Disc Brake Conversion
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  1. #1
    Junior Member JLM's Avatar
    Join Date
    Jul 2013

    Disc Brake Conversion

    I just purchased a 1992 with drum brakes, the brakes are questionable at best. How difficult is it to convert to later model disc front brake?

  2. #2
    Senior Member lizrdbrth's Avatar
    Join Date
    Jul 2010
    Desert, SoCal
    Just my opinion, but if you find the drum questionable you probably won't be tremendously impressed by the disc, either. I consider them pretty much apples-for-apples.

    That said, in terms of parts you'll need the following:

    Left lower fork leg (rights are all the same, earlier is better cuz it some still had drain plugs)
    Front wheel w/disc.
    Master cylinder and brake hose.

    Starter/kill switch from post-'01 TW (optional). If you use your existing switches the starter button will be pointing toward the ground due to the master cylinder and throttle cable locations. More of an inconvenience than it is a complete nuisance, but worth doing.

    You'll need to splice the plugs from your early model brake switch onto the master cylinder brake switch because the later switches are a larger diameter.

    Last edited by lizrdbrth; 07-01-2013 at 12:03 PM.
    I can explain it to you, but I can't understand it for you.

    Powdercoated '87 frame, extended swingarm, YZ fork legs, ATV tire, 14/55, XT350 tank, spliced quick-release seat, disc brake conversion, beeg headlight, beeger rack, Lizrdcooler, Lizrdventz and bunch of other stuff all covered in invisible ink.

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  3. #3
    Senior Member r80rt's Avatar
    Join Date
    Sep 2011
    I gotta agree with that, it's not worth the effort. I've had TW's with both, and the disc doesn't stop any better than the drum.
    Only a fool would attempt it, and God help me, I am that fool!

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