How to Bleed and Replace Brake Fluid on a 2019 Honda Rincon 680 4X4

Shop parts for a 2019 Honda RINCON680 ATV.

This MotoSport exclusive step-by-step guide covers tools, safety, and best practices for a complete brake fluid change and bleeding procedure on the 2019 Honda Rincon 680 4X4 (MMY). Follow these steps to maintain braking performance, avoid contamination, and protect hydraulic components specific to the Rincon platform.

Notes specific to the 2019 Honda Rincon 680

  • Factory system: The Rincon 680 uses a hydraulic front and rear brake system with a sealed master cylinder and dedicated bleeder valves at each caliper. The master cylinder reservoir is plastic and located on the right-hand side of the handlebar area.
  • Brake fluid type: Use DOT 4 brake fluid only. The reservoir cap will specify the required fluid; do not mix with DOT 3 or DOT 5 silicone fluid.
  • ABS/Traction: The Rincon 680 does not have ABS. That simplifies bleeding to a standard wheel-by-wheel sequence.
  • Reservoir size and placement: Small plastic reservoir can overflow if overfilled during pumping. Keep reservoir level below maximum and top up as needed to prevent air intake.
  • Recommended interval: Replace brake fluid every 2 years or sooner if fluid is dark or contaminated, or if you ride in wet/muddy conditions often.

Tools & supplies

  • DOT 4 brake fluid, unopened bottle
  • Clear vinyl tubing that fits snugly over the bleeder nipples
  • 10 mm wrench for bleeder nipples (confirm size visually)
  • Small catch bottles or jars for old fluid
  • Brake bleeding kit or vacuum pump (optional but speeds the job)
  • Turkey baster or fluid siphon (for old fluid removal)
  • Clean shop rags and isopropyl alcohol for cleanup
  • Disposable gloves and eye protection
  • Jack/stands or ramps if needed to access calipers easier

Preparation

  1. Park the Rincon on a level surface, engage park and set the parking brake. Turn off the engine and remove the key.
  2. Clean the area around the brake fluid reservoir and calipers with a rag and isopropyl alcohol to prevent contamination.
  3. Open the reservoir cap and remove the diaphragm/foam pad carefully. Use a turkey baster or siphon to remove most of the old fluid from the reservoir to avoid spillage when you bleed.
  4. Inspect hoses, lines, and calipers for leaks, cracks, or damage. Replace any suspect components before proceeding.

Bleeding order and rationale

Standard sequence for the Rincon: farthest caliper first, working toward the master cylinder. For most configurations this means:

  1. Right front caliper (if set up as right front is farthest)
  2. Left front caliper
  3. Rear caliper

This sequence minimizes the chance of drawing air back toward the master cylinder.

Manual (two-person) bleeding method

  1. Top up the reservoir with fresh DOT 4 fluid to the max line.
  2. Attach clear tubing to the first caliper bleeder nipple and place the other end into a catch bottle partially filled with old fluid to maintain a small fluid column and prevent air re-entry.
  3. Have an assistant sit on the machine and pump the brake lever/pedal several times, then hold steady pressure.
  4. With the lever/pedal held, open the bleeder nipple about 1/4 turn until fluid flows with bubbles. Close the nipple before the assistant releases pressure to prevent air being sucked back in.
  5. Repeat pump-hold-open-close until clear, bubble-free fluid emerges.
  6. Top up the reservoir frequently to prevent it running dry.
  7. Move to the next caliper and repeat the process following the bleeding order above.
  8. After the last caliper is bled, cycle through the calipers once more quickly to ensure no air remains and reservoir is at correct level. Tighten all bleeder nipples to factory torque and reinstall the reservoir diaphragm and cap.

One-person vacuum or pressure bleeding method

Using a handheld vacuum pump or pressure bleeder simplifies the job and reduces the risk of drawing in air.

  1. Connect the vacuum pump hose to the bleeder nipple, or use a pressure bleeder on the reservoir following device instructions.
  2. Open the bleeder and draw fluid until clear, bubble-free fluid is seen. Keep the reservoir topped up.
  3. Proceed caliper-by-caliper in the prescribed order.
  4. Close nipples and verify system is firm when finished.

Finishing steps and checks

  • Clean any spilled fluid immediately. DOT 4 eats paint and plastic.
  • Check pedal/lever firmness. If soft or spongy, repeat bleeding until firm.
  • Inspect bleeder nipples, lines, and connections for leaks with the system pressurized.
  • Properly dispose of old brake fluid according to local regulations.
  • Test ride at low speed in a safe area to verify braking performance before regular use.

Common troubleshooting

  • Persistent spongy brake feel: Check for remaining air, collapsed brake hose, or master cylinder issues.
  • Brake fade or poor pedal return: Contaminated fluid or overheating may require a repeat fluid change or component inspection.
  • Leaking bleeder nipple: Replace nipple or caliper seal if weeping persists after tightening.

Maintenance tips for Rincon owners

  • Keep a sealed spare bottle of DOT 4 in your shop; never top up from an open bottle that may be contaminated.
  • After extended wet or trail use, inspect and, if needed, bleed brakes sooner than the scheduled interval.
  • Replace rubber hoses every 6-8 years or sooner if cracked or softened.
  • If the master cylinder shows external leakage or the reservoir is brittle, replace those parts with OEM or high-quality replacements to avoid failures.

Follow these steps and checks to ensure safe, reliable braking on your 2019 Honda Rincon 680 4X4. Proper fluid maintenance protects the entire brake system and extends component life.

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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.