The Honda Rincon 680 is a legend in the world of utility ATVs, known for its brute power and smooth ride. But even legends can have their quirks, and being aware of potential Honda Rincon 680 problems is key to keeping your machine running strong for years. This guide covers the crazy 6 issues you should never ignore, helping you diagnose, fix, and prevent costly repairs down the trail.
Owning a Rincon means you value reliability and performance. We’ll walk you through the most common trouble spots with clear, practical advice. From pesky electrical gremlins to more serious engine concerns, knowing what to look for can save you time, money, and a lot of frustration. Let’s get started on ensuring your adventures aren’t cut short.
Honda Rincon 680 Problems
While built to last, the Rincon 680 isn’t perfect. Certain problems tend to pop up more than others, especially as the machine ages or if it hasn’t been maintained perfectly. The key is to catch these issues early. Addressing them promptly can prevent a small problem from turning into a major engine failure or a complete breakdown miles from home.
Here are the six most critical areas to pay attention to.
1. The Dreaded Reverse Override Button and Gear Selection Issues
This is arguably the most famous quirk of the Rincon 680. The system uses a complex electronic shifting mechanism with a separate reverse override button. Problems here can leave you stuck in one gear or unable to shift at all.
Common Symptoms:
* The ATV won’t shift out of neutral or first gear.
* You hear a loud “clunk” or grinding noise when trying to shift.
* The reverse override button seems to do nothing, or the machine won’t go into reverse.
* The gear indicator on the dash flashes or shows incorrect information.
Primary Causes and Fixes:
The issue often lies in the shift motor or its position sensor. Dirt, water, and wear can cause these components to fail. The shift linkage can also become misadjusted or corroded.
1. Check the simple stuff first. Ensure the battery is fully charged. A weak battery can’t provide enough power for the shift motor to operate correctly.
2. Inspect the shift linkage. Look for any obvious binding, corrosion, or loose connections. A bit of cleaning and lubrication can sometimes work wonders.
3. Listen for the shift motor. When you press the shift button, you should hear a distinct whirring sound from under the seat. If you hear nothing, or just a click, the motor or its relay may be faulty.
4. Diagnose the sensor. A faulty gear position sensor will confuse the computer. This often requires a multimeter and a service manual for proper testing.
5. Consider the shift switch itself. The actual button on the handlebar can wear out. It’s a relatively simple and inexpensive part to replace compared to the motor.
2. Fuel Pump and Fuel Delivery Failures
A failing fuel pump is a common problem that can strand you. The Rincon’s fuel pump is located inside the fuel tank, and symptoms can start intermittently before a complete failure.
Common Symptoms:
* The ATV starts fine cold but dies when it gets warm, then restarts after cooling down.
* Loss of power, especially under load or going uphill.
* Sputtering or hesitation at higher RPMs.
* The engine cranks but won’t start. You won’t hear the brief fuel pump whir when you turn the key to “ON.”
What You Can Do:
1. Listen for the pump. Turn the key to “ON” (don’t start it). You should hear a humming sound from the fuel tank for 2-3 seconds. No sound is a big clue.
2. Check fuel pressure. This is the most accurate test. You’ll need a fuel pressure gauge that connects to the schrader valve on the fuel line. Refer to your manual for the correct pressure spec.
3. Inspect the filter. The Rincon has an in-line fuel filter. A clogged filter can mimic pump symptoms. It’s a cheap and easy part to replace regularly.
4. Don’t forget the relay. The fuel pump relay can fail. Try swapping it with another identical relay in the fuse box (like the cooling fan relay) to see if the problem moves.
3. Overheating and Cooling System Troubles
The liquid-cooled 680cc engine needs its cooling system to function properly. Overheating can cause severe engine damage, including warped heads and blown head gaskets.
Common Culprits:
* Clogged Radiator: Mud, grass, and debris pack into the fins, blocking airflow.
* Failing Thermostat: A thermostat stuck closed will cause immediate overheating.
* Weak or Dead Water Pump: The impeller can wear out or corrode.
* Low Coolant or Air Pockets: Leaks or improper burping of the system reduces cooling capacity.
* Faulty Fan or Switch: The electric fan not kicking on is a major issue at low speeds.
Prevention and Fix Steps:
1. Clean the radiator before every ride. Use compressed air or a gentle spray from the backside of the radiator to blow debris out. Never poke the fins with a screwdriver.
2. Check coolant level regularly in the overflow tank when the machine is cold.
3. Verify the fan operates. Let the ATV idle until it reaches operating temperature. The fan should turn on automatically. If it doesn’t, check the fuse, relay, fan switch (on the thermostat housing), and the fan motor itself.
4. Flush and replace coolant according to the maintenance schedule. This helps prevent corrosion in the water pump and passages.
4. Electrical Gremlins: Stators and Rectifiers
The charging system is vital. A failing stator (the part that generates AC power) or rectifier/regulator (converts AC to DC and controls voltage) will drain your battery and leave you powerless.
Warning Signs:
* A battery that constantly goes dead, even after a fresh charge.
* Dimming headlights that get brighter when you rev the engine.
