How to Bleed & Replace Brake Fluid on a 2019 Suzuki King Quad 500AXi 4X4

Shop parts for a 2019 SUZUKI KINGQD500A ATV.

This MotoSport proprietary guide walks you step-by-step through replacing and bleeding the brake fluid on a 2019 Suzuki King Quad 500AXi 4X4. Follow every step carefully, use the correct fluid, and wear safety gear. If you're not confident in brake work, have a professional perform the service.

What you'll need

  • Manufacturer-specified brake fluid (use the DOT rating called out in your owner's manual; DOT 4 is commonly used)
  • Clear plastic tubing that fits bleeder nipples
  • Brake fluid catch bottle or jar
  • Disposable squeeze bottle or Fluid transfer pump
  • Brake cleaner, rags & nitrile gloves
  • Wrenches for bleeder nipples (typically 8mm or 10mm)
  • Torque wrench, basic hand tools, jack or ramps
  • Assistant for manual pump-and-hold bleeding (unless using vacuum or pressure bleeder)

Important model notes for the 2019 King Quad 500AXi 4X4

  • Brake system layout: hydraulic front brakes and rear brake assembly as fitted to your MMY (inspect whether rear is disc or drum on your specific unit). Caliper bleeder nipples are located on the caliper bodies; rear fasteners can be harder to access depending on rack & skid setup.
  • Brake reservoir(s) are mounted on/near the handlebars; they are translucent on most models – do not allow reservoir to run dry during bleeding or you will introduce air into the system and repeat the procedure.
  • 2019 King Quad models are not typically equipped with ABS; if your unit has electronic brake controls, consult an authorized Suzuki tech before bleeding.
  • Brake fluid is corrosive to paint – immediately wipe spills and avoid contact with plastics, rubber, and painted surfaces.
  • Recommended fluid change interval: drain & replace every 1-2 years or if fluid appears dark/contaminated; also replace if system has been opened for repairs.

Preparation

  1. Park ATV on level ground, engage park/neutral and set the parking brake. Chock wheels.
  2. Clean around master cylinder caps and bleeder nipples with brake cleaner to prevent contamination.
  3. Remove master cylinder cap(s) and diaphragm; keep reservoir top sealed with a clean rag to limit moisture ingress.
  4. If possible, lift the front and/or rear wheels slightly so calipers are accessible and hydraulic lines run gently without sharp kinks.

Drain & Replace Brake Fluid (recommended full replacement)

  1. Use a syringe or fluid transfer pump to remove as much old fluid from the reservoir as possible. Dispose of old fluid properly.
  2. Top reservoir with fresh fluid to maximum fill line. Keep cap loosely installed to avoid contamination while bleeding.
  3. Perform bleeding on each caliper in the recommended sequence. For King Quad 500AXi, bleed farthest caliper from master cylinder first, then closer calipers. Typical sequence: rear (if remote), then front passenger, then front driver. Adjust sequence to your machine's plumbing layout.
  4. Attach clear tubing to bleeder nipple; place other end into catch bottle partially filled with a little fresh fluid to prevent air re-entry.
  5. Have an assistant slowly pump the brake lever/pedal several times and hold pressure. Open bleeder nipple about 1/4 turn until fluid & bubbles flow into tubing, then close nipple. Repeat until no bubbles appear and fluid runs clear.
  6. Keep reservoir topped during the process; never let it run below the minimum line.
  7. Repeat for each caliper following the bleed sequence. For a single-master setup bleed all lines sequentially; for dual-master systems treat each circuit separately.
  8. After final caliper is bled, pump brake lever/pedal to confirm firm pressure and no sponginess. If spongy, repeat bleeding steps or consider bench-bleeding master cylinder.
  9. Clean bleeder nipples, torque them to spec if called out in the manual (light torque; typically 8-12 Nm on bleeder screws), reinstall caps, and top reservoir to the proper level. Replace reservoir diaphragm & cap.
  10. Dispose of old fluid per local regulations. Clean up any spills immediately.

Bench-bleeding the master cylinder (if replaced or if persistent air)

  1. Remove master cylinder from handlebar mount and bench-mount in a vice or secure holder without damaging bodywork.
  2. Attach clear tubing from output ports back into the master cylinder reservoir so fluid circulates back into the reservoir as you push the piston.
  3. Fill reservoir with fresh fluid and slowly actuate piston by hand until no bubbles appear in the return lines.
  4. Reinstall master cylinder, reconnect lines, then bleed calipers again as above.

Checks & final steps

  • Verify brake lever & pedal feel is firm and consistent under load. If soft, there may still be air or a leak.
  • Inspect all hose fittings, banjo bolts, and caliper bolts for leaks. Tighten to Suzuki torque specs if available.
  • Test ride at low speed in a safe area; confirm normal stopping performance before full operation.
  • Record the service date and replace brake fluid again per schedule or sooner if contamination is suspected.

Troubleshooting

  • Persistent spongey lever: re-bleed, bench-bleed master, check for flexible hose swelling or internal caliper leaks.
  • Fluid level drops quickly: inspect for external leaks at lines, calipers, banjo bolts & master cylinder.
  • Brake drag after bleeding: caliper pistons may be seized or over-extended during bleeding — inspect and clean or rebuild calipers if necessary.

Safety reminders

  • Always use fresh, manufacturer-specified brake fluid. Mixing different DOT fluids can harm components.
  • Brake fluid absorbs moisture; keep bottles sealed and use within the manufacturer's recommended timeframe after opening.
  • Do not let fluid contact painted surfaces; it will damage finish.
  • If you are unsure about any step, have brakes inspected and serviced by a licensed technician.

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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.