YFZ Dual Piston Calipers - On Z400

[XC Z440]

My next review is of a modification that may be of interest to those who are looking to stop in a hurry! This probably ranks pretty low on everyones to-do list, since we all want to have the fastest quad but I believe brakes are just as important (if not more) than straight line power.

The front brakes off of the Yamaha YFZ 450 are dual (or twin) piston calipers. This means there are two pistons that push on the brake pad, giving more stopping power.

What you need:
You will want to get the calipers (and brake pads, since you can not re-use the Z400 pads in these) from a YFZ 450. I am not sure if the YFZ 450X or YFZ 450R calipers are the same, however a few quick measurements are all thats needed to see if they will fit.

You may also want to upgrade to steel braided brakelines at this time. I did. Either way, you will want to get new copper washers for around the banjo bolts, as these are a one time use item.


Install:
The install is fairly straight foreward. The caliper holes line right up, however, you will need to do some minor trimming of the dust sheild (or remove it) in order for the new calipers to fit. To trim the sheild, I marked the area that needed to be removed with chalk, and then used a cutting wheel on my electric grinder. You have to take off, about 2 inches or so.

I also received the stock brake lines, however I chose to upgrade to steel braided lines at this time. When setting up the system, be patient, it will take time for the fluid to fill the new lines and calipers...and unfortunately the resevoir is so small that you must keep a close eye on it to make sure it doesn't run dry. If it does, you will have more work on your hands. Bleeding brakes is another topic, that I am sure has been covered here numerous times.

Be sure to tighten the bolts that hold the calipers in place well, and use loc-tight to ensure they do not come out on their own.

The Ride
Like Can-Am says, the ride says it all. You should notice increased brake power. I know the brakes have the power to lock up the tires on the road at will! With the new calipers, especially if you have steel braided lines, you should notice a firmer lever (from the new lines) and increased braking power. Now get out there and practice those nose wheelies!



The yellow outline on the picture below gives a rough idea of how the sheild must be cut (if someone can get me a picture similar to this with the stock sheild in place that would be more helpful...it has been about over a year since I did this mod and don't really remember how the sheild used to look).

[sberg]

From what year yfz's will this work? The part number is the same for 2004 & 2005 but changed for all the 2005+ models. Seems like you can get the calipers for $100 or less. Hope my new SS brake lines will fit these calipers this would be a good mod

[pimpit_r6]

can you still use the ltz brake lever and reservoir?

[XC Z440]

Originally Posted by dealer374

From what year yfz's will this work? The part number is the same for 2004 & 2005 but changed for all the 2005+ models. Seems like you can get the calipers for $100 or less. Hope my new SS brake lines will fit these calipers this would be a good mod

I believe mine are from a 2005, however I have tried and tried to track down where I purchased them from to confirm with not luck. I thought it was on YFZcentral.com, but my only PMs there are for FCRs.

I will continue to try to figure out what year I have.

Originally Posted by pimpit_r6

can you still use the ltz brake lever and reservoir?

Yes, you can. I added another picture showing my master cylinder with the new brake lines. As you will notice, I have two lines coming directly from the master cylinder, one goes to each front wheel. They say eliminating that T (in the stock setup) gives firmer and more even brake control.

You also could upgrade to the Honda 450R master cylinder/lever perch for even better braking performance. I do not know any more about that mod than that though.

[pimpit_r6]

sweet ... Thanks for posting the picture

[XC Z440]

According to YFZcentral.com, the 06+ front calipers are interchangable with the 04-05, although nobody seems to know what the difference is between the two. I made a thread over there about it, and will monitor it to see if anyone else has any input.

[CFM-Z440]

Excellent contribution!

[TonyPham]

So anyone know what the difference is I found some 06 ones for 75$

[BigMikesZ]

I will be doing this mod, have question regarding brake lines. I will be ordering new ss lines, should I go with the z400 lines? Are length's and diameter the same?

[sandman74]

Originally Posted by TonyPham

So anyone know what the difference is I found some 06 ones for 75$

If I remember right, there is no difference in the calipers throughout the years. In 07, yamaha upgraded the RESERVIOR in effort to match the Honda 450 brakes

[sandman74]

Originally Posted by BigMikesZ

I will be doing this mod, have question regarding brake lines. I will be ordering new ss lines, should I go with the z400 lines? Are length's and diameter the same?

The banjo fittings are identical, the stock lines will work if needed. For SS lines I recommend checking e-bay for Polaris outlaw or KTM brake lines - these bikes came stock with stainless galfer lines. They might be a bit long on stock a-arms, but a perfect fit on extended arms

[CFM-Z440]

I moved this to the suspension forum and stuck it. I left a re-direct though. This looks like a good mod.

[TonyPham]

Originally Posted by sandman74

The banjo fittings are identical, the stock lines will work if needed. For SS lines I recommend checking e-bay for Polaris outlaw or KTM brake lines - these bikes came stock with stainless galfer lines. They might be a bit long on stock a-arms, but a perfect fit on extended arms

Do you mean stock lines from the Z or Yfz?

Which KTM bike should I be looking for the lines?

Thanks for the help guys

[sandman74]

Originally Posted by TonyPham

Do you mean stock lines from the Z or Yfz?

Which KTM bike should I be looking for the lines?

Thanks for the help guys

Stock Z lines.

KTM 450 or 525 xc or the Solid axle Polaris Outlaw
like these: Polaris 450 525 OUTLAW Ktm Front Brake Hoses Lines - eBay (item 190335512275 end time Mar-09-11 16:20:35 PST)

Ebay search "Outlaw brake lines" -- I guess I should clarify, The reason I said solid axle outlaw, is because if you get the full set you can use the rear one on the Z too. (The rear one from IRS outlaw is too short.) If its just the fronts, it doesn't matter either model will work.

[TonyPham]

Do the calipers mount to the stock plate thing? Or do I need the YFZ one too? and what about the 2 mounting bolts