How to Bleed & Replace Brake Fluid on a 2008 Suzuki King Quad 400AS 4X4 AUTO
Shop parts for a 2008 Suzuki King Quad 400AS 4X4 AUTO ATV.
This MotoSport-exclusive guide walks you through safely flushing and bleeding the brake system on a 2008 Suzuki King Quad 400AS 4X4 AUTO. Follow these steps carefully, use proper tools and fresh DOT brake fluid as called out in your owner's manual, and inspect brake components while you work.
Safety & prep
- Work on a level surface with the engine off and key removed.
- Wear eye protection and gloves. Brake fluid is corrosive to paint & plastics; protect painted surfaces and clean spills immediately.
- Park with the parking brake engaged. Chock wheels if lifting any corner.
- Have fresh DOT brake fluid ready (use the DOT rating specified in your owner's manual). Never mix old & new fluids or different DOT types unless compatible.
Tools & supplies
- Fresh DOT brake fluid (manufacturer specified)
- Clear hose and catch bottle
- Wrenches for bleeder nipples (usually 8mm-12mm)
- Turkey baster or syringe for removing old fluid from reservoir
- Rags, brake cleaner, drip tray
- Assistant (hand-pump or pedal operator) or a one-man vacuum or pressure bleeder
- Torque wrench for caliper/banjo hardware if removed
Know the King Quad 400AS specifics
- The 2008 King Quad 400AS uses a hydraulic brake system with a visible plastic reservoirobserve min/max marks and do not let the reservoir run dry during bleeding.
- This model is an automatic 4x4 with mechanical parking brake; wheel chocks and parking-brake engagement are essential when bleeding.
- Typical failures on this platform include softened pedal feel from moisture-contaminated fluid and pad/caliper wear from off-road useinspect pads, caliper pistons and hoses while bleeding.
- If you encounter spongy pedal travel after bleeding, check master cylinder seals, banjo bolt crush washers and hose condition; replace hoses that swell under pressure.
Step-by-step: Replace & bleed brake fluid
- Locate the master cylinder/reservoir. Clean the area around cap to prevent contamination. Remove cap and diaphragm; cover the opening to limit airborne dust entry.
- Use a syringe or turkey baster to remove most old fluid from the reservoir. Dispose of old fluid responsibly.
- Top the reservoir with fresh DOT fluid to the max mark. Keep the cap off during the process, but cover lightly to avoid contamination.
- Identify bleed sequence. Bleed lines should start with the wheel farthest from the master cylinder and finish with the closest. On most King Quad setups that equates to: rear right (farthest), rear left, front right, front left (closest). Confirm visually on your machine before starting.
- Attach clear hose to the bleeder nipple and place other end into a catch bottle partially filled with fresh fluid to prevent air re-entry.
- Have an assistant slowly depress the brake pedal several times and hold it down. Open the bleeder nut about a quarter turn to allow fluid and air to escape until the flow runs clear and free of air bubbles. Tighten the nut before the assistant releases the pedal. Repeat until no bubbles are visible, then move to the next wheel.
- If working solo, use a hand vacuum or pressure bleeder on the reservoir to draw fluid through each caliper in the same sequence. Follow tool instructions to avoid cavitation or drawing air into the master cylinder.
- Keep the reservoir topped up between each wheel to avoid drawing air into the system. Never let the fluid level fall below the minimum mark while bleeding.
- After finishing all wheels, verify a firm brake lever/pedal feel at operating pressure. If the pedal is still spongy, repeat the full sequence. Persistent sponginess can indicate internal master-cylinder air, collapsed hoses, or caliper piston issues.
- Wipe all fittings, tighten bleeder nipples to proper snugness, reinstall reservoir diaphragm and cap, and clean any spilled fluid. If any banjo bolts were removed, torque to spec and replace crush washers as required.
Inspection & finishing checks
- Inspect pads, rotors and caliper boots for wear, scoring or leaks. Replace worn pads and repair leaks before returning to service.
- Check brake hose condition for cracks, swelling or rubbing points; replace suspect hoses with OEM-equivalent parts.
- Test brakes at low speed in a safe area to confirm firm, consistent stopping before riding hard.
- Record service date and fluid change interval – brake fluid is hygroscopic and typically needs replacement every 1-2 years depending on use.
Troubleshooting common King Quad issues
- Persistent low pedal: re-bleed entire system; inspect master cylinder and hoses for internal failure.
- Brake dragging after bleed: caliper pistons may be sticking or overfilled reservoir causing pressure; verify caliper piston movement and correct fluid level.
- Leaks at banjo fittings: replace crush washers and torque bolts to proper torque; inspect threads for damage.
Performing a clean, methodical fluid change and bleed on your 2008 Suzuki King Quad 400AS restores braking performance and extends component life. If you encounter internal master-cylinder failure, seized calipers or persistent problems after bleeding, consult a qualified ATV technician and consider genuine replacement parts from MotoSport for reliable fit and performance.
Related Shopping Categories
Shop Brake Fluid for a 2008 Suzuki King Quad 400AS 4X4 AUTO ATV.
Shop Brake Bleeders for a 2008 Suzuki King Quad 400AS 4X4 AUTO ATV.
Shop Brake Pads for a 2008 Suzuki King Quad 400AS 4X4 AUTO ATV.
Shop Brake Lines for a 2008 Suzuki King Quad 400AS 4X4 AUTO ATV.
Shop Brake Tools for a 2008 Suzuki King Quad 400AS 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.
