How to Bleed & Replace Brake Fluid on a 2008 Can-Am Outlander 800

Shop parts for a 2008 Can-Am Outlander 800 ATV.

This MotoSport proprietary guide walks you through safely flushing and bleeding the hydraulic brakes on a 2008 Can-Am Outlander 800 (OL800). Follow every step carefully, use the right fluid, and inspect brake hardware while you work. If your Outlander is fitted with factory ABS or an aftermarket system, read the model notes below before proceeding.

What you need

  • DOT 4 brake fluid (Do not mix different DOT types)
  • Clear plastic tubing that fits snugly on the bleeder nipples
  • Catch bottle (marked for used brake fluid)
  • Brake bleeder wrench or appropriate sized box wrench
  • Brake-flushing syringe, vacuum pump, or pressure bleeder (recommended)
  • Clean rags, brake cleaner, small funnel, and gloves
  • Jack or ramps to lift the machine safely and stands to stabilize
  • Service manual or torque wrench for fastener specs (recommended)

Know your Outlander 800 setup

  • The Outlander 800 uses hydraulic disc brakes with a hand lever for the front and a foot pedal for the rear. Confirm which master cylinder feeds which calipers before bleeding.
  • Some 2008 models may have optional ABS or aftermarket components. If ABS is present, follow ABS-specific bleed procedures in the service manual; using a pressure bleeder may still be acceptable but verify ABS manufacturer guidance.
  • Always use DOT 4 fluid unless the cap or owner manual specifies otherwise. DOT 4 has higher boiling point and better heat resistance for this application.

Preparation

  • Work on a level surface, turn ignition off, remove key, and secure the machine against rolling.
  • Clean the master cylinder reservoir cap, surrounding area, and the reservoir itself to prevent contamination entering the system when you open it.
  • Remove or clean the cap and diaphragm; do not let dirt fall into the reservoir. Use a clean funnel if topping up.
  • Note or mark brake pad wear and caliper condition while you're at it. Replace pads or damaged hoses now – do not rely on bleeding to fix mechanical issues.

Bleed order

Always begin at the caliper farthest from the master cylinder and progress to the nearest. On most Outlander layouts that means:

  • 1st: Rear caliper (if rear is farthest)
  • 2nd: Front passenger-side caliper
  • 3rd: Front driver-side caliper (closest to master cylinder)

If you are unsure which caliper is farthest, identify the master cylinder feed lines and choose the caliper with the longest hydraulic line run as the first point.

Step-by-step bleed & fluid replacement

  1. Top the reservoir to the MAX mark with fresh DOT 4 fluid. Do not overfill.
  2. Start at the farthest caliper. Fit clear tubing onto the bleeder nipple and submerge the other end in a catch bottle partially filled with fresh fluid to avoid drawing air back in.
  3. Have an assistant slowly operate the brake lever or pedal (depending on which circuit you are bleeding) while you open the bleeder nipple about 1/4 to 1/2 turn. The assistant should hold the lever/pedal down until you close the nipple. Repeat until fluid runs clear and bubble-free from the tubing.
  4. Keep the reservoir topped between cycles so it never runs dry. If the reservoir level drops to near empty, stop and top up before proceeding; otherwise you will reintroduce air into the system.
  5. When the line is clean, tighten the bleeder nipple and move to the next caliper in the bleed order. Use a torque figure from the service manual for final tightening if available, or snug plus a small turn to seat (avoid over-tightening).
  6. For a one-person method, use a vacuum pump on the bleeder nipple or a syringe to pull fluid through each caliper while you operate the lever/pedal lightly to seat pistons and pads as needed.
  7. If using a pressure bleeder, follow the bleeder tool manufacturer's instructions and keep the reservoir monitored so it never runs low.
  8. After bleeding all calipers, pump the brake lever/pedal several times to ensure firm pedal/lever feel. Check reservoir level and top to MAX, then reinstall cap securely.
  9. Clean any spilled fluid from painted or plastic parts immediately with water and mild detergent or a brake-safe cleaner. Brake fluid is corrosive to paint and some plastics.
  10. Test brakes at low speed in a safe area before returning to normal operation. Confirm firm, consistent feel &mdash if sponginess remains, repeat the bleeding procedure.

Inspection & maintenance notes specific to the 2008 Outlander 800

  • Inspect caliper guide pins, boots, and hose fittings for cracks or leaks. Replace any degraded rubber lines to prevent air ingress under pressure.
  • Check brake pads and rotors for uneven wear. Many Outlander owners find pad replacement intervals vary widely depending on terrain & load &mdash inspect frequently if you ride aggressively or carry heavy loads.
  • The OEM system is sensitive to contaminated fluid. If your fluid is dark or contains debris, perform a complete flush rather than partial topping. Contaminated fluid lowers boiling point and performance.
  • If your ATV has been stored for long periods or used in wet conditions, water can accumulate in the system. Replace fluid every 1-2 years or sooner with heavy use in wet/muddy environments.
  • ABS-equipped models may require pump cycling or scan-tool commands to properly purge air from the modulator &mdash consult the model's service information if ABS is present before attempting a DIY bleed.

Troubleshooting

  • Persistent soft lever/pedal after bleeding: re-bleed, check for leaking fittings, collapsed hoses, or internal master cylinder failure.
  • Brake drag after bleeding: check caliper pistons and sliding hardware for sticking; retract pistons slightly and ensure pads return freely.
  • Brake warning lights or ABS faults: clearance of air in ABS modules may require specific service steps; do not assume bleeding will clear ABS faults.

Disposal & final checks

  • Dispose of used brake fluid per local regulations. Do not pour down drains or onto the ground.
  • After a short test ride, recheck reservoir level and bleeder nipples for leaks. Re-torque any hardware if necessary.

Performing a full fluid flush and bleed restores braking performance and extends the life of components on your 2008 Can-Am Outlander 800. If you encounter persistent problems, or if the machine is ABS-equipped and shows faults, schedule professional service.

Related Shopping Categories

Shop Brake Fluid for a 2008 Can-Am Outlander 800 ATV.

Shop Brake Bleeders for a 2008 Can-Am Outlander 800 ATV.

Shop Brake Pads for a 2008 Can-Am Outlander 800 ATV.

Shop Brake Lines for a 2008 Can-Am Outlander 800 ATV.

Shop Brake Tools for a 2008 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.