Honda TRX680 FourTrax Rincon / TRX650 Rincon service schedule

1. Lift the seat latch and take off the seat. Unlatch the clips and remove the air cleaner housing cover.
2. Remove the element holder, loosen the screw and lift out the air cleaner assembly. Unscrew the clamp and take the foam off its body.
3. Wash it gently in non-flammable solvent such as paraffin, never petrol. Squeeze it out; do not twist it.
4. Replace it if torn. Let it dry, then work foam filter oil through it in a plastic bag and squeeze out the excess.
5. Refit the foam and clamp, grease the sealing face lightly, refit the assembly, holder and screw.
6. Refit the cover with its FRONT mark facing forward and the tab in the holder, then refit the seat.

Tools: Screwdriver, Bowl of high-flash-point solvent (such as paraffin), Plastic bag, Grease, Gloves

1. With the engine off, find the drain tube under the air cleaner housing.
2. Remove the clip and drain tube, drain the deposits and refit them.

Tools: Pliers for the clip

1. Let the engine cool and remove the seat. Remove the pin and clip, loosen the band screw and take off the resonance chamber, then unhook the rubber cover.
2. Remove the oil filler cap lid and the left engine side cover.
3. Clean round the plug bases, pull off the top and side plug caps and remove both plugs.
4. Replace any plug that is heavily fouled, worn or cracked. Set the gap to 0.80–0.90 mm with a wire gauge.
5. Screw in by hand. A used plug: 1/8 turn after it seats. A new plug: 1/2 turn after it seats, loosen, then 1/8 turn after it seats.
6. Refit the caps without pinching any wires, then the covers and seat.

Tools: Plug spanner (in the tool kit), Phillips screwdriver, Wire-type feeler gauge, Wire brush

1. Only check with the engine cold.
2. Follow the Honda service manual to reach the valves and set the piston at top dead centre on the compression stroke.
3. Check the gaps: inlet 0.15 ± 0.02 mm, exhaust 0.32 ± 0.02 mm.
4. Adjust if needed and recheck. Otherwise have your dealer do it.

Tools: Feeler gauges, Spanners and adjusting tool, Service manual

1. With the quad upright, check the front reservoir on the right handlebar is above LOWER, and the rear reservoir behind the right side cover is between UPPER and LOWER.
2. If the level is low, check the pads. Remove the front wheels and look at the wear indicators; if the indicator meets the reference mark, both pads must be replaced.
3. Check the rear caliper wear indicator the same way.
4. Check the rear brake lever free play is 25–30 mm and adjust at the caliper nut if needed.
5. Look for leaks and cracked hoses. Have the dealer renew fluid every 2 years and fit pads.

Tools: Torch, Clean rag

1. Let the engine and silencer cool.
2. Remove the bolts, spark arrester and gasket from the silencer.
3. Brush the carbon off the screen without damaging it. Replace it if broken or holed.
4. Refit with the gasket and tighten the bolts to 12 N·m.

Tools: Socket set, Torque wrench (12 N·m), Soft brush

1. Park on level ground, stop the engine and take the key out. Oil and exhaust may be hot, so wear gloves.
2. Remove the oil filler cap on the left of the crankcase, put the tray under the engine and remove the drain bolt.
3. Remove the oil filter bolt and filter cover and let the last oil drain. Take the filter out of the cover. Keep the spring and washer.
4. Oil the new O-rings and fit them to the grooves in the cover and filter bolt. Put the new filter in the cover.
5. Refit the cover and tighten the filter bolt to 18 N·m. A loose filter bolt can cause serious engine damage.
6. Fit a new sealing washer and oiled O-ring to the drain bolt and tighten it to 25 N·m.
7. Fill with about 2.9 L of 10W-30 JASO MA oil and refit the filler cap.
8. Idle for 5 minutes, stop, wait 2–3 minutes and check the level is between the marks with the dipstick resting in, not screwed in. Check for leaks.
9. Take the old oil to a proper disposal point.

Tools: Drain tray (5 L), Socket set, Torque wrench (18–25 N·m), Funnel, Shop towels, Gloves

1. Change the oil warm, with the quad on level ground.
2. Rear: remove the filler cap and drain bolt, let it drain, refit the drain bolt at 12 N·m and fill with 80 ml until oil reaches the lower edge of the inspection hole.
3. Front: remove the filler cap and drain bolt, let it drain, refit the drain bolt at 12 N·m and fill with 180 ml until oil reaches the lower edge of the inspection hole.
4. Refit the filler caps and check for leaks.

Tools: Drain tray, Socket set, Torque wrench (12 N·m), Oil pump or squeeze bottle

1. Only work on a cold engine. Never take the radiator cap off hot.
2. Follow the Honda service manual to drain, refill and bleed the system.
3. Day to day, top up only through the reserve tank under the steering cover, to the UPPER mark.
4. Wash mud out of the radiator and oil cooler with low-pressure water after removing the cover plate.

Tools: Drain tray, Funnel, Service manual