How to Bleed and Replace Brake Fluid on a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5)

Shop parts for a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5) ATV.

This MotoSport guide gives a step-by-step, model-specific procedure for flushing and bleeding the brake system on a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5). Follow these steps carefully to maintain braking performance and safety. Always work on a cool vehicle and wear eye protection and gloves.

Important notes specific to the 2020 Rubicon 520 DCT (FA5)

  • The Rubicon 520 has separate master cylinders for front and rear brakes: a handlebar lever for the front calipers and a foot pedal master for the rear. Each circuit is bled independently.
  • The Rubicon 520 DCT designation refers to the transmission; the braking system is conventional hydraulic and is serviced the same as other TRX520 models. DCT components do not change brake procedures.
  • Use a high-quality DOT 4 brake fluid unless your owner’s manual specifies otherwise. Do not mix DOT 3 with DOT 5 silicone fluids.
  • If your machine is equipped with any electronic ABS or traction control hardware, confirm whether a dealership procedure is required before bleeding. If unknown, inspect for wheel sensors and consult MotoSport service if needed.
  • Replace rubber hoses, banjo bolts with new crush washers if leaking, and inspect calipers and pads while bleeding.

Tools & supplies

  • DOT 4 brake fluid
  • Clear plastic tubing that fits over bleed nipple
  • Clean container to catch fluid
  • Wrenches for bleed nipples (commonly 8mm or 10mm) and banjo bolts
  • Turkey baster or syringe (to remove old fluid from reservoirs)
  • Shop rags, gloves, safety glasses
  • Optional: one-way bleed valve, vacuum bleeder, or pressure bleeder for easier operation

Preparation

  1. Park the ATV on level ground and secure it on a stand so wheels can rotate freely.
  2. Clean around both brake fluid reservoirs (front & rear) to prevent contamination.
  3. Remove caps from reservoirs and use a turkey baster to remove most old fluid. Wipe clean inside the cap &ndash do not allow dirt to fall in.
  4. Top each reservoir with fresh DOT 4 fluid to the max mark. Keep caps loose but seated to minimize air ingress.
  5. Identify bleed nipples on each caliper. Typical locations: front left & right calipers and rear caliper on axle. Fit clear tubing onto the nipple and submerge the other end in a container partially filled with fresh fluid to avoid drawing air back in.

Bleeding strategy

Bleed each hydraulic circuit separately: front circuit (both front calipers served by handlebar master) and rear circuit (rear pedal master). For each circuit, start with the caliper furthest from its master cylinder and work toward the closest caliper. This minimizes trapped air.

Two-person manual bleed (recommended if no bleed tool)

  1. Assistant slowly squeezes the brake lever or depresses the brake pedal while you open the caliper bleed nipple about 1/4 turn. Fluid and bubbles will flow into the tubing. Close the nipple before the assistant releases the lever/pedal to prevent sucking air in.
  2. Repeat squeeze & open cycles until the fluid runs clear and bubble-free, topping the reservoir frequently so it never drops below the minimum and draws air.
  3. Proceed to the next caliper in the correct order. For front: start at the caliper furthest from the handlebar master; then the other front caliper. For rear: bleed the rear caliper(s) starting with the furthest from the pedal master if multiple outlets exist.
  4. After final caliper, pump the lever/pedal quickly a few times and hold it while you tighten the bleed nipple to check firmness. Clean any spilled fluid immediately.

Single-person vacuum or pressure bleed (preferred for cleaner, faster service)

  1. Attach a vacuum pump to the caliper bleed nipple and draw fluid until clear and bubble-free while topping the reservoir. Repeat for each caliper in the proper sequence.
  2. Or use a pressure bleeder on the reservoir to force fluid through the system into the caliper drain tubes. Cycle each caliper bleed nipple until clear.

Finishing steps

  1. Confirm all bleed nipples are tightened to specification gently — snug but do not over-torque banjo bolts or nipples. Clean up any brake fluid traces immediately; brake fluid damages paint and plastics.
  2. Top reservoirs to the correct level, reinstall caps, and secure them. Wipe area clean.
  3. Test lever & pedal firmness with the engine off. They should feel firm and not sink to the bar/floor under steady pressure. If soft, re-bleed the affected circuit.
  4. Carefully test ride at low speed in a safe area to confirm braking performance. Re-check fluid levels and inspect for leaks after the test ride.

Additional maintenance tips for the Rubicon 520

  • Inspect brake pads and rotor condition when bleeding. Replace pads if pad thickness is near the wear limit or rotors are scored.
  • Replace banjo bolt crush washers whenever you remove the brake lines to avoid leaks.
  • Store DOT 4 fluid in a sealed container and avoid prolonged exposure to air &ndash brake fluid is hygroscopic and absorbs moisture which degrades braking performance.
  • If tread or wheel bearings have recently been serviced, re-check brake lines and hose routing for proper clearance and no kinking when steering or suspension cycles.
  • Keep a maintenance log at MotoSport for your MMY ATV noting fluid change date and mileage/hours for future service intervals.

If you prefer MotoSport-assisted service parts or need step-specific replacement hardware for your 2020 Honda TRX520 Rubicon 4X4 DCT, use the parts link above to find calipers, hoses, bolts, and recommended fluids tailored to your MMY ride.

Related Shopping Categories

Shop Brake Fluid for a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Bleeders for a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Pads for a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Lines for a 2020 Honda TRX520 Rubicon 4X4 DCT (FA5) ATV.

Shop Brake Tools for a 2020 Honda TRX520 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.