How to Bleed & Replace Brake Fluid on a 2016 Suzuki King Quad 400FSi 4X4 AUTO

Shop parts for a 2016 Suzuki King Quad 400FSi 4X4 AUTO ATV.

This MotoSport-exclusive procedure walks you through safely flushing and bleeding the brake system on the 2016 Suzuki King Quad 400FSi 4X4 AUTO. Follow each step carefully, use proper brake fluid, and keep the work area clean to avoid contamination. This guide assumes basic mechanical skills and common hand tools. If you are not comfortable working on brakes, seek professional service.

Important model notes

  • The King Quad 400FSi uses a hydraulic disc brake system with separate front and rear circuits. Reservoirs are accessible beneath the handlebar/fairing and near the rear carrier/under-seat area; remove small plastics or the seat to access them.
  • Confirm required fluid type in your owner's manual; Suzuki recommends DOT 3 or DOT 4 fluid for many models — use the grade specified for your machine and never mix glycol-based fluid with silicone-based fluid.
  • This model does not have an integrated ABS pump; bleeding is performed at caliper bleed nipples and the master cylinder reservoirs only. If you have a different MMY tag or aftermarket ABS, consult a tech.
  • Brake line routing on the King Quad is exposed; inspect hoses for cracking, chafing, or corrosion at fittings while you work. Replace any damaged components before bleeding.

Tools & supplies

  • Correct DOT brake fluid (per owner's manual)
  • Clear vinyl tubing sized to bleed nipple
  • Catch bottle with a little fresh fluid to prevent air draw-back
  • Box/flaring wrench for bleed nipples (usually 8mm or 10mm)
  • Ratchet, sockets, screwdrivers, pliers
  • Brake bleeder wrench or vacuum bleeder (optional)
  • Clean rags, rubber gloves, safety glasses
  • Torque wrench for reassembly and a container for old fluid

Safety & preparation

  • Work on a cool machine; hot brake parts or fluid can burn.
  • Protect paint/plastics from spilled brake fluid — it damages finishes. Keep rags and a container handy.
  • Park on level ground and secure the ATV with the parking brake engaged. Use stands to lift wheels if you want better access, but this is not always required.
  • Clean reservoir caps & surrounding area before opening to prevent contamination.

Step-by-step: flush & bleed

  1. Open reservoirs: Remove caps and diaphragms. Siphon old fluid from each reservoir with a hand pump or turkey baster to reduce spillage. Do not allow reservoirs to run dry yet.
  2. Top up reservoirs with fresh DOT fluid to a safe level. Use separate bottles for front & rear if required by system layout to avoid cross-contamination.
  3. Locate bleed nipples: front calipers (left & right) and rear caliper bleed screw. Clean threads and fit clear tubing over nipple, route into catch bottle partially filled with fresh fluid to prevent air re-entry.
  4. Bleeding order: follow manufacturer sequence for best results: typically start with the caliper furthest from the master cylinder and work toward the closest. For the King Quad 400FSi this generally means: rear caliper first, then passenger-side front, then driver-side front. If in doubt, begin with the caliper farthest from each reservoir one circuit at a time.
  5. Hand-pump method: one person operates the lever/pedal while another opens/closes the bleed nipple.
    • Have a helper slowly pull the brake lever (or press the pedal) to build pressure and hold it.
    • Open the bleed nipple about a quarter turn. Fluid and air will flow into the tubing. Close the nipple before the lever/pedal is released to prevent sucking air back in.
    • Repeat: pump, hold, open, close until clear, bubble-free fluid appears and lever feel is firm.
  6. Vacuum/pressure bleeder option: attach a vacuum pump to the bleed nipple or use a pressure bleeder on the reservoir for one-person operation. Follow tool manufacturer instructions. Keep the reservoir topped up during this process.
  7. After bleeding each caliper, top off the corresponding reservoir to prevent overflow and contamination. Monitor fluid level closely; never let the reservoir run dry during bleeding.
  8. Sequence repeat: After completing the far-to-near sequence for one circuit, double-check all nipples for tightness and repeat the sequence if necessary until lever/pedal feel is firm and consistent.
  9. Final checks:
    • Torque bleed nipples to specification if available or snug to manufacturer guidance; avoid overtightening.
    • Clean any spilled fluid and reinstall reservoir diaphragms & caps securely.
    • Verify brake lever and pedal travel are correct and firm with no sponginess.
    • Spin wheels and operate calipers to confirm no leaks. Road- or trail-test at low speed to confirm braking performance before full use.

Flushing the entire system (full fluid replacement)

  • To fully replace old fluid, repeatedly siphon fluid from reservoir, top with fresh fluid, then bleed each caliper until new fluid flows out clear. Repeat until reservoir fluid remains clear after bleeding each caliper.
  • Dispose of used brake fluid responsibly — it is hazardous waste.

Torque & maintenance tips

  • Inspect brake pads and rotors while bleeding; replace if pad thickness is near minimum or rotors are scored/excessively worn.
  • Replace soft rubber hoses showing cracks, bulges, or stiff spots. A blown hose can cause brake failure.
  • Bleed nipple threads are often soft; use the correct wrench to avoid rounding and ensure a snug fit.
  • After any brake-service, recheck pedal/lever feel after the first ride and again after a few miles of use.

Troubleshooting

  • Persistent spongy lever/pedal after proper bleeding: inspect for air entry points, leaking seals, or collapsed brake hose; consider bench-bleeding master cylinder if applicable.
  • If you cannot achieve firm feel, replace the master cylinder or have a professional inspect internal components.

Following this MotoSport procedure will keep your King Quad 400FSi braking system safe and responsive. Regular brake fluid replacement maintains performance & prevents internal corrosion – aim for replacement intervals recommended in your owner's manual or sooner if the machine sees heavy use or wet conditions.

Related Shopping Categories

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Shop Brake Lines for a 2016 Suzuki King Quad 400FSi 4X4 AUTO ATV.

Shop Brake Tools for a 2016 Suzuki King Quad 400FSi 4X4 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.