How to Bleed and Replace Brake Fluid on a 2019 Yamaha Kodiak 700 4X4 EPS IRS
Shop parts for a 2019 Yamaha Kodiak 700 4X4 EPS IRS ATV.
This MotoSport-exclusive procedure walks you through safely flushing old brake fluid and properly bleeding the hydraulic system on the 2019 Yamaha Kodiak 700 4X4 EPS IRS. Follow every step carefully and consult your owner's manual for specifications unique to your unit. If you're not comfortable with hydraulic work, have a certified technician do the job.
What you need
- DOT brake fluid type specified by Yamaha (check owner's manual; commonly DOT 3 or DOT 4). Use only fresh, unopened fluid and keep caps closed to avoid moisture.
- Clear vinyl bleed hose, collection bottle, and line clamp
- Wrench set (bleeder wrench typically 8 mm or 10 mm depending on caliper)
- Screwdrivers, funnel with filter or brake fluid syringe
- Clean rags, nitrile gloves, safety glasses
- Jack or ramps and wheel chocks to stabilize the ATV
- Optional: vacuum brake bleeder or pressure bleeder for faster, cleaner bleeding
Model-specific notes for the 2019 Kodiak 700 4X4 EPS IRS
- Brake system layout: The Kodiak 700 uses hydraulic front brakes and a hydraulic rear brake; the front brake master reservoir is located at the handlebar assembly and the rear master cylinder & reservoir are frame-mounted near the rear brake pedal. Confirm reservoir locations before starting.
- EPS and IRS considerations: Power steering and independent rear suspension don't change bleeding order, but take care when jacking or lifting the ATV so electrical connectors and suspension linkages are not stressed.
- No factory ABS on this model year. Bleeding is straightforward without ABS valves, but watch for caliper and master cylinder access limitations due to skid plates or racks.
- Use Yamaha-specified fluid and torque values for banjos and bleeder screws where provided in the service manual.
Safety and prep
- Work on a level surface. Chock wheels and disconnect the battery if you will be removing electrical components.
- Protect painted surfaces. Brake fluid damages paint & plastics; cover fenders and frame with rags.
- Wear eye protection and gloves. Brake fluid is corrosive to skin and materials.
- Inspect hoses, lines, calipers, master cylinders and reservoir caps for damage or leaks before starting. Replace any cracked hoses or corroded fittings.
Step-by-step: Replace brake fluid and bleed system
- Raise the ATV slightly so wheels are free to move (use jack stands or ramps) and remove any skid plates or racks blocking access to bleeder screws.
- Clean the exterior of the brake fluid reservoirs. Remove the reservoir cap(s) and diaphragm. Siphon or pump out most of the old fluid into a container for proper disposal, leaving a small amount to keep air out while you work.
- Add fresh DOT fluid to the reservoir(s) up to the specified level. Keep the reservoir cap nearby but do not seal it completely while bleeding so air can escape.
- Start with the caliper farthest from the master cylinder and progress to the nearest. For most Kodiak layouts: bleed the rear caliper first (if the rear master cylinder is separate), then the front calipers, right then left, or follow the manual's recommended sequence. The goal: start at the most remote hydraulic endpoint.
- Attach a clear bleed hose to the bleeder screw and submerge the other end in a small bottle partially filled with fresh fluid to prevent air re-entry. Slightly open the bleeder screw (about a quarter turn).
- Have a helper slowly squeeze the brake lever/pedal several times and hold pressure. While pressure is held, open the bleeder screw to allow fluid and air out until the stream is steady and free of bubbles, then close the screw before the helper releases pressure. Repeat until no air bubbles appear. If using a vacuum or pressure bleeder, follow the tool's instructions but still monitor fluid level in the reservoir continuously.
- Keep the master reservoir topped up throughout the process. Running the reservoir dry will introduce air into the system and force you to start over.
- After finishing the farthest caliper, move to the next farthest and repeat until all calipers are bled and free of bubbles. Finish with the caliper nearest the master cylinder.
- Torque bleeder screws and any banjo bolts to the values in the Yamaha service manual. Wipe all fittings dry and inspect for leaks.
- Refill the reservoir to the correct level, reinstall diaphragms and caps securely. Clean any spilled fluid immediately.
- Lower the ATV, pump the brakes gently to build firm lever/pedal pressure, and test brake performance at low speed in a safe area before normal use.
Common problems & troubleshooting
- Spongy lever/pedal after bleeding: likely air remains in the system; repeat bleeding sequence and ensure reservoir never ran dry during procedure.
- Persistent leaks or fluid loss: locate and replace leaking hose, fitting, or caliper seal. Do not operate until repaired.
- Contaminated fluid (dark, dirty smell): a full system flush is required. Replace hoses or rubber parts showing swelling or deterioration.
- Calipers sticking after service: clean caliper slide pins and pistons, lubricate specified areas with brake-safe grease, and confirm caliper hardware is functioning properly.
Disposal and final checks
- Dispose of old brake fluid as hazardous waste at an approved facilitydo not pour down drains.
- Recheck fluid level after a short test ride and again after a few rides. Inspect for leaks and re-torque fittings if necessary.
- Record the service date and fluid type used for future maintenance intervals.
Perform brake fluid replacement at least every two years or as recommended in the Yamaha owner's manual, and sooner if fluid is dark or contaminated. When in doubt, use OEM parts and follow MotoSport's parts recommendations to maintain braking performance and safety.
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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.