How to Bleed & Replace Brake Fluid on a 2016 Suzuki King Quad 500AXi 4X4 POWER STEERING

Shop parts for a 2016 Suzuki King Quad 500AXi 4X4 POWER STEERING ATV.

This MotoSport exclusive procedure covers safe, complete brake fluid replacement and bleeding for the 2016 Suzuki King Quad 500AXi 4X4 POWER STEERING (MMY: KINGQD500P). It combines shop-grade technique with ATV-specific tips so you can restore firm, reliable braking and avoid common owner pitfalls.

Before you start & tools

  • Brake fluid: use fresh DOT 3 brake fluid (confirm cap/owner's manual for exact spec). Never mix with mineral oil or old fluid types.
  • Tools: wrench set (bleeder nipple size typically 8mm), clear hose, catch bottle, vacuum or pressure bleeder (recommended), turkey baster or fluid syringe, funnels, clean lint-free rags, gloves, safety glasses, jack/stands or ramps, torque wrench, rubber plugs for caliper ports.
  • Prep area: level ground, cool brakes, cool engine. Protect painted surfaces with cardboard/rags – brake fluid will damage paint.
  • Safety: work in a well-ventilated area. Dispose of old fluid per local regulations.

Model-specific notes for the 2016 King Quad 500AXi POWER STEERING

  • The King Quad 500AXi typically uses a front master cylinder reservoir that supplies the front brakes and a separate line for the rear brake circuit. Confirm reservoir locations on your machine before beginning.
  • Power steering on this model is hydraulic and uses a separate reservoir – do NOT open or contaminate the power steering reservoir when servicing brakes.
  • The ATV's compact routing means caliper bleed nipples are often low or tight to access. Use a short flex hose or angled wrench to avoid rounding nipples.
  • If the machine has an ABS or traction-control module (rare on this model), follow manufacturer service steps for ABS bleeding; otherwise proceed with standard bleeding sequence below.

Step 1 – Initial fluid removal & reservoir prep

  1. Remove the brake fluid reservoir cap(s) and diaphragm. Clean the cap area before opening to keep contamination out.
  2. Use a turkey baster or syringe to suck most old fluid out of the reservoir(s) into a waste container. Refill with fresh DOT 3 fluid to the maximum line. Keep reservoir topped during the job to avoid drawing air into the master cylinder.
  3. Inspect master cylinder and reservoir for sludge, water intrusion, or debris. If fluid is very dark or contaminated, repeat reservoir siphon until reasonably clear before bleeding.

Step 2 – Lift, secure & locate bleeder nipples

  1. Lift the ATV so wheels hang or at least are off the ground; secure with jack stands or ramps. Ensure parking brake is released and vehicle stays stable.
  2. Locate each caliper bleed nipple. There are four brake bleed nipples: two front, two rear. Clean around each nipple to avoid contamination.

Step 3 – Bleeding sequence (recommended)

Use the standard "farthest from master cylinder first" approach. For most King Quads that means:

  1. Rear right (farthest)
  2. Rear left
  3. Front right
  4. Front left (closest)

If you're unsure which wheel is farthest from the master cylinder, pick the wheel with the longest line run from the reservoir as the first step.

Step 4 – Bleeding methods

Two professional methods follow. Use one; don't mix.

Method A – Vacuum bleeder (recommended for one-person jobs)

  1. Attach clear hose from bleeder nipple to a catch bottle partially filled with used fluid. Attach vacuum pump hose to bottle or directly to nipple as your tool requires.
  2. Crack the bleeder nipple ~1/4 turn. Apply vacuum and slowly pull fluid while an assistant gently squeezes the brake lever/pedal several times then holds down. Continue until you see clear fluid with no air bubbles, then tighten nipple while pressure is held.
  3. Top off reservoir after each wheel to keep air out of master cylinder.
  4. Repeat sequence for all four wheels.

Method B – Bench/pressure or two-person pump method

  1. If you have a pressure bleeder, pressurize the reservoir per tool instructions and open each bleeder nipple in sequence until clean fluid flows. Close nipple, move to next wheel.
  2. For two-person manual bleeding: one person pumps and holds the brake lever/pedal; the other opens nipple until fluid runs clear & bubble-free, then closes nipple while pressure is held. Repeat until all air is expelled.

Step 5 – Finish checks

  • After all four calipers are clear, top reservoir to its max line and reinstall cap/diaphragm securely.
  • Pump the brake lever/pedal with the ATV still safely supported until a firm pedal/lever is achieved.
  • Lower the ATV, test brakes at low speed in a safe area to confirm bite and no pulling or sponginess.
  • Inspect bleeder nipples for leaks and torque to manufacturer spec if you removed any caliper hardware (light snug is typical — avoid over-torque).

Troubleshooting

  • Persistent spongy feel: re-bleed, paying particular attention to keeping the reservoir topped at all times and cycling the brake lever/pedal fully.
  • Air returning: check for leaking rubber hoses, cracked master cylinder seals, or loose banjo bolts; these can introduce air and require part replacement.
  • Stiff lever but poor braking: check caliper pistons for sticky movement or seized slider pins; inspect pads and rotor/drum condition.

Maintenance & owner tips

  • Change brake fluid every 2 years or sooner if the fluid darkens or the machine is used heavily in wet/muddy conditions.
  • Store replacement DOT 3 fluid sealed; brake fluid is hygroscopic and absorbs moisture over time.
  • Keep a small bleed kit, clear tubing, and spare bleeder caps in your trail tool kit for emergency top-ups or field bleeding.
  • If you encounter ABS/ESP fault lights (if equipped), consult a dealer or use a diagnostic tool before repeated bleeding attempts — electrical faults may mimic hydraulic problems.

Performing a full fluid change and bleed correctly will keep your King Quad 500AXi stopping reliably and extend the life of the brake system. If you run into stubborn air, damaged hoses, or suspect master cylinder failure, contact a qualified technician or bring your parts list to MotoSport for OEM & performance components.

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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.