How to Bleed & Replace Brake Fluid on a 2007 Can-Am Outlander 800

Shop parts for a 2007 Can-Am Outlander 800 ATV.

This MotoSport guide walks you step-by-step through replacing old brake fluid and properly bleeding the brakes on a 2007 Can-Am Outlander 800. Follow every step carefully to avoid air in the system and protect components from contamination. Work in a well-ventilated area and wear eye protection and gloves.

What you need

  • DOT 4 brake fluid (Do not use silicone DOT 5)
  • Factory service manual or torque specs for fasteners
  • Clear vinyl hose and a catch bottle
  • Brake bleeder wrench or box wrench (size depends on bleeders)
  • Flat screwdriver, rags, brake parts cleaner
  • Vacuum or pressure bleeder (optional but speeds job)
  • Torque wrench (for caliper/master cylinder hardware)
  • Container for old brake fluid for proper disposal

Model notes for the 2007 Can-Am Outlander 800

  • The Outlander 800 uses DOT 4 hydraulic fluid from the factory; mixing DOT types or using DOT 5 (silicone) will damage seals and alter performance.
  • This model typically has separate front and rear circuits and conventional caliper bleeder screws. Start bleeding at the caliper furthest from the master cylinder.
  • Some 2007 Outlander variants may have optional ABS components; if your machine has ABS, full bleed may require the ABS cycle procedure or a scan tool to operate the pump and valves. If uncertain, treat ABS-equipped units with extra caution and consult the service manual.
  • Check hoses, banjo fittings, and banjo bolt crush washers for leaks or deterioration while servicing. Replace any cracked hose or corroded fitting.
  • Brake fluid absorbs moisture over time; replacement every 1-2 years is best practice for trail use.

Preparation

  1. Park on level ground, set the parking brake, and remove the key. Block the wheels to prevent movement.
  2. Clean the master cylinder cap area before opening to prevent dirt entry. Remove the cap and diaphragm carefully.
  3. Inspect fluid color: dark brown or black indicates contamination and warrants a full fluid change. Keep the reservoir topped up with new DOT 4 fluid during bleeding to avoid drawing air in.
  4. If you'll be removing calipers or lines, have new crush washers and replacement parts ready.

Step-by-step fluid replacement & bleeding

  1. Identify the bleed order. General rule: start with the caliper that is farthest from the master cylinder and finish with the closest. On many Outlanders this will be rear right, rear left, front right, front left, but confirm by tracing lines from the reservoir/master cylinder.
  2. Attach a clear hose to the bleeder screw, submerge the other end in a small catch bottle partially filled with fresh fluid to prevent air re-entry.
  3. Add fresh DOT 4 to the master cylinder reservoir, keep the cap loosely in place so you can see fluid level but avoid contamination.
  4. Open the bleeder screw about 1/4 turn. Have a helper slowly squeeze the brake lever or press the brake pedal several times and then hold it depressed. While held, open the bleeder (if not already) to let fluid and air purge, then close the bleeder before the lever/pedal is released. Repeat until fluid runs clear and bubble-free. Maintain reservoir level throughout.
  5. If working solo, use a one-way valve bleed kit, vacuum pump, or pressure bleeder to perform the same sequence without a helper.
  6. Work through each caliper in the chosen sequence. After each caliper, top the reservoir to the proper level.
  7. When the final caliper is clear of air and contamination, tighten the bleeder screws to the correct snugness. If you don't have torque specs, tighten securely but avoid rounding the bleederconsult the service manual for torque values.
  8. Clean any spilled fluid immediately with brake cleaner and rags. Brake fluid will damage paint and plastics.
  9. Test brake lever/pedal firmness with the engine off. If it feels spongy, repeat bleeding until firm. If repeated bleeding doesn't firm the system, inspect master cylinder, hoses, and calipers for internal leaks or damaged seals.

Finishing steps

  • Top the reservoir to the specified level and reinstall the diaphragm and cap securely.
  • Cycle brakes several times with the ATV on the ground and wheels installed to confirm firm operation and that there are no leaks.
  • Road-test carefully at low speed in a safe area. Confirm braking performance before normal riding.
  • Dispose of old fluid per local hazardous waste regulations.

Common problems & checks

  • Spongy brake feel after bleeding: likely remaining air, a leaky line, or a failing master cylinder.
  • Brake drag after reassembly: caliper pistons may be sticking or bleeder screws overtightenedinspect and correct.
  • Damaged or swollen rubber parts: replace any rubber seals, hoses, or the master cylinder cap diaphragm that show swelling or deterioration.
  • ABS-equipped Outlanders may need an electronic ABS bleed cycle to purge trapped air; if you're unsure about ABS procedures, contact a MotoSport technician or reference factory service material.

Maintenance interval recommendation

For trail and utility use, change brake fluid every 12-24 months. More frequent changes are recommended if you ride in wet conditions or do heavy braking routinely.

Parts & supplies

Use DOT 4 brake fluid only and genuine replacement washers and seals where applicable. Refer to your Outlander 800 parts list for correct components and part numbers.

Following this MotoSport procedure will give you a clean brake system and reliable stopping power. If you encounter ABS issues or suspect internal master cylinder damage, schedule professional service.

Related Shopping Categories

Shop Brake Fluid for a 2007 Can-Am Outlander 800 ATV.

Shop Brake Bleeders for a 2007 Can-Am Outlander 800 ATV.

Shop Brake Pads for a 2007 Can-Am Outlander 800 ATV.

Shop Brake Lines for a 2007 Can-Am Outlander 800 ATV.

Shop Brake Tools for a 2007 Can-Am Outlander 800 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.