How to Bleed & Replace Brake Fluid on a 2009 Suzuki King Quad 500AXi 4X4 POWER STEERING

Shop parts for a 2009 Suzuki King Quad 500AXi 4X4 POWER STEERING ATV.

This guide from MotoSport walks you through a full brake fluid replacement and bleeding procedure for the 2009 Suzuki King Quad 500AXi 4X4 POWER STEERING (MMY code KINGQD500P). It covers safety, tools, model-specific notes, step-by-step flushing and bleeding technique, and tips to avoid contamination and air traps.

Model-specific notes & safety

  • The King Quad 500AXi has separate front and rear brake circuits with individual master cylinders. Verify which circuit you are working on before bleeding.
  • Factory-specified brake fluid type is listed in the owner's manual. Use fresh DOT-rated fluid as specified by Suzuki; never mix mineral oil with DOT fluids.
  • The King Quad 500AXi POWER STEERING system uses its own hydraulic pump and reservoir for steering; do not confuse power steering fluid with brake fluid.
  • Park on a level surface, secure the ATV with wheel chocks, put the engine off, and remove the key. Wear nitrile gloves and eye protection.

Tools & supplies

  • New, sealed DOT brake fluid (type per Suzuki spec)
  • Clear plastic tubing sized to bleed nipple
  • Clean catch bottle partially filled with used fluid to prevent air draw-back
  • Wrenches to fit bleeder nipples (usually 8mm or 10mm)
  • Turkey baster or fluid syringe to remove old fluid from reservoir
  • Brake cleaner, rags, and a small brush
  • Torque wrench for caliper fasteners if you remove components

Preparation

  1. Locate master cylinder reservoirs: one at the handlebar area for front brakes and one near the rear brake pedal for rear brakes. Clean the filler caps and surrounding area to prevent dirt entry.
  2. Remove reservoir caps and diaphragms; cover reservoirs with clean shop towel to limit debris. Siphon out most of the old fluid with a turkey baster.
  3. Top up reservoirs with new brake fluid so they do not run dry during the procedure.

Bleeding sequence & strategy

Use the standard furthest-first rule: start with the caliper farthest from the master cylinder for each circuit. On most King Quads the typical sequence is:

  • Rear circuit: far rear wheel first, then the closer rear wheel.
  • Front circuit: far front wheel first, then the near front wheel.

If you are unsure which is far or near relative to the master cylinder, identify the longest hydraulic line run and start there. Bleed each circuit separately, completing one circuit before moving to the next.

Open-bleed method (recommended for single operator)

  1. Attach clear tubing to the bleeder nipple and submerge the other end in a catch bottle partially filled with used fluid. The tube should point downward into the bottle to prevent air re-entry.
  2. Have an assistant gently pump the brake lever or pedal 3-4 times and hold steady at pressure. If alone, use a one-man vacuum or pressure bleeder adapter at the reservoir to maintain pressure while opening the nipple.
  3. Open the bleeder nipple about 1/4 turn. Fluid and air will flow into the tubing. Close the nipple before the lever/pedal returns to avoid drawing air back in.
  4. Repeat pump-and-open cycles until clear fluid with no air bubbles flows out. After each cycle, top up the reservoir to keep it from running low.
  5. Once clear, fully tighten the bleeder nipple to specified snugness, wipe any spilled fluid, and move to the next caliper.

Full-flush replacement (recommended)

  1. Start with reservoirs siphoned as in Preparation.
  2. For each circuit, continuously add fresh fluid to the reservoir while bleeding at the far caliper until the expelled fluid runs completely clear and the reservoir fresh fluid level remains stable.
  3. Flush until several reservoir changes have passed through each caliper to ensure old, water-contaminated fluid is removed.

Tips to avoid problems

  • Never let reservoir run dry; introducing air is the most common reason bleeding fails.
  • Replace any cracked hoses, worn caliper seals, or sticky caliper pistons before bleeding. They can hide as slow-response or spongy brakes after fluid change.
  • Use clear tubing so you can see air bubbles. Keep the catch bottle capped loosely to prevent splashing and contamination.
  • Do not reuse brake fluid; dispose of old fluid according to local hazardous-waste rules.
  • Clean any spilled brake fluid immediately from painted surfaces with water and brake cleaner — brake fluid can damage paint and plastics.

Final checks and road test

  1. With all bleeder nipples closed and reservoirs filled to the correct level, press the brake lever and pedal several times to verify a firm feel.
  2. Inspect all fittings, lines, calipers, and reservoirs for leaks.
  3. Perform a low-speed brake test in a safe area to confirm stopping performance and that no pulling or soft pedal exists.
  4. Recheck fluid level after the initial test and again after a short ride; top off if required.

Maintenance intervals & recommendations

  • Brake fluid absorbs moisture over time; replace every 1-2 years or per Suzuki service intervals to maintain performance and prevent internal corrosion.
  • After heavy water crossings, inspect and consider bleeding sooner to remove water-contaminated fluid.
  • Keep a sealed spare bottle of the correct DOT fluid in your shop for timely top-ups; store away from moisture.

Follow these steps to get a complete, reliable brake fluid replacement and bleed on your 2009 Suzuki King Quad 500AXi 4X4 POWER STEERING. If you encounter stubborn air or a soft pedal after thorough bleeding, inspect master cylinder seals, caliper pistons, and hoses for internal leakage or contamination; replace components as needed for a safe repair.

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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.