How to Bleed and Replace Brake Fluid on a 2010 Suzuki King Quad 500AXi 4X4 POWER STEERING

Shop parts for a 2010 Suzuki King Quad 500AXi 4X4 POWER STEERING ATV.

This MotoSport-exclusive service guide walks you step-by-step through draining, flushing, and bleeding the hydraulic brakes on a 2010 Suzuki King Quad 500AXi 4X4 POWER STEERING. Follow these instructions carefully to maintain safe, predictable braking performance. Read fully before starting and gather tools and supplies.

What you need

  • DOT 4 brake fluid (Suzuki specifies DOT 3 or DOT 4; we recommend DOT 4 for higher boiling point). Use only fresh, unopened fluid.
  • Clear 3/16" I.D. hose and a clean catch bottle or jar
  • Brake bleeding wrench or box wrench to fit bleed nipples (usually 8 mm or 10 mm)
  • Vacuum bleeder or handheld brake bleeder (optional but speeds and simplifies the job)
  • Clean rags, small brush, and isopropyl alcohol for cleanup
  • Gloves and eye protection
  • Jack or ramp to safely raise the ATV (if needed) and wheel chocks
  • Torque wrench for final tightening

Model-specific notes for the 2010 King Quad 500AXi PS

  • The King Quad 500AXi uses hydraulic disc brakes front and rear with individual caliper bleed nipples. There is no ABS on this model year, so bleeding is straightforward.
  • The front master cylinder reservoir is located at the right handlebar. The rear master cylinder/reservoir is mounted near the rear brake assembly/frame on the right side. Access may require removing plastic shrouds or racks for clearance.
  • Power steering uses a separate hydraulic system; brake fluid must never be mixed with power steering fluid. Brake fluid is DOT type and corrosive to paint & plasticsavoid spills.
  • If your machine has aftermarket racks, guards, or skid plates, remove or reposition them to access bleed nipples and reservoirs.

Preparation

  • Park on a level surface, secure the ATV with the engine off and key removed. Chock wheels.
  • Clean around the brake fluid reservoirs and bleed nipples to prevent contamination.
  • Remove reservoir caps and diaphragms carefully. Keep them clean and reuse only if undamaged.
  • Inspect hoses, lines, calipers, and master cylinders for leaks or damage. Replace any suspect components before bleeding.

Drain & replace fluid recommended procedure (two-circuit flush)

The King Quad 500AXi has separate circuits for front and rear. Flush them one at a time.

1. Replace old fluid in reservoir

  • Siphon or turkey-baste as much old fluid from the reservoir as possible. Do not let the reservoir run dry if you are mid-procedure.
  • Refill to the upper level with fresh DOT 4 fluid.

2. Bleed order

Work one circuit at a time. For each circuit, begin bleeding at the caliper farthest from the related master cylinder and finish at the closest. For the front circuit that usually means right then left, and for the rear circuit bleed the caliper furthest from the rear master cylinder first. If unsure, identify master cylinder location and pick the furthest caliper first.

3. Hand-pump / two-person method (traditional)

  1. Attach clear hose to the caliper bleed nipple and submerge the other end in a bottle partially filled with clean brake fluid to prevent air re-entry.
  2. Have an assistant slowly pump the brake lever or pedal several times and hold pressure.
  3. With lever held, open the bleed nipple about a quarter turn until fluid and air bubbles flow into the hose. Close the nipple before your assistant releases pressure.
  4. Repeat pump-hold-open-close cycles until fluid runs clear with no bubbles. Keep reservoir topped up to avoid drawing air back in.
  5. Work through each caliper in the correct order. Torque bleed nipples to spec (light snug, typically 8-12 Nm) once finished and wipe away spilled fluid.

4. Single-person / vacuum or pressure bleeder

  • Connect a vacuum pump to the bleed nipple hose or use a pressure bleeder on the reservoir per tool instructions.
  • Open the bleed nipple and draw fluid until clear, refilling reservoir as needed. Vacuum bleeders reduce risk of drawing air into the system.
  • Close nipple before removing hose. Repeat for each caliper in order.

5. Gravity bleeding (slow, acceptable)

  • With reservoir filled, open bleeder and allow fluid to flow by gravity into the hose until clear. Monitor reservoir level continuously; never let it run dry.

Finishing steps

  • When each circuit is clear, top the reservoir to the proper level, install diaphragm and cap, and secure.
  • Wipe any spilled fluid with isopropyl alcohol and clean rags. Brake fluid will damage paint and plastics.
  • Cycle the brake lever/pedal several times to confirm firm feel. If the lever/pedal is spongy, repeat bleeding until firm.
  • Check for leaks at calipers, lines, and master cylinders. Tighten fittings as needed.
  • Test ride at low speed in a safe area to confirm braking performance before returning to full operation.

Torque & tightness guidance

  • Bleed nipple snug torque: light snug, usually 8–12 Nm. Do not over-torque the nipples or caliper fittings.
  • Master cylinder fasteners: check Suzuki torque specs in the service manual when reinstalling covers or components removed for access.

Safety & disposal

  • Brake fluid is toxic and corrosive. Wear gloves and eye protection. Clean spills immediately.
  • Dispose of old brake fluid at an approved hazardous waste facility. Do not pour down drains.

Troubleshooting & common issues

  • Persistent spongy lever after proper bleeding: inspect for air ingress from cracked hoses, collapsed internal lines, or a failing master cylinder. Replace damaged components.
  • Plastic reservoir cracks or warped diaphragm: replace before final bleeding to avoid leaks and contamination.
  • If brake pedal/lever sinks slowly under pressure, suspect internal master cylinder seal failure; do not continue to rely on the brakes until repaired.

Final MotoSport tips for 2010 King Quad owners

  • Keep an extra bottle of DOT 4 in your toolbox. The King Quad's handlebar-mounted front reservoir is exposed to trail contaminants when caps are removed, so use care when topping off on the trail.
  • Inspect and replace aged rubber brake lines on machines with high hours; UV and heat can degrade lines even without visible damage.
  • When replacing any brake hardware choose quality replacement parts. MotoSport parts for this MMY are tested to fit and perform see the parts link above to source correct caliper bolts, seals, hoses, and fluid.

Follow these steps and your King Quad 500AXi will have clean, responsive brakes and safe stopping power. When in doubt, consult a certified mechanic or Suzuki service manual for torque specs and component replacement procedures.

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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.