How to Bleed & Replace Brake Fluid on a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6)

Shop parts for a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.

Overview

This procedure covers draining the old brake fluid, flushing the system, and properly bleeding the four-wheel hydraulic brakes on the 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6). Use DOT 4 brake fluid only. Work in a clean, well-lit area and follow safety precautions to avoid contamination or damage to painted/plastic surfaces.

Tools & Supplies

  • DOT 4 brake fluid, new unopened bottle
  • Brake bleeding kit or clear tubing & catch bottle
  • Small adjustable wrench or 8 mm box wrench for bleed nipples
  • Syringe or turkey baster (for reservoir removal of old fluid)
  • Clean rags, shop towels, disposable gloves, safety glasses
  • Jack or ramps and blocks to lift wheels (if needed) & basic stands
  • Torque wrench for caliper/re-installation if removing components
  • Brake cleaner & container for used fluid

Model Notes & Precautions Specific to the TRX500 Rubicon PS

  • The TRX500R_PS uses a single master reservoir mounted near the handlebars; both front and rear calipers feed from this reservoir. Keep the reservoir cap and diaphragm clean when opened.
  • The POWER STEERING system is separate from the brake hydraulic circuit; do not add power steering fluid to the brake system. Avoid spilling DOT 4 on power steering components, plastics, or painted surfaces — DOT fluid will damage them.
  • This model typically does not have ABS; bleeding is a straightforward gravity/mechanical bleed. If your unit has optional ABS, consult a dealer for model-specific ABS bleeding procedures.
  • Brake lever/pedal free play and linkage should be checked after bleeding; the PS variant's steering effort does not affect brake geometry, but check for any brake linkage interference from aftermarket racks or accessories.
  • If you find rusty calipers, corroded tubing, or swollen hoses, replace those components before bleeding for a reliable system.

Safety First

  • Wear eye protection & gloves. Avoid skin contact with DOT 4.
  • Keep a clean area around the reservoir to prevent contamination.
  • Dispose of old fluid responsibly — it's hazardous waste.

Preparation

  1. Park on a level surface, engage parking brake and turn off the engine. Block wheels as needed.
  2. Clean the area around the brake fluid reservoir cap at the handlebars.
  3. Remove the reservoir cap and diaphragm slowly, wiping any dirt from the cap and reservoir lip to prevent contamination.
  4. Note fluid color: dark or contaminated fluid indicates a full replace/flush is needed.
  5. If replacing all fluid, use a syringe or turkey baster to remove as much old fluid from the reservoir as possible before adding new fluid.

Bleeding Sequence (Recommended)

Use the standard "farthest-from-master-first" sequence: right rear, left rear, right front, left front. For TRX500R_PS geometry that equates to: rear calipers first, then front calipers. This reduces the chance of drawing old fluid back into bled lines.

Step-by-Step Bleed & Replace

  1. Top the reservoir with fresh DOT 4 to just below the max mark. Keep the cap nearby but off to allow topping during the process.
  2. Start with the right rear caliper (farthest from the master reservoir). Put a clear tube over the bleed nipple and route into a catch bottle partially filled with fresh brake fluid to prevent air re-entry.
  3. Crack the bleed nipple about a quarter turn with an 8 mm wrench. Have an assistant slowly depress the rear brake pedal several times and hold it down, or pump the pedal slowly and hold depending on your pump method.
  4. Open the nipple while the pedal is held down to let fluid & air out. Close the nipple before the pedal is released. Repeat until clear, bubble-free fluid runs and no air is present.
  5. Keep reservoir topped with fresh fluid during the entire process to avoid drawing air back into the system.
  6. Repeat for the left rear, then right front, then left front, following the same method.
  7. After all calipers are bled, verify bleed nipples are snug. Do not over-torque; snug plus a small quarter turn is sufficient (feel for firmness). If you removed calipers or lines, use proper torque specs from a service manual for fasteners.
  8. Top the reservoir to the correct level, reinstall diaphragm and cap, clean any spilled fluid, and wipe down calipers/rotors with brake cleaner if contaminated by fluid.

Full Flush Recommendation

If fluid is very dark, perform multiple reservoir exchanges: remove as much old fluid as possible from the reservoir, add fresh fluid, then bleed until the fluid leaving each caliper is clear. Repeat until new fluid is consistently present at every caliper.

Common Troubleshooting

  • Spongy lever/pedal after bleeding: likely trapped air. Repeat bleeding sequence, ensuring the reservoir never runs low.
  • Persistent air in system: inspect hoses and connections for leaks or collapsed hoses; replace deteriorated rubber lines.
  • If a caliper bleeds air continuously, rebuild or replace caliper seals because internal leakage can allow air in.

Final Checks

  • Confirm lever and pedal feel are firm with normal travel. Adjust brake lever free play per owner's manual if needed.
  • Check all fittings for leaks with the system pressurized.
  • Test ride at low speed in a safe area to verify braking performance before regular use.
  • Dispose of used fluid per local hazardous waste regulations.

Maintenance Tips

  • Replace brake fluid every 1-2 years depending on use and exposure to water/contaminants.
  • Keep the reservoir cap sealed when not servicing to minimize moisture absorption.
  • Inspect brake hoses, caliper boots, pads, and rotors regularly on UTV/ATV that sees heavy-duty or water use.

Perform this maintenance carefully to maintain safe, reliable braking on your TRX500 Rubicon PS. If you encounter complex issues or ABS-related systems, contact a qualified technician or your local dealer.

Related Shopping Categories

Shop Brake Fluid for a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.

Shop Brake Bleeders for a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.

Shop Brake Pads for a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.

Shop Brake Lines for a 2012 Honda TRX500 Rubicon 4X4 POWER STEERING (FM6) ATV.

Shop Brake Tools for a 2012 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.