 front disc brake conversion can be successfully installed with minimal modifications.
| Origin | Aftermarket |
|---|---|
| Condition | New |
| ATV Make | Honda |
| ATV Model | FL400R, FL400R - Rotax |
| Height | 18 |
| Width | 18 |
| Depth | 12 |
