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Big Bear Brake job

This is a discussion on Big Bear Brake job within the Kodiak/Big Bear/Bruin/Wolverine Discussion forums, part of the Other Yamaha Forums category; What can I expect? I have done numerous brake jobs on cars; disc and drums. I asked a shop how much they would charge and ...


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#1
04-08-2013, 11:13 AM
Big Bear Brake job

What can I expect? I have done numerous brake jobs on cars; disc and drums. I asked a shop how much they would charge and he said it depends on how much labor was involved, saying they can be a pain in the a**.
This bike is so old and all of the bolts are seized. I broke quite a few removing the racks so I could remove and paint the fenders.

I have the rear shoes. Is it a straight forward process like on a truck? It are there special tools I need? This is my first ATV so bare with me. Took the Mrs. on a ride yesterday and she enjoyed it....so maybe I can get her one too! LOL


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#2
04-08-2013, 11:46 AM
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Originally Posted by 01BigBear400 View Post
What can I expect? I have done numerous brake jobs on cars; disc and drums. I asked a shop how much they would charge and he said it depends on how much labor was involved, saying they can be a pain in the a**.
This bike is so old and all of the bolts are seized. I broke quite a few removing the racks so I could remove and paint the fenders.

I have the rear shoes. Is it a straight forward process like on a truck? It are there special tools I need? This is my first ATV so bare with me. Took the Mrs. on a ride yesterday and she enjoyed it....so maybe I can get her one too! LOL


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An ATV brake job is a heck of a lot easier than an auto brake job. Everything is smaller and lighter and simpler
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#3
04-08-2013, 11:49 AM
The hardest part of a brake job is just getting everything apart. The rest is like any car really. The worst part is damaged or seized cylinders or bad linings. Those will cost you some bucks. However, if you can get it apart, doing the job is pretty easy and hopefully putting it back together will be easy also.

My Bear has no front brakes because the PO neglected them to the point they are literally gone. I'm in the process of trying to find parts to change out the drum brakes to disc, but that is proving to be a challenge too.
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#4
04-08-2013, 01:01 PM
Re: Big Bear Brake job

I'm hoping all I have to do is replace the shoes that I've already bought.

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#5
04-09-2013, 04:54 PM
Re: Big Bear Brake job

Well...as you would know it....my luck with this Big Bear just ain't that good. I can not get the drum off and on top of that I broke a tap off of the backing plate!
The one that the spring clips to. The way it looks in my Clymer manual is the drum/hub is one assembly.
True?

Help, if you know how to get the drum off.


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#6
04-09-2013, 09:55 PM
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Well...as you would know it....my luck with this Big Bear just ain't that good. I can not get the drum off and on top of that I broke a tap off of the backing plate!
The one that the spring clips to. The way it looks in my Clymer manual is the drum/hub is one assembly.
True?

Help, if you know how to get the drum off.


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Honestly youre wasting your time rebuilding the rear brakes anyway. I gutted all the brake stuff off mine (shoes brake lever and cable). Get your front brakes working 100% and those are more than enough to stop the whole bike. The rear is nothing more than a parking brake. But it sounds like your drum is seized to the axle splines. Soak it in penetrating oil, or heat it off, or persuade it off with a BFH. Just make sure you don't hammer directly on the axle shaft threads(where the large hub nut goes).
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#7
04-11-2013, 02:23 AM
Re: Big Bear Brake job

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Honestly youre wasting your time rebuilding the rear brakes anyway. I gutted all the brake stuff off mine (shoes brake lever and cable). Get your front brakes working 100% and those are more than enough to stop the whole bike. The rear is nothing more than a parking brake. But it sounds like your drum is seized to the axle splines. Soak it in penetrating oil, or heat it off, or persuade it off with a BFH. Just make sure you don't hammer directly on the axle shaft threads(where the large hub nut goes).
I may be wasting my time rebuilding the rear brakes, but it will gimmie peace of mind....especially if my kid is riding it.
It will be a few days before I can get back to looking at it.

