How to bleed and replace brake fluid on a 2008 Can-Am Outlander 650

Shop parts for a 2008 CAN_AM OL650 ATV.

This MotoSport guide walks you step-by-step through draining, replacing, and properly bleeding the brake fluid on a 2008 Can-Am Outlander 650. Procedures below are written for the common non-ABS and ABS-equipped versions of the MMY Outlander 650. Follow manufacturer service intervals and use DOT 4 brake fluid unless your owner's manual specifies otherwise.

What you need

  • DOT 4 brake fluid (fresh, unopened)
  • Clear tubing that fits bleed nipples
  • Catch bottle or jar
  • Wrench for bleed nipples (usually 8 mm)
  • Syringe, turkey baster, or small pump for reservoir fluid removal
  • Torque wrench for caliper/banjo bolts if you remove lines
  • Brake-clean spray & rags
  • Latex or nitrile gloves and safety glasses
  • Optional: pressure or vacuum bleeder for faster, cleaner service

Important notes for the 2008 Can-Am Outlander 650 owner

  • The Outlander 650 commonly uses a single master cylinder feeding front & rear circuits; bleed the farthest caliper from the master cylinder first, then move closer.
  • Some 2008 models were equipped with ABS or combined braking systems – if your machine has ABS, consult the ABS bleed procedure before starting. ABS units may require activating the ABS pump or using a scan/diagnostic tool to cycle valves to purge trapped air.
  • Brake fluid is hygroscopic – replace at regular intervals (every 1-2 years) and always top from a sealed container.
  • Brake fluid will damage plastics and painted surfaces — clean spills immediately with brake cleaner and a rag.
  • Inspect banjo bolts, copper crush washers, hoses and calipers for leaks or wear while servicing the system.

Preparation

  • Park the ATV on level ground; engage parking brake (if fitted) and use a stand to keep wheels off the ground if you need to spin them.
  • Remove seat and any panels needed to access the master cylinder reservoir. Clean around the reservoir cap to prevent contamination.
  • Wear gloves & safety glasses. Have rags and brake cleaner ready for spills.
  • Open a fresh bottle of DOT 4 only when ready; do not reuse old fluid.

Drain old fluid from the reservoir

  1. Suspend a clean rag under the reservoir. Remove the cap and diaphragm. Use a syringe or turkey baster to remove as much old fluid as possible from the reservoir without introducing air into the lines.
  2. Refill the reservoir with fresh DOT 4 to the specified level marking. Replace the diaphragm and loosely fit the cap so air can escape but contamination is minimized.

Bleeding order

Most Outlander 650 setups: bleed the wheel farthest from the master cylinder first, then the next farthest, ending with the wheel closest to the master cylinder. If unsure, bleed in this order: rear (if single rear brake), then right front, then left front. For combined-brake systems, follow the physical routing of hoses and bleed the calipers from farthest to nearest.

Manual bleeding procedure (recommended for most DIY)

  1. Attach clear tubing to the bleed nipple on the farthest caliper; place the other end in the catch bottle partially filled with fresh fluid to prevent air re-entry.
  2. Have an assistant slowly pump the brake lever/pedal several times and then hold firm pressure. While they hold pressure, open the bleed nipple about 1/4 turn to let fluid and air escape. Close the nipple before your assistant releases the lever/pedal to avoid sucking air back in.
  3. Repeat pump-hold-open-close cycles until the fluid exiting the tubing is clear and bubble-free. Top off the reservoir frequently to prevent the master cylinder from running dry and pulling air in.
  4. Move to the next caliper and repeat the process in the specified order.
  5. When finished, ensure bleed nipples are snug (do not overtighten); wipe clean and reinstall diaphragm & cap. Dispose of old fluid properly.

Using a vacuum or pressure bleeder

  • Vacuum bleeder: attach vacuum to the bleed nipple and draw until fluid is clear. Keep reservoir level up during the process.
  • Pressure bleeder: pressurize the master cylinder reservoir (follow device instructions) and open bleed nipples sequentially until clear. Pressure bleeding is faster and especially useful on ABS systems when combined with ABS activation steps.

ABS-specific considerations

  • If your Outlander 650 has ABS, there can be trapped air in the ABS hydraulic unit. After bleeding calipers, follow ABS bleed steps: cycle the ABS pump if you have a service tool, or run the ABS purge procedure described in the service manual (pump activation – usually requires power or diagnostic tool). If unsure, use a pressure bleeder plus ABS cycling to ensure no air remains in the module.
  • Do not operate the ABS system at speed until brakes are verified to be firm and air-free.

Final checks

  • With all bleed nipples closed and reservoir full to spec, firmly apply the brake lever & pedal until pressure feels solid and consistent. There should be no sponginess.
  • Inspect for leaks at bleed nipples, banjo fittings & hose connections. Torque any fittings you removed to manufacturer specs if available.
  • Test ride slowly in a safe area to confirm braking performance. Recheck reservoir level after the first short ride and top to correct level if needed.
  • Record date and mileage of service for future maintenance.

Common problems & troubleshooting

  • Persistent spongy brakes after bleeding: likely trapped air in ABS or master cylinder; repeat bleeding, use pressure/vacuum bleeder or consult a dealer for ABS purge.
  • Continual low reservoir level: check for leaks in lines, calipers, or master cylinder; replace damaged components.
  • Brake drag after bleeding: ensure caliper pistons move freely and caliper guide pins are clean & lubricated.

Parts & replacement items to consider

  • Fresh DOT 4 fluid, OEM or high-quality equivalent
  • Caliper seals or rebuild kits if you find leaking pistons
  • New copper crush washers for banjo bolts when reassembling lines
  • Bleeder screws if rounded or damaged

Following these steps will keep the brake system on your 2008 Can-Am Outlander 650 safe and responsive. If you encounter ABS-specific complications or internal master cylinder problems, visit a qualified technician or authorized dealer for factory-level diagnostics and service.

Related Shopping Categories

Shop Brake Fluid for a 2008 CAN_AM OL650 ATV.

Shop Brake Bleeders for a 2008 CAN_AM OL650 ATV.

Shop Brake Pads for a 2008 CAN_AM OL650 ATV.

Shop Brake Lines for a 2008 CAN_AM OL650 ATV.

Shop Brake Tools for a 2008 CAN_AM OL650 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.