How to Bleed and Replace Brake Fluid on a 2002 Yamaha Bear Tracker

Shop parts for a 2002 Yamaha Bear Tracker ATV.

This MotoSport guide gives step-by-step, model-specific instructions for draining, replacing, and properly bleeding the hydraulic brakes on a 2002 Yamaha Bear Tracker. Follow these procedures carefully to restore firm lever/pedal feel and maintain safe stopping performance. If you are unsure at any point, consult a trained technician or bring the ATV to a shop.

What you need

  • Brake fluid: DOT 4 (use the fluid specified in your owner’s manual)
  • Clear hose to fit bleeder nipple
  • Bleeder bottle or catch container
  • Turkey baster or fluid syringe (for reservoir evacuation)
  • Wrenches for bleeder nipple and banjo bolts (usually 8-12 mm)
  • New banjo bolt crush washers (copper or aluminum) for each brake hose removal
  • Clean rags, brake-clean spray, and protective gloves
  • Jack or ramps and stands to safely support the ATV
  • Torque wrench (for banjo bolts and caliper fasteners)

Safety first

  • Work on a cool vehicle; avoid hot components.
  • Wear eye protection and nitrile gloves; brake fluid will damage paint and plastics.
  • Keep brake fluid sealed and dispose of old fluid per local regulations.
  • Park on a level surface and securely support the ATV before removing wheels.

Model notes for the 2002 Yamaha Bear Tracker

  • The Bear Tracker uses a simple hydraulic system without ABS; bleeding order is determined by distance from the master cylinder.
  • Common weak points on this MMY include aged rubber hoses and corroded banjo fittings on older machines—inspect lines and replace if cracked or bulged.
  • Replace banjo crush washers whenever you loosen the banjo bolt to avoid leaks.
  • If you experience continued sponginess after bleeding, check master-cylinder seals and caliper pistons for wear or corrosion; rebuild kits are inexpensive and often necessary on high-mileage ATVs.
  • Recommended brake-fluid change interval for trail/utility use is every 1-2 years to avoid moisture contamination and boiling under heavy use.

Step-by-step procedure

1. Preparation

  • Park ATV on level ground, engage parking brake (if fitted), and block wheels.
  • Elevate the wheel(s) you’ll work on enough to rotate freely; remove wheel(s) if it improves access.
  • Clean the master cylinder reservoir cap area thoroughly to prevent contamination when opened.
  • Remove reservoir cap and diaphragm; inspect fluid color. Old fluid is dark and should be replaced.

2. Remove old fluid from reservoir

  • Use a turkey baster or fluid syringe to remove as much old fluid as possible from the reservoir without introducing air.
  • Refill reservoir with fresh DOT 4 fluid to the specified level but do not overfill.

3. Determine bleeding order

  • Start bleeding at the caliper farthest from the master cylinder and finish with the closest. For the Bear Tracker this usually means: rear caliper(s) first, then front caliper(s). If unsure, identify master-cylinder location and work outward.

4. Manual one-person bleed (bench and lever method)

  • Fit a clear hose to the bleeder nipple and place the other end in a catch container partially filled with fresh fluid to prevent air re-entry.
  • Crack the bleeder nipple about 1/4 turn using the appropriate wrench.
  • Slowly squeeze the brake lever (or press the pedal) until firm, hold pressure, then open the bleeder to let fluid and air out. Close the nipple before releasing the lever. Repeat until you see clean, bubble-free fluid exiting.
  • Top the reservoir frequently to avoid drawing air into the system.
  • Tighten the bleeder nipple to the specified snug torque when done (apply manufacturer-recommended torque if available).

5. Two-person bleed (recommended for easier control)

  • Assistant slowly squeezes the lever/pedal while you open the bleeder nipple to let fluid out. Close the nipple before the assistant releases pressure. Repeat until clear fluid exits and no bubbles remain.
  • Keep reservoir topped to prevent air ingress.

6. Replace fluid and repeat for all calipers

  • After bleeding the far caliper, move to the next-farthest and repeat the process. Finish with the caliper nearest the master cylinder.
  • When swapping brake hoses or banjo bolts, install new crush washers and torque the banjo bolt to the correct spec (snug, then to spec if known).

7. Final checks

  • Top the reservoir to the proper level and reinstall the diaphragm and cap securely.
  • Pump the lever/pedal several times until firm. With ATV supported, verify that pistons move slightly and there are no leaks.
  • Lower the ATV, torque wheels if removed, and perform a low-speed test in a safe area to confirm braking performance.

Troubleshooting

  • Persistent spongy lever after thorough bleeding: likely contaminated master cylinder or caliper seals or internal air pockets. Consider rebuilding the master cylinder and calipers.
  • Visible leaks at banjo bolts or bleeder nipples: replace crush washers and tighten to spec; replace corroded fittings or hose ends.
  • Foamy or milky fluid: indicates moisture contamination; fully flush system and replace fluid, then monitor performance.

Maintenance tips & final notes

  • Always use fresh, unopened brake fluid from a sealed container and keep the reservoir cap on when not actively bleeding.
  • Label the service date and next recommended fluid change in your maintenance log; 12-24 months is a common interval for ATVs used regularly.
  • If you’re replacing hoses or caliper hardware, use OEM or high-quality aftermarket parts designed for the 2002 Yamaha Bear Tracker to ensure fit and performance.
  • After any brake service, perform a careful functional test at low speed to confirm safe stopping before returning to normal use.

Performing a thorough brake-fluid change and bleed will restore braking performance and extend component life on your Bear Tracker. If you need seals, hoses, or caliper rebuild kits, MotoSport has parts and supplies matched to the 2002 Yamaha Bear Tracker.

Related Shopping Categories

Shop Brake Fluid for a 2002 Yamaha Bear Tracker ATV.

Shop Brake Bleeders for a 2002 Yamaha Bear Tracker ATV.

Shop Brake Pads for a 2002 Yamaha Bear Tracker ATV.

Shop Brake Lines for a 2002 Yamaha Bear Tracker ATV.

Shop Brake Tools for a 2002 Yamaha Bear Tracker ATV.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.