How to Bleed & Replace Brake Fluid on a 2016 Honda Rincon 680 4X4

Shop parts for a 2016 Honda RINCON680 ATV.

This MotoSport guide walks you through a safe, complete brake fluid change and bleed on a 2016 Honda Rincon 680 4X4. Follow every step carefully. If you are not comfortable with brake systems, have a qualified technician perform the work.

Why replace brake fluid

Brake fluid absorbs moisture over time, which lowers boiling point and can cause spongy lever feel, corrosion, and reduced braking performance. Regular replacement restores system reliability and extends component life.

What you need

  • Honda-specified brake fluiduse DOT 3 or DOT 4 as recommended in your owner’s manual (confirm before starting)
  • Clear hose that fits bleeder nipples snugly
  • Catch bottle and fresh disposable container for old fluid
  • Hand vacuum pump or fluid syringe (optional but speeds reservoir flushing)
  • 10 mm wrench (bleeder nut size may vary; have set on hand)
  • Clean rags, brake cleaner, rubber gloves, eye protection
  • Small funnel or reservoir cap adapter to minimize air ingress
  • Torque wrench for fastener reassembly and caliper mounting torque verification
  • Jack and stands or ramps rated for ATV use (secure supports)

Preliminary safety & prep

  • Work on a flat surface. Engage parking brake, shift to park/neutral per manual, and remove ignition key.
  • Allow brakes to cool if recently used.
  • Clean around the master cylinder reservoir cap to prevent contamination when opened.
  • Wear eye protection & gloves. Brake fluid damages paint & plasticscover painted surfaces with rags.

System layout & bleed order

The Rincon 680 4X4 uses hydraulic front and rear brakes with a master reservoir. Bleed starting with the caliper farthest from the master cylinder and progress to the closest. On many Rincon configurations that is typically:

  1. Rear caliper opposite side from master (usually right rear if master is left-front oriented)
  2. Rear caliper same side
  3. Front caliper farthest
  4. Front caliper closest

If unsure which caliper is farthest, follow the longest hydraulic line first. Always bleed the system from farthest to nearest to minimize trapped air.

Step-by-step fluid replacement

  1. Raise & secure the ATV so wheels can turn freely if needed. Remove any body panels blocking access to reservoir or bleeder screws.
  2. Open the reservoir cap and remove the diaphragm. Siphon or syringe out most old fluid from the reservoir to reduce contamination when pumping in fresh fluid.
  3. Top the reservoir with fresh brake fluid until near full. Keep the cap off during bleeding but prevent dirt entry.
  4. Attach a clear hose to the bleeder nipple of the farthest caliper and submerge the other end in a small catch bottle partially filled with fresh fluid to avoid drawing air back in.
  5. Have an assistant pump the brake lever slowly several times and hold pressure, or use a one-person vacuum/bottle bleeder at the reservoir. While pressure is held, open the bleeder nipple one or two turns to allow fluid and air to escape into the hose. Close the nipple before the assistant releases the lever. Repeat until clear fluid with no air bubbles flows, then tighten the nipple.
  6. Top up the reservoir between each caliper until clean fluid flows and no bubbles appear. Never let the reservoir run dry during the procedure.
  7. Repeat bleeding for each caliper following the bleed order. Change the catch bottle as needed to avoid contamination and to clearly see bubbles.
  8. After the final caliper, pump the brake lever to build firm pressure. Check for any sponginess. If present, repeat bleeding at the suspect caliper or perform a system-wide flush by cycling each caliper again.
  9. Once satisfied, tighten all bleeder nipples to proper snugness, reinstall reservoir diaphragm & cap, and clean any spilled fluid with brake cleaner.
  10. Lower the ATV, torque caliper hardware and wheel fasteners to factory specs, and perform a careful low-speed test to confirm braking performance before normal operation.

Full system flush (recommended every 1-2 years)

For a full flush, remove nearly all fluid from the reservoir first, then add fresh fluid and bleed each caliper until the fluid exiting is the new color with no bubbles. A vacuum pump at the reservoir accelerates a full system flush by pulling fluid through each line into the catch bottle.

Common pitfalls & model-specific notes for the 2016 Rincon 680

  • Reservoir location: the Rincon’s brake master reservoir is in a recessed area under the seat/battery cover on some configurations. Removing seat panels improves access and reduces contamination risk.
  • ABS/combined braking systems: the 2016 Rincon generally uses a simple hydraulic system, but check for any combined braking features on your unit. If equipped with any hydraulic proportioning or combined systems, follow the bleed order carefully and never power-bleed if manufacturer cautions against it.
  • Rust & seized bleeder nipples: older Rincons may have corroded bleeder screws. Apply penetrating lubricant and work carefully to avoid rounding. If a nipple rounds, replace the caliper or use correct extraction methodsdo not force with excessive torque.
  • Rubber lines & fittings: inspect hoses, banjo bolts, and crush washers while bleeding. Replace any cracked hoses or leaking fittings. Use new copper crush washers on banjo bolts when reassembling.
  • Brake fluid compatibility: only use fresh fluid from sealed containers. Do not mix silicone-based fluids with DOT 3/4 systems. If in doubt, drain fully and use a single specified fluid.
  • After service: store the ATV for a short test period. Expect slight initial settling as air is purged; recheck lever firmness and bleed again if necessary.

Disposal & final checks

  • Dispose of used brake fluid per local hazardous-waste regulations.
  • Reinspect for leaks, verify reservoir level, and confirm there is no brake fade during a cautious test ride.

Perform routine brake inspections and fluid changes at intervals appropriate for your riding conditions & mileage. Keeping the Rincon 680's brake system clean, dry, and properly bled protects you and extends the life of pads, calipers, and master components.

Related Shopping Categories

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Shop Brake Tools for a 2016 Honda RINCON680 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.