How to Bleed & Replace Brake Fluid on a 2016 Yamaha Kodiak 700 4X4 EPS IRS

Shop parts for a 2016 Yamaha Kodiak 700 4X4 EPS IRS ATV.

This step-by-step MotoSport guide covers a full brake fluid change and bleeding procedure tailored to the 2016 Yamaha Kodiak 700 4X4 EPS IRS. Read safety notes first, then follow the preparation, fluid replacement, and bleeding steps. This procedure assumes basic mechanical skill and common shop tools. If you’re unsure about any step, consult a qualified technician or the factory service manual.

Safety & preparation

  • Work on a flat, stable surface. Chock wheels and use a center stand or jack and jackstands rated for ATVs.
  • Wear eye protection and nitrile gloves. DOT brake fluid is corrosive to paint and plastics.
  • Use only fresh DOT 4 brake fluid unless the factory manual specifies otherwise. Do not mix DOT 3/4 with DOT 5 silicone.
  • Have rags, a catch bottle, clear tubing, and a proper bleeder or syringe ready. Label all removed hardware if needed.
  • Keep a clean, sealed container for old fluid disposal and dispose of it per local regulations.

Tools & supplies

  • DOT 4 brake fluid (fresh bottle)
  • Clear plastic tubing that fits bleeder nipples
  • Catch bottle or reservoir jar
  • Brake bleeder pump, hand vacuum pump, or pressure bleeder (recommended)
  • 10 mm or 8 mm wrench for bleeder nipples (verify on your bike)
  • Screwdrivers, pliers, box wrenches, and torque wrench
  • Clean shop rags and isopropyl alcohol for cleaning

Model-specific notes for the 2016 Kodiak 700 EPS IRS

  • The Kodiak 700 EPS IRS commonly uses DOT 4 fluid and has separate front and rear hydraulic circuits. Confirm reservoir locations before starting; the front master cylinder reservoir is on the right handlebar, rear reservoir is near the rear brake master cylinder.
  • Independent Rear Suspension (IRS) rear brake hardware and hose routing differ from solid-axle models. Inspect the flexible hose to each rear brake caliper for wear and pinch points while you work.
  • Electric Power Steering (EPS) can be sensitive to fluid contamination. Keep brake fluid away from EPS wiring, sensors, and painted surfaces.
  • If your Kodiak has aftermarket accessories near reservoirs or lines, clear them out of the way to access bleeders safely.

Step 1: Inspect & prepare the bike

  • Wash brake area gently to remove dirt and grit that could contaminate fluid or enter calipers.
  • Remove wheels or access panels as needed to reach caliper bleeder nipples and pads for inspection.
  • Check pad thickness, rotors, hoses, and caliper seals. Replace worn pads or damaged hoses before bleeding.

Step 2: Drain old fluid from reservoirs

  • Open the front and rear master cylinder reservoirs. Use a clean syringe or turkey baster to remove as much old fluid as possible. Do not let the reservoirs run dry if lines are open to avoid drawing air back in; if you must, be prepared to thoroughly re-bleed.
  • Wipe the reservoir caps and surrounding area clean before removing cap to prevent contamination.

Step 3: Fill reservoirs with fresh fluid

  • Top the reservoirs with fresh DOT 4 fluid. Keep the cap off but positioned to minimize contamination during bleeding. Maintain fluid level during the entire bleed operation.

Step 4: Bleeding order & method

Use the following recommended order for the Kodiak 700 4X4 EPS IRS to minimize trapped air. Work one wheel/caliper at a time.

  1. Front right caliper (front master circuit outlet side)
  2. Front left caliper
  3. Rear caliper(s) — depending on configuration, bleed the outer first then inner, or bleed each rear wheel individually. For IRS models bleed each rear caliper in turn.

Use one of these proven methods:

  • Pressure bleeder (professional – easiest single-person method): Attach to the reservoir and pressurize per bleeder tool instructions. Open each bleeder nipple until clear fluid, then close.
  • Hand vacuum pump: Attach tubing to bleeder nipple, pump until clear bubbles stop and fluid is clear, then close bleeder while under vacuum.
  • Gravity or two-person pump-and-release: One person slowly squeezes the brake lever/pedal while the other opens the bleeder briefly to expel fluid, then closes it. Do not let the lever/pedal fully bottom out; keep firm strokes to avoid air intake.

Step 5: Bleeder technique (detailed)

  • Attach clear tubing to the bleeder nipple and route into a catch bottle partially filled with used fluid to prevent air backflow.
  • Crack the bleeder about a quarter-turn. Actuate the lever or use your vacuum/pressure tool to move fluid out. Watch for air bubbles in the tubing.
  • Close the bleeder while the lever/pedal is held in the actuated position or while vacuum is applied. Release the lever only after the bleeder is tightened.
  • Repeat until no air bubbles appear and fluid is clear. Keep reservoir topped up during the process to avoid pulling new air into the system.
  • Tighten bleeder nipple to service manual specification or snug plus a small fraction; avoid rounding the nipple.

Step 6: Final checks

  • With all calipers bled, ensure both front and rear reservoirs are filled to the correct level and secure reservoir caps with fresh seals if they were removed.
  • Pump the brake lever and pedal several times to get firm, consistent pressure. If the lever feels spongy, repeat bleeding steps for the affected circuit.
  • Inspect bleeder nipples and lines for leaks at operating pressure. Torque caliper mounting bolts to factory spec if you removed any parts for access (refer to the service manual for exact torque values).
  • Road-test at low speed in a safe area, checking braking performance and watching for fluid leaks or abnormal pedal/lever travel.

Tips & cautions specific to the Kodiak 700

  • Avoid spilling brake fluid on painted plastics or metal; it will damage finishes. Clean any spills immediately with mild detergent and water, then dry.
  • If you find rust, pitting, or severe contamination in calipers or master cylinders, rebuild or replace components rather than relying on a fluid flush alone.
  • Inspect the EPS harness routing near the master cylinder area. Don’t let fluid puddle on electrical connectors.
  • If the rear parking brake or actuator is present, ensure it does not block proper bleeding flow; disengage parking brake during bleeding if required by your service manual.

Disposal & maintenance interval

  • Dispose of used brake fluid as hazardous waste at an approved facility.
  • Change brake fluid every 1-2 years or per the service manual interval, sooner if the fluid darkens or you notice degraded brake performance.

When to consult a professional

  • If you cannot achieve firm brake lever/pedal feel after repeated bleeding.
  • If you find leaking seals, collapsed brake hoses, damaged calipers, or internal master cylinder issues.
  • If ABS or other system warning lights appear (if equipped) or if the EPS system is affected by contamination.

This procedure is provided exclusively by MotoSport for owners of the 2016 Yamaha Kodiak 700 4X4 EPS IRS. Follow factory torque specs and service manual procedures for disassembly and reassembly tasks not fully described above.

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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.