How to Bleed and Replace Brake Fluid on a 2003 Suzuki Eiger 400 2X4 AUTO

Shop parts for a 2003 Suzuki Eiger 400 2X4 AUTO ATV.

This MotoSport guide walks you through safely flushing and bleeding the hydraulic brake system on a 2003 Suzuki Eiger 400 2X4 AUTO. Follow these steps precisely to maintain braking performance and avoid contamination. Recommended interval: every 1-2 years or whenever fluid becomes dark or spongy.

Tools & supplies

  • DOT 3 or DOT 4 brake fluid (Suzuki allows DOT 3; DOT 4 is acceptable) use fresh, unopened bottle
  • Clear plastic tubing that fits snugly over bleeder screws
  • Drain catch bottle or jar
  • Brake bleeder wrench or appropriately sized open-end wrench
  • Turkey baster or syringe (for removing fluid from master cylinder reservoir)
  • Clean shop rags and nitrile gloves
  • Jack and stands or wheel chocks to stabilize ATV (if removing wheels)
  • Brake cleaner and small brush (optional for caliper cleaning)

Pre-checks specific to the 2003 Eiger 400 2X4 AUTO

  • The Eiger 400 uses a single front hydraulic caliper and a rear drum or caliper depending on submodel; confirm whether your machine has rear hydraulic brakes. This guide covers hydraulic bleeds only.
  • Master cylinder reservoir is located under the left-hand handlebar cover; remove the cover carefully to access the cap.
  • ABS is not present on this model, making a conventional gravity or manual bleed effective.
  • Brake lines on older Eigers can be brittle; inspect lines, banjo fittings, and rubber hoses for cracks or leaks before pressurizing the system.

Safety

  • Work on a level surface with the engine off and keys removed.
  • Keep brake fluid off painted surfaces & plastic; it damages finish. Wipe spills immediately.
  • Dispose of used brake fluid according to local hazardous waste rules.

Step-by-step: Replace master cylinder fluid (reservoir flush)

  1. Remove the left handlebar cover and clean around the reservoir cap to prevent dirt entry.
  2. Open the reservoir cap — do not remove the rubber diaphragm unless necessary. Use a turkey baster or syringe to remove as much old fluid as possible from the reservoir.
  3. Top the reservoir with fresh DOT 3 or DOT 4 fluid until near the max level.
  4. Pump the brake lever slowly several times and hold it in. While held, open front caliper bleeder screw slightly to allow old fluid to exit into clear tubing. Close bleeder, then release lever. Repeat until the fluid from the bleeder runs clear and bubble-free. Keep reservoir topped up to prevent air entry.
  5. If the Eiger has a rear hydraulic caliper, repeat the same process at the rear bleeder. For a rear drum (mechanical) no hydraulic bleed is needed.

Step-by-step: Full system bleed (recommended if very dirty or contaminated)

  1. Start by topping the reservoir with fresh fluid. Identify bleeder order: farthest from master cylinder first. For Eiger 400 typical order is rear caliper (if hydraulic) then front caliper. If only front hydraulic, bleed front only.
  2. Attach clear tubing to bleeder nipple and place other end in catch bottle partially filled with fresh fluid to prevent drawing air back.
  3. Have an assistant slowly depress the brake lever/pedal several times and hold it down. Open the bleeder 1/4 turn to let fluid flow, then close before the lever/pedal is released. Repeat, watching for clear fluid without air bubbles.
  4. Keep reservoir topped up the entire time. If reservoir runs dry, start over because air will enter the system.
  5. When fluid exiting the bleeder is clean and bubble-free, tighten bleeder to specified torque (light snug — typically 8-12 Nm for small bleeders). Wipe any spilled fluid.
  6. Repeat for other bleeder(s) as required.

Alternative single-person methods

  • Gravity bleed: Open bleeder and let fluid drain slowly while keeping reservoir topped. Slow and messy; works but takes time.
  • Vacuum pump bleeder: Attach to bleeder nipple and pull fluid through while topping reservoir. Efficient and limits air entry.

Bleeder screw locations & notes for the Eiger 400

  • Front caliper bleeder is on the back side of the caliper, facing upward when ATV is level. You may need to turn the handlebars for better access.
  • Rear hydraulic caliper (if present) bleeder is accessible from the rear wheel area. Clean before opening to avoid contamination.
  • Banjo bolts use crush washers; inspect and replace crush washers if leaking when reassembled.

After bleeding

  • Top reservoir to proper level, reinstall diaphragm & cap, and reattach handlebar cover.
  • Pump brakes with engine off until lever/pedal feels firm. Start engine and recheck for proper operation.
  • Test ride at low speed to confirm braking performance. Check for leaks and re-tighten fittings if necessary.
  • Proper disposal: used brake fluid is hazardous; take to a recycling center or hazardous waste facility.

Model-specific maintenance tips for the 2003 Suzuki Eiger 400 2X4 AUTO

  • Automatic transmission model requires periodic transmission and final drive fluid checks separate from brakes; don't confuse fluids.
  • Because the Eiger is often used in wet/muddy conditions, inspect and clean calipers & pads regularly to prevent contamination and corrosion.
  • Brake pads and rotors on older Eigers can wear unevenly; measure pad thickness and rotor runout during service. Replace pads in pairs.
  • OEM parts and replacement hoses are available; consider replacing rubber hoses if they show aging to avoid soft pedal or failure.
  • Keep torque specs and banjo bolt crush washers on hand when servicing; loose banjo bolts commonly cause leaks after maintenance.

Following this MotoSport procedure will give you a safe, reliable brake system on your 2003 Suzuki Eiger 400 2X4 AUTO. If you encounter persistent sponginess after a correct bleed, inspect the master cylinder and caliper seals for internal leakage and consider rebuild kits.

Related Shopping Categories

Shop Brake Fluid for a 2003 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Bleeders for a 2003 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Pads for a 2003 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Lines for a 2003 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Tools for a 2003 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.