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

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

This MotoSport guide shows a safe, step-by-step method to replace and bleed the brake fluid on a 2007 Can-Am Outlander MAX 800. It covers tools, fluid choice, bleed order, techniques for both vacuum and manual bleeding, and model-specific notes to keep your MMY ATV stopping reliably.

What you need

  • DOT 4 brake fluid (Can-Am specifies DOT 4; do not mix DOT 3 unless emergency)
  • Clear tubing that fits over bleed nipples and a catch bottle
  • Brake bleeder kit (vacuum hand pump or pressure bleeder preferred) or a helper
  • Turkey baster or fluid siphon for reservoir drainage
  • Clean rags, gloves, eye protection
  • Wrenches to fit bleed nipples (typically 8 mm or 10 mm) and a small screwdriver for reservoir cap seal
  • Torque wrench for caliper and wheel fasteners (follow MotoSport parts specs)

Safety and prep

  • Work on a level surface with the ignition OFF and key removed.
  • Protect paint and plastics from brake fluid – it will damage finishes. Cover panels with rags or plastic.
  • Park with wheels chocked; place ATV on its center stand or securely supported so wheels can be rotated if needed.
  • Clean around the master cylinder reservoir and bleed nipples before opening to keep contamination out.

Model notes for the 2007 Can-Am Outlander MAX 800

  • The Outlander MAX 800 uses DOT 4 brake fluid in the front and rear circuits. Confirm your reservoir cap labeling when in doubt.
  • Brake master cylinder and reservoirs are accessible but plastic covers and cargo racks may need removal on the MAX (two-seat) configuration to reach hoses and fittings.
  • This model commonly has separate front and rear hydraulic circuits. Bleed each circuit independently to avoid cross-contamination.
  • If your machine has optional towing or accessory hydraulic attachments, ensure lines are isolated and not connected to the brake system.
  • If you find spongy brakes after bleeding, recheck for air, soft lines, or caliper piston seizing on this older model — caliper rebuild kits are available at MotoSport if seals are leaking or pistons drag.

Step 1 – Drain old fluid from reservoirs

  • Remove the reservoir cap(s) and diaphragm. Use a turkey baster or syringe to remove as much old fluid as possible. Dispose of fluid properly.
  • Refill the reservoir with fresh DOT 4 fluid to the full mark before beginning the bleed process to limit air entry.

Step 2 – Determine bleeding order

Always start with the caliper farthest from its master cylinder and work toward the nearest. Typical sequence for the Outlander MAX 800:

  • Rear caliper (if single rear circuit, bleed rear first)
  • Right front caliper
  • Left front caliper
  • If there are separate master cylinders for front/rear, treat each circuit independently, starting farthest from each master cylinder.

Step 3 – Bleeding technique (vacuum bleeder)

  1. Attach clear tubing to the bleed nipple and place the other end in a bottle partially filled with old fluid to prevent air ingress.
  2. Attach a hand vacuum pump to the nipple, open the nipple about a quarter turn, and draw fluid until clear, bubble-free fluid emerges and no air is visible.
  3. Close the nipple while maintaining vacuum, release vacuum, then remove hose. Top off the reservoir immediately.
  4. Repeat for each caliper in the chosen order, keeping the reservoir level above the minimum at all times.

Step 4 – Bleeding technique (pressure or two-person manual)

  • Pressure bleeder: Fill the pressure bleeder with DOT 4, pressurize per tool instructions, open bleed nipple, let fluid push out until clear, then close nipple before releasing pressure.
  • Two-person method: Have assistant pump the brake pedal several times and hold it, open bleed nipple to let fluid/air out, close nipple, then have assistant release pedal. Repeat until clear fluid with no bubbles. Keep reservoir topped up.

Step 5 – Flushing the system (full fluid replacement)

  • To fully replace old fluid, continue bleeding each wheel until the fluid exiting is bright and free of contamination, and the reservoir has been completely replaced with fresh DOT 4.
  • Start with the reservoir full, perform bleeding sequence, refill as needed. Aim to flush multiple reservoir volumes through each circuit.

Step 6 – Final checks

  • Tighten bleed nipples to spec snugness (do not over-torque). Wipe fittings clean.
  • Ensure reservoir is filled to the proper level and reinstall cap & diaphragm securely.
  • Pump the brake lever/pedal until firm; verify no sponginess. If spongy, repeat bleeding sequence and inspect lines/calipers for leaks or soft hoses.
  • Check for fluid leaks at calipers, hoses, fittings & master cylinder after a short test ride at low speed.

Maintenance tips — keep your Outlander MAX 800 reliable

  • Replace brake fluid every 1-2 years or sooner if the fluid looks dark or contaminated.
  • Inspect caliper boots, hoses and banjo fittings for leaks or wear while you bleed: the 2007 MAX can develop hose swelling and banjo bolt leaks with age.
  • If the calipers stick or pads wear unevenly, rebuild calipers or replace seals; MotoSport stocks caliper rebuild kits and replacement calipers for this model.
  • Avoid brake fluid contact with painted plastics and seat material – keep rags handy and clean spills immediately.

Troubleshooting

  • Persistent soft lever/pedal: likely air remains, a leaking hose, or a failing master cylinder. Re-bleed and inspect components.
  • Brake fade after bleeding: check for contaminated pads or overheated fluid; flush and replace fluid again if contaminated with moisture.
  • Brake drag after bleeding: caliper pistons may be sticking; remove caliper and inspect pistons/seals and slide pins.

Follow these steps to safely replace and bleed the brake fluid on your 2007 Can-Am Outlander MAX 800. For OEM replacement parts, seals, hoses, or brake components specific to this MMY ATV, use the MotoSport parts link above to find the exact fit items for your model.

Related Shopping Categories

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

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

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

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

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