How to Bleed & Replace Brake Fluid on a 2007 Can-Am Outlander 650

Shop parts for a 2007 Can-Am Outlander 650 ATV.

This MotoSport-exclusive service guide walks you step-by-step through draining, replacing, and properly bleeding the brake system on a 2007 Can-Am Outlander 650 (OL650). Follow every safety precaution, use the recommended fluid, and observe model-specific notes below so your ATV stops the way it should.

What you need

  • DOT 4 brake fluid (clean, unopened container)
  • Clear 3/16" or 1/8" tubing to fit bleed nipples
  • Catch bottle and a small clamp or pliers
  • Wrenches to open bleed nipples (usually 8 mm or 10 mm)
  • Brake cleaner, rags, and gloves
  • Bench-bleed kit or a screwdriver for master cylinder bench bleeding
  • Floor jack or ATV lift and stands (secure support)
  • Torque wrench (for reassembly to factory specs)

Important model notes for the 2007 Can-Am Outlander 650

  • The OL650 uses hydraulic disc brakes with a remote reservoir on the handlebar/master cylinder and a rear brake reservoir depending on configuration. Confirm which master cylinder setup your unit has before beginning.
  • Many 2007 Outlander 650s are equipped without traction-control electronic braking systems, but some variants may have ABS or sensor wiring near the calipers. If your unit has ABS, follow any additional ABS service steps in the manual and cycle the system per manufacturer directions after bleeding.
  • Use DOT 4 as the first choice; DOT 5 is silicone-based and not compatible. Always confirm the brake-fluid type stamped on the reservoir cap or in the owner's manual.
  • Inspect brake hoses, banjo fittings, and caliper boots while you have the system open. The OL650 is an older MMY model; braided or cracked rubber hoses should be replaced to prevent soft lever feel and contamination.

Preparation

  • Park the ATV on level ground, put it in park, remove the key, and disconnect the battery negative terminal if you will be working near electrical components or ABS wiring.
  • Securely lift and support the ATV so wheels are off the ground for caliper access. Chock wheels if necessary.
  • Clean the reservoir caps and area around bleed nipples to prevent contamination. Remove the reservoir cap and diaphragm carefully.
  • If replacing fluid completely, have a drain container ready and keep the reservoir cap loosely installed to avoid debris falling into the system.
  • Wear eye protection and gloves. Brake fluid damages paint & plastics; protect finishes and wipe any spills immediately with brake cleaner.

Step 1 Bench-bleed the master cylinder (critical when replacing fluid)

  • Remove the master cylinder per service instructions or bench-bleed it while still mounted by pumping the lever slowly and opening the bleed port to allow trapped air out into a clean container until only fluid, no bubbles, returns.
  • If you remove the master cylinder, use a bench-bleed kit to push fluid through the ports until no air remains.

Step 2 Drain old fluid from the reservoir

  • Use a turkey-baster or siphon to remove as much old fluid from the reservoir as possible, minimizing contamination of new fluid.
  • Refill reservoir with fresh DOT 4 fluid to the recommended level but do not overfill.

Step 3 Bleeding sequence (farthest caliper first)

Work one circuit at a time. For most OL650 configurations the sequence is: the caliper farthest from the master cylinder first, then next-farthest, finishing with the closest caliper. If unsure, bleed rear before front and then the closest caliper last. If your unit has a separate rear master cylinder, treat it as its own circuit.

  1. Attach clear tubing to the bleed nipple and submerge the other end in a small catch bottle partially filled with fresh fluid to avoid drawing air back into the system.
  2. Loosen the bleed nipple just enough to allow fluid to flow when pressure is applied.
  3. Have an assistant steadily hold the brake lever/pedal and apply pressure, then hold. Open the bleed nipple to let fluid and air escape. Close the nipple before the assistant releases the lever/pedal.
  4. Repeat until bubble-free fluid flows and the lever/pedal feels firm. Replenish reservoir frequently to prevent it running dry.
  5. Move to the next caliper until all calipers are bled. If your unit has an integrated parking brake caliper, ensure its bled as part of the rear circuit.

Alternative: Vacuum or pressure bleeding

Using a vacuum pump on the bleed nipple or a pressure bleeder on the reservoir speeds the job and reduces the risk of sucking air in. If using a pressure bleeder, apply small pressure (per tool instructions) and open bleed screws sequentially until clear fluid appears.

Step 4 Final checks

  • Top off the reservoir to the correct mark and securely reinstall diaphragm and cap.
  • Torque bleed nipples and any banjo bolts to factory specs (consult your service manual). If you don't have the manual, tighten evenly and avoid over-torquing to prevent stripping.
  • Reconnect the battery if disconnected.
  • Lower the ATV, test the brake lever/pedal feel at low speed in a safe area. Expect a firm feel; if it feels spongy, rebleed the affected circuit.
  • Carefully check for leaks around bleed nipples, hoses, banjo fittings, and calipers after a short test ride.

Troubleshooting & tips

  • Persistent sponginess after several bleed attempts can indicate contaminated master cylinder, collapsed hose, internal caliper sealing issues, or ABS complications. Replace suspect hoses & seals and bench-bleed new master cylinders before installation.
  • If your OL650 has ABS, do not manually short or tamper with sensor wiring; follow ABS-specific diagnostics if you suspect ABS faults.
  • Always cap and seal leftover brake fluid in the original container to avoid moisture absorption; dispose of used fluid responsibly per local regulations.
  • Inspect rotors and pads while bleeding. Replace pads with uneven wear or rotors with scoring/warpage for consistent stopping.

Maintenance schedule recommendation

MotoSport recommends replacing brake fluid on the Outlander 650 every 12-24 months depending on use and storage conditions. Frequent wet-weather, muddy riding, or heavy towing/tandem riding merits annual changes to avoid moisture buildup and corrosion.

Final note for 2007 OL650 owners

The 2007 Can-Am Outlander 650 is a durable platform, but age can show in hoses, reservoir diaphragms, and caliper seals. When you replace the fluid, inspect and replace worn rubber components to get the most reliable braking performance. If you need parts or upgraded hoses, see MotoSport's parts catalog for the OL650 to source OEM & aftermarket options.

Related Shopping Categories

Shop Brake Fluid for a 2007 Can-Am Outlander 650 ATV.

Shop Brake Bleeders for a 2007 Can-Am Outlander 650 ATV.

Shop Brake Pads for a 2007 Can-Am Outlander 650 ATV.

Shop Brake Lines for a 2007 Can-Am Outlander 650 ATV.

Shop Brake Tools for a 2007 Can-Am Outlander 650 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.