How to Change the Brakes on a Yamaha Kodiak

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The conditions encountered on an off-road foray can work the Yamaha Kodiak ATV's brakes pretty hard, even while traveling at a slow pace, wearing the machine's brake pads away quickly. If left unchecked, the brake pads can wear down to their metal backing plates, preventing the brakes from operating correctly and increasing the risk of damaging the metal brake rotors.

Things You'll Need

  • Service jack
  • 14 and 17 mm sockets
  • Socket wrench
  • 5 mm Allen wrench
  • Brake pads
  • Set the ATV's parking brake, using the shift lever on the left side of the ATV.

  • Loosen the lug nuts on both front wheels, using a 17 mm socket wrench and a long-handled socket wrench. Raise the front wheels off of the ground, using a service jack.

  • Unscrew the front wheels' lug nuts completely and pull the wheels off the front axle hub.

  • Reach around the right brake rotor and unscrew the caliper mounting bolts, using a 14 mm socket and a socket wrench. Slide the caliper off the brake rotor.

  • Unscrew the brake pad pins from the back of the caliper, using a 5 mm Allen wrench. Pull the brake pads out the caliper.

  • Separate the worn brake pads from their holder spring. Place a new set of brake pads around the holder spring and insert them into the caliper.

  • Insert the brake pad pins through the holes on the ends of the brake pads. Screw the pins into the caliper, using a 5 mm Allen wrench.

  • Slide the caliper onto the brake rotor. Bolt the caliper onto the front axle hub, using a 14 mm socket and a socket wrench.

  • Replace the left caliper's brake pads, following the method shown above. Reinstall the wheels and tighten the lug nuts, using a 17 mm socket and a socket wrench. Lower the front wheels to the ground and remove the service jack.

Tips & Warnings

  • The rear brake pads can be replaced without the need to remove the rear wheels using the method shown above. The rear brake caliper is easily accessible on the rear axle.

References

  • "The Professional Motorcycle Repair Program"; Professional Career Development Institute; 1995
  • "Yamaha YFM400FAT Service Manual"; Yamaha Motor Corp.; 2002
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