Yamaha RD400 caliper conversion

[2smokenNick]

Hello all! I am pretty new to the forum and have found a gold mine! I am only 19 and have already been hooked by old two strokes! I am in the process of getting my '77 RD400 on the road for the first time in 35+ years and would like to do a brake upgrade. I have seen many great builds of the folks on the forum and would like to give it a shot. So far I have been able to acquire a 2001 r6 caliper and a fzr600 rotor, and am working on the caliper adapter by hand. Pretty much all I need is a rotor spacer. I don't have the precision equipment needed to make one and would like to know if anybody could help me out.
Thanks everybody!
Nick

[The Red Scourge]

http://www.2strokeworld.net/forum/index.php?topic=184.0

Mark mentions a 12mm spacer at the beginning of this post.  I'm about to embark on this journey myself.  This one is in the Tech Library section.

[sav0r]

I'm about five days from having my mill back on line. I can machine you one once I'm back working. I forget what I charge to do that, but as I recall it's not too expensive as it's a fairly easy part to make.

[m in sc]

TBH I THINK I NEED TO UPDATE THAT TO 13MM. SORRY CAPS, DOING SPEC SHEETS AT WORK. I'LL MEASURE MINE, THE PROJECT IS HERE AT WORK IN THE WAREHOUSE.

[2smokenNick]

Thanks guys! Much appreciated!

[m in sc]

yup. 13mm (1/2")

[Frank B]

I used 1/2 and I barely had to file the caliper for clearance.

I've got to say now that I've actually made the rotor spacer, pretty much by eye and trial and error, I should have just bought one..! I used close to $150 in materials and tools when one could be bought for 50 now...

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675

[2smokenNick]

I used 1/2 and I barely had to file the caliper for clearance.

I've got to say now that I've actually made the rotor spacer, pretty much by eye and trial and error, I should have just bought one..! I used close to $150 in materials and tools when one could be bought for 50 now...

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675

Cool! It's nice to see I have some options! What caliper/rotor did you use? I'm not sure what size thickness spacer to use...
Nick

[Frank B]

I used fzr600 rotor and an fz8 caliper, Zuma 50 11mm master cylinder . Just because that's what was a good price when I did it. There are a lot of models that use the same rotors and calipers and different colors too. You'll need A new or different brake line, cheap on eBay as well. Longer bolts to hold the rotor on, and chase the threads in the wheel with a tap all the way in.
There still was a little filing and massaging to do but it works great. Don't be put off if it rubs a little and you need to file something to get it to clear..

[m in sc]

yeah, frank did good on his for sure. 

[2smokenNick]

Sweet thanks for the tips. Found a master cylinder that will work, but can't seem to find the right brake line. Any advice? Most seem like the universal type that probably won't work...
Nick

[rodneya]

Sweet thanks for the tips. Found a master cylinder that will work, but can't seem to find the right brake line. Any advice? Most seem like the universal type that probably won't work...
Nick

Russell stainless brake lines come in all sorts of lengths and ends just thread on so you can chose straight or angled as needed

[Frank B]

Cheap eBay ones I used, front and rear.

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704

[Frank B]

yeah, frank did good on his for sure. 

I had great guidance  ;D

[2smokenNick]

Cheap eBay ones I used, front and rear.

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704

Thank you for the link. I'll give the 31.5 inch ones a try...or maybe go longer? Shorter?
Nick