How to Bleed and Replace Brake Fluid on a 2011 Honda TRX500 Rubicon 4X4

Shop parts for a 2011 Honda TRX500RUBI ATV.

This MotoSport guide walks you step-by-step through a full brake fluid replacement and bleed on the 2011 Honda TRX500 Rubicon 4X4 (MMY: Honda;TRX500RUBI;2011). Follow these procedures to restore firm lever/pedal feel, prevent corrosion, and keep brake components functioning reliably. Work on a level surface, wear eye protection and gloves, and dispose of used fluid responsibly.

About the TRX500 Rubicon brakes & notes for this model

  • Brake system type: hydraulic disc brakes, non-ABS on the 2011 TRX500 Rubicon.
  • Reservoirs: separate master cylinder reservoirs for front (handlebar) and rear (foot pedal). Check both levels and condition.
  • Recommended fluid: DOT 4 synthetic brake fluid is commonly specified for Honda ATVs of this era. Use fresh, unopened DOT 4 and keep it sealed to avoid moisture pickup.
  • Banjo fittings and crush washers: the TRX500 uses banjo bolts at calipers that require new copper crush washers when reassembled if disturbed.
  • Bleeder nipples: accessible at each caliper. Front uses two calipers (left & right). Rear uses a single caliper. The farthest-from-master order is recommended for best results.

Tools & supplies

  • DOT 4 brake fluid (fresh, unopened)
  • Clear plastic tubing and a catch bottle (to observe air bubbles)
  • 10mm and 8mm wrenches (bleeder and banjo bolts; verify sizes on your machine)
  • Brake bleeder kit or vacuum pump (optional but speeds the job)
  • Turkey baster or syringe to remove old fluid from reservoirs
  • Clean rags, safety gloves, eye protection
  • Torque wrench (for banjo bolts & caliper fasteners; use moderate torque and new crush washers)
  • Brake cleaner and a container for old fluid

Preparation

  1. Park ATV on level ground and secure with parking brake and wheel chocks. Remove cargo racks if they block access.
  2. Clean reservoir caps and surrounding areas thoroughly to prevent contamination entering the system when opened.
  3. Remove cap and diaphragm from both front and rear reservoirs. Use a turkey baster to remove most old fluid from each reservoir; leave a small amount to prevent introducing air inadvertently when refilling.
  4. Top reservoirs with fresh DOT 4 fluid to the proper level. Keep caps off but reservoirs covered with clean paper to reduce fluid exposure to air while bleeding.

Recommended bleed sequence

Farther from the master first, then closer. For the TRX500 Rubicon the usual sequence is:

  1. Rear caliper
  2. Front right caliper
  3. Front left caliper
  4. Final check at master reservoirs

Manual (two-person) bleeding method

  1. Attach clear tubing to rear caliper bleeder nipple and place the other end submerged in a catch bottle partially filled with clean fluid.
  2. Have an assistant slowly depress and hold the brake pedal/lever while you open the bleeder nipple 1/4 to 1/2 turn. Fluid and air will flow into the bottle. Close nipple before assistant releases pedal. Repeat until no air bubbles appear and fluid runs clear. Keep reservoir topped up to avoid drawing air into the master.
  3. Torque bleeder nipple snug after finishing the caliper. Do not overtighten; refer to service manual torque if available.
  4. Repeat the process for front right caliper, then front left caliper. Keep reservoir level topped during the entire process.
  5. After all calipers are bled, pump the lever/pedal several times with caps open to settle fluid, then recheck reservoir levels and tighten caps.

Single-operator or vacuum-method

  1. Use a vacuum bleeder on each caliper bleeder nipple, one at a time, while topping off the master reservoir. Open the bleeder and draw fluid until clear, then close nipple before releasing vacuum. Work farthest to nearest.
  2. If using a pressure bleeder on the master reservoir, follow the bleeder tool instructions and observe reservoir pressure limits; never pressurize beyond the tool/manufacturer spec. This method forces old fluid out and usually requires less manual pumping.

Finishing steps & checks

  • Ensure reservoirs are at the correct level and caps & diaphragms are seated properly. Wipe any spilled fluid immediately — brake fluid will damage paint and plastics.
  • Check brake lever and pedal feel for firmness. If spongy, re-bleed the affected circuit and confirm no leaks exist at calipers, lines, or master cylinders.
  • Inspect hoses for swelling, cracks, or soft spots. Replace any suspect lines. Replace banjo bolt crush washers any time the banjo fitting is loosened.
  • Perform a low-speed brake test in a safe area to confirm proper operation before regular riding.

Common pitfalls and model-specific tips

  • Do not mix DOT 4 with DOT 5 silicone fluid. If DOT 3 was previously used, DOT 4 is compatible but ensure the system is flushed thoroughly.
  • The TRX500 master reservoirs are compact & can pick up moisture quickly once opened. Keep the job quick and fluid containers sealed between uses.
  • If the parking brake or caliper sticks after bleeding, inspect caliper slide pins and piston boots for corrosion or contamination common to ATVs ridden in wet conditions.
  • When replacing banjo bolts, use new copper crush washers on both sides of the banjo to prevent leaks.
  • Record the date and mileage of fluid replacement. For trail-heavy use, consider annual replacement; for light use, every 2 years is a common interval for DOT 4.

Troubleshooting

  • Persistent spongy lever: check for air, soft hoses, or a leaking master cylinder. Press a finger against the front caliper piston to see if it moves freely; seized pistons cause uneven feel.
  • Leaking nipples or fittings: re-torque fittings and replace crush washers. If leaks persist at a caliper body, service or replace the caliper.
  • Brake drag after bleed: caliper piston may be stuck or overfilled reservoir; back off caliper bolts slightly, actuate pedal, and re-torque to spec after confirming free movement.

Following this MotoSport procedure will keep your 2011 Honda TRX500 Rubicon 4X4 braking smoothly and safely. If you prefer professional service or need OEM replacement parts, Shop parts for your ride now!

Related Shopping Categories

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Shop Brake Tools for a 2011 Honda TRX500RUBI 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.