Honda Bravo Front Disc Brake Conversion

Several months of study, planning and search for parts finally paid off.  My puny but trusty Bravo is now sporting a disc brake in its front.  Well, the conversion isn't really complete at the moment but it is more on the aesthetics that needs to be ironed out.  But functional, yes it is and it is like a new found freedom brought about by more stopping power provided by the new equipment.

Here's a list of parts that I bought for the conversion

1.) disc brake system  (master, caliper, ABS, disc, hose, lever) - i got these items from an internet seller.  The master and caliper were both Nissin brand.  Dunno about the ABS which is like a small shiny canister between the hose and caliper.  Hose needs to be replaced because of cracks.  Lever also needs to be sanded and repainted to make it look good.  Disc is Ok which is good news.

2.) wheel set - 1.4 x 17 rims with hub and bearings also from the same internet seller.  I've got some spare tires, took one and it fitted perfectly on the rim.

3.) speedometer sensor - not sure if this is the correct name but it is the thing that attaches to the hub and  where one end of the speedometer cable is also connected.

4.) brake light switch - it was missing in the brake master.  It's a safety feature and therefore a must!

5.) bolts and washers - so that the brake caliper can be mounted on the fork.

6.) fork assembly - I bought this from another internet seller.  He used it in his own conversion but he eventually sold the the bike with the original forks.  I guess from a China bike because it is quite different.  Also not a Showa brand.

7.) speedometer cable - the original one for Bravo won't fit.

8.) side mirror thread adapter - the master caliper that also holds the right side mirror has a small hole.  The stock mirror's threaded end is a little bit larger.  I was thinking of having it rebored or rethreaded and the adapter is quite a lucky find.

9.) disc pads
10.) front fender - it is cheap, the old one won't fit because of the hole placements.
11.) retaining clips or brackets - this is for the front fender.  This thing clamps on the fork slider and holds the fender in place.

Whoa!!! I didn't realize that I bought all of those items above.  Cash spent is about 4k Php.  To recover some amount, I am thinking of selling the parts I removed from the bike.

Things to do :

1.) fix the handle bar - i sawed the metal that holds the right side mirror to give way for the brake master.  Some grinding, filing, sanding and painting will be required.

2.) brake system overhaul - i have this feeling the brake is quite sticky.  Some parts might be stuck.

3.) replace that brake hose

4.) tune the front forks - i am in the process of doing this at the moment.  I found out that the ride is too harsh specially for an old man's back.

Related posts:

Bravo R Conversion 1 and 2

Modified Honda Bravo