Before you guys spend any money, remove your front caliper, pump till the pistons move out a little and then reinstall the caliper. You’ll have to spread the pads just far enough to get it started on the rotor and wiggle/force it back in place. Pump the lever a few times then bolt it back down and you’re good to go. The free play at the lever is due to excessive piston pullback. I’m guessing the lip seals they use in the caliper are different from what Brembo uses and it doesn’t keep us close of an adjustment. Front brake on a 23 501s is rocksolid now.
Update: I installed a Brembo caliper and the pull/engagement is spot on. Now I can run in the lever adjuster so it’s not such a reach. Thanks to the OP for posting the fix.
@@michaelbartz4077 great, I'm happy my expenditures helped, lol. I've been happy since I made the change also. If only suspension tuning was that easy.
@@lucgallant I put the Race Tech FMGV-27523XC kit in the front and in the rear a .48 spring, gold valve/separator valve with a bladder kit in the rear. The kits come with several shim sets; RT will work up a profile for you with stack recommendation. I’ve done 4-5 bikes with RT components, all have worked really well for me. I’m riding gnarly, rocky desert with some single track and some fast 2 track. The suspension is great every where.
What a PITA. I kinda just did the same thing when I converted my Beta 300 Xtrainer to KTM forks, also had to use all KTM brake hardware as I didn't want to mix Nissin and Brembo parts, although they may have worked together.
The difference probably comes from the fact that the Braktec caliper pistons are 25mm versus the Brembo caliper pistons are 24mm which is significant. That's why when you swapped only to the Brembo master the lever pull was still long. I haven't taken apart brake masters to compare but pretty certain that the Brembo master piston diameter is also smaller than the Braktec.
Ya I feel your pain. Feels about the same as taking money out of your wallet and lighting it on fire. Anyway I'm very happy I fixed the problem so I stopped hating the brake and hence the bike....
Just got a 23 450 FE and noticed immediately how mushy the front brake was, I have a 2015 501FE with Brembo s- they are spot on. Thinking I can swap out the units. I was wonering if just replacing the Calipier would cure the mush since the master swap in your video did'nt really do anything? I did notice that the map switch has it's own carrier on the bar, so that would make the swap that much simpler.
If I had to choose between two components I'd definitely try the caliper first because as you say the master did not do anything. But, the problem I think will be to find one on its own, it may be almost cheaper to get both off a take-off. Let me know how you make out!
Also just a note - these brakes weren't mushy. They basically didn't engage until that 1.25", then they felt normal. If they start to engage from the beginning and braking action occurs and you just feel mush, it could be air. I'd definitely give them a good backbleed before spending any money.
Mushy was perhaps a poor choice, it was the amount of travel before the caliper engages the pads. Two in my regular ride group have 22 Braktec. I’m used to my 2015 501 Brembo engagement. I’m use aggressive trail braking. I do find the Brembo rear locks up too easily and my buddies really like the the slower engagement of the Braktec. Up front I haven’t had any problem with the Brembo, it’s spot on and even through the full stroke. Granted I haven’t ridden the 450 except to run a few heat cycle and load it. Loading it, I literally pulled it to the grip to lock up the front. I’ll bleed the system but it’s that inch and a half lag that got my attention. Swapping, if they are comparable with my 501 is probably too much trouble. I’ll see how it holds up before I look for a Brembo caliper. Right now I’m just going over the bike, putting the proper spring rate and a bladder kit on the rear, putting the twin air power flow filter frame/air cleaner and opening the end cap on the stock bike. Since the bike is mapped for close course, I’m thinking I won’t have to advance the TPS. I did all 3 on my -5 and it run on the stock map without flame out- it’s been a great ride, just time to update my Baja machine. Appreciate the original post on the Brembo conversion!
I was going to ask Can you not use part of bracket from a KTM setup for the mapswitch to hold it in place? but then realized that the Husky mapswitch is made to be part of the master cyclinder mount? I've see the map switch for the KTMs and they mount in place of the top clamp on the brake.. , I guess you would just need to get a lower clamp to mount it elsewhere if you didnt want to have it on the clutch/brake .
FWIW- the 23 450 fe map switch is on it own plastic mount. It was closest to handgrip, I took the start button off and slide the switch to the other side. You have take the gripes off to move it, it’s not the smartest mount. I might move it to the other side if the wiring harness allows it. I thought I saw one mounted on the left side of a 22 501. Maybe the ktm/Husky switches are interchangeable?
@@RobertoBurta sorry, I misunderstood what you asked, or was asleep still.... I bought a takeoff so it came caliper and bracket together. I was half asleep sorry... if you send me your email I'll email you a pic of the assembly I installed.
Before you guys spend any money, remove your front caliper, pump till the pistons move out a little and then reinstall the caliper. You’ll have to spread the pads just far enough to get it started on the rotor and wiggle/force it back in place. Pump the lever a few times then bolt it back down and you’re good to go. The free play at the lever is due to excessive piston pullback. I’m guessing the lip seals they use in the caliper are different from what Brembo uses and it doesn’t keep us close of an adjustment. Front brake on a 23 501s is rocksolid now.
@@ajbarrick1894 hey that's awesome info thanks!!
@@lucgallantplease pin aj,s comment just tried it and the front brake no more play on it. Only the couple of mm that are nessesary.
@@bertr286 great news! I don't see a pin option but I liked and hearted, should help it be up top!
