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Honda Rincon 680 Service Manual Repair 2006-2017 TRX680

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The Honda Rincon 680, a first-generation model produced from 2006 to 2017, stands as a premium, full-size utility ATV. It is powered by a robust 675cc liquid-cooled engine featuring PGM-FI...
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Type: Atv
Vendor:
Honda
Sku: 136444
Tags: 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 ATV Honda Powersports Rincon 680 Rincon Series TRX680
Honda Rincon 680 Service Manual Repair 2006-2017 TRX680
The Honda Rincon 680, a first-generation model produced from 2006 to 2017, stands as a premium, full-size utility ATV. It is powered by a robust 675cc liquid-cooled engine featuring PGM-FI fuel injection and is renowned for its sophisticated, patented automatic transmission, independent front and rear suspension, and the option of power steering on the TRX680FGA variant. This model is engineered for riders who demand performance and ease of operation across diverse terrains, building on a strong heritage of reliable and technologically advanced powersports vehicles. This comprehensive 640-page service manual, written in English, provides in-depth guidance for the maintenance, diagnostics, and repair of the Honda Rincon 680 (TRX680FA and TRX680FGA) from 2006 to 2017. It covers all essential systems, including the engine, fuel, transmission, drivetrain, suspension, brakes, and electrical systems, offering detailed step-by-step procedures, troubleshooting guides, and technical specifications. The manual is designed to assist both owners and professional technicians in maintaining the vehicle's optimal performance and ensuring its longevity.
🏷️ Basic Information
Identification
Make:
Honda
Model:
Rincon 680
Model Variant:
TRX680FA (with Automatic Transmission), TRX680FGA (with Automatic Transmission and Power Steering)
Model Code:
TRX680
Generation
Generation:
First Generation
Codes
Engine Code:
H7J
👋 Introduction
Market Position
Market Position:
The Honda Rincon 680 is positioned as a premium, full-size utility ATV known for its powerful engine, comfortable ride, and advanced automatic transmission, targeting riders who prioritize performance and ease of operation in various terrains.
Competitive Analysis
Competitors:
Competes with other premium full-size ATVs from manufacturers like Yamaha (Grizzly 700), Polaris (Sportsman XP 850), Can-Am (Outlander 850), and Suzuki (KingQuad 750).
Key Features
Key Features:
675cc liquid-cooled, SOHC, 4-valve, 4-stroke engine; Honda's patented Hondamatic automatic transmission; independent front and rear suspension; power steering (on FGA models); four-wheel drive with torque-sensing front differential.
Manual Value Proposition
Value Proposition:
This comprehensive service manual empowers owners and technicians to perform all necessary maintenance, diagnostics, and repairs on their Honda Rincon 680, ensuring optimal performance, longevity, and cost savings on professional servicing.
📋 Manual Details
Coverage Areas
Applicable Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017
Engine Variants Covered:
All 680cc engine variants for the specified model years.
Trim Levels Covered:
TRX680FA, TRX680FGA
Page Count
Page Count:
640 pages
Manual Type
Manual Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (piston, rings, connecting rod, crankshaft, cylinder head, valves, camshafts, timing chain, etc.).
Fuel System:
PGM-FI (Programmed Fuel Injection) system diagnostics, component testing (fuel pump, injectors, throttle body, sensors), troubleshooting no-spark conditions, and adjustments.
Transmission:
Automatic transmission (AT) system, including operation, maintenance, troubleshooting, and internal component servicing. Covers torque converter, planetary gears, hydraulic control system.
Drivetrain:
Front and rear drive systems, including driveshafts, differentials, CV joints, and wheel hubs. Covers lubrication and maintenance.
Suspension:
Front independent double-wishbone suspension and rear swingarm suspension. Covers fork seals, shock absorbers, bushings, and linkage components. Includes adjustment procedures.
Brakes:
Hydraulic disc brake system (front and rear). Covers brake calipers, master cylinders, brake lines, brake pads, brake rotors, and brake fluid replacement. Includes bleeding procedures.
Electrical System:
Starting and charging system (starter motor, alternator/stator, regulator/rectifier), ignition system (spark plug, ignition coil), lighting (headlights, taillights, brake lights), instrumentation, and wiring diagrams.
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, and water pump. Covers coolant replacement and system bleeding.
Frame And Bodywork:
Chassis, frame, body panels, fenders, seat, handlebars, and plastic components. Covers removal, installation, and inspection.
Procedures Included
Maintenance:
Regular maintenance procedures, including oil changes, filter replacements (oil, air), spark plug checks and replacement, lubrication points, tire pressure checks, and general inspections.
Troubleshooting:
Comprehensive troubleshooting guides for common and complex problems, including diagnosis of starting issues, engine performance problems, electrical faults, and transmission issues. Includes flowcharts and diagnostic steps.
Repair:
Step-by-step repair procedures for virtually every component and system of the ATV, from minor adjustments to complete engine and transmission rebuilds.
