Fuel Hose Service for the 2023 Honda Rincon 680 4x4
Shop parts for a 2023 Honda Rincon 680 4X4 ATV.
Set Up the Job Before You Touch a Fitting
A fuel line swap on the 2023 Rincon 680 takes less than an hour if everything you need is already on the bench, and turns into a mess if it is not. Collect the following before you start:
- Nitrile or rubber gloves, since gasoline pulls the oils out of your hands quickly
- Replacement hose rated for injection pressure and matched to the original inside diameter
- Fresh clamps in the same style the machine already uses, plus a quick-disconnect release tool if your Rincon has a locking coupler at the pump outlet
- Line-clamping pliers, which are the closest thing to a shutoff valve you get on an injected quad
- An approved sealed fuel container and a shallow drain pan
- A socket set, a small flat-blade screwdriver, a razor blade, and a stack of rags
Now the part that actually matters: gasoline vapor is heavier than air and settles at floor level, exactly where you will be kneeling. Work outdoors if you can, and if you cannot, open the door fully and put a fan on the floor moving air out of the building. No battery charger, no shop heater, no water heater pilot, no grinder anywhere nearby. Let the engine cool all the way down first, because a hot header and dripping fuel are a genuinely bad pairing.
Injection Changes the Procedure
The Rincon 680 is fuel injected, with an electric pump inside the tank feeding a pressurized hose to the throttle body. Practically speaking, that means there is no petcock to shut off, no gravity feed to wait out, and no float bowl drain to open. If you have replaced a line on an older carbureted quad, forget the valve step entirely. On this machine, pressure comes off electrically: pull the pump fuse or relay, let the engine stall, then kill the key and the battery. Some Rincons in this era use a self-locking quick-connect coupler at the tank end rather than a plain barb, so look before you start prying.
The 4x4 driveline also matters a little. With a front differential, a driveshaft, and the crossmembers that carry them occupying the front of the frame, the hose passes clearance points a two-wheel-drive quad simply does not have. Take the plastics off rather than fishing around by feel.
Why the Hose Fails in the First Place
Fuel hose gets stiff with age as the plasticizers that keep it flexible slowly leach out under repeated heat cycles. A hose that once compressed easily between two fingers eventually feels like hard tubing, and once flexibility is gone, ordinary vibration cracks the surface. Arid climates make this worse, since low ambient humidity draws moisture out of the rubber and accelerates the hardening from the outside.
Meanwhile, ethanol-blended fuel attacks the liner from within. E10 left sitting in a parked machine absorbs water and degrades the inner wall, releasing fine material into a system that depends on clean flow. That is why hose age is as meaningful as hose appearance, and why a line that looks acceptable can still be worth replacing.
What a Dying Line Looks Like
- Fuel visible on the skid plate or a spot on the floor under the front of the machine
- A strong gasoline smell, most noticeable right after shutdown while the circuit still holds pressure
- Surface cracking, a chalky texture, or a stiff section that will not pinch
- Bogging on hills, hesitation under load, or symptoms that mimic a nearly empty tank
- A crust of dirt ringing a fitting, which is what dried seepage always looks like
Because the line is pressurized, a small leak may spray a fine mist that evaporates before it drips. A fuel smell with no puddle is still a fuel leak.
Taking the Old Line Off
With pressure relieved and the battery disconnected, remove the seat and the tank plastics so both ends of the hose are visible together. Position the drain pan and keep a rag over each joint as you open it, because residual fuel comes out even from a depressurized line.
Slide any spring clip or screw clamp back down the hose before you disturb the connection. A quick-connect releases by pressing its tabs squarely and pulling straight off, never by levering it sideways, since the plastic collar becomes brittle over time. Where varnish has bonded the hose to a barb, twist it gently instead of pulling, and if it will not release, slit it lengthwise with a razor and peel it away. Snap photos of the routing and each retaining clip before the hose is completely free, particularly where it clears the front driveline.
Fitting the Replacement and Checking Your Work
Trim the new hose to match the original exactly. Extra length has nowhere useful to go and ends up rubbing a frame tube or drifting toward hot exhaust. Push each end fully onto its barb, dry, with no grease, oil, or silicone anywhere near a sealing surface. Lubricant on a fitting gives pressurized fuel a path to creep out past a clamp that is otherwise perfectly tight. A quick dip in hot water softens a stubborn hose end enough to slide it home.
Set the clamps just behind the bead on each fitting and tighten them evenly, snug rather than crushed. Self-locking quick-connects take no clamp at all: push until it clicks and tug to verify. Run the hose back through every original guide so it stays away from the differential hardware and the header.
To verify, reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. Each cycle pressurizes the hose so you can inspect dry connections for beading before the engine ever fires. Wipe, look again, then start it and let it idle a few minutes while you check with a clean rag. One platform note for afterward: on this injected Rincon the fuel filter is part of the in-tank pump module, not an inline piece you can swap on the visible line, so lingering delivery problems point there next.
Related Shopping Categories
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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV'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.