Update: I installed a Brembo caliper and the pull/engagement is spot on. Now I can run in the lever adjuster so it’s not such a reach. Thanks to the OP for posting the fix.
Great news, still got the Braktec up top?
@@lucgallant yes, thanks to you, I left the master on. Not wild about the Braktec perch mounts though.
@@michaelbartz4077 great, I'm happy my expenditures helped, lol. I've been happy since I made the change also. If only suspension tuning was that easy.
@@lucgallant I put the Race Tech FMGV-27523XC kit in the front and in the rear a .48 spring, gold valve/separator valve with a bladder kit in the rear. The kits come with several shim sets; RT will work up a profile for you with stack recommendation. I’ve done 4-5 bikes with RT components, all have worked really well for me. I’m riding gnarly, rocky desert with some single track and some fast 2 track. The suspension is great every where.
You can move the map switch onto the clutch side. My Husky actually came that way from the dealer, the clamps are compatible side to side.
Oh, man, never realized? Thanks for pointing that out!!
Thanks for positing this..
What a PITA. I kinda just did the same thing when I converted my Beta 300 Xtrainer to KTM forks, also had to use all KTM brake hardware as I didn't want to mix Nissin and Brembo parts, although they may have worked together.
The difference probably comes from the fact that the Braktec caliper pistons are 25mm versus the Brembo caliper pistons are 24mm which is significant. That's why when you swapped only to the Brembo master the lever pull was still long. I haven't taken apart brake masters to compare but pretty certain that the Brembo master piston diameter is also smaller than the Braktec.
Did the same. Swapped out the 9mm brake teck for a nissan 12.5 master and still a weak leaver. Looks like the caliper is the fault.
Thanks for sharing. I too have a TE300i with Braktec and am not impressed with the front brake.
Ya I feel your pain. Feels about the same as taking money out of your wallet and lighting it on fire. Anyway I'm very happy I fixed the problem so I stopped hating the brake and hence the bike....
Overbleed them. Make sure your pistons are all the way out, them bleed. Trick is used the make Sram brakes work nicely
Just got a 23 450 FE and noticed immediately how mushy the front brake was, I have a 2015 501FE with Brembo s- they are spot on. Thinking I can swap out the units. I was wonering if just replacing the Calipier would cure the mush since the master swap in your video did'nt really do anything? I did notice that the map switch has it's own carrier on the bar, so that would make the swap that much simpler.
If I had to choose between two components I'd definitely try the caliper first because as you say the master did not do anything. But, the problem I think will be to find one on its own, it may be almost cheaper to get both off a take-off. Let me know how you make out!
Also just a note - these brakes weren't mushy. They basically didn't engage until that 1.25", then they felt normal. If they start to engage from the beginning and braking action occurs and you just feel mush, it could be air. I'd definitely give them a good backbleed before spending any money.
Mushy was perhaps a poor choice, it was the amount of travel before the caliper engages the pads. Two in my regular ride group have 22 Braktec. I’m used to my 2015 501 Brembo engagement. I’m use aggressive trail braking. I do find the Brembo rear locks up too easily and my buddies really like the the slower engagement of the Braktec. Up front I haven’t had any problem with the Brembo, it’s spot on and even through the full stroke. Granted I haven’t ridden the 450 except to run a few heat cycle and load it. Loading it, I literally pulled it to the grip to lock up the front. I’ll bleed the system but it’s that inch and a half lag that got my attention. Swapping, if they are comparable with my 501 is probably too much trouble. I’ll see how it holds up before I look for a Brembo caliper. Right now I’m just going over the bike, putting the proper spring rate and a bladder kit on the rear, putting the twin air power flow filter frame/air cleaner and opening the end cap on the stock bike. Since the bike is mapped for close course, I’m thinking I won’t have to advance the TPS. I did all 3 on my -5 and it run on the stock map without flame out- it’s been a great ride, just time to update my Baja machine. Appreciate the original post on the Brembo conversion!
@@michaelbartz4077 I fully agree it's that lever travel that got my going on this too. Good luck with the conversion!
Thanks for the video. What model / year is the ktm caliper and can you send a picture. Thanks
I think it was off a 2022 SX 150. If you send me your email address I can send photos.
@@lucgallant thank you, I am going to try the caliper first and see if does the trick.
I was going to ask Can you not use part of bracket from a KTM setup for the mapswitch to hold it in place? but then realized that the Husky mapswitch is made to be part of the master cyclinder mount?
I've see the map switch for the KTMs and they mount in place of the top clamp on the brake.. , I guess you would just need to get a lower clamp to mount it elsewhere if you didnt want to have it on the clutch/brake .
FWIW- the 23 450 fe map switch is on it own plastic mount. It was closest to handgrip, I took the start button off and slide the switch to the other side. You have take the gripes off to move it, it’s not the smartest mount. I might move it to the other side if the wiring harness allows it. I thought I saw one mounted on the left side of a 22 501. Maybe the ktm/Husky switches are interchangeable?
For fitting the brembo caliper, did you also need to change the mounting support, or you can use the one from braktec? Thank you!
Reused the Braktec one no issue! 👍
@@lucgallant i also got a new brembo caliper, but mine dosen't seem to fit the braktec support
@@RobertoBurta sorry, I misunderstood what you asked, or was asleep still.... I bought a takeoff so it came caliper and bracket together. I was half asleep sorry... if you send me your email I'll email you a pic of the assembly I installed.
Does it work with the brembo pump an braktec caliper ?
See the description and I mention it in the video.