How to Bleed & Replace Brake Fluid on a 2004 Suzuki Eiger 400 4X4 AUTO
Shop parts for a 2004 Suzuki Eiger 400 4X4 AUTO ATV.
This MotoSport guide walks you step-by-step through replacing and bleeding the brake fluid on a 2004 Suzuki Eiger 400 4X4 AUTO (MMY SUZUKI;EIGER400A;2004). Follow the procedures exactly, use the correct fluid, and keep safety first.
What you need
- Brake fluid – DOT 3 (use DOT 4 only if specified by your owner's manual; do not mix fluids)
- Clear plastic tubing that fits snugly over bleeder nipples
- Clean catch bottle
- Wrenches for bleeder nipples (typically 8 or 10 mm)
- Turkey baster or syringe for fluid removal
- Clean shop rags and gloves
- Floor jack or ramps and safety stands if needed
- Assistant (recommended for manual pump bleeding)
- Brake cleaner
Safety & preliminary checks
- Work on a level surface with the engine off, key removed, and parking brake engaged.
- Wear eye protection and gloves. Brake fluid damages paint & plastic — clean spills immediately.
- Locate the master cylinder/reservoir on the handlebar area for the front circuit and the rear reservoir or portion of the shared reservoir for the rear brakes (some Eiger 400 models share a single reservoir with internal split circuits).
- Inspect lines, hoses, calipers, and master cylinder for leaks or damage before bleeding. Replace any leaking or damaged parts before proceeding.
Full fluid replacement overview
Complete replacement combines reservoir flushing with bleeding each caliper until new, clear fluid runs through. Follow the sequence below to avoid pulling air back into the system.
Bleeding sequence
Bleed from the wheel farthest from the master cylinder first, then proceed to the next farthest. Typical sequence for the Eiger 400 is:
- Right rear (if applicable)
- Left rear
- Right front
- Left front
Note – if your model has a single rear drum or combined circuits, confirm which calipers are on each circuit before starting. If in doubt, bleed one circuit at a time and change fluid in-between.
Step-by-step procedure
- Remove the reservoir cap and diaphragm. Siphon or use a turkey baster to remove as much old fluid as possible from the reservoir. Wipe the cap and reservoir neck clean.
- Top the reservoir with fresh DOT 3 fluid to the recommended level. Keep the reservoir topped during the process to prevent air intake.
- Start with the furthest caliper. Fit clear tubing over the bleeder nipple and place the other end in the catch bottle partially filled with clean fluid to prevent air re-entry.
- Have an assistant pump the brake lever/pedal several times and hold pressure (or use a one-person vacuum or pressure bleeder). While pressure is held, open the bleeder nipple about 1/4 turn to allow fluid and air to escape. Close the nipple before the assistant releases the lever/pedal. Repeat until fluid runs clear with no bubbles.
- After each bleed cycle, top the reservoir immediately to maintain fluid level. Do not let the reservoir run low.
- Move to the next caliper following the sequence. Repeat the bleeding cycles until each caliper shows clear, bubble-free fluid.
- Once all calipers are bled, check lever/pedal feel — it should be firm without sponginess. If soft, repeat bleeding for the affected circuit.
- Tighten bleeder nipples to proper snugness (do not over-torque), reinstall reservoir diaphragm and cap, and clean any spilled fluid from painted surfaces with brake cleaner and fresh water to avoid damage.
- Test ride at low speed in a safe area, checking brake response. Re-inspect calipers, lines, and reservoir for leaks.
Notes specific to the 2004 Suzuki Eiger 400 4X4 AUTO
- The Eiger 400 often uses a compact combined master reservoir for both front and rear circuits; keep the reservoir upright and avoid overfilling to prevent fluid foam and overflow while turning/handling the machine.
- Some 2004 Eiger models have two front calipers and a single rear caliper — confirm your layout before ordering parts or planning bleed order.
- The automatic 4X4 linkage and ATC components are sensitive to brake fluid contamination & corrosion. Protect nearby electrical connectors and linkage from spills.
- If you find significant rust, swollen hoses, or a soft master cylinder feel even after bleeding, replace the affected hoses or master cylinder. Old rubber hoses can internally deteriorate and allow fluid aeration that standard bleeding won't fix.
- Store opened brake fluid tightly sealed and discard any fluid that appears dark or contaminated. Brake fluid is hygroscopic – it absorbs moisture, which lowers boiling point and performance.
Common troubleshooting
- Persistent spongy lever/pedal: re-bleed the circuit, replace old hoses, or inspect master cylinder seals.
- Brake drag after bleeding: ensure bleeder nipples fully closed and caliper pistons move freely; check for stuck caliper slides or overfilled reservoir.
- Low pedal travel but soft feel: check for air in system or internal master cylinder failure.
Aftercare
- Record the fluid change date and mileage. Plan to replace brake fluid every 1-2 years depending on use and storage conditions.
- Dispose of used fluid responsibly at a recycling or hazardous-waste facility.
For model-specific replacement parts and brake components for your 2004 Suzuki Eiger 400 4X4 AUTO, use the MotoSport parts listing to find calipers, hoses, reservoirs, and OEM-equivalent items.
Related Shopping Categories
Shop Brake Fluid for a 2004 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Bleeders for a 2004 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Pads for a 2004 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Lines for a 2004 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Tools for a 2004 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.