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

Shop parts for a 2019 Suzuki King Quad 500AXi 4X4 POWER STEERING ATV.

This MotoSport guide walks you through a complete brake fluid change and bleed on the 2019 Suzuki King Quad 500AXi 4X4 Power Steering (MMY code KINGQD500P). Follow these steps to restore firm brake feel, prevent corrosion, and maintain safe stopping performance. Work on a cool machine, use proper PPE, and dispose of used fluid responsibly.

Tools & Supplies

  • DOT 4 brake fluid (Suzuki factory spec DOT 4 recommended) & a sealed new container
  • Clear plastic tubing to fit bleeder nipples
  • Clean catch container (marked for brake fluid)
  • Brake bleeder wrench or correctly sized box wrench
  • Hand vacuum or pressure bleeder (optional but speeds and improves results)
  • Turkey baster or fluid syringe for reservoir drain
  • Shop rags, nitrile gloves, safety glasses
  • Jack stands or ramps and wheel chocks if you remove wheels
  • Wire brush (light) and small spanner to clean bleeder threads

Model Notes & Precautions for the 2019 King Quad 500AXi

  • The King Quad 500AXi POWER STEERING uses a hydraulic master cylinder feeding two front calipers and two rear calipers (or combined front/rear depending on model sub-configuration). Bleed the system from the caliper farthest from the master cylinder to the nearest.
  • This model does not use ABS; bleeding is a conventional hydraulic job. If your unit has optional electronic features, isolate electrical connectors before spraying or using liquids near them.
  • Avoid getting brake fluid on painted plastics and bodywork – DOT fluid will damage finishes. Keep rags between lines and paint, and wipe spills immediately with water.
  • Replace fluid every 2 years or when it appears dark or contaminated; fresh fluid improves boiling point and corrosion protection.

Preparation

  1. Park on level ground, engage parking brake, chock wheels. Remove ignition key.
  2. Locate the brake fluid reservoir under the front storage panel or near the handlebar area. Clean the cap and surrounding area to prevent contamination.
  3. Inspect hoses, calipers, and connections for leaks or damage. Replace any cracked hoses or corroded fittings before bleeding.
  4. If you plan to remove wheels for better caliper access, lift the ATV on a stable lift or stands and remove wheels; follow safe lifting procedures.

Drain Old Fluid from the Reservoir

  1. Remove the reservoir cap and diaphragm. Use a turkey baster or syringe to remove as much old fluid as possible from the reservoir without introducing air into the master cylinder. Dispose of old fluid properly.
  2. Top the reservoir with fresh DOT 4 fluid to the maximum mark and replace the cap loosely so it breathes without trapping pressure.

Bleeding Sequence & Technique

General rule: start with the caliper farthest from the master cylinder and move to the closest. If you do not know exact routing, use this approach: far rear > near rear > far front > near front. Keep the reservoir topped during the entire process.

  1. Attach clear tubing to the caliper bleeder nipple and submerge the other end in the catch container partially filled with fresh fluid to prevent air re-entry.
  2. Open the bleeder nipple one-quarter to one-half turn. Do not completely remove the nipple or allow it to shear. Have an assistant slowly apply firm pressure to the brake lever (or pump the pedal) and hold it down while you watch fluid flow. For single-person work, use a vacuum bleeder or a one-way syringe pump.
  3. While the lever is held down, close the bleeder nipple, then instruct the assistant to release the lever. Repeat until you see clean, bubble-free fluid at the tubing outlet and the fluid color is clear/new.
  4. Keep the reservoir level above the minimum mark at all times to avoid drawing air into the master cylinder. Refill as needed with fresh DOT 4 only from the sealed container.
  5. Repeat the process for each caliper in sequence. When finished, ensure bleeder nipples are tightened to snug factory fit; do not overtighten and strip threads.

Using a Vacuum or Pressure Bleeder

  • Vacuum bleeder: attach the vacuum cup to the reservoir and connect the bleeder hose to the bleeder nipple. Open the nipple and pump the vacuum; fluid will be drawn out. Close nipple before releasing vacuum. Maintain reservoir level.
  • Pressure bleeder: pressurize reservoir per tool instructions (do not overpressurize). Open bleeders in sequence until clean fluid flows. Pressure bleeders speed the job and reduce assistant need.

Final Checks & Reassembly

  1. When all calipers show clean fluid and no air bubbles, tighten each bleeder to proper snugness. Wipe fittings and remove tubing.
  2. Top the reservoir to the correct level and securely install the cap and diaphragm. Clean any spilled fluid immediately.
  3. Reinstall wheels if removed, torque wheel nuts to factory spec, lower the ATV, and remove stands/blocks.
  4. Pump the brake lever/pedal several times to confirm firm feel. If the lever is spongy, repeat bleeding until solid resistance is achieved.
  5. Road-test the ATV at low speed in a safe area to confirm braking performance. Recheck fluid level and bleeder nipples after initial ride.

Maintenance Tips Specific to the King Quad 500AXi

  • Power steering servo and brake reservoir are in close proximity on some trim levels – avoid cross-contamination and keep fluids clearly labeled.
  • Inspect front CV boots and brake hose routing after wheel removal; King Quad steering and suspension movement can stress hoses over time. Replace any hose with cracks or swelling.
  • If you notice persistent soft brakes after multiple bleeds, inspect the master cylinder bore and caliper pistons for corrosion or seal leakage. Replace seals or remanufactured units as needed.
  • Keep a service record of brake fluid changes; fresh fluid prevents internal corrosion of aluminum components in the Suzuki hydraulic system.

Safety & Environmental Notes

  • Brake fluid is hygroscopic and corrosive to paint. Wear gloves and eye protection. Clean spills with water and a cloth immediately.
  • Dispose of old brake fluid at an appropriate hazardous waste facility. Do not pour down drains or onto the ground.

Following this MotoSport procedure will get your 2019 Suzuki King Quad 500AXi 4X4 POWER STEERING braking system bled and filled with fresh fluid safely and reliably. If uncertain about any step or if you uncover hardware damage, consult a qualified technician or refer to the official Suzuki service manual for torque values and component replacement details.

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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.