Overhaul Rebuild:
Complete tear-down and rebuild instructions for the engine, transmission, and suspension components, enabling full restoration or major repairs.
Technical Specifications:
Detailed technical specifications for all components, including torque values for fasteners, clearance specifications (valve, piston, etc.), fluid capacities, and recommended lubricant types.
Diagnostics:
Diagnostic procedures for the PGM-FI system and other electronic components.
Technical Depth
Depth:
In-depth coverage suitable for professional mechanics and advanced DIY enthusiasts, covering everything from routine maintenance to complete engine and transmission rebuilds.
Illustrations:
Includes detailed illustrations, diagrams, and exploded views for clear identification of parts and assembly sequences.
Searchability:
Searchable PDF format allowing users to quickly locate specific information, procedures, or specifications.
Navigability:
Clickable chapters for easy navigation and quick access to different sections of the manual.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, suitable for printing without loss of detail. No restrictions on printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Usage Rights
Usage Rights:
Unlimited saving and burning to disc permitted.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, OHC, 3-valve gasoline
Displacement:
675 cc
Bore X Stroke:
100.0 mm x 85.4 mm
Compression Ratio:
9.2:1
Carburetion:
PGM-FI (Programmed Fuel Injection)
Performance
Horsepower:
Approximately 42 hp (varies slightly by year and specific model configuration)
Torque:
Approximately 40 lb-ft (varies slightly by year and specific model configuration)
Fuel System
Fuel Type:
Unleaded gasoline (87 octane or higher)
Fuel Tank Capacity:
3.0 US gallons (11.4 liters)
🔧 Transmission
Standard
Transmission Type:
Hydro-electronic shift, Continuously Variable Transmission (CVT) with 3 forward gears and reverse (Hondamatic)
Features
Transmission Features:
Torque converter automatic transmission with electronic control, offering seamless shifting and optimal power delivery. Features a rider-selectable drive mode.
Fluid Requirements
Transmission Fluid Type:
Honda Genuine ATF-DW1 (or equivalent)
Transmission Fluid Capacity:
Approximately 1.5 US quarts (1.4 liters)
📐 Dimensions
Exterior
Overall Length:
83.3 inches (2116 mm)
Overall Width:
47.2 inches (1199 mm)
Overall Height:
47.2 inches (1199 mm)
Wheelbase:
50.2 inches (1275 mm)
Weights
Curb Weight:
Approximately 640-660 lbs (290-300 kg) depending on model variant
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheel Bolt Pattern:
4x110mm
Ground Clearance:
7.5 inches (191 mm)
🛡️ Safety Features
Ratings
Safety Ratings:
As an ATV, safety ratings are primarily based on operational guidelines and rider responsibility. Specific crash test ratings are not applicable in the same way as passenger vehicles.
Active Features
Active Safety Features:
Powerful hydraulic disc brakes, torque-sensing front differential for enhanced traction, stable independent suspension system.
Passive Features
Passive Safety Features:
Ergonomic seating position, sturdy handlebar, integrated lighting for visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (ATV technology focuses on performance and utility, not infotainment).
Driver Assistance
Driver Assistance Features:
Power steering (on FGA models) significantly reduces steering effort and rider fatigue, especially at lower speeds and over rough terrain.
Connectivity
Connectivity Features:
N/A (ATV technology focuses on performance and utility, not connectivity).
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 600 miles or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Every 600 miles or 6 months, concurrent with oil change.
Air Filter Cleaning Inspection:
Inspect every 600 miles, clean as needed. Replace as needed.
Spark Plug Check Interval:
Every 600 miles.
Valve Clearance Check:
Every 2,500 miles or 12 months.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher motorcycle oil (with JASO MA certification).
Engine Oil Capacity:
Approximately 2.6 US quarts (2.5 liters) with filter change.
Coolant Type:
Honda genuine coolant or equivalent (50/50 mix of ethylene glycol based coolant and demineralized water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Known Issues:
While generally reliable, some owners have reported occasional issues with the automatic transmission shift actuator, potential for overheating in extreme conditions if cooling system is not maintained, and wear on suspension components due to rugged use.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Honda has a long-standing reputation for producing reliable, high-quality, and technologically advanced powersports vehicles. The Rincon line builds upon this heritage, offering a premium ATV experience.
Model Evolution
Model Evolution Summary:
The Honda Rincon was introduced in 2003 with a 650cc engine. The TRX680 model, launched for the 2006 model year, featured an increased engine displacement to 675cc, along with an improved PGM-FI fuel injection system and refinements to the automatic transmission. Minor updates and feature adjustments continued through the 2017 model year, with the core platform remaining consistent.
Production
Production Years Covered By Manual:
2006-2017
🏆 Awards & Recognition
Recognitions
Recognitions:
The Honda Rincon has consistently received positive reviews from automotive and powersports media for its performance, reliability, and sophisticated automatic transmission system.
Ratings
Owner Satisfaction Ratings:
Generally high owner satisfaction due to Honda's reputation for build quality and durability.
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