How to Bleed and Replace Brake Fluid on a 2009 Honda Rincon 680 4X4

Shop parts for a 2009 Honda RINCON680 ATV.

This MotoSport-exclusive service guide walks you through a safe, complete brake fluid replacement and bleed for a 2009 Honda Rincon 680 4x4. Follow every step precisely. If you’re unsure at any point, stop and consult a professional mechanic.

What you need

  • DOT 4 brake fluid (Honda recommends DOT 4; do not mix with DOT 5 silicone)
  • Clear tubing and a catch bottle or reservoir (for gravity or vacuum bleed)
  • Brake bleeder wrench or 8mm open wrench (verify bleeder size visually)
  • Vacuum brake bleeder or hand pump (optional but speeds and cleans the job)
  • Large syringe or fluid transfer pump (for master reservoir and cleaning)
  • Shop rags, brake cleaner, and gloves
  • Torque wrench for caliper bolts (recommended) and small container to dispose of old fluid
  • Service manual or a phone reference for torque specs and component locations

Important safety notes for the 2009 Rincon 680

  • Brake fluid will damage painted surfaces and plastic. Protect bodywork and wipe any spills immediately with brake cleaner and rags.
  • The Rincon uses hydraulic disc brakes front and rear; bleed each line individually. The master cylinder reservoir must remain above the minimum level during bleeding to avoid sucking air into the system.
  • Use only DOT 4 fluid. Do not mix DOT 4 with DOT 5 (silicone) and avoid contamination between types.
  • If the quad has ABS aftermarket modifications, follow ABS-specific procedures. The stock 2009 Rincon typically does not have ABS, but confirm before starting.
  • Dispose of used brake fluid responsibly at a recycling center; don’t pour it down drains.

Locate reservoirs and bleeder screws

On the Rincon 680 the front brake master cylinder reservoir is near the right handlebar (front brakes). The rear brake uses a separate reservoir or a remote reservoir integrated near the rear brake master cylinder depending on model year configuration—consult the factory sticker under the seat if unsure. Each caliper has a bleeder screw; identify left and right front, and the rear caliper bleeder.

Preparation

  1. Park the ATV on level ground, engage parking brake, and place on a stand so wheels can turn freely.
  2. Clean the master cylinder cap area and surrounding components to prevent contamination when opened.
  3. Remove the master cylinder cover and diaphragm, wiping the inside clean. Do not let dirt fall into the reservoir.
  4. Top the reservoir with fresh DOT 4 fluid to the max line. Keep the cap and diaphragm nearby but covered from dirt.
  5. Determine bleed sequence: start with the caliper furthest from the master cylinder and work toward the closest. Typical sequence: right front, left front, rear (confirm actual hose routing on your unit and follow furthest-to-closest rule).

Bleeding methods

Choose one method below. MotoSport recommends a vacuum or pressure bleeder for best results and minimal air ingestion, but the manual pump method works if done carefully.

1) Vacuum or pressure bleeder (recommended)

  1. Attach clear tubing to the caliper bleeder screw and route the other end to a catch bottle partially filled with old fluid (prevents air drawing back in).
  2. If using a vacuum bleeder, clamp the line at the bottle, open the bleeder screw one-quarter to one-half turn and operate the vacuum pump until fresh fluid appears in tubing with no bubbles.
  3. Close the bleeder screw while under vacuum, then repeat next caliper. Keep master reservoir topped during the entire procedure.
  4. Work through the bleed sequence: furthest caliper first, then next furthest, finishing with the caliper closest to the master cylinder. Frequently squeeze or operate the front lever and rear pedal if needed to move fluid through, but with a vacuum pump you usually won't need to pump the lever.

2) Manual pump / two-person method

  1. Attach clear tubing to the bleeder and immerse the outlet in a bottle with some old fluid to prevent air re-entry.
  2. Person A slowly pumps the brake lever or pedal several times and holds it applied.
  3. Person B opens the bleeder screw quickly; fluid and air will flow into the tubing. Close the screw before the lever/pedal is released.
  4. Repeat pump-and-hold cycles until clear, bubble-free fluid appears. Keep the master reservoir topped between cycles.

3) Gravity bleed (slow, less effective for stubborn air)

  1. Open bleeder slightly and let gravity feed fresh fluid from the master reservoir through the lines into a catch bottle. Monitor reservoir level and close bleeder when done.
  2. Use only if air presence is minimal — not recommended if brakes have been opened for extended periods or if the lines were replaced.

Finishing each caliper

  1. When fluid runs clear and bubble-free, tighten the bleeder screw to a snug fit. For the Rincon bleeder threads, tighten securely but avoid over-torquing; hand tool plus a small additional turn is typical. If you have a torque spec from the service manual, use it.
  2. Wipe the caliper and assembly clean. Top off the master reservoir to the max line, reinstall diaphragm and cap.

System-level checks

  • After bleeding all calipers, check brake lever and pedal feel. Lever should feel firm with little travel; pedal should be firm underfoot. If sponginess remains, repeat the bleeding sequence.
  • Start the engine and apply the brakes at idle to check operation. Don’t ride at speed until brakes are confirmed strong and consistent.
  • Inspect for leaks around bleeders, caliper mounts, hoses, and the master cylinder.

Notes specific to the 2009 Rincon 680 owner

  • Rincon calipers and hoses can harden with age on 2009 models. Inspect hose rubber and banjo fittings for cracking or corrosion; replace if any sign of deterioration is present.
  • The rear caliper on some Rincon units is a single-piston design; if you find uneven pad wear, clean and inspect the slide/piston for smooth operation and replace seals if leaking.
  • If you’ve replaced any line or caliper, do a full system bleed twice to be certain all air is purged.
  • Keep records of service intervals. Brake fluid should be replaced every 1-2 years depending on use and exposure to water/mud to prevent moisture absorption and reduced boiling point.
  • After a heavy water crossing or riding in salt, flush and replace brake fluid sooner to prevent internal corrosion of master cylinder and caliper components.

Troubleshooting

  • Continued spongy pedal after thorough bleeding: suspect collapsed brake hose, internal master cylinder leak, or ABS/valve issue if equipped. Pressure-test lines and inspect master cylinder.
  • Persistent leaks from bleeder screws: replace bleeder screw and copper crush washer if applicable.
  • Brake pedal drop with engine running: test for internal master cylinder leakage; rebuild or replace master if confirmed.

Maintenance tips

  • Label the service date on the reservoir cap area after fluid change.
  • Always keep a small spare bottle of DOT 4 in your kit for topping off during rides in remote areas.
  • Use only clean funnels and tools dedicated to brake use to prevent contamination.

Follow these steps for a safe, reliable brake-fluid replacement and bleed on your 2009 Honda Rincon 680 4x4. If any procedure or symptom is outside your comfort or skill level, schedule a professional service through MotoSport-certified technicians.

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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.