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

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

This proprietary MotoSport guide walks you step-by-step through draining and replacing the brake fluid on a 2007 Can-Am Outlander MAX 800 XT. Follow these instructions carefully to maintain braking performance and safety. Perform this job on a level surface with the engine off and the key removed.

Tools & Supplies

  • Fresh DOT 4 brake fluid (do not use DOT 3 or DOT 5 silicone in place of DOT 4)
  • Clear plastic tubing that fits over bleed nipples
  • Brake fluid collection bottle or container
  • Wrenches for bleed nipples and banjo or caliper fittings (open-end or line wrench set)
  • Turkey baster or fluid pump for reservoir removal
  • Clean rags and isopropyl alcohol for cleanup
  • Disposable gloves and safety glasses
  • Jack or ramps and stands if required to access wheels
  • Assistant to press brake lever/pedal (recommended)

Model Notes & Precautions for the 2007 Outlander MAX 800 XT

  • The Outlander MAX 800 XT uses hydraulic disc brakes designed for DOT 4 fluid. Always confirm reservoir cap labeling before filling.
  • This model typically has a single master cylinder feeding multiple calipers. Bleed order should follow farthest-to-closest relative to the master cylinder to avoid trapped air.
  • There is no factory ABS on the 2007 Outlander MAX 800 XT; bleeding is straightforward hydraulic bleeding rather than ABS cycling procedures.
  • The brake reservoirs are plastic & painted surfaces nearby can be damaged by brake fluid. Wipe spills immediately with isopropyl alcohol and a clean rag.
  • Do not mix DOT fluid types. If prior fluid is unknown, fully flush and replace with DOT 4 only.

Preparation

  1. Park the ATV on level ground and block wheels to prevent movement. Remove key from ignition.
  2. Clean the reservoir cap area to prevent contamination. Remove the cap and diaphragm carefully; set aside on a clean surface.
  3. Use a turkey baster or fluid pump to extract old fluid from the master reservoir to reduce spillage during bleeding.
  4. Top the reservoir with fresh DOT 4 so fluid level is at the minimum fill line. Keep the reservoir level topped throughout the procedure to avoid introducing air.

Bleeding Sequence

Use the farthest-to-closest method relative to the master cylinder. On the Outlander MAX 800 XT the common sequence is:

  1. Rear right (farthest)
  2. Rear left
  3. Front right
  4. Front left (closest)

If your specific machine shows a different plumbing layout, follow farthest-to-closest from the master cylinder instead of wheel naming.

Traditional Two-Person Bleed Procedure

  1. Attach clear tubing to the bleed nipple of the first caliper. Place the other end in a container partially filled with clean brake fluid to prevent air re-entry.
  2. Have your assistant slowly depress the brake lever or pedal and hold pressure.
  3. Open the bleed nipple about a 1/4 turn so fluid and air flow into the tubing. Watch for bubbles. Close the nipple before the assistant releases the lever/pedal.
  4. Top the master cylinder reservoir as needed to keep the fluid level above the minimum line.
  5. Repeat the squeeze/open/close cycle until no bubbles appear and fluid runs clear at that caliper.
  6. Tighten the bleed nipple securely and move to the next caliper in the sequence.

Single-Person Pump & Hold Method (If No Assistant)

  1. Use a one-way check valve brake bleeder or a fluid hand pump designed for brake bleeding to create vacuum at the bleed nipple, or use a pedal depressor to hold the lever while releasing the nipple.
  2. Attach clear tubing and either pump or depress — open the nipple to allow fluid to flow, then close before releasing the pedal if using manual depress-hold technique.
  3. Maintain reservoir level and repeat until clear, bubble-free fluid appears.

Complete Reservoir Flush

If you are replacing all fluid, repeat bleeding at each caliper until fresh fluid appears and the reservoir contains only new DOT 4 fluid. Continuously monitor and top the reservoir; never let it run dry during the process.

Post-Bleed Checks

  • Bleed nipples and any banjo fittings should be tightened to a snug fit; avoid overtightening. Use an appropriate wrench and ensure no leaks under pressure.
  • Clean all exposed fittings and paintwork with isopropyl alcohol to remove any stray brake fluid.
  • Check lever and pedal feel — they should be firm with no sponginess. If spongy, repeat bleeding focusing on the affected circuit.
  • Test-ride at low speed in a safe area to confirm proper braking. Recheck fittings and reservoir level after the first ride.

Maintenance Tips

  • Replace brake fluid every two years or sooner if the fluid appears dark or contaminated.
  • Inspect brake lines, hoses, calipers, and pads while bleeding. Replace any components showing cracking, corrosion, or excessive wear.
  • Store brake fluid sealed and upright; DOT 4 is hygroscopic and absorbs moisture from air which reduces boiling point and performance.

Safety Reminders

  • Brake fluid is corrosive to paint and plastic; handle carefully and clean spills immediately.
  • Dispose of used brake fluid in accordance with local hazardous waste regulations.
  • If you are not confident performing hydraulic brake work, have a certified technician at MotoSport service or your local shop perform the job.

This procedure and these tips are proprietary to MotoSport and tailored for owners of the 2007 Can-Am Outlander MAX 800 XT. Follow these steps to keep your brakes safe, reliable, and responsive.

Related Shopping Categories

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

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

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

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

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