My 85' 250sx disk brake and various upgrades!

[cajun1104]

Hello all,

Just wanted to share my 85' 250sx. I bought it a year or so ago and use it to trail ride. I love the way this bike handles the trails.



Anyways, I have been very disappointed in the drum brakes. The brakes would fade throughout the day which would require constant adjustment. I had to replace the front and rear shoes every third ride or so. I was inspired by ATC500 and his disk brake conversion. Finding the parts were a bit of a challenge but luckily we have an ATV salvage yard nearby and I was able to look around until I found parts that would work.

I will start with the easy part, the front disk. I bought the front end off of a 200x. mounted the forks in the 250sx triple trees and had to make .860" spacers to center the wheel and space out the caliper bracket.





The rear was a bit more difficult. The parts that I used was a 95' 600 CBR F3 rear master cylinder, 05' yamaha kodiak 400 left rear hub/rotor, and a 03' yamaha YZ125 front caliper. After all parts were gathered i made a trip to the machine shop and started taking metal off of the kodiak hub. I got the hub to fit over the axle tub, then I had the challenge of keeping the axle bearing. Luckily, the bearing carrier that is in the backing plate for the 250sx will press out of the backing plate and bolted back up to the axle tube. I then made some 2.25" spacers that were welded to the studs of the stock hub and drilled and tapped to bolt the modified kodiak hub/rotor to. now all that was left was to fab up some brackets for the caliper and master cylinder. The rear brake is a really nice addition. I can now lock the rear tires up with ease.






















I also updated my rear tail light to LED and also has a brake light feature now. Used and LED trailer brake light and trimmed it to fit inside the stock tail light housing. While I was back there, i decided to paint the swingarm and rear shock. Thanks for looking!

[Jd110]

nice job! Looks awesome.

[UPNATM]

Yeah, very cool man. Nice work.

[cajun1104]

Thanks guys, been stolling this site for several years, but just now done something to my wheeler that I felt was good enough to share with the rest of you. ATC500x was a huge inspiration to me.