Lt500r front and rear brake options

• Lt500r front and rear brake options
  Posted by Ywnmn on 19 Oct, 2015 03:33
• Hey guys, I'm building a 87 500 and been looking for info on what other front master cylinder works with the 500 and is economical, (ltz400)?. Also stainless brake lines, calipers (either rebuild kit or other options) and front/ rear rotors.  My rotors and master are beat and not really digging the bulky master in 500. I'm not looking to upgrade with expensive aftermarket, just standard stuff that fits. Any help is much appreciated. Thanks for looking.
  Sean
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• #1 Reply
  Posted by Sixpack577 on 20 Oct, 2015 17:01
• Z400 hubs fit, and you can bolt Yfz450 calipers to those.
  Honda 450R and a Yfz450 master cylinder also work/have the same thread pitch. The Ltr 450 mc may/may not fit, as I'm unsure of the thread pitch on it.
  The Z400 hubs require new wheels though, as they are a different bolt patternn than the 500. There are alot of aftermarket wheels available that fit multiple brands, not just the Z400. It's a common size.
  SS brake lines of standard length may work as long as you have stock a-arms.
  Sorry, I don't know what(if anything)will work to replace the rear brake.
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• #2 Reply
  Posted by Ywnmn on 20 Oct, 2015 17:19
• The z400 hubs and spindles to bolt calipers to? Thanks man. Appreciate the reply. 
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• #3 Reply
  Posted by Sixpack577 on 21 Oct, 2015 00:11
• Yes, the Suzuki Z400, Kawasaki KFX400, and Artic Cat DVX 400 are all identical machines manufactured by Suzuki(minus the Artic Cat's plastics/fenders). So you can use parts from ANY of them. They are cheap and easy to find on ebay or CraigsList.
  The 400 spindles will bolt to the 500 A-arms.
  The Yamaha YFZ 450 calipers will bolt to the 400 spindles. That is a common brake upgrade for the 400's.
  As far as I know the 03-08 YFZ calipers work, and possibly later years but I can't say for sure.
  The Honda 450R and YFZ450 front master cylinders also have the same brake line thread pitch as the 400's do.
  The Suzuki LTR450 may/may not work, as I am unfamiliar with it.
  Those stock MC's are all over ebay, and rebuild kits are cheap. There are also new stock copies for $30 to $50 on average.
  It is anyone's guess as to which MC is best, but both are an improvement to the 400's already decent brakes.
  I don't have a 500 for measurements of brake lines or thread pitch.
  Plus 2", or 3" ss brake lines cost almost if not the same as stock length.
  I would go longer just to be safe, as the 500 is wider and longer than the 400.
  I have owned a 400 and ridden several, but have not put 400 spindles on a 500.
  The 400 rotors are also drilled, which provides better stopping than a solid rotor.
  I would also use carbon fiber pads in the 450 calipers, cf pads themselves are a noticeable braking improvement.
  All will be a dramatic difference compared to the 500's ancient brakes.
  I have read that the 400 spindles slightly widen the 500, so again I would go with a longer line.
  You can however mount the 400 spindles and use string or fine wire to mock up the brake lines.
  Several companies like Galfer and Spiegler will make custom length lines for you, which is not uncommon.
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• #4 Reply
  Posted by Ywnmn on 21 Oct, 2015 02:15
• Wow, what a wealth of information. I really appreciate the input. I knew other parts would fit, just had no idea which ones. I purchased ltr450 master already and plus 2" ss brake lines. The brake line manufacturer said the banjo bolt was the same as 500. I'm hoping they're right. Lol. In hind site, I wish I didn't powder coat my spindles and hubs, I would've bought the 400 spindles/hubs and yfz calipers. Lol. Along with rear g force hubs for 400. Then I could've upgraded my rims to bead locks. Oh well, a future project to look forward to. This is actually my 16 yo son's quad. He worked all summer to own another Zilla, paid $3200. Motor was beat along with almost all the bearings in chassis. He put another $800 out for parts and I'm helping with the rest. Little bastard better appreciate it. Ha ha. I should just buy it off him, I'm falling in love with this beast. I remember when they first came out when I was his age. Ha.
  Thanks again for all the insight, helps a whole lot. Still figuring out how to navigate this site, I'm like a caveman.
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• #5 Reply
  Posted by Sixpack577 on 21 Oct, 2015 02:43
• Yes sir
  I do know that you can use LTR 450 rear hubs on the 500 axle.
  They make it 1.5" wider, .75" per side.
  The 450 and 400 also share wheel bolt spacing, so wheels from either will fit.
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• #6 Reply
  Posted by ZillaFreak on 21 Oct, 2015 05:55
• 1) SS lines. Any SS line should work. As they usually have the same diameter outlet. The difference will be the banjo bolt. Make sure you get the right one for the MC and caliper. My guess is any sport ATV uses the same one.
  
  2) Rotors. For a zilla, http://www.jdscustoms.com/product-category/atv/suzuki/lt500/brake-components-lt500/
  
  3) Don't know of any direct replacement but the Z400 front swap is great. Also gives you more wheel options too. This is not cheap at first though. If you do this, yfz450 calipers are great and dual piston. This is a major upgrade for banshees.
  
  4) Master cylinder. Any front MC should work, as long as it bolts to 7/8" bar. I would suggest a newer YFZ450 like '10 as it is bigger and better than the older ones.
  
