How to Bleed and Replace Brake Fluid on a 2006 Suzuki Eiger 400 4X4 AUTO
Shop parts for a 2006 Suzuki Eiger 400 4X4 AUTO ATV.
This MotoSport guide walks you through safely replacing and bleeding the hydraulic brake fluid on a 2006 Suzuki Eiger 400 4X4 AUTO (EIGER400A). Follow the sequence below, use recommended fluids and tools, and inspect brake system components while you work.
Notes specific to the 2006 Suzuki Eiger 400 4X4 AUTO
- Factory setup: single hydraulic front disc brakes and a rear disc brake system driven by a single master cylinder. No factory ABS.
- Recommended fluid type: DOT 4 is commonly used on this model – confirm with your owner's manual before starting.
- Master cylinder and brake reservoir are mounted on the right side of the handlebar area (small plastic reservoir). The remote reservoir cap is plastic — keep it clean to avoid contamination.
- Inspect caliper boots, hoses and banjos for cracking or leaks while draining fluid — these components age on older Eiger units and should be replaced if any deterioration is found.
- Bleed order: start with the wheel farthest from the master cylinder and finish at the closest to ensure all air is purged.
Tools & supplies
- DOT 4 brake fluid (1 pint minimum)
- Clear plastic tubing, small diameter to fit bleeder nipple
- Brake bleeder catch bottle or jar
- Wrenches for bleeder nuts (typically 8mm or 10mm)
- Turkey baster or fluid siphon (for reservoir)
- Brake cleaner, lint-free rags
- Floor jack or ATV stand and jack stands to safely lift and support wheels
- Assistant (hand pump method) or a vacuum/pressure bleeder
- Torque wrench for caliper/banjo bolts if you remove them
- Gloves and eye protection
Preparation & safety
- Work on a level surface. Secure the ATV with a parking brake, engine off, key removed.
- Protect painted surfaces from spilled brake fluid — it damages paint. Cover nearby panels with rags or cardboard.
- Wear gloves and eye protection. Brake fluid is hygroscopic & corrosive to paint.
- Dispose of old fluid per local regulations.
Step-by-step: flush & bleed procedure
- Park and lift: Raise the ATV so wheels can turn freely. Remove wheels if needed to access bleeder screws easily.
- Clean reservoir area: Remove dust and debris around the master cylinder reservoir cap to prevent contamination.
- Remove old fluid from reservoir: Use a turkey baster or siphon to remove as much old fluid as possible from the reservoir. Do not let the reservoir run dry during bleeding.
- Fill reservoir with new fluid: Pour fresh DOT 4 into the reservoir to the full mark.
- Identify bleed sequence: For Eiger 400 AUTO, begin with the wheel farthest from the master cylinder (usually rear then front opposite side; confirm by observing lines). Typical safe sequence: rear wheel, front passenger side, front driver side — but visually confirm hose routing on your machine.
- Attach tubing and open bleeder: Put a short clear tube over the bleeder nipple and submerge the far end in a small jar partially filled with fresh brake fluid to avoid drawing air back in. Crack the bleeder about 1/4 turn with the appropriate wrench.
- Pump or vacuum method:
- With an assistant: Have them slowly squeeze the brake lever or pedal until firm, then hold pressure. Open the bleeder slightly to allow fluid and bubbles to flow into the tube, then close the bleeder before the assistant releases the lever. Repeat until clear, bubble-free fluid appears. Keep reservoir topped up between cycles.
- With a vacuum bleeder: Connect the vacuum line to the bleeder, open the bleeder, and draw fluid until clear. Keep reservoir topped up.
- With a pressure bleeder: Pressurize the reservoir per tool instructions and open bleeders in sequence until clear fluid flows.
- Work through all wheels: Repeat the bleed process at each wheel following the chosen sequence. Always maintain reservoir level to prevent air entry.
- Tighten bleeders: When each wheel is clear, tighten the bleeder screw snugly. Avoid over-torquing; snug plus a small additional turn is sufficient. Clean any spilled fluid.
- Final reservoir top-up: Fill the reservoir to the correct level, secure the cap, and clean spill areas with brake cleaner and rags.
- Check lever/pedal feel: With engine off, operate the brake lever/pedal for firm, consistent resistance. If it feels spongy, repeat bleeding until firm.
- Inspect for leaks: Start the ATV, apply brakes several times, then recheck all fittings, caliper bolts and banjo connections for leaks.
- Test ride: Perform a low-speed test in a safe area to confirm braking performance before regular use.
Replacing brake hoses or banjo fittings
- If you remove banjo bolts or hoses, replace crush washers with new copper or aluminum washers. Torque banjo bolts to manufacturer spec if available — if not, tighten to a safe snug value and recheck for leaks after test rides.
- Bleed again after any hose/banjo removal to remove trapped air.
Maintenance tips & recommended intervals
- Brake fluid absorbs moisture; replace fluid every 1-2 years or sooner if fluid is dark or contaminated.
- Inspect caliper pistons and dust boots on older Eigers — pitting or torn boots require caliper service or replacement.
- Brake pads: inspect thickness and replace if worn close to minimum. Uneven wear can indicate seized caliper slides.
- Keep extra crush washers and a spare bleeder screw on hand for older machines where parts can be corroded.
Troubleshooting
- Persistent spongy pedal after bleeding: check for internal master cylinder issues or soft/expanding brake hoses; consider hose replacement or master cylinder rebuild.
- Continuous loss of fluid: locate and repair leaks at caliper banjo joints, hose fittings, or master cylinder seals.
- Brake drag after bleeding: ensure caliper pistons are free, pins are lubricated and pads retract properly.
Following this MotoSport procedure will give your 2006 Suzuki Eiger 400 4X4 AUTO crisp, reliable brakes. If you encounter damaged components beyond routine maintenance, source OEM-quality parts and consider professional help for master cylinder or caliper rebuilding.
Related Shopping Categories
Shop Brake Fluid for a 2006 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Bleeders for a 2006 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Pads for a 2006 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Lines for a 2006 Suzuki Eiger 400 4X4 AUTO ATV.
Shop Brake Tools for a 2006 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.