Question 1: Do the brake cables have to be removed before the drum will come off??? I agree with you that its probably seized onto the axle.. But I read somewhere that the cable has to be removed.

Question 2: Is there any other site for OEM Yamaha parts that are less expensive than Partzilla.com? I have checked quite a few Websites and partzilla seems to be the lowest priced.

Question 3: Does anyone make aftermarket brake parts; ie rear brake plate, drum, etc?

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#8
04-11-2013, 08:51 AM
It is strange they put drum brakes on your newer bear 400 but my 1991 bear 350 has disc brakes on the rear.

I have found partzilla to have the lowest prices, or their partner company boats.net sometimes. The one thing about them is they take up to 3 days just to ship the order, so you won't get anything from them in a hurry.

Keep working on it. You need to have functioning brakes, especially if the kids are riding that bike.
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#9
04-11-2013, 12:40 PM
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Originally Posted by 01BigBear400 View Post
I may be wasting my time rebuilding the rear brakes, but it will gimmie peace of mind....especially if my kid is riding it.
It will be a few days before I can get back to looking at it.

Question 1: Do the brake cables have to be removed before the drum will come off??? I agree with you that its probably seized onto the axle.. But I read somewhere that the cable has to be removed.

Question 2: Is there any other site for OEM Yamaha parts that are less expensive than Partzilla.com? I have checked quite a few Websites and partzilla seems to be the lowest priced.

Question 3: Does anyone make aftermarket brake parts; ie rear brake plate, drum, etc?

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Only part of the cable you need to touch is at the wingnut adjuster/cam lever at the backing plate. Even then you don't need to remove the cable just back the wingnuts off all the way to take off all tension off the cam. I don't think anyone will carry "cheap" OEM Yamaha parts. Yamaha sets their own price regardless of who you buy OEM parts from. Its like Microsoft and their software, they set the price and that's THE price you pay anywhere. Some places vary by a buck or two. OEM Yamaha parts are retardedly expensive.
For aftermarket parts, just go to any place that sells powersports/atv`s. They have aftermarket parts books IE: Motovan, Parts Canada (or Parts Unlimited for folks in the U.S.),Moose Utility/Moose Racing...and a few others.
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#10
04-11-2013, 12:43 PM
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It is strange they put drum brakes on your newer bear 400 but my 1991 bear 350 has disc brakes on the rear.

I have found partzilla to have the lowest prices, or their partner company boats.net sometimes. The one thing about them is they take up to 3 days just to ship the order, so you won't get anything from them in a hurry.

Keep working on it. You need to have functioning brakes, especially if the kids are riding that bike.
Ya I never understood Yamaha`s theory on replacing a good sealed disk rear brake solid axle with a problematic drum. We 1993 and up guys got hosed.
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#11
04-16-2013, 09:05 PM
Re: Big Bear Brake job

Finally got everything off. Old shoes were broken and moldy! Nasty! Gotta order some new parts now. Hopefully my friend can have the back plate welded back together to save me $200!! I can't believe the back plate is $204!!!
...Don't always get the BFH first!......


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#12
04-17-2013, 09:00 AM
Yeah, the BFH has a a place in repairs, but usually as a last resort.

And, check ebay for back plates if you need one. I saw plenty on there recently for fair prices.
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#13
04-19-2013, 09:58 PM
Re: Big Bear Brake job

Haven't had luck with eBay. All I see are ones people have taken off from their old quads... and they ate different from my model year.

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#14
04-19-2013, 11:21 PM
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Haven't had luck with eBay. All I see are ones people have taken off from their old quads... and they ate different from my model year.

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Doesn't the 01 bear have the rear drum on the left side, unlike the 90`s had it on the right?
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#15
04-20-2013, 09:10 PM
Re: Big Bear Brake job

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Doesn't the 01 bear have the rear drum on the left side, unlike the 90`s had it on the right?
No, my 01 has the drum on the rear passenger right side.

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