How to Bleed and Replace Brake Fluid on a 2004 Suzuki Eiger 400 2X4 AUTO
Shop parts for a 2004 Suzuki Eiger 400 2X4 AUTO ATV.
This MotoSport guide walks you through safely flushing and bleeding the hydraulic brake system on a 2004 Suzuki Eiger 400 2X4 AUTO. Follow each step carefully, use proper safety gear, and work in a clean, well-ventilated area. Brake fluid is hygroscopic and corrosive – avoid spills on painted or plastic surfaces.
What you need
- Correct brake fluid (DOT 3 or DOT 4 as specified in your owner's manual)
- Clear plastic tubing that fits bleeder nipples
- Small catch bottle (preferably sealed)
- Wrench for bleeder nipples (usually 8mm or 10mm)
- Clean rags and isopropyl alcohol for cleanup
- Disposable gloves and eye protection
- Brake bleeder pump or vacuum pump, or a helper for the manual pedal/pump method
- Torque wrench for caliper and banjo bolts
- Jack or ramps and wheel chocks if wheel removal is required
Model notes specific to the 2004 Suzuki Eiger 400 2X4 AUTO
- The Eiger 400 2X4 AUTO uses a simple hydraulic brake system without ABS. Bleeder nipples are on the caliper(s) and the master cylinder reservoir is under the seat/near handlebar area depending on submodel – locate the translucent fluid reservoir and clean its cap & surrounding area before opening.
- Use fresh, unopened brake fluid. The Eiger has rubber hoses and aluminum fittings; contamination or old fluid accelerates hose and seal wear.
- Check condition of hoses, banjo bolts, copper crush washers, and caliper seals while the system is drained. Replace any cracked hoses or corroded fittings before refilling.
- After bleeding, verify pedal lever travel and that the brake engages consistently before riding. Allow system to sit and re-check fluid level after a short test ride.
Preparation
- Park ATV on level ground, engage park/neutral and block wheels. Remove seat or access panel to reach the brake reservoir if required.
- Clean top of reservoir thoroughly. Remove cap slowly to relieve any pressure, then remove diaphragm or foam insert and set aside on a clean surface.
- Top reservoir with fresh fluid to the recommended level. Keep the cap loosely in place to limit contamination while bleeding.
- Identify bleeder nipples on each caliper. Place a rag under each nipple to catch drips and slip clear tubing over the nipple leader, with the other end submerged in a small volume of fresh brake fluid in a bottle to prevent air being drawn back in.
Bleeding methods
Use one of these proven methods based on available tools and helpers.
1) Vacuum pump method (recommended for single operator)
- Attach vacuum hose to bleeder nipple and the pump. Pump to create light vacuum (about 15-20 inHg), then open bleeder nipple about a quarter turn.
- Allow fluid and bubbles to flow until clear, then close nipple before releasing vacuum. Top reservoir as needed to avoid drawing air into master cylinder.
- Repeat until only clear, bubble-free fluid emerges. Work from the caliper farthest from the master cylinder to the closest.
- Ensure bleeder nipple is properly tightened after each step and wipe clean. Torque caliper and banjo fittings to factory spec if disturbed.
2) Pressure bleeder method
- Attach a pressurized brake-fluid reservoir to the master cylinder and pressurize to the recommended low pressure. Open bleeder nipples in sequence from farthest to closest to master cylinder until clear fluid exits without bubbles.
- Keep reservoir topped off and do not let it run dry.
3) Two-person pump-and-hold method
- One person slowly presses the brake lever or pedal 3-4 times and holds it down. The second person opens the bleeder nipple to let fluid out, then closes it before the lever/pedal is released. Repeat until fluid runs clear and bubble-free.
- Always close the bleeder before the pedal is released to prevent sucking air back into the system. Top off reservoir frequently.
Order of bleeding
- Bleed the caliper farthest from the master cylinder first, then work to the closest. For many Eiger layouts this means rear then front, but verify routing visually on your unit.
Refill and final checks
- When bleeding is complete, top reservoir to the correct level and reinstall diaphragm and cap securely.
- Wipe any spilled fluid immediately with isopropyl alcohol and clean rags. Inspect for leaks at bleeder nipples, banjo bolts and hose ends.
- Reinstall any removed body panels or seat. Torque any fasteners to proper spec.
- Test brake lever/pedal for firm feel. Perform a low-speed static brake check in a safe open area. Re-check fluid level and inspect for leaks after a short test ride.
Safety and maintenance tips
- Never mix DOT 3 and DOT 5 fluids; DOT 3 and DOT 4 are generally compatible but follow the vehicle specification.
- Brake fluid absorbs moisture – replace every 1-2 years or sooner if you detect sponginess or contamination.
- Keep reservoir cap closed as much as possible during the job to minimize moisture pickup.
- If you detect persistent sponginess after bleeding, inspect master cylinder seals, caliper pistons and hoses for internal leakage and replace components as needed.
- Record the date and mileage of the brake fluid change for future service intervals.
Follow these MotoSport procedures to keep your 2004 Suzuki Eiger 400 2X4 AUTO braking system reliable and safe. If you encounter stubborn air, damaged components, or unexpected leaks, stop and consult a qualified technician.
Related Shopping Categories
Shop Brake Fluid for a 2004 Suzuki Eiger 400 2X4 AUTO ATV.
Shop Brake Bleeders for a 2004 Suzuki Eiger 400 2X4 AUTO ATV.
Shop Brake Pads for a 2004 Suzuki Eiger 400 2X4 AUTO ATV.
Shop Brake Lines for a 2004 Suzuki Eiger 400 2X4 AUTO ATV.
Shop Brake Tools for a 2004 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.