How to Bleed and Replace Brake Fluid on a 2002 Suzuki Eiger 400 4X4 AUTO

Shop parts for a 2002 Suzuki Eiger 400 4X4 AUTO ATV.

This MotoSport guide walks you step-by-step through changing the brake fluid and properly bleeding the front and rear hydraulic brakes on a 2002 Suzuki Eiger 400 4X4 AUTO (EIGER400A). Follow these instructions for safe, reliable stopping performance and to protect the master cylinder, calipers & lines from moisture and contamination.

Safety & preparation

  • Work on a level surface with the ignition OFF and parking brake engaged.
  • Wear eye protection and nitrile gloves. Brake fluid is corrosive to paint & plastics.
  • Use DOT 3 brake fluid unless a different spec is shown in the owner's manual. Confirm compatibility before use.
  • Have a clean container for old fluid, clear tubing, a wrench to fit banjo or bleed nipples, rags, and a helper for manual bleeding.
  • Keep a funnel and a clean rag over the master reservoir to prevent dirt ingress while working.

What you'll need

  • DOT 3 brake fluid (or spec'd fluid), new crush washers for banjo bolts if disturbing the caliper lines
  • Clear 1/4" I.D. tubing, a small catch bottle, a wrench set, Phillips screwdriver, 8mm & 10mm sockets or wrenches for bleed nipples
  • Shop rags, gloves, safety glasses, and a disposable container for old fluid

Model-specific notes for the 2002 Suzuki Eiger 400 4X4 AUTO

  • The Eiger 400 AUTO uses a combined master cylinder design for front and rear brakes; the master reservoir is located under the dash/plastic shroud. Removing plastics may be required for clear access.
  • The factory system is DOT 3; do not mix DOT 4 unless the entire system is flushed and components are compatible.
  • ABS is not present on this model, so bleeding is manual only, but the combined lever/pedal system needs careful attention to reservoir level to avoid pulling air into the chambers.
  • Some 2002 models show brittle plastic fittings; inspect hoses, fittings, and the reservoir for cracks before adding fluid.

Step 1 Access the reservoir & inspect

  • Remove the front dash/plastic cover to expose the master cylinder reservoir. Clean the area around the cap to prevent contamination.
  • Check fluid color & level. Dark, contaminated fluid or a low level indicates immediate replacement.

Step 2 Drain old fluid from reservoir

  • Use a syringe or turkey baster to remove as much old fluid as possible from the reservoir. Dispose of fluid properly.
  • Top the reservoir with clean DOT 3 fluid to the fill line and keep the cap loosely in place to limit exposure while you bleed.

Step 3 Bleeding order & general approach

For the Eiger 400 AUTO, bleed from the brake caliper farthest from the master cylinder first, then work toward the nearest. Typical order:

  1. Rear caliper (if single rear unit, bleed it first)
  2. Right front caliper
  3. Left front caliper

If your machine has a different routing, follow the same principle: farthest to nearest.

Step 4 Manual two-person bleed method (recommended)

  1. Attach clear tubing to the bleed nipple and place the other end into the catch bottle partially filled with used fluid to prevent air re-entry.
  2. Have your helper slowly pump the brake lever/pedal 6–8 times and then hold pressure.
  3. Open the bleed nipple one turn to allow old fluid and air to escape; close it before the helper releases pressure. Repeat until fluid runs clear with no bubbles.
  4. Keep the reservoir topped up between cycles to avoid drawing air into the master cylinder.
  5. Move to the next caliper and repeat in the order above.

Step 5 Single-person vacuum or pressure bleeding (optional)

  • Vacuum pump: attach to bleed nipple, draw fluid until clear, then tighten nipple while holding vacuum. Keep reservoir topped off.
  • Pressure bleeder: follow manufacturer instructions. Use low pressure — excessive pressure can damage seals.

Step 6 Complete system flush & final checks

  • When all calipers show clear fluid with no bubbles, top the reservoir to the correct level and reinstall the cap securely.
  • Clean any spilled fluid immediately; it will damage paint and plastics.
  • Operate the brake lever/pedal multiple times to confirm a firm feel. If spongy, repeat bleeding until firm.
  • Inspect all fittings, lines, and hose clamps for leaks with the machine on level ground and weight off the brakes.

Tightening specs & torque notes

  • Bleed nipple snug: hand tight plus a quarter turn. Avoid over-torquing; these nipples are small and can strip.
  • Banjo bolt torque (if removed): replace crush washers and torque to the manufacturer spec if available; snug firmly but do not over-stress aluminum components.

Maintenance tips specific to the Eiger 400

  • Change brake fluid every 1–2 years to limit moisture buildup and corrosion, especially if the ATV sees wet or salty conditions.
  • Inspect flexible hoses for cracking at the fittings. The Eiger's routing can rub hoses on frame edges over time.
  • Replace the reservoir cap diaphragm if brittle or deformed to prevent contamination and premature fluid degradation.
  • Keep spare crush washers and a small amount of DOT 3 fluid in your tool kit when riding remote trails.

Troubleshooting

  • Persistent spongy brake feel: check for air left in the system, damaged caliper seals, or a failing master cylinder.
  • Brake drag after bleeding: ensure caliper pistons were not pushed out too far and that pads are correctly seated.
  • Fluid foaming or rapid darkening: contamination or incompatible fluid; perform a full flush and inspect internal components for corrosion.

Final inspection & road test

  • After bleeding, reassemble any removed bodywork. Clean surfaces where brake fluid contacted paint with water and mild detergent.
  • Perform a low-speed test ride in a safe area to verify braking performance under load. Listen for unusual noises and recheck for leaks.

Following this MotoSport-specific procedure keeps your 2002 Suzuki Eiger 400 4X4 AUTO stopping reliably. If you encounter hardware failure or suspect master cylinder issues, replace affected parts with quality components matched to your model.

Related Shopping Categories

Shop Brake Fluid for a 2002 Suzuki Eiger 400 4X4 AUTO ATV.

Shop Brake Bleeders for a 2002 Suzuki Eiger 400 4X4 AUTO ATV.

Shop Brake Pads for a 2002 Suzuki Eiger 400 4X4 AUTO ATV.

Shop Brake Lines for a 2002 Suzuki Eiger 400 4X4 AUTO ATV.

Shop Brake Tools for a 2002 Suzuki Eiger 400 4X4 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.