I have a 2004 Yamaha Kodiak 450. When I bought it the previous owner happened to rip the rear brake line right off the rear caliper just at the rear banjo. The brakes sat for some time rendering the caliper seals "stuck" with gunk to the rear caliper piston assembly. I cleaned the whole caliper out and got the piston moving w/ new seals. I replaced the rear brake line. I disconnected the master Cylinder assembly and made sure there was flow coming out of that and the tank reservoir emptied out. So when I went to put it back together I just cannot get it to bleed. There's some blockage somewhere. Nothing comes out of the banjo at the caliper nor the bleed screw. I have tried to syringe it with the brake lever clamped. Anybody have any ideas before I rip the whole thing out to try to find the culprit?

 

I can suggest that you get a hand vacuum pump and try putting vacuum on it at the bleed screw. On the other hand I wonder if there is a bench bleed procedure for the master cylinder. With a new master cylinder on a car you hook up hoses from the outlet back into the reservoir and pump it until no air bubbles come out of the hoses.

 

If the line is completely empty... you cannot simply put fluild in it and start bleeding [img]i/expressions/face-icon-small-smile.gif[/img] you need to get all the air out of the line.. the best way to do it is either get a hand vaccuum brake pump or do a gravity bleed. When you do a gravity bleed, I would remove the rear caliber from the quad.. let it hang over a drip pan. Crack open the bleeder and fill up the Rear master cylinder but keep an eye on it as you will need to keep filling the master cylinder up. Once you get a solid drip/stream out of the bleeder you know you have no air in the line.. Then you can close the bleeder, top off the rear brake resevouir (under the "hood") then re-install rear caliper, then bleed the brakes [img]i/expressions/face-icon-small-smile.gif[/img]

Check out the Manual Chapter 8 it might help you out

Link to 03-06 Kodiak 450 Service Manual (07 Grizzly 450's the same quad... and the only diff with the 08 is the new Wet Rear Brake)

http://www.savefile.com/files/74511

 

Crazy Steve, Thanks for the Service Manual!
That is Awesome....
Thanks Traildad. I hope to get it fixed sometime this week. I think I will goto harbor freight and get a vacumme pump.

Joel