How to Bleed & Replace Brake Fluid on a 2016 Suzuki King Quad 400ASi 4X4 AUTO
Shop parts for a 2016 SUZUKI KINGQD4ASI ATV.
This MotoSport-proprietary guide walks you through safely flushing and replacing the brake fluid on your 2016 Suzuki King Quad 400ASi 4X4 AUTO and highlights model-specific details every owner should know.
What you’ll need
- DOT 4 brake fluid (unless your owner’s manual specifies otherwise)
- Clear hose that fits the bleed nipples
- Clean plastic bottle or catch container
- Wrenches to fit bleed nipples and reservoir cap
- Screwdriver or pliers (to remove reservoir cover clips)
- Latex or nitrile gloves and eye protection
- Shop rags and a small funnel
- Torque wrench (recommended for caliper hardware)
- Optional: vacuum or pressure bleeder for faster, cleaner bleeding
Model notes – King Quad 400ASi 2016
- The 400ASi uses a hydraulic brake system with a master cylinder and separate calipers for front & rear. It is not fitted with cornering ABS; bleeding follows a standard sequence.
- Master-cylinder reservoir is located under a plastic cover near the handlebars; access may require removing small panels. Keep the area clean before opening to avoid contamination.
- Some units have linked brake operation between front & rear; bleed both circuits completely to ensure balanced stopping.
- Inspect rubber hoses, caliper seals, and pads while you’re working—age-related swelling or cracking is common on older ATVs and should be addressed before finishing.
Safety first
- Work on a level surface with the engine off, parking brake engaged (if applicable), and wheels chocked.
- Brake fluid is corrosive to paint and plastics. Wipe spills immediately and dispose of old fluid safely.
Step-by-step bleed & replace procedure
1. Prepare the ATV
- Remove any body panels needed to access the master reservoir and bleed nipples. Clean the reservoir cover area to prevent dirt entry.
- Loosen the reservoir cap slowly to relieve any pressure. Remove cap and diaphragm and keep the top covered with a clean cloth to reduce contamination.
- Top the reservoir with fresh DOT 4 fluid to the fill line. Do not let it run dry during the process.
2. Identify bleed sequence
- Use the rule: bleed the caliper farthest from the master cylinder first, then proceed to the nearer calipers. On the King Quad 400ASi this usually means: rear caliper(s) first, then front passenger side, then front driver side. If in doubt, follow the physical routing from master cylinder to calipers.
3. Attach clear hose & prepare catch bottle
- Place one end of the clear hose over the bleed nipple and the other into a bottle partially filled with fresh fluid (or a little fluid to avoid drawing air back in).
- Have a helper ready if using the pump-style method; otherwise set up a vacuum/pressure bleeder per manufacturer instructions.
4. Bleed each caliper
- Open the bleed nipple about 1/4 turn. If using the two-person method, have the helper slowly squeeze the brake lever or press the foot pedal until firm, hold it, then you open the nipple to let fluid & air pass, then close the nipple before the helper releases pressure. Repeat until clear fluid free of bubbles flows.
- If using a vacuum or pressure bleeder, follow the device instructions and monitor reservoir level closely so it never runs dry.
- Always close the bleed nipple tightly after each cycle to prevent air ingress. Wipe the nipple clean between cycles.
- Continue bleeding until fluid coming out is clean and bubble-free, and the brake lever/pedal feel solid.
5. Flush entire system
- Replace reservoir fluid as needed during the process, topping with fresh DOT 4. Continue bleeding each caliper in sequence until the reservoir contains only new, clear fluid and all air is expelled.
6. Finalize
- Torque bleed nipples and any caliper hardware to manufacturer specifications if available. If you don’t have a spec to hand, snug to prevent leaks but avoid over-tightening.
- Replace reservoir diaphragm and cap, reinstall any removed panels, and clean any spilled fluid.
- Check pedal/lever travel; if it feels spongy, re-bleed. If sponginess persists, inspect master cylinder and calipers for internal issues.
Post-service checks
- Inspect for leaks around calipers, hoses, and the master cylinder after a short test ride.
- Check pad thickness and rotor condition; replace pads or resurface rotors if worn or glazed.
- Monitor brake performance over the next few rides and re-check fluid level once the system has settled.
Maintenance tips specific to this MMY
- The King Quad 400ASi is commonly used in wet & muddy conditions. Schedule brake fluid replacement every 1-2 years or sooner if you use the ATV in water frequently, since moisture contamination reduces boiling point and performance.
- Inspect the reservoir cap seal and master-cylinder boot for cracks — these can allow contamination. Replace aged rubber components to maintain system integrity.
- If you notice uneven braking or unusual noises after bleeding, check for seized caliper pistons or a sticking brake lever/pedal pivot; these are common on older units and easy to service.
Performing a full brake-fluid flush and proper bleed restores stopping performance and extends the life of the brake components on your 2016 Suzuki King Quad 400ASi. When in doubt about parts or fitment, use MotoSport to source OEM-quality parts and replacement fluids for your exact MMY.
Related Shopping Categories
Shop Brake Fluid for a 2016 SUZUKI KINGQD4ASI ATV.
Shop Brake Bleeders for a 2016 SUZUKI KINGQD4ASI ATV.
Shop Brake Pads for a 2016 SUZUKI KINGQD4ASI ATV.
Shop Brake Lines for a 2016 SUZUKI KINGQD4ASI ATV.
Shop Brake Tools for a 2016 SUZUKI KINGQD4ASI 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.