How to Bleed & Replace Brake Fluid on a 2011 Suzuki King Quad 400FSi 4X4 AUTO

Shop parts for a 2011 Suzuki King Quad 400FSi ATV.

This MotoSport-exclusive guide walks you through flushing and bleeding the hydraulic brake system on the 2011 Suzuki King Quad 400FSi 4X4 AUTO (MMY: KINGQD4FSI). Follow safety steps exactly & use fresh DOT 4 brake fluid unless your owner's manual specifies otherwise.

What you need

  • DOT 4 brake fluid, unopened bottle
  • Clear bleed hose – small diameter to fit bleeder nipple
  • Catch container (sealed-cap recommended)
  • 10 mm and 8 mm wrenches (bleeder & banjo/line fittings)
  • Brake cleaner, rags, nitrile gloves, eye protection
  • Turkey baster or fluid syringe
  • Floor jack or stands to safely lift ATV (if needed)
  • Assistant for manual bleeding (optional for vacuum or pressure bleeder)

Safety & model notes

  • Always wear eye protection & gloves. Brake fluid damages paint & plastics; wipe spills immediately with brake cleaner.
  • The King Quad 400FSi uses hydraulic disc brakes front & rear with a single master cylinder for the rear brake pedal and a handlebar master cylinder for the front. Confirm reservoir locations before starting: one handlebar reservoir for front brakes, one frame-mounted reservoir for rear.
  • On this model the ABS is not fitted; however, hydraulic layout includes short feed lines and compact calipers – take care with banjo bolts and crush washers when removing lines.
  • Replace crush washers on banjo fittings whenever you disconnect the brake lines. Torque specs: banjo bolts typically 20-25 Nm – refer to torque spec marking in your service manual for exact value.
  • Use only DOT 4 fluid. If the system has been contaminated or you do not know prior fluid type, flush completely and refill with DOT 4.

Preparation

  1. Park ATV on level surface, engage parking brake (if equipped), and remove key. Secure chassis on stands so wheels hang free if you intend to cycle calipers.
  2. Clean around both master cylinder reservoirs and calipers with brake cleaner to prevent contamination.
  3. Open each reservoir, cover with clean rag to catch splashes. Use turkey baster to remove old fluid from reservoirs – don't let reservoirs empty to air; keep level above minimum by topping with fresh fluid during the process to avoid introducing air into the system.
  4. Locate bleeder nipples on each caliper. Fit clear hose onto nipple and submerge other end into catch container partially filled with fresh brake fluid to avoid drawing air back in.

Recommended sequence

Bleed closest caliper to master cylinder first, then move to the farthest. For the King Quad 400FSi typical order:

  1. Front right caliper (closest to handlebar master)
  2. Front left caliper
  3. Rear caliper (operated by foot master)

Manual bleeding procedure (two-person)

  1. Top up both reservoirs with DOT 4 fluid.
  2. Have assistant sit on the ATV and slowly apply steady pressure to the brake lever/pedal and hold.
  3. Open bleeder nipple ~1/4 turn with wrench. Fluid & air will flow into the hose. Close nipple before assistant releases lever/pedal.
  4. Repeat pump-hold-open-close cycle until clear, bubble-free fluid runs and no air is present. Keep reservoir topped throughout.
  5. Work through bleed order. Finish by ensuring nipples are closed tight and wipe clean residual fluid.

Single-operator vacuum or pressure method

  1. If using a vacuum pump, attach pump hose to bleeder and create vacuum while an open reservoir is kept topped. Pump until clear fluid flows, then close bleeder.
  2. If using a pressure bleeder on the reservoir, pressurize according to tool instructions and open each bleeder in sequence until clear fluid appears, then close.

Master cylinder bench-top flush (handlebar and rear master)

  1. If fluid is dark or contaminated, perform a reservoir-to-return flush: remove hose from caliper and direct fluid into a sealed catch while pumping lever/pedal slowly, replacing with fresh fluid until clear. Reconnect line, then bleed calipers normally.

Final checks

  1. Confirm reservoirs are filled to the proper level and caps are sealed.
  2. Operate lever and pedal multiple times with ATV off. Feel should be firm & consistent; sponginess indicates remaining air — repeat bleeding until firm.
  3. Inspect all fittings, hoses, and mounts for leaks. Torque banjo bolts to spec and replace crush washers where lines were disturbed.
  4. Lower ATV, test brakes at low speed in a safe area before normal riding.
  5. Properly dispose of used brake fluid per local regulations.

Specific maintenance tips for the 2011 King Quad 400FSi

  • Front calipers on the King Quad are compact and can trap air pockets; when bleeding, position the ATV upright and cycle the lever slowly, allowing the caliper pistons to retract slightly between cycles to help purge trapped air.
  • The handlebar master cylinder reservoir cap uses a diaphragm & filter — inspect and clean on service, replace diaphragm if cracked to avoid contamination.
  • ABS is not present on this MMY, so no ABS pump bleeding procedure is needed; simple hydraulic bleeding is sufficient.
  • If front brake lever travel is long after bleeding, check caliper piston seals and slider condition — seized sliders or corroded pistons will reintroduce sponginess and require caliper service or replacement parts available through MotoSport.

Troubleshooting

  • Persistent soft lever/pedal: re-bleed, ensure reservoirs never go dry, inspect hoses for internal collapse, check caliper pistons for corrosion.
  • Brake drag after bleed: caliper pistons may be stuck or overextended. Retract pistons, inspect pads and caliper slides, reassemble and bed brakes gently.
  • Leaking banjo or bleeder: replace crush washers and retorque. Replace bleeder screw if rounded or damaged.

Perform brake fluid replacement every 1-2 years for best performance and corrosion prevention. For parts, service items, or OEM replacement components specific to the 2011 Suzuki King Quad 400FSi, use the MotoSport parts link above.

Related Shopping Categories

Shop Brake Fluid for a 2011 Suzuki King Quad 400FSi ATV.

Shop Brake Bleeders for a 2011 Suzuki King Quad 400FSi ATV.

Shop Brake Pads for a 2011 Suzuki King Quad 400FSi ATV.

Shop Brake Lines for a 2011 Suzuki King Quad 400FSi ATV.

Shop Brake Tools for a 2011 Suzuki King Quad 400FSi 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.