How to Bleed and Replace Brake Fluid on a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6)
Shop parts for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
This MotoSport.com service guide walks you step-by-step through safely replacing and bleeding the brake fluid on a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6). Procedures here are written for the TRX500 Rubicon platform; always cross-check the stock Honda service manual for torque values and any model-specific safety notices before starting.
What you need
- Fresh brake fluid of the DOT specification recommended in your owner’s manual (Honda ATVs commonly specify DOT4 – confirm before use)
- Clear tubing and a catch bottle
- Wrench for bleed nipples and any banjo bolts
- Brake bleeder kit or one-person pump/assist tool (vacuum or pressure bleeder recommended for speed and cleanliness)
- Clean rags, disposable gloves, eye protection
- Jack or ramps and stands to safely access wheels (if needed)
- Disposable container for old fluid and means to dispose of it legally
Model notes – things every TRX500 Rubicon owner should know
- The Rubicon FA6 has DCT (Dual Clutch Transmission) and EPS (Electric Power Steering). Brake fluid contamination or spills on electrical connectors, EPS components, or painted plastics can damage them. Protect nearby wiring, EPS components and bodywork when working.
- Master cylinder and reservoir location may differ slightly between model years; identify the primary brake master cylinder and the reservoir vent to decide bleeding sequence.
- If your machine has aftermarket accessories (crash bars, racks, skid plates), remove or protect them to access bleed nipples and to avoid fluid contamination.
- Use only fresh, unopened brake fluid. Mixing different DOT types or using contaminated fluid can damage seals and degrade braking performance.
Overview of the process
The goal is to replace all old fluid and remove air from the system. General sequence: top up and flush reservoir, then bleed calipers from the wheel furthest from the master cylinder to the closest. Maintain reservoir level throughout to prevent air re-entry.
Step-by-step replacement & bleed
- Prep: Park on level ground, secure the ATV, block wheels, and remove ignition key. Clean the area around the brake fluid reservoir cap to prevent dirt entering the system. Put on gloves and eye protection.
- Locate reservoir: Open the brake fluid reservoir cap. Wipe clean the cap, diaphragm and surrounding area. Note whether front and rear systems share a reservoir or are separate on your unit.
- Inspect: Check hoses, lines and calipers for damage or leaks. Replace any compromised components before bleeding.
- Top up: Fill the reservoir with fresh fluid to the max line. Do not overfill. Keep the cap loosely on to limit contamination while allowing venting if the cap design requires it.
- Determine bleed order: Identify the caliper furthest from the master cylinder. On many ATV setups that will be a rear caliper; if uncertain, follow the master cylinder line path and choose the most distant caliper first. Typical sequence: furthest rear, then other rear, then front right, then front left – but confirm by inspection.
- Attach tubing: Place clear tubing over the bleed nipple and route the other end into a catch bottle partially filled with fresh fluid to prevent air re-entry.
- Bleeding method — two common approaches:
- Two-person pump method: One person gently pumps the brake pedal or lever to build pressure and holds it. Open the bleed nipple for a second to let fluid & air out, then close it before the pedal/lever is released. Repeat until no air bubbles are visible and fluid is clear. Always close the nipple before releasing pressure.
- Vacuum or pressure bleeder: Connect the tool per manufacturer instructions and draw/pressurize fluid through each caliper in sequence until clear. This is faster and cleaner for single-operator jobs.
- Maintain reservoir level: Check and top up the reservoir frequently. Never allow the level to drop below the minimum, or you will draw air into the system.
- Work each caliper: Repeat bleeding at each caliper in the chosen order until each produces clear, bubble-free fluid at the bleed nipple.
- Final purge: After all calipers are done, pump the brake pedal/lever firmly several times to bed the fluid and check for a firm feel. If the lever or pedal feels spongy, re-bleed the system or inspect for leaks/unseated air.
- Torque and check fittings: Tighten bleed nipples and any banjo bolts to the manufacturer torque spec from the service manual. Wipe all spillages immediately; brake fluid can damage paint and plastics.
- Clean up: Replace the reservoir cap and ensure the vent is unobstructed. Dispose of old fluid per local regulations. Test brakes at low speed in a safe area before returning to normal riding.
Tips specific to the Rubicon DCT EPS
- Protect EPS wiring and connectors from spilled fluid. Use rags or plastic sheeting when opening the reservoir or removing lines.
- If your Rubicon shows any unusual braking behavior after bleeding &mdash such as ABS-like pulsing (if equipped), warning lights, or loss of assist &mdash stop and consult the Honda service manual or a qualified technician. Electrical systems like DCT/EPS can interact with diagnostics and should be inspected if faults appear.
- After replacing fluid, monitor pedal/lever feel over the next few rides and recheck fluid level. New fluid can absorb moisture faster in humid climates; plan routine replacements every 1-2 years depending on use and storage conditions.
Safety and disposal
- Brake fluid is corrosive to paint and harmful to skin/eyes. Clean spills promptly and wash hands after handling.
- Store brake fluid sealed and upright. Do not reuse drained fluid.
- Dispose of used brake fluid at a hazardous waste facility or through an approved collection program.
When to seek professional help
If bleeding does not restore firm pedal/lever feel, if you find damaged lines or calipers, if there is persistent leaking, or if electrical warnings appear on your DCT or EPS systems after service, stop and have a certified ATV technician or Honda dealer diagnose and repair the issue.
Performing a clean, methodical brake fluid change and bleed will keep your TRX500 Rubicon stopping reliably and protect the DCT & EPS systems from corrosive spills. For parts, seals, bleed screws or specialty tools you need for this job, find what fits your model at MotoSport.com.
Related Shopping Categories
Shop Brake Fluid for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Bleeders for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Pads for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Lines for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Tools for a 2017 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) 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.
