How to Bleed and Replace Brake Fluid on a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6)
Shop parts for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.
This MotoSport guide walks you through draining, replacing, and bleeding the brake fluid on a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6). Follow these steps carefully to maintain braking performance and avoid contamination of the power steering system or painted surfaces.
What you need
- DOT 3 or DOT 4 brake fluid (use the type specified in your owner’s manual; do not mix with mineral-based fluids)
- Brake bleeder kit or clear vinyl hose and a catch bottle
- Wrench or socket set for bleeder nipples (8mm or 10mm typically)
- Turkey baster or fluid syringe
- Clean lint-free rags and isopropyl alcohol for cleaning
- Gloves and eye protection
- Torque wrench for caliper/line hardware (recommended)
- Vehicle stand or ramps to lift wheels off the ground
Model-specific notes for the 2009 TRX500 Rubicon PS (FM6)
- The TRX500R_PS uses a hydraulic brake system with a single master cylinder reservoir. The power steering on this model is a separate hydraulic circuit; do not open or mix fluid between systems.
- Bleeder screws are located at each caliper. The Rubicon typically has two front calipers and one rear caliper; the rear caliper is often the farthest from the master cylinder. Confirm caliper positions visually before starting.
- Protect painted plastics and fenders from brake fluid spills – brake fluid can damage paint. Keep rags handy and clean spills immediately with isopropyl alcohol.
- If your ATV has a brake fluid level sensor, avoid opening the reservoir for extended periods; top up as needed during the procedure to prevent air ingress.
Preparation
- Park on level ground, engage parking brake, and remove key. Lift the ATV so wheels are off the ground or at least accessible.
- Clean the master cylinder reservoir cap and surrounding area to prevent contamination when opened.
- Remove the reservoir cap and diaphragm. Use a turkey baster to remove old fluid to below the minimum mark, then top up with fresh DOT 3/4 fluid to the full mark.
- Identify the bleed screws on each caliper and have your clear hose and catch bottle ready. Place a cloth under each caliper to protect finish and catch drips.
Bleeding sequence
Always keep the master reservoir topped up during bleeding. The correct sequence is to bleed the caliper farthest from the master cylinder first, then work toward the closest caliper. On most TRX500 Rubicon PS units that means:
- 1st: Rear caliper (farthest from master cylinder)
- 2nd: Right front caliper
- 3rd: Left front caliper (closest)
Bench (manual) bleeding vs. pressure/vacuum bleeding
You can use a pressure bleeder or vacuum pump for faster, cleaner bleeding. If you don’t have those tools, manual pumping works fine but requires an assistant.
Step-by-step bleeding (manual with assistant)
- Attach clear hose to the first caliper’s bleeder screw and submerge the other end in a small bottle partially filled with old fluid to prevent air return.
- Have an assistant slowly depress and hold the brake pedal (or lever) at about half travel.
- Open the bleeder screw about 1/4 turn; fluid and air will flow into the bottle. Close the screw before the assistant releases the pedal. Repeat until clear, bubble-free fluid emerges.
- Keep topping the master reservoir so it never falls below the minimum mark. If it does, you must restart the bleeding sequence to avoid introducing air.
- Repeat for each caliper following the sequence above. After the last caliper is bled, cycle the pedal several times and verify firm feel.
Using a pressure bleeder or vacuum pump
- Connect the pressure bleeder to the master cylinder reservoir per the bleeder tool instructions. Pressurize the reservoir to the tool’s recommended pressure.
- Open the bleeder screw at the caliper until clear fluid runs out, then close it. Proceed through the calipers by sequence.
- If using a vacuum pump on each bleeder screw, attach the hose, pump until fluid runs clear, then close the screw before removing the hose.
Finishing steps
- Ensure all bleeder screws are tightened to proper snugness (avoid over-torqueing). Clean any spilled fluid with isopropyl alcohol and fresh rags.
- Refill the master reservoir to the full mark, reinstall diaphragm and cap, and secure it.
- Test the brake lever and pedal feel with the vehicle on the ground. Brakes should feel firm and consistent. If the pedal is spongy, re-bleed the circuit.
- Properly dispose of old brake fluid according to local regulations.
Troubleshooting
- Persistent soft pedal after thorough bleeding can indicate a leaking line, collapsed hose, or internal master cylinder problem. Inspect flexible hoses, caliper seals, and the master cylinder for leaks or damage.
- If one wheel feels different, re-bleed that caliper and verify caliper pistons move freely and pads are not binding.
Maintenance tips & recommended intervals
- Brake fluid absorbs moisture over time. MotoSport recommends replacing brake fluid every 1-2 years or sooner if you ride in wet conditions or notice degraded performance.
- Always use fresh, unopened DOT-specified fluid and never reuse drained fluid.
- Inspect brake hoses and fittings for cracking, swelling, or leaks whenever you service the fluid.
Follow these steps and the specific recommendations in your owner’s manual for safe, reliable braking on your 2009 TRX500 Rubicon 4X4 POWER STEERING. If you’re unsure or suspect master cylinder or caliper failure, consult a qualified ATV technician.
Related Shopping Categories
Shop Brake Fluid for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.
Shop Brake Bleeders for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.
Shop Brake Pads for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.
Shop Brake Lines for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.
Shop Brake Tools for a 2009 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) 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.