How to Bleed and Replace Brake Fluid on a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5)

Shop parts for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) ATV.

This MotoSport procedural guide walks you through flushing and bleeding the hydraulic brake system on a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5). Follow every step carefully, use proper safety gear, and work in a clean, well-ventilated area. This guide is written for owners familiar with basic tools and maintenance; if you encounter internal master cylinder problems, call a trained technician.

What you need

  • DOT 3 or DOT 4 brake fluid (Honda recommends DOT 3; check cap markings on your master cylinder)
  • Clear plastic tubing sized to fit bleeder nipples
  • Brake fluid catch bottle or clear jar
  • Wrenches: 8mm and 10mm typically for caliper bleeders and banjo bolts
  • Turkey baster or fluid syringe
  • Clean rags and gloves
  • Brake cleaner
  • Zip ties or clamps for tubing
  • Assistant (recommended) or a vacuum/bottle bleeder
  • Torque wrench for banjo bolt reassembly

Model-specific notes for the 2017 TRX500 Rubicon 4X4 DCT (FA5)

  • This model uses a combined braking system with separate master cylinder reservoirs for front and rear circuits; the DCT does not change brake procedure but be careful around the dual-clutch components and CVT area.
  • Stock rotors and calipers are accessed easily by removing wheels; front wheels remove with axle nuts, rear with hub nut – keep track of spacers and torque specifications from your owner's manual.
  • Remote reservoir placement: check reservoir level often during procedure; do not let reservoirs run dry to avoid drawing air into ABS/combined circuits.
  • ABS &mdash this model may have ABS or combined systems depending on region; if ABS is present, flushing with a pressure or vacuum bleeder is preferred and cycling ABS valves per factory procedure may be needed to purge trapped air.
  • Use only the specified DOT fluid type from the master cylinder cap; mixing fluid types can damage seals.

Preparation

  • Park on level ground and secure the ATV with parking brake engaged and engine off.
  • Remove wheels if needed to access bleeder nipples easily. Support the machine on stands so calipers hang naturally, not twisted.
  • Clean around reservoirs, master cylinders, and bleeder nipples with brake cleaner to avoid contamination.
  • Open reservoir caps – remove caps and diaphragms carefully; cover openings with a clean rag when not actively adding fluid.
  • Check the service manual for reservoir fluid capacity and torque specs for banjo bolts.

Step-by-step fluid replacement and bleeding

Use the front-to-rear sequence when bleeding: furthest caliper first. On the TRX500 that sequence is usually: rear caliper(s) first, then front calipers. If in doubt, bleed the caliper farthest from the master cylinder first.

  1. Top up the master cylinder reservoir with fresh DOT fluid. Never reuse drained fluid.
  2. Attach clear tubing to the bleeder nipple and place the other end into a catch bottle partially filled with fresh fluid to prevent air return.
  3. Have your assistant pump the brake lever/pedal slowly 3–5 times and hold pressure. While held, open the bleeder nipple one-quarter to one-half turn to let fluid and air escape until flow slows, then close before the assistant releases pressure. Repeat until fluid runs clear and bubble-free. Keep reservoir level topped off throughout.
  4. If using a vacuum or pressure bleeder, follow the tool manufacturer instructions and monitor reservoir level to avoid running dry. Attach vacuum tubing to the bleeder nipple and pump until clean fluid appears without bubbles.
  5. Bleed each caliper in sequence: farthest wheel → next farthest → closest. For dual-piston calipers, bleeding each bleeder is recommended.
  6. When finished, tighten bleeder nipples to spec (hand-snip then snug with wrench — typical small bleeder torque is low; avoid rounding). Clean any spilled fluid immediately; brake fluid damages paint and plastics.
  7. Reassemble diaphragms and reservoir caps. Pump brakes several times to confirm firm pedal/lever feel. If spongy, repeat bleeding until firm.
  8. Check for leaks around calipers, lines, master cylinder, and banjo bolts. If any leak is present, resolve before riding.

Additional details & troubleshooting

  • Spongy brake feel after bleeding usually means air still in the system. Repeat bleeding, keeping reservoir topped up. Use gravity bleed then pressure/vacuum if stubborn air remains.
  • If pedal/lever travel remains excessive, inspect master cylinder pushrod and caliper pistons for binding or contamination.
  • ABS/combo systems may trap air. If available, use a scan tool to cycle ABS pump/valves through a bleed routine or consult a dealer for ABS purge steps.
  • Always dispose of used brake fluid per local regulations; do not pour down drains.

Reassembly and final checks

  • Torque wheel, axle, and caliper mounting hardware to factory specs. Confirm no contact between caliper/hoses and moving parts.
  • Test brakes at low speed in a safe area before returning to normal riding. Confirm consistent braking and no pull or noise.
  • Record the service date and mileage in your maintenance log. Plan to flush brake fluid every 2 years or according to Honda/MotoSport recommendations for off-road use, sooner if contaminated.

Safety & maintenance tips from MotoSport

  • Always wear gloves and eye protection. Brake fluid is corrosive to skin and damaging to surfaces.
  • Use genuine-quality lines and fittings if replacing hoses; do not reuse severely cracked or swollen hoses.
  • Inspect pads and rotors while bleeding. Replace pads near end-of-life and machine rotors that show heavy scoring or warpage.
  • Keep a compact service kit on-trail with spare fluid, small wrench, and rags for emergency top-offs.

Performing a complete brake fluid change and bleed on your 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) will restore braking performance and reliability. If you encounter persistent issues or suspect ABS-related complications, have the machine inspected by a qualified technician.

Related Shopping Categories

Shop Brake Fluid for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Bleeders for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Pads for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Lines for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Tools for a 2017 Honda TRX500 Rubicon 4X4 DCT (FA5) 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.