How to bleed and replace brake fluid on a 2008 Can-Am Outlander MAX 800
Shop parts for a 2008 Can-Am Outlander MAX 800 ATV.
This MotoSport proprietary guide walks you through safely flushing and bleeding the hydraulic brakes on a 2008 Can-Am Outlander MAX 800 (OLM800). Follow every step carefully, use fresh DOT-specified fluid, and perform a full inspection while you have the system open.
What you need
- DOT 4 brake fluid (do not mix DOT 3/4/5 incompatibly & follow your reservoir cap label)
- Clear plastic tubing that fits bleeder screws
- Catch bottle for old fluid
- Brake bleeder or vacuum pump (optional but speeds the job)
- Wrenches for bleeder screws and banjo bolts (usually 8-12 mm)
- Torque wrench (for re-torquing banjo bolts & caliper hardware)
- Shop rags, gloves, eye protection
- Cotton-free swabs and brake cleaner for cleanup
Model-specific notes for the 2008 Outlander MAX 800
- The OLM800 commonly uses DOT 4 fluid; confirm on the master cylinder cap label before starting.
- Many 2008 Outlander models are non-ABS; if your machine has ABS or an electronic brake module, follow manufacturer procedures for that system and avoid bench-bleeding electronic units unless you have the correct scan/bleed tool.
- Brake reservoirs may be separate for front and rear or combined depending on your trim; identify both reservoirs and keep them topped off during the procedure.
- Replace crush washers on banjo fittings whenever you disturb them to prevent leaks.
- The Outlander MAX has longer brake lines for the two-up configuration &ndash check lines for abrasion where they pass under racks and seats.
- Parking brake components are rear-mounted; inspect cable condition and adjust after bleeding if necessary.
Preparation
- Park on level ground, engine off, ignition key removed. Secure machine with block or lift so wheels can turn freely.
- Clean around reservoir caps before opening to prevent contamination. Remove caps and diaphragms; cover openings with clean shop towels to limit dust ingress.
- Inspect hoses, calipers, master cylinder, and bleeder screws for damage or corrosion. Replace damaged parts before bleeding.
- Have fresh DOT 4 fluid ready. Never reuse old fluid or top off with a different DOT family.
Bleed sequence overview
Use a logical sequence that starts at the caliper farthest from the master cylinder and works toward the closest. On many Outlander MAX layouts this general order works well:
- Rear caliper furthest from the master (usually passenger-side rear)
- Other rear caliper
- Front caliper furthest from master
- Other front caliper (closest to master)
If you have a combined reservoir that serves both front & rear, still keep the reservoir topped up at all times during bleeding.
Manual (pressure-free) bleeding method
- Attach clear tubing to the bleeder screw and route to a catch bottle partially filled with a little fresh brake fluid to avoid drawing air back in.
- Open the bleeder screw about a 1/4 turn. Do not remove it completely.
- Have an assistant slowly pump the brake lever or pedal several times and then hold pressure.
- With pressure held, open the bleeder to let fluid and air escape into the tubing, then close the bleeder before the assistant releases the lever/pedal. Repeat until only clear fluid with no bubbles flows.
- Keep reservoir level well above the minimum during the whole process to avoid sucking air into the master cylinder.
- Move to the next caliper in the sequence and repeat.
- After all calipers are bled, check lever/pedal firmness. If spongy, repeat the sequence or consider a two-person rapid-bleed or vacuum bleeder.
Vacuum or pressure bleeder method (recommended for convenience)
- Connect a vacuum pump to the bleeder screw or use a pressure bleeder on the reservoir per tool instructions.
- Open bleeder and draw until fluid runs clear and bubble-free, then close bleeder.
- Work through calipers in the same far-to-near order, keeping reservoir topped.
Special tips & maintenance actions while bleeding
- Replace banjo crush washers when you loosen hydraulic fittings. Torque banjo bolts to OEM spec in the manual after reassembly.
- If a bleeder screw is stuck, soak with corrosion penetrant, be prepared to replace it if rounding occurs.
- Inspect pads and rotors while calipers are off &ndash check pad thickness, rotor wear and runout.
- After bleeding, clean any spilled fluid immediately &ndash brake fluid damages paint and plastics.
- Dispose of old fluid per local hazardous waste rules.
Final checks
- Ensure all bleeder screws are closed and torqued appropriately. Refit reservoir diaphragms & caps securely.
- Test brake lever/pedal for firm, consistent feel before riding. With machine stationary, apply brakes repeatedly to confirm pressure holds and no leaks appear.
- Perform a cautious low-speed test ride in a safe area, applying brakes multiple times to bed components and confirm performance.
- Re-check fluid level after initial test ride and after a short break-in period.
Common issues and troubleshooting
- Persistent spongy feel: likely residual air; repeat bleed or use reverse/pressure bleeding method.
- Leaking at banjo bolt: replace crush washers & torque correctly.
- Contaminated/dirty fluid: full system flush required until fluid runs clear.
- If ABS or an electronic unit is present: follow factory procedures; some systems require cycling with diagnostic tools.
Perform brake fluid replacement and bleeding on a regular maintenance schedule and after any brake-line or caliper service. If you encounter damaged components, uncertain torque specs, or an ABS issue, consult a factory service manual or a trained technician.
Related Shopping Categories
Shop Brake Fluid for a 2008 Can-Am Outlander MAX 800 ATV.
Shop Brake Bleeders for a 2008 Can-Am Outlander MAX 800 ATV.
Shop Brake Pads for a 2008 Can-Am Outlander MAX 800 ATV.
Shop Brake Lines for a 2008 Can-Am Outlander MAX 800 ATV.
Shop Brake Tools for a 2008 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.