How to Bleed & Replace Brake Fluid on a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6)
Shop parts for a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
This MotoSport service guide walks FA6 Rubicon owners through safely flushing old brake fluid, bleeding the system correctly, and refilling with fresh fluid. Follow these steps precisely — brake work affects safety. If you're uncomfortable working on brakes, have a shop do the job.
What you need
- Brake fluid meeting Honda specification (check reservoir cap/owner's manual; Honda commonly lists DOT 3 or DOT 4 — confirm on your unit)
- Clear plastic tubing that fits snugly over bleed nipples
- Catch bottle partially filled with clean brake fluid to avoid air draw
- Brake bleeder or 2-person pump-and-hold or vacuum pump (hand pump or Mityvac)
- Wrenches for bleed nipples (typically 8mm or 10mm) and wrench for master cylinder banjo bolts if replacing lines
- Clean rags, isopropyl alcohol, small funnel, shop manual or torque specs
- Latex/nitrile gloves and eye protection
- Jack/stands or ramps to safely lift and support the ATV
Model-specific notes for the 2019 TRX500 Rubicon 4X4 DCT EPS (FA6)
- Reservoir location: the front master cylinder reservoir is on the right handlebar under a plastic cap; there is typically a single front master cylinder serving front brakes. Rear brake reservoir may be integrated or linked — visually confirm fluid level and cap labeling before starting.
- Brake layout: hydraulic disc brakes front and rear. Bleed nipples are on the calipers; the farthest caliper from the master cylinder should be bled first.
- DCT/4X4/EPS systems do not change brake bleeding order, but watch wiring and sensors near calipers when lifting or removing wheels.
- Paint and plastics: brake fluid will damage painted surfaces and plastic. Cover nearby bodywork and clean spills immediately with water and isopropyl alcohol.
- Torque: bleed nipple and banjo bolt torque varies by component; use service manual torque specs when reinstalling hardware.
Safety first
- Work on a flat, stable surface with the engine off and parking brake engaged (if equipped).
- Wear eye protection and gloves. Brake fluid is corrosive to paint and irritating to skin.
- Never reuse drained fluid; dispose of used fluid per local regulations.
Step-by-step: Drain, replace & bleed
- Prepare the machine: put the Rubicon on a stand or ramps so wheels are off the ground and the machine is stable. Remove any plastic covers obstructing reservoir access or calipers.
- Clean: wipe around reservoir cap and caliper bleed nipples to prevent contamination.
- Open the reservoir: remove the cap and diaphragm carefully. Siphon or absorb as much old fluid from the reservoir as possible with a syringe or clean turkey baster without introducing air into the master cylinder.
- Top up with fresh fluid: pour fresh DOT-rated fluid into the reservoir to the fill mark to maintain system pressure while you bleed.
- Locate bleed order: identify master cylinder position and determine farthest caliper. Typical order for a handlebar master cylinder is rear caliper first, then front calipers furthest to closest. Follow the farthest-to-closest rule.
- Attach tubing: push clear tubing onto the bleed nipple and route the other end into the catch bottle partially filled with fresh fluid to prevent air return.
- Two-person pump-and-hold method (recommended if available):
- Person A: slowly squeeze the brake lever/pedal until firm, hold it.
- Person B: open the bleed nipple one-quarter to one-half turn. Fluid and air bubbles will travel through the tube to the bottle. Close the nipple before Person A releases the lever/pedal.
- Repeat until no air bubbles appear and the lever/pedal feels firm. Keep reservoir topped between cycles to avoid drawing air into the master cylinder.
- Vacuum or pressure bleeder method (single person):
- Attach vacuum pump to the bleed nipple or use a pressure bleeder on the reservoir per tool instructions. Operate until clear, bubble-free fluid appears.
- Bleed each caliper in order: after the farthest caliper is clear, move to the next farthest. For front dual calipers bleed left then right or vice versa depending on distance.
- When finished, squeeze the lever/pedal to confirm firm feel and consistent pressure. The lever should not pull to the handlebar or go soft after holding pressure.
- Top the reservoir to the proper level and reinstall the diaphragm and cap. Clean all fittings and remove protective covers. Torque banjo bolts and bleed nipple to spec if you removed them; otherwise snug bleed nipples and check for leaks.
- Lower the ATV, test brakes at low speed in a safe area to confirm operation before riding at normal speed.
Tips & troubleshooting
- If lever feels spongy after bleeding, re-check for air, check hose condition and all fittings for leaks, and re-bleed beginning with the farthest caliper.
- If fluid remains cloudy or contaminated, flush the system by repeatedly replacing reservoir fluid and bleeding until the exiting fluid is clean and clear.
- Never mix DOT 3 and DOT 4 in the same system unless allowed by the manufacturer; check cap/manual. If switching fluid type, flush completely before adding new type.
- Replace rubber hoses if spongy or visibly cracked; old hoses can trap air and degrade braking performance.
Aftercare
- Inspect for leaks after a short test ride and re-torque fittings if necessary.
- Record the service date and fluid type for future maintenance; brake fluid should be replaced periodically per Honda recommendations or every 1-2 years in severe use.
- Dispose of old fluid responsibly at a hazardous-waste facility or approved collection point.
Following this MotoSport procedure will help keep your FA6 Rubicon's brakes reliable and responsive. If you encounter persistent softness, contamination, or internal caliper issues, consult a professional technician.
Related Shopping Categories
Shop Brake Fluid for a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Bleeders for a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Pads for a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Lines for a 2019 Honda TRX500 Rubicon 4X4 DCT EPS (FA6) ATV.
Shop Brake Tools for a 2019 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.
