How to Bleed & Replace Brake Fluid on a 2006 Suzuki Eiger 400 2X4 AUTO

Shop parts for a 2006 Suzuki Eiger 400 2X4 AUTO ATV.

This MotoSport-exclusive guide walks you through flushing and bleeding the hydraulic brake system on a 2006 Suzuki Eiger 400 2X4 AUTO. Follow each step carefully. If you are not confident with brake work, have a qualified technician perform the job.

What you need

  • DOT4 brake fluid (use DOT4 unless your owner's manual specifies otherwise)
  • Clear plastic tubing that fits the bleeder nipples
  • Clean catch container for old fluid
  • Wrenches for bleeder nipples (usually 8mm or 10mm) and reservoir cap
  • Clean rags and isopropyl alcohol for cleaning
  • Assistant to operate the brake pedal/pedal pump (or a vacuum/pressure bleeder)
  • Jack/blocks to lift and secure the machine safely
  • Latex or nitrile gloves and eye protection

Model notes — 2006 Suzuki Eiger 400 2X4 AUTO

  • The Eiger 400 2X4 AUTO is a utility-style ATV with a simple hydraulic brake system and no ABS. Bleeder nipples and caliper hardware can seize from corrosion on older machines, so penetrating oil and care are often needed.
  • The brake master cylinder reservoir is small and may sit near the handlebars or under a plastic cover; always keep the cap on while working to avoid contamination.
  • Inspect brake lines for cracking or swelling & caliper pistons for corrosion while you have the system open. Replace any compromised components before filling with new fluid.
  • Park the ATV on level ground and chock wheels; shifting between 2WD/4WD does not affect the bleeding order, but avoid engaging the drive while jacked up.

Preparation

  • Park machine level, engine off, key off. Secure with parking brake or blocks.
  • Clean around the master cylinder cap to prevent contaminants entering the reservoir.
  • Remove cap and diaphragm; gently top up reservoir with fresh DOT4 fluid so it is near the "MAX" mark but not overfilled.
  • Locate all bleeder nipples on calipers. Fit clear tubing over the nipple and place the other end into a catch container partially filled with old fluid to maintain a one-way path and prevent air re-entry.

Bleeding sequence

Bleed the system starting with the caliper farthest from the master cylinder and finish with the closest. Typical effective order for the Eiger: rear caliper first, then right front caliper, then left front caliper. If unsure where the master cylinder feeds, follow the route of the brake lines and start with the farthest wheel.

Manual two-person bleeding method

  1. Have your assistant slowly depress and hold the brake pedal/pedal pump to a firm position (not to hard stop) while you work the bleeder.
  2. Open the bleeder nipple about a quarter to a half turn. Fluid and air will flow into the tubing; close the nipple before your assistant releases the pedal. Repeat until clear, bubble-free fluid exits and the pedal feels firm.
  3. Top up the master cylinder reservoir frequently to prevent it from running low and drawing air into the system.
  4. Work each caliper in the designated sequence. After the last caliper is bled, cycle the pedal several times and re-check the reservoir level.

One-person vacuum/pressure bleeder method

  • Attach your vacuum or pressure bleeder to the master cylinder or bleeder nipple per tool instructions. Use the tool to draw fluid through the system until clear, then close bleeders and re-torque nipples.
  • Always monitor reservoir level and refill as needed.

Finishing steps

  • When bleeding is complete, tighten bleeder nipples snugly to the manufacturer's torque or a firm feel; avoid over-torquing. Wipe all fittings and clean spilled fluid immediately.
  • Refit and seal the master cylinder cap and diaphragm. Ensure reservoir level is at the proper mark.
  • Dispose of old brake fluid according to local hazardous-waste rules; do not reuse or pour on the ground.
  • Before riding, test brakes at low speed in a safe area until pedal feel and stopping performance are confirmed. Bed new fluid by making several low-speed controlled stops.

Common problems & remedies

  • Seized bleeder nipples: apply penetrating oil, allow to soak, then use a correct-size wrench. If stripped, the caliper may need replacement or repair.
  • Soft or spongy pedal after bleeding: re-bleed, ensure no air remains, inspect lines for damage, and confirm master cylinder internals are working properly.
  • Contaminated system (dirt/water present): perform a full system flush — drain until clear new fluid appears at all outlets and consider replacing rubber hoses if aged.

Safety reminders

  • Brake fluid is highly corrosive to paint & plastics — clean spills immediately with water and alcohol.
  • Never mix DOT3 with DOT5 (silicone-based). DOT4 blends with DOT3 but use DOT4 if specified.
  • If brake feel does not return to normal after bleeding, stop and have the system inspected; compromised brakes are a serious hazard.

Keep a maintenance log after service — date, mileage/hours, and fluid type used. Regular brake fluid replacement keeps the Eiger 400's stopping performance reliable and protects hydraulic components from moisture-related corrosion.

Related Shopping Categories

Shop Brake Fluid for a 2006 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Bleeders for a 2006 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Pads for a 2006 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Lines for a 2006 Suzuki Eiger 400 2X4 AUTO ATV.

Shop Brake Tools for a 2006 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.