How to Bleed and Replace Brake Fluid on a 2005 Suzuki Eiger 400 4X4 AUTO
Shop parts for a 2005 Suzuki Eiger 400 4X4 AUTO ATV.
This MotoSport-exclusive guide walks you through replacing and bleeding the brake fluid on a 2005 Suzuki Eiger 400 4X4 AUTO. Follow these steps carefully to restore firm, reliable brakes and keep your Eiger safe on trail or work duty. All procedures below are presented as a clear, practical workshop routine specific to small ATV hydraulic systems; consult your owner's manual for any torque specs or fluid type if you want factory confirmation.
What you'll need
- Fresh brake fluid (check the owner's manual for the recommended DOT rating; if uncertain use DOT 4 for higher boiling point)
- Clear plastic tubing that fits snugly over the bleeder nipples
- Brake fluid reservoir suction pump or turkey-baster to remove old fluid from the master cylinder
- Wrench set sized for bleeder nipples (usually 8mm or 10mm)
- Catch bottle for old fluid; clamp or small spring clamp for tubing
- Clean rags and isopropyl alcohol for cleaning, and gloves/eye protection
- Torque wrench for final fasteners (recommended)
- Jack or ramps and stands to safely raise and support the ATV if needed
Safety first
- Work on a level surface with the engine off and the key removed.
- Use wheel chocks and a secure lift or stands if raising the unit.
- Brake fluid will damage paint and plastics — wipe spills immediately and clean surfaces with isopropyl alcohol.
- Dispose of used fluid responsibly at a recycling center or hazardous-waste facility.
Pre-checks specific to the 2005 Suzuki Eiger 400 4X4 AUTO
- The Eiger 400 AUTO uses a simple hydraulic system without complex ABS electronics, making manual bleeding straightforward. Confirm reservoir location and bleeder nipples on the front calipers and the rear brake assembly before starting.
- Inspect brake lines for cracks, abrasion, or swelling. On older Eigers the rubber lines can exhibit age-related softening; replace any suspect hoses during the fluid change.
- Check caliper pistons for free movement. Seized pistons or sticky slides will compromise bleeding results and should be serviced or rebuilt.
- Confirm the master cylinder reservoir is clean and not contaminated with dark, oily residue from engine fluids (a sign of internal failure).
Step-by-step: Replace old fluid in the master cylinder
- Locate the brake master cylinder reservoir (usually under the handlebar cover for the front brakes and a separate reservoir or line for the rear). Clean around the cap to avoid contamination.
- Remove the cap and diaphragm. Use a suction pump or turkey-baster to remove as much old fluid as possible from the reservoir.
- Refill the reservoir with fresh brake fluid to the specified level (do not overfill).
Step-by-step: Bleeding the system (recommended order: farthest to nearest)
Bleed each caliper/bleeder starting with the wheel farthest from the master cylinder and finish with the nearest. For a typical Eiger layout this means: rear (if hydraulic) – then one front, then the other front. If the rear uses a mechanical drum or different circuit, bleed the hydraulic circuit wheels accordingly.
- Attach clear tubing to the bleeder nipple and route the other end into a catch bottle partially filled with clean fluid to prevent air draw-back.
- Have an assistant pump the brake lever/pedal slowly several times and hold it down. If working alone, use a one-person vacuum bleeder on the bleeder nipple or use the squeeze-and-hold method with careful timing.
- With the lever/pedal held, open the bleeder nipple with the wrench about a quarter to half-turn. Fluid and bubbles will flow into the tubing. Close the nipple before the lever/pedal is released to avoid sucking air back in.
- Repeat: pump, hold, open nipple, close nipple until you see clear, bubble-free fluid in the tubing.
- Top off the master cylinder after every few cycles to prevent it running dry and introducing air into the system.
- Work through each wheel in order. Once all calipers are clear of bubbles, tighten bleeder nipples to spec or snug them securely (do not over-torque).
Two useful bleeding methods
- Helper method – Assistant pumps and holds while you open/close bleeders. Gives fast, reliable results for small systems.
- Vacuum or pressure bleeder method – Single-person method using a hand vacuum pump on each bleeder or a pressure reservoir on the master cylinder. Cleaner, less messy, and preferred if you're working alone.
Final checks
- Ensure the reservoir is filled to the correct level and the cap & diaphragm are sealed properly.
- Operate the brakes several times with the ATV on stands to feel a firm, consistent pedal/lever. Check for any sponginess — any remaining sponginess indicates air still in the lines and repeat bleeding.
- Inspect all fittings, hoses, calipers, and the master cylinder for leaks while pressure is applied.
- Road-test or trail-test at low speed in a safe area to confirm braking performance before normal use. Bed new fluid/brake pads if installed per standard bedding procedure.
Notes on parts & common service items for this model
- Rubber brake hoses and bleeder screws are wear items on a 2005 Eiger — replace corroded bleeders and cracked hoses during the service.
- Caliper seals and piston boots tend to wear on older units; a caliper rebuild kit is often a smart preventative purchase during a fluid change.
- If your Eiger has rear drum-style brakes on some variants, those are adjusted differently and do not use the same bleeding routine. Verify wheel brake type before beginning.
- MotoSport carries OEM and upgraded replacement hoses, bleeder screws, and caliper components tailored to the 2005 Suzuki Eiger 400 MMY for owners who want a complete service kit or performance upgrades.
Troubleshooting
- Persistent soft pedal after bleeding: check for internal master cylinder leaks, collapsed hoses, or an air pocket trapped in a caliper. Re-bleed and inspect components; replace failing parts.
- Fluid contamination (dark, oily fluid): stop and inspect for oil ingress or master cylinder failure. Replace all fluid and service the master cylinder as needed.
- Brake drag after bleeding: ensure bleeder nipples are properly tightened and caliper pistons are not over-extended during service. Clean and lubricate slide points per OEM guidance.
This procedure is written for technicians and knowledgeable home mechanics. If you're uncomfortable performing hydraulic system work, seek professional service to ensure safe braking performance. For parts and specific replacement items for the 2005 Suzuki Eiger 400 4X4 AUTO, MotoSport stocks everything from brake fluid to hoses and rebuild kits tailored to this MMY.
Related Shopping Categories
Shop Brake Fluid for a 2005 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Bleeders for a 2005 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Pads for a 2005 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Lines for a 2005 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Tools for a 2005 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.