How to Bleed & Replace Brake Fluid on a 2020 Yamaha Kodiak 450 EPS

Shop parts for a 2020 Yamaha Kodiak 450 EPS ATV.

This step-by-step MotoSport guide walks you through safely replacing and bleeding the brake fluid on your 2020 Yamaha Kodiak 450 EPS. Procedures are written specifically for this MMY ATV platform and include model notes you should know before you start.

Model notes & cautions for the 2020 Kodiak 450 EPS

  • The Kodiak 450 EPS uses hydraulic brakes with a hydraulic master cylinder and calipers; EPS denotes electric power steering but the EPS system is separate from the brake hydraulics.
  • Use DOT 4 brake fluid unless the factory service manual for 2020 Kodiak 450 EPS specifies otherwise. Do not mix DOT 3, DOT 4 & DOT 5 (silicone) fluids.
  • Brake fluid is hygroscopic — it absorbs water. Replace fluid at regular intervals or when performance degrades. Contaminated fluid can cause corrosion and reduced braking performance.
  • Protect painted surfaces & plastic: brake fluid will damage paint and plastics. Clean spills immediately with water and shop rags.
  • Have replacement crush washers, bleed screws in good condition, and use fresh tubing & a clean catch bottle to prevent contamination.

Tools & supplies

  • DOT 4 brake fluid (fresh, unopened)
  • Bleeder kit or clear vinyl tubing and a catch bottle
  • Wrenches for bleed nipples (typically 8mm-10mm)
  • Phillips/flat driver to remove reservoir cap & diaphragm
  • Clean shop rags, gloves, safety glasses
  • Brake cleaner for external cleanup
  • Optional vacuum or pressure bleeder if you prefer faster, one-person bleeding

Preparation

  1. Park the Kodiak on level ground, engage park/parking brake, and remove the key. For added safety, block the wheels.
  2. Clean the master cylinder reservoir cap area thoroughly to prevent dirt falling into the system.
  3. Remove the reservoir cap and diaphragm carefully; cover the opening with a clean shop rag to catch any contaminants.
  4. Top up the reservoir with fresh DOT 4 fluid to the specified level (do not overfill).
  5. Identify bleed screws at each caliper. For dual caliper systems, you will bleed the caliper farthest from the master cylinder first then proceed toward the closest.

Bleeding sequence & method

Standard gravity or manual pump method (one- or two-person):

  1. Attach clear tubing to the first bleed nipple and place the other end in a catch bottle partially filled with fresh fluid to prevent air re-entry.
  2. Have an assistant slowly pump the brake lever or pedal several times and hold it under light pressure. Open the bleed nipple slightly to let fluid and air escape, then close the nipple before the assistant releases the lever/pedal. Repeat until fluid runs clear without bubbles.
  3. Keep reservoir level topped up throughout the process to prevent air being drawn into the master cylinder.
  4. Move to the next caliper following the farthest-to-nearest rule. Repeat the process until all calipers are bled and the fluid is clear and bubble-free.
  5. If using a vacuum bleeder, attach the bleeder to the nipple, open the nipple, and allow the vacuum tool to draw fluid until clear. Maintain reservoir level.

Flushing & full replacement

  • To fully replace old fluid, perform the bleed procedure at each caliper until the fluid leaving the system is the same fresh color and clarity as the new fluid in the reservoir.
  • For best results, start with the system emptying as much old fluid as possible from the lowest bleed point, then continue until the reservoir and return show only fresh fluid.

Final checks & reassembly

  1. Close all bleed nipples securely and torque to the factory specification in the service manual.
  2. Top the reservoir to the proper level and reinstall the diaphragm and cap, ensuring a good seal.
  3. Wipe any spilled fluid, inspect lines & fittings for leaks, and confirm bleed screws are tight.
  4. Firmness test: with the ATV on the ground, test pedal and lever feel — both should be firm. If soft or spongy, repeat bleeding.
  5. Road/ride test at low speed in a safe area to verify braking performance before normal use.

Disposal & maintenance tips

  • Dispose of used brake fluid per local hazardous-waste regulations.
  • Record the service date and mileage on your maintenance log. Replace brake fluid regularly as recommended by Yamaha or if it looks dark or contaminated.
  • Inspect brake lines, pads, calipers, and rotors while you work. Replace worn pads or damaged hardware to maintain safe braking.
  • If you encounter persistent air, swollen rubber lines, or internal master cylinder leakage, stop — the master cylinder or hoses may need replacement or professional servicing.

When to seek professional help

If bleeding doesn't restore firm pedal/lever feel, you see fluid leaking internally, or you aren't comfortable performing the job, have a certified mechanic inspect and service the brake system. Incorrect bleeding or the wrong fluid can compromise 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.