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• #7 Reply
  Posted by Ywnmn on 21 Oct, 2015 11:00
• Cool, thank you. Is there any other rear mc? Just took mine apart and it's corroded bad.
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• #8 Reply
  Posted by ZillaFreak on 21 Oct, 2015 11:13
• I don't know of any that will just bolt up, but it can't be hard to use a MC from something else and make a mounting plate for it.
  Just need something that pins to the brake lever, use aluminum plate, drill holes for the current mount, then make 2 holes for the new MC. That simple. Only issue I can see with this is the reservoir mounting.
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• #9 Reply
  Posted by Ywnmn on 21 Oct, 2015 13:17
• I thought about that too. Lt250 seems to fit according to partzilla. It's actually just the push rod that's corroded. Getting a new one with rebuild kit. Thank you.
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• #10 Reply
  Posted by Sixpack577 on 21 Oct, 2015 23:24
• I don't know if the 250 MC is the same as the 500, but they do share several parts from what I've seen.
  Two parts may be identical, but the one for the 500 usually costs more.
  Based on sellers not knowing, or hoping their customers don't know.
  Keeping interchangeable 250/500 parts just like the rest of the 500 parts...expensive.
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• #11 Reply
  Posted by john.templeton02 on 24 Nov, 2015 14:53
• Mounting ltz400 spindles/hubs on the front of the zilla isn't too complicated and definitely gives you more wheel options with 4/144 vs. 4/166.  Easiest way is to run lt500 upper ball joints on lower and upper mounts with a 5/8 thru 3/4 in spacer sleeve between ball joint and upper a-arm.  This will require some fairly easy but tedious fab work with a dremel and correct your camber.  Also needed are  two 14x1.5mm 2.5in length grade 8 or higher bolts to allow lengthening of upper ball joints when installed.  Use of the 400 spindles will also require you to flip your tie-rods over also. Then as previously mentioned, the raptor700/yfz450 dual piston caliper is a direct bolt on to these spindles.  I also got the 4/110 durablue rear hubs made for the lt500 to complete a matched modern hub pattern set.
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• #12 Reply
  Posted by AustenW on 15 Dec, 2015 04:42
• Any updated options for the rear caliper?
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• #13 Reply
  Posted by El Diablo on 21 Dec, 2015 18:39
• Austen, not sure if I would consider it an update, but the Banshee caliper is an identical replacement to the Zilla caliper... as long as you also use the Banshee banjo bolt. The thread pitch is different from the Suzuki to the Yamaha. With that being said, there may be aftermarket replacements out there for the Banshee that we are not aware of.
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• #14 Reply
  Posted by PCS on 22 Dec, 2015 02:28
• rear banshee is also the same as a 660 raptor.
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• #15 Reply
  Posted by Marcman804 on 21 Sep, 2017 08:04
• Hate to bring up an old thread but I need front brake calipers and was wondering if the Banshee calipers fit the front or rear?
  
  

  Quote from: El Diablo on 21 Dec, 2015 18:39

  Austen, not sure if I would consider it an update, but the Banshee caliper is an identical replacement to the Zilla caliper... as long as you also use the Banshee banjo bolt. The thread pitch is different from the Suzuki to the Yamaha. With that being said, there may be aftermarket replacements out there for the Banshee that we are not aware of.
  
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• #16 Reply
  Posted by ZillaFreak on 21 Sep, 2017 10:32
• Why would you want banshee brakes, they suck.
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• #17 Reply
  Posted by Marcman804 on 21 Sep, 2017 11:43
• Because I know where I can source Banshee brakes fairly easy and Im having a difficult time finding front calipers for the Zilla. I bought a 2 different sets from eBay and both times they were trash. Thanks for your concern, but Banshee brakes are better than no brakes. So again, will Banshee front brakes fit to the Zilla factory hubs?
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• #18 Reply
  Posted by BadMoonRacing500 on 21 Sep, 2017 22:16
• Quote from: Marcman804 on 21 Sep, 2017 11:43

  So again, will Banshee front brakes fit to the Zilla factory hubs?

  No.
  
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• #19 Reply
  Posted by ZillaFreak on 22 Sep, 2017 05:06
• IIRC, z400 spindles allow yfz450 caliper.
  if a front banshee brake fits, use a yfz450 caliper.
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• #20 Reply
  Posted by Marcman804 on 25 Sep, 2017 05:25
• I have a parts Raptor 660, would the brakes or anything else swap over to the quadzilla?
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• #21 Reply
  Posted by El Diablo on 30 Sep, 2017 15:40
• Years ago, Rickey from RIS sold a twin piston caliper conversion kit for the rear of a Banshee. He never admitted what the caliper was from but I heard it was a  front left YFZ-450 caliper. While there is currently no bolt on upgrade for a Zilla that I'm aware of, I'm sure a custom bracket can be fabbed up to mount the bigger caliper.
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• #22 Reply
  Posted by El Diablo on 01 Oct, 2017 10:00
• ZillaFreak, what these guys need is a pair of custom brackets to mount the YFZ calipers to stock zilla spindles. How hard to CAD / CAM a prototype?
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• #23 Reply
  Posted by ZillaFreak on 02 Oct, 2017 07:30
• Not hard at all really. If I had a zilla in front of me, could make a bracket quickly.
  The hard part is if it can actually be made. If the bracket moves the caliper up or down then it wouldn't have good contact on the rotor. If it moves left or right, then it would interfere with the rotor.
  Anyone know if the 250 spindles are the same as the zilla, if not, anyone want to send me a spindle or both and I can see what I can model up. I can even print a prototype to make sure it all works.
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