How to Bleed & Replace Brake Fluid on a 2008 Can-Am Outlander 800 XT
Shop parts for a 2008 Can-Am Outlander 800 XT ATV.
This MotoSport proprietary guide covers step-by-step fluid replacement and bleeding for the 2008 Can-Am Outlander 800 XT (MMY: CAN_AM;OL800XT;2008). It is written for owners who want a reliable, safe brake fluid service — not just a quick bleed. Follow the steps below exactly, use the recommended fluid, and address any worn hydraulic components discovered during the job.
Important model notes for the 2008 Outlander 800 XT
- The Outlander 800 XT uses two separate brake circuits: the handlebar lever master cylinder for the front brakes and the foot pedal master for the rear. Bleed each circuit independently.
- MotoSport recommends using DOT4 brake fluid for replacement; confirm the reservoir cap marking before starting. DOT5 silicone fluid is not compatible with DOT3/DOT4 systems.
- This model generally does not include factory ABS. If your ATV has an aftermarket or factory ABS unit, follow a manufacturer-specific ABS bleed procedure before road use.
- Inspect calipers, hoses, banjo fittings, and pads while bleeding. Replace damaged hoses or corroded fittings; dirty fluid often indicates internal corrosion or caliper wear.
Tools & supplies
- DOT4 brake fluid (fresh, unopened)
- Clear plastic tubing to fit bleeder nipples
- Catch bottle partially filled with brake fluid to prevent air entry
- Brake bleed kit or vacuum pump (hand pump or syringe alternative)
- Socket set, wrench for bleeder nipples (typically 8mm or 10mm), screwdriver
- Clean lint-free rags, nitrile gloves, safety goggles
- Torque wrench for reassembly if available
- Brake cleaner and small brush for calipers
Preparation
- Park on level ground and secure the ATV so it cannot move. Block wheels as needed.
- Clean the brake fluid reservoirs, cap area, and surrounding paint to prevent contamination.
- Remove the reservoir caps for both front and rear masters. Do not let dirt fall in. Use a clean rag to cover openings if you must pause.
- Top each reservoir with fresh DOT4 fluid to the recommended level. Do not overfill.
- Identify bleeder nipple locations on each caliper. Fit clear tubing over the nipple and route into the catch bottle with a small amount of fluid in the bottle to prevent air reentry.
Bleed order & method
Bleed each circuit separately. Start with the circuit farthest from its master cylinder if two calipers are on one circuit. Because the Outlander uses separate masters for front/rear, bleed all front calipers via the handlebar master first, then the rear via the pedal master.
Common methods (choose one):
- Vacuum pump or pressure bleeder — fastest and least messy.
- Manual two-person pump — one person pumps the lever/pedal while the other opens/closes bleeders.
- Syringe or gravity drip — only for small top-ups or if no pump is available; slower and requires patience.
Step-by-step bleed (recommended vacuum or hand-pump method)
- Attach the clear tubing to the bleeder nipple and place the other end in the catch bottle.
- With the master reservoir open and topped, attach your vacuum pump to the bleeder nipple and apply steady vacuum.
- Open the bleeder nipple about a 1/4 turn. Allow fluid and air to draw out until you see only clear fluid with no bubbles. Close the nipple while maintaining vacuum, then release vacuum and detach.
- If using a hand-pump method: have an assistant slowly pull the lever/pedal several times then hold pressure. Open the bleeder to let fluid/air out, close it, then release the lever/pedal. Repeat until clear fluid appears.
- Keep the reservoir filled during the entire process. Never let the reservoir run dry — doing so will reintroduce air into the lines and require a full repeat.
- Work systematically through all calipers for that circuit. Typical order for multi-caliper front circuits is farthest then nearest, but because the Outlander front uses a handlebar master, bleed each front caliper completely before finalizing the master.
- After bleeding a circuit, pump the brake lever/pedal gently to confirm firm feel. If spongy, repeat bleeding until firm.
- Torque bleeder nipples to a snug setting (do not over-torque). If a torque spec is needed, use a moderate 8-12 ft-lb range for small bleeder screws or tighten to factory spec if known.
Reservoir refill & final checks
- Top reservoirs to the correct level, replace caps and secure breather hoses.
- Wipe all fittings and painted surfaces with brake cleaner. Remove any spilled fluid immediately — brake fluid damages paint.
- Inspect hoses, banjo bolts and copper crush washers for leaks. Replace any leaking hardware; always use new crush washers when reassembling banjo fittings.
- Perform a slow operational test: with the ATV still supported, apply brakes to confirm immediate, firm engagement. Then perform a low-speed brake test in a safe area to confirm full braking performance.
Disposal & maintenance notes
- Dispose of used brake fluid as hazardous waste per local regulations. Do not pour on soil or down drains.
- If brake fluid turned very dark or contained debris, consider inspecting/caliper rebuilding or replacing that caliper. Dirty fluid indicates internal system contamination.
- Replace brake fluid every 1-2 years if you ride in high-humidity or heavy-use conditions; moisture absorption degrades DOT4 performance over time.
Troubleshooting
- Spongy pedal/lever after bleeding: re-bleed, ensure reservoir never ran dry, check for leaks or compressible hoses; replace soft or swollen hoses.
- Persistent air: use a pressure bleeder or perform the gravity/syringe purge method starting at the highest point in the line and moving downward.
- Brake drag after bleed: check caliper pistons for proper retraction — clean and lubricate piston seals or replace caliper if seized.
Perform this service in a clean, well-lit area and do not rush. Proper brake function is critical to safe operation of your Can-Am Outlander 800 XT. For replacement parts compatible with this model, visit the MotoSport parts page above.
Related Shopping Categories
Shop Brake Fluid for a 2008 Can-Am Outlander 800 XT ATV.
Shop Brake Bleeders for a 2008 Can-Am Outlander 800 XT ATV.
Shop Brake Pads for a 2008 Can-Am Outlander 800 XT ATV.
Shop Brake Lines for a 2008 Can-Am Outlander 800 XT ATV.
Shop Brake Tools for a 2008 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.