* Difficulty starting, with slow cranking that gets worse.
* The ATV runs fine until the battery is drained, then it dies.
Diagnosis Guide:
You’ll need a multimeter for accurate testing.
1. Test Battery Voltage. With the engine off, a healthy battery should read about 12.6V. With the engine running at mid-RPM, voltage should rise to between 13.5V and 14.5V. If it’s below 13V or above 15V, you have a charging problem.
2. Test the Stator. Disconnect the stator connector. Set your multimeter to measure resistance (Ohms). Check the resistance between each of the three stator wires. They should all read similarly (usually a low resistance). Also, check that each wire has infinite resistance to ground.
3. Inspect Connections. The rectifier/regulator plug, located near the battery, is notorious for melting due to poor connections and heat. Look for browned or melted plastic.
5. Driveshaft and Differential Woes
The Rincon’s independent rear suspension uses driveshafts with CV joints. These can wear out, especially if the rubber CV boots tear and let in dirt.
Symptoms of Failure:
* A loud “clicking” or “popping” noise when turning, especially under power.
* Vibration felt through the footpegs or seat that increases with speed.
* Grease slung around the inside of the rear wheels or on the frame from a torn boot.
* In severe cases, a complete seizure or breakage, leaving you without drive.
Maintenance is Key:
1. Visually inspect the CV boots every time you wash your ATV. Look for any cracks, tears, or missing clamps.
2. If a boot is torn, replace it immediately. Don’t wait for the joint to fail. A boot kit is much cheaper than a whole new driveshaft.
3. Listen for noises. That classic clicking on turns is the hallmark of a worn-out CV joint.
4. Check the front and rear differential oil during regular service intervals. Metal shavings on the drain plug indicate internal wear.
6. Throttle Position Sensor (TPS) and Idle Problems
A faulty TPS can cause a myriad of frustrating driveability issues. This sensor tells the ECU how far open the throttle is, and incorrect readings mess with the fuel mixture.
How It Manifests:
* Erratic or high idle speed.
* Hesitation or stumbling during acceleration.
* Poor performance and lack of power.
* Sometimes, the engine will backfire through the intake or exhaust.
Adjustment and Replacement:
The TPS on the Rincon 680 can sometimes be adjusted, but if it’s faulty, it needs replacement.
1. Check for trouble codes. The Rincon has a self-diagnostic mode. You can make the dash blink error codes by shorting a connector under the hood. A specific blink pattern can point to the TPS.
2. Test with a multimeter. You can check the TPS for a smooth change in voltage as you slowly open the throttle. Any sudden jumps or dropouts signal a bad sensor.
3. Ensure the throttle cable is properly adjusted and moves smoothly before blaming the TPS. A sticky cable can cause similar issues.
Proactive Maintenance: Your Best Defense
The single best way to avoid these Honda Rincon 680 problems is consistent, proactive maintenance. It’s always cheaper than a repair.
Essential Maintenance Checklist:
* Oil and Filter Changes: Do this more often if you ride in severe conditions (mud, dust, water).
* Air Filter Service: A clogged air filter is an engine killer. Clean or replace it frequently, and always oil a foam filter properly.
* Drivetrain Fluids: Change the front and rear differential oil and the sub-transmission oil per the manual’s schedule.
* Grease All Fittings: The Rincon has grease zerks on the suspension and driveshafts. Hit them with a grease gun every few rides.
* Battery Care: Keep the terminals clean and tight. Use a battery tender if the ATV sits for long periods.
* Tire Pressure: Check it often. Incorrect pressure affects handling, performance, and can even strain drivetrain components.
Frequently Asked Questions (FAQ)
Q: What is the most common problem with the Honda Rincon 680?
A: Shifting issues related to the electronic shift motor and reverse override button are extremely common, followed by fuel pump failures.
Q: Are Honda Rincon ATVs reliable?
A: Absolutely. When properly maintained, they are among the most reliable ATVs ever built. Being aware of their common failure points allows you to prevent them.
Q: How can I tell if my Rincon’s stator is bad?
A: The classic signs are a constantly dead battery and dimming lights. Testing the charging voltage with a multimeter is the best way to confirm. If voltage doesn’t rise above 13V when running, the stator or rectifier is likely bad.
Q: Why does my Rincon 680 overheat?
A: The most common cause is a radiator clogged with mud and debris. Next, check that the cooling fan is working, and ensure the coolant level is correct with no air in the system.
Q: Is the Honda Rincon 680 good for mud and water?
A: It has good ground clearance and power, but its complex shifting and electrical systems are vulnerable. Always deep water crossings and ensure the CV boots are intact. Extended mud use requires meticulous cleaning and cooling system attention afterwards.
By understanding these six common problem areas, you’re already ahead of the game. Your Honda Rincon 680 is a incredibly capable machine. With a bit of knowledge and preventative care, you can keep it running smoothly and reliably for countless adventures. Always consult your official service manual for specific repair procedures and torque specifications, and don’t hesitate to seek help from a qualified mechanic for complex jobs. Remember, catching a small issue early is the secret to a long and trouble-free life for your ATV.