How to bleed and replace brake fluid on a 2007 Can-Am Outlander 800 XT ATV

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

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

This MotoSport guide gives step-by-step, model-specific instructions to drain, flush, and bleed the hydraulic brakes on a 2007 Can-Am Outlander 800 XT. Follow these directions carefully for safe, reliable stopping power. This procedure assumes basic mechanical skill and proper safety precautions.

What you’ll need

• DOT 4 brake fluid (Can-Am uses glycol-based DOT fluid — do NOT use mineral oil)
• Clear plastic tubing that fits snugly over bleed nipples
• Brake fluid catch bottle or jar and rags
• Wrenches to fit bleed nipples and caliper bolts (metric)
• Turkey baster or fluid syringe (to remove old fluid from reservoirs)
• Rubber gloves, eye protection, and a clean workspace
• Optional: vacuum bleeder or pressure bleeder for faster, cleaner bleeding
• Service manual or owner’s manual for bolt torque specs and component locations

Safety & prep

• Work on a level surface with the ATV secure on a stand so wheels can turn freely.
• Wear gloves & safety glasses. Brake fluid is corrosive to paint & plastics — wipe spills immediately.
• Keep the reservoir caps closed except when adding fluid to avoid contamination and absorb moisture from the air.
• Use only DOT 4 or the fluid specified in your owner’s manual for the Outlander 800 XT.

Identify reservoirs & bleed points

The 2007 Outlander 800 XT has a front brake master cylinder on the right handlebar with a small plastic reservoir, and a rear master cylinder mounted near the rear brake pedal with its own reservoir. Each caliper has a bleed screw/bleed nipple. Inspect lines & fittings for leaks, damage, or soft hose sections before starting.

Step 1 – Remove old fluid from reservoirs

1. Clean the area around each reservoir cap.
2. Remove the caps and diaphragms carefully. Use a turkey baster or syringe to remove as much old fluid as possible from each reservoir without allowing air into the system.
3. Dispose of the old fluid properly per local regulations.

Step 2 – Fill with fresh fluid

1. Top both reservoirs with fresh DOT 4 fluid until just below the max line. Do not overfill.
2. Close the reservoir caps loosely so you can open them during bleeding without contamination.

Step 3 – Bleeding order — MotoSport recommended sequence

MotoSport recommends bleeding in this order to minimize trapped air: 1) rear caliper, 2) right front caliper, 3) left front caliper. This sequence suits the Outlander 800 XT hydraulic layout and helps move air toward the reservoirs.

Step 4 – Manual bleeding procedure (per caliper)

1. Have an assistant slowly depress the brake lever or pedal several times and hold it down. Alternatively, use a one-way bleeder or vacuum tool.
2. Open the bleed nipple about a quarter turn and allow fluid and air to flow into the clear tubing and catch bottle. Close the nipple before the assistant releases the lever or pedal.
3. Repeat pump, hold, open, close cycles until no air bubbles appear and fluid runs clear.
4. Keep the reservoir topped up between cycles to prevent introducing more air into the system.
5. Once the caliper is clear, tighten the bleed nipple securely and wipe clean.

Step 5 – Front lever & rear pedal specifics

• When bleeding the front system with the handlebar master cylinder, have the assistant apply steady pressure to the front brake lever and follow the same open/close routine.
• For the rear system, use the pedal. If the rear master cylinder has an integrated reservoir low on the frame, keep extra fluid on hand to keep that reservoir full during bleeding.

Step 6 – Final checks & test

• After bleeding all calipers, top off reservoirs to the proper level and secure caps and diaphragms.
• Operate both brakes several times to confirm firm, consistent lever/pedal feel. If you feel sponginess, repeat bleeding until firm.
• Inspect all bleed screws, lines, and fittings for leaks under pressure.
• Clean any spilled fluid from painted or plastic surfaces immediately.
• Perform a low-speed brake test in a safe area before full use.

Notes specific to the 2007 Can-Am Outlander 800 XT

• The Outlander 800 XT uses DOT 4 compatible components; mixing DOT 3 & DOT 4 is possible but DOT 4 is recommended for higher boiling point and performance under load.
• The handlebar reservoir is small — it can run low quickly during bleeding. Keep a dedicated fresh fluid supply and top frequently to avoid air intake.
• Some 2007 Outlander models have protective caliper guards and splash shields. Remove or loosen these as necessary to access bleed nipples safely.
• If your machine has ABS or combined braking systems, consult the shop manual before using pressure or vacuum bleeders; ABS systems may require specialized cycling procedures or a dealer scan tool to fully purge air.
• Replace any rubber hose that feels soft, cracked, or swollen. Old hoses can collapse internally and trap air even after bleeding.
• Brake pad wear on the Outlander can change reservoir level significantly; if pads are near end-of-life, consider replacing them before bleeding for accurate reservoir capacity readings.

Maintenance tips

• Brake fluid absorbs moisture over time; replace fluid every 1-2 years depending on use and environment.
• Always use fresh, unopened fluid from an intact container to avoid contamination and moisture uptake.
• Record the date and mileage/hours when you replace fluid so you can maintain consistent service intervals.

Following these MotoSport-specific steps will get the hydraulic system on your 2007 Can-Am Outlander 800 XT clean, responsive, and reliable. If you encounter persistent air, spongy brakes, or an ABS-related issue, contact a qualified technician or authorized service center for advanced diagnostics.

Related Shopping Categories

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

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

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

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

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