How to Bleed & Replace Brake Fluid on a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO

Shop parts for a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO ATV.

This MotoSport guide walks you through a safe, complete brake fluid change and bleed procedure specific to the 2009 Suzuki King Quad 400FS 4x4 SEMI-AUTO. Follow the steps below precisely. If you are unsure or uncomfortable, have a qualified technician perform the service.

What you need

  • Brake fluid: DOT 3 or DOT 4 per Suzuki recommendation — DO NOT mix brake fluids that are not compatible; DOT 4 is commonly recommended for modern ATVs
  • Clear hose to fit bleed nipple, catch bottle, and fresh container
  • Brake bleeder kit (hand vacuum pump or pressure bleeder) or a helper
  • Wrenches to fit bleed nipples (usually 8mm or 10mm)
  • Clean rags, gloves, safety glasses
  • Small funnel for reservoir, non-metallic tubing cap if needed
  • Service manual or a way to confirm bleed nipple sizes/locations

Model notes — 2009 King Quad 400FS SEMI-AUTO

  • This model typically has separate master cylinders for front and rear brakes (handlebar lever for front, foot pedal for rear). Bleed and flush each circuit separately.
  • The master cylinder reservoirs are compact; top off frequently during the flush to avoid introducing air.
  • There is no ABS system on this model, but the semi-auto (CVT with automatic clutch) drivetrain means keep the machine in park/neutral and engine off when bleeding to avoid unexpected movement.
  • Parking brake and driveline do not affect hydraulic bleeding, but secure the machine on level ground with the parking brake engaged and wheels chocked.
  • Brake caliper bleed nipple locations are on each caliper body — front left/right and rear left/right. Identify the nipple orientation before beginning.

Preparation

  • Park the ATV on a flat, stable surface, engine off, ignition off, key removed.
  • Chock wheels and engage parking brake.
  • Clean around each reservoir cap and bleed nipple to prevent contamination.
  • Remove reservoir caps slowly; cover reservoir with clean rags to keep dirt out.
  • Loosen but do not remove bleed nipples to confirm fit of hose and wrench.

Brake fluid replacement strategy

Complete replacement is a circuit-at-a-time flush. Replace fluid in the entire system by repeatedly drawing out old fluid from the calipers while topping the master cylinder reservoir with fresh fluid so no air is introduced.

Bleeding order

Always start at the caliper farthest from the master cylinder and work toward the closest. Common sequence on this ATV:

  • Rear caliper far side (if rear has two calipers, start with the caliper farthest from the rear master cylinder)
  • Rear caliper near side
  • Front caliper far side
  • Front caliper near side

Manual (pump-and-hold) bleed method

  1. Fill the corresponding master cylinder reservoir with fresh DOT fluid to the recommended level. Keep the reservoir cap loosely on or covered to slow contamination.
  2. Attach clear hose to the bleed nipple and submerge the other end in a bottle partially filled with a little brake fluid to prevent air backflow.
  3. Have an assistant press and hold the brake lever or pedal firmly.
  4. Open the bleed nipple about a quarter to half turn to allow fluid and air to escape into the hose. Close the nipple before the assistant releases the lever/pedal.
  5. Repeat: pump to hold, open nipple, close nipple, release. Continue until you see only clean, clear fluid with no air bubbles in the hose.
  6. Top off the master cylinder after every few cycles to ensure it never runs low.
  7. When clear fluid flows, tighten the bleed nipple securely, wipe away any spilled fluid, and move to the next caliper following the bleed order.

Vacuum or pressure bleeder method (recommended for speed & cleanliness)

  • Connect the vacuum pump hose to the caliper bleed nipple or the pressure bleeder to the master cylinder reservoir per kit instructions.
  • If using a pressure bleeder on the reservoir, pressurize to the kit spec, then open each bleed nipple in sequence until clear fluid flows.
  • If using a vacuum on each caliper, pull fluid through each caliper until clean fluid appears, topping the master reservoir as needed.

Replacing all fluid (full system flush)

  • Repeat bleeding at each caliper until reservoir fluid looks new and clear; typically several cycles per caliper are required.
  • After the final caliper, top the reservoir to the proper level, reinstall and seal the reservoir cap, and wipe any drips from painted surfaces immediately (brake fluid can damage paint).

Finish & checks

  • Check pedal/lever firmness — it should be firm and resist travel. If it feels spongy, repeat bleeding until firm.
  • Inspect for leaks at each bleed nipple, line connection, and caliper after tightening.
  • Test brakes at low speed in a safe area to confirm proper operation before returning to normal riding.
  • Dispose of old brake fluid per local hazardous-waste regulations.

Safety & important warnings

  • Never let the master cylinder reservoir run dry during bleeding — doing so will introduce air and require additional bleeding.
  • Do not reuse expelled fluid or let it contact painted surfaces; brake fluid is corrosive to paint and plastics.
  • Use only the specified DOT fluid. Mixing incompatible fluids can harm the braking system.
  • If the brake lever or pedal travel remains excessive after thorough bleeding, inspect the master cylinder, calipers, lines, and hoses for internal failure or air trapped in hidden areas; replace components as needed.

Maintenance tips specific to this model

  • Inspect flexible brake hoses for cracks or swelling; replace hoses on the King Quad 400FS at the first sign of wear to prevent sudden failure.
  • Check caliper guide pins and sliding surfaces for corrosion; lubricate with brake-approved grease if applicable.
  • Because the reservoirs are small, plan for extra brake fluid on hand when performing a full flush.
  • Record the service date and mileage/hours in your maintenance log so you can repeat fluid replacement per MotoSport recommended intervals or your riding conditions (severe use requires more frequent changes).

Related Shopping Categories

Shop Brake Fluid for a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO ATV.

Shop Brake Bleeders for a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO ATV.

Shop Brake Pads for a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO ATV.

Shop Brake Lines for a 2009 Suzuki King Quad 400FS 4X4 SEMI-AUTO ATV.

Shop Brake Tools for a 2009 Suzuki King Quad 400FS 4X4 SEMI-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.