Join Date: Oct 2010
Location: Arlington, Tn (Outside Memphis)
I looked around and didn't really see any instructions on how to change the front brake pads on the Rhino. It make be elementary to most, and once I got in there, it really is. Thought I'd post about it for anyone else who may be looking for a how to.
Tools you'll need:
A floor jack
11/16" socket and your choice of driver
Allen wrench (didn't notice the size, but I think it was a 1/4")
1 or 2 large C-clamps
Can of brake fluid (optional)
Compressed air or nylon bristle brush
Shop light or flashlight
Emry cloth or fine sand paper
Light oil or grease
Start by loosening the front lug nuts on which ever side you start on (usually best to start away from the master cylinder)
Raise the Rhino and support with jack stand (i leave the jack in place for extra support).
Remove the lugnuts and place in a safe place along with the front wheel.
Look at the back of the spindle and you will see a 12mm (head) bolt at the top of the caliper and one at the bottom. Remove these bolts and set aside. Remove the caliber from the spindle and gently turn it so you can see the inboard side (rear). You will notice two countersank allen bolts. Loosen and remove the bolts. If yours are like mine, they will require some effort to remove from the caliper. It helps to use the flat screwdriver to push the pads towards the rear of the caliper as there is a spring at the back of the caliper. If that doesn't work, a thin shaft screwdriver or other tool can be used to GENTLY tap the pins out. Mine were in horrible shape so i used some light sand paper to slick them out. I applied a light oil to them when I was done before reinstalling them. I think you could use a thin layer of grease as well, just don't over do it. Use a C-clamp and the old pad to drive the pistons back into the caliper. I worked side to side with even pressure until they were seated completely. Install the new pads one at a time, place the inboard pad in the housing and start the pins back in one at a time. Don't insert them too far as you will have to install the outboard pad too. Once you have them both in, start the caliper pins and tighten. Hang the caliper back on the spindle and reinstall the caliper bolts and tighten. Replace the wheel and snug the lugs. Once the Rhino is back on the ground, tighten the lug nuts to Yamaha's specified torque for your wheels (steel or alloy). Repeat the process for the opposite side. Once you are done, press the brake pedal down, it will probably go to the floor or near it. Dont worry! Pump it about 8 times you will get full pressure back. When you are done, check your master cylinder fluid level. Adjust if needed. Go for a slow test drive in a safe area and test your brakes.
Alternatively, you can choose to bleed your brakes when you are done, but if you don't introduce air into the system, you shouldn't need to.
It took me longer to type this that it did to remove and replace one side!
Hope this helps someone who isn't sure, if you still aren't sure, consult a professional!
2006 660 SE, 3" Extreme Lift, 26" XTR's, Seizmik CDI