How to Bleed & Replace Brake Fluid on a 2002 Suzuki Eiger 400 2X4 AUTO

Shop parts for a 2002 Suzuki Eiger 400 2X4 AUTO ATV.

This MotoSport-exclusive guide walks you through safely draining, replacing, and bleeding the brake system on a 2002 Suzuki Eiger 400 2X4 AUTO. Follow each step carefully and use proper safety gear. If you are not comfortable with brake work, schedule service with a qualified technician.

Safety, tools & supplies

  • Safety glasses, nitrile gloves, and shop towels
  • Brake fluid: DOT 3 or DOT 4 (follow cap labeling; Suzuki commonly uses DOT 3confirm reservoir cap)
  • Clear plastic tubing to fit bleed nipples, catch bottle, and ample rags
  • Wrenches for bleeder nipples (typically 8mm or 10mm), screwdriver, socket set, torque wrench
  • Turkey baster or hand pump for removing old fluid from reservoir
  • Brake cleaner, container for used fluid, and gasket-safe surface protection (brake fluid damages paint/plastic)

Model notes for the 2002 Suzuki Eiger 400 2X4 AUTO

  • The Eiger 400 2X4 AUTO typically features front hydraulic disc brakes and a rear drum brake assembly. Confirm your machine's configuration before you start.
  • Rear drum systems have wheel cylinders & internal brake shoes which require different service than disc calipers; bleeding of the hydraulic line to the rear wheel cylinder is performed at the wheel cylinder bleed nipple.
  • The master cylinder reservoir is small & mounted near the handlebars. Keep the cap tightly covered except when adding fluid to avoid contamination and moisture absorption.
  • Avoid mixing DOT 3 and DOT 4 fluids during the job. Always top with the same type that was in the system or follow the reservoir cap recommendation.

Preparation

  • Park on level ground, engage park/gear, and disable the ignition. Block the wheels to prevent movement.
  • Clean the reservoir cap area thoroughly to keep dirt out. Remove the cap & diaphragm and set them on a clean surface.
  • Use the turkey baster to extract as much old fluid as possible from the reservoir. Dispose waste fluid per local regulations.
  • Inspect hoses, calipers, wheel cylinder boots, and lines for leaks, cracks, or corrosion. Replace any damaged components before bleeding.

Drain & replace fluid (recommended overall procedure)

For complete fluid replacement, combine reservoir flushing with sequential bleeding at each bleed nipple. Perform bleeding with the fleet-style sequence: furthest caliper/wheel from the master cylinder first, then closer ones. On the Eiger 400 2X4 AUTO that typically means: rear wheel (if hydraulic) > right front > left front, but confirm plumbing for your machine (follow visible line routing).

  1. Refill the reservoir with fresh brake fluid to the MAX mark.
  2. Start at the furthest bleed nipple. Place clear tubing over the nipple and the other end into the catch bottle partially filled with fresh fluid to prevent air entry back into the system.
  3. Have an assistant slowly pump the brake lever/pedal several times and hold pressure. While held, open the bleed nipple about a quarter turn to allow fluid & air out. Close nipple before the assistant releases pressure. Repeat until clear, bubble-free fluid flows. Keep the reservoir topped off during the entire process.
  4. Move to the next furthest wheel and repeat. Work quickly so the reservoir never runs low. If it drops low, air will enter the master cylinder and you will need to start over at that point.
  5. For drum rear wheel cylinders: the process is identical at the wheel cylinder bleed nipple. If shoes were recently serviced, manually compress the wheel cylinder pistons to help purge trapped air.
  6. When all wheels are clear, tighten bleed nipples to proper snugness (do not overtighten). Refill reservoir to MAX, reinstall diaphragm & cap, and clean any spilled brake fluid.

Bench/pressure bleeding alternative

If available, a pressure bleeder or vacuum pump speeds the job and reduces assistant errors. If using a pressure bleeder, set it to the manufacturer-recommended low pressure (not exceeding 15 psi). Attach to the reservoir and open each bleeder in sequence until fluid runs clear. Always keep an eye on reservoir level.

Master cylinder bench flush (if contaminated)

  • If the reservoir or master cylinder is contaminated or dark with moisture, remove the master cylinder assembly (note linkage and routing) and perform a bench flush. Push fresh fluid through the master cylinder until clear, then reinstall and perform wheel bleeding sequence as above.

Final checks & road test

  • After bleeding, check lever/pedal firmness. The brake lever or pedal should be firm with no sponginess. If spongy, repeat bleeding focusing on any suspicious section.
  • Inspect all lines, nipples, and fittings for leaks. Tighten as needed to spec.
  • Carefully test brakes at low speed in a safe area to confirm proper operation before normal riding.
  • Record the service date and mileage. Brake fluid absorbs moisture over time; plan to replace fluid every 1-2 years depending on use and storage conditions.

Maintenance tips specific to this Eiger model

  • Because the Eiger 400 is often used in wet or muddy conditions, inspect and, if needed, replace caliper slide pins and rubber dust boots to prevent uneven pad wear and sticking calipers.
  • Rear drum hardware corrodes in wet environments; inspect return springs, adjusters, and wheel cylinder boots when you service the brakes.
  • If you ride in salt-prone areas, flush and replace brake fluid more frequently and inspect brake lines for corrosion regularly.
  • Keep spare sealing washers for bleed nipples on hand; they can leak once disturbed. Replace them if they show deformation or corrosion.

Performing a thorough bleed and fluid replacement restores stopping power and extends component life. When in doubt, consult MotoSport's parts specialists for correct replacement parts or book professional brake service.

Related Shopping Categories

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Shop Brake Lines for a 2002 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Tools for a 2002 Suzuki Eiger 400 2X4 AUTO ATV.

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.