How to Bleed and Replace Brake Fluid on a 2010 Can-Am Outlander 650

Shop parts for a 2010 Can-Am Outlander 650 ATV.

This MotoSport guide gives step-by-step, model-specific instructions to safely replace and bleed brake fluid on a 2010 Can-Am Outlander 650 (OL650). Follow all safety precautions, use the specified fluid, and perform the procedure on a clean, level surface. This guide is proprietary to MotoSport and tailored for the OL650 owner.

What you need

  • DOT 4 brake fluid (new, unopened bottle)
  • Clear 1/4" vinyl tubing
  • Brake bleeder wrench or appropriate spanner
  • Small catch bottles or jars
  • Turkey baster or fluid transfer syringe
  • Clean lint-free rags and isopropyl alcohol
  • Gloves and safety glasses
  • Floor jack or ATV stand, wheel chocks
  • Assistant (recommended) or a one-person vacuum/pressure bleeder

Model notes — 2010 Can-Am Outlander 650

  • The OL650 uses hydraulic disc brakes front and rear; the front lever has its own master cylinder on the handlebars and the rear brake uses a foot-operated master cylinder. Bleed each system separately.
  • Factory systems are designed for DOT 4 fluid. Do not mix DOT 3, DOT 4 & DOT 5 (silicone) incorrectly; use DOT 4 unless you have an aftermarket recommendation to change.
  • If your OL650 is equipped with ABS or an electronic brake control option, consult MotoSport or your service manual before pressure-bleeding to avoid damaging ABS components. Many 2010 models are non-ABS; if in doubt, inspect the brake lines for ABS modulators.
  • Brake line routing on the OL650 exposes hoses to mud and rock chips. Inspect for cuts, swelling, or corrosion at banjo fittings; replace damaged lines rather than just bleeding.
  • Caliper and banjo bolt threads on the OL650 are soft aluminum or steel; use correct-sized tools and avoid rounding fittings. Apply new crush washers at banjo fittings when reinstalling.

Preparation

  • Park on level ground, chock wheels, and remove ignition key. Allow brakes to cool.
  • Raise the ATV with a stand to access wheels if needed. Remove wheel if you need better access to bleed nipples.
  • Clean master cylinder reservoirs, caps, and surrounding area to prevent contamination when opening.
  • Top up each reservoir with DOT 4 before starting; do not let reservoirs run dry during bleeding.

General bleeding principles

  • Always keep the master cylinder reservoir at least partially full to avoid drawing air into the system.
  • Start bleeding at the caliper farthest from the master cylinder, then move closer. For each master cylinder bleed the sequence is typically: rear-most caliper > next furthest > closest.
  • Work one system at a time: handlebar/front lever system first, then the rear/foot system.

Step-by-step — Front brake (handlebar lever) system

  1. Remove the master cylinder cap, diaphragm, and reservoir insert. Clean around the cap first.
  2. Attach clear tubing to the front caliper bleed nipple; submerge the far end in a jar partially filled with fresh DOT 4 to prevent air re-entry.
  3. Have an assistant slowly pull the front brake lever several times and hold it in. Open the caliper bleed nipple a 1/4 turn until fluid and air bubbles flow into the tubing. Close nipple, then instruct the assistant to release the lever. Repeat until no air bubbles appear and fluid runs clear.
  4. Top the master cylinder reservoir as fluid level drops. Never let it run dry mid-process.
  5. Once clear, tighten the bleed nipple to spec snug (avoid overtightening). Replace reservoir diaphragm and cap.
  6. Wipe any spilled fluid off painted/plastic surfaces immediately with water & isopropyl alcohol. DOT fluid will damage paint and plastics.

Step-by-step — Rear brake (foot master cylinder) system

  1. Locate the rear master cylinder reservoir near the foot lever; clean the cap area and open the reservoir.
  2. Attach tubing to the rear caliper bleed nipple and submerge the end in clean DOT 4 in a jar.
  3. If you have an assistant, pump the foot brake pedal several times and hold. Open the caliper bleed nipple until fluid and air exit, close it, and allow pedal to return. Repeat until clear fluid appears with no bubbles.
  4. If working alone, use a vacuum bleeder or a syringe to pull fluid through from the caliper to the jar while keeping the reservoir topped up.
  5. When complete, tighten nipple, clean all fluid remnants, and reassemble reservoir cap.

Full fluid replacement (flush) procedure

  1. Perform bleeding per-system as above, but continue until old fluid is fully replaced with new DOT 4 and runs clear at each bleed nipple.
  2. If severe contamination or moisture is suspected (dark fluid, poor pedal feel), repeat a second flush cycle to ensure system purity.
  3. After final bleeding, pump brakes to build pressure, check pedal/lever firmness, and inspect for leaks at calipers, hoses, and banjo bolts.

Post-service checks

  • Lower the ATV, remount wheels if removed, torque wheel and caliper fasteners to factory specs (refer to your service manual or contact MotoSport for spec values).
  • Test brakes at low speed in a safe area before riding normally. Confirm firm lever and pedal feel with no sponginess.
  • Dispose of old brake fluid per local regulations; don't pour down drains or on ground.

Troubleshooting & tips

  • Persistent soft pedal/lever after thorough bleeding can indicate caliper piston seal issues, collapsing hose, or contamination in master cylinderinspect and rebuild or replace components as needed.
  • If you encounter stuck caliper pistons, a careful piston retraction using proper tools and cleaning will help before reassembly.
  • Replace crush washers whenever banjo bolts are removed. Reuse of old washers can leak.
  • Keep DOT 4 fresh; brake fluid is hygroscopic and absorbs moisture over time, degrading performance. Replace every 1-2 years depending on use and storage.

For OEM and aftermarket replacement components, brakes hardware, master cylinder rebuild kits, hoses, and DOT 4 fluid specific to your 2010 Can-Am Outlander 650, MotoSport stocks the parts you need to complete this job reliably.

Related Shopping Categories

Shop Brake Fluid for a 2010 Can-Am Outlander 650 ATV.

Shop Brake Bleeders for a 2010 Can-Am Outlander 650 ATV.

Shop Brake Pads for a 2010 Can-Am Outlander 650 ATV.

Shop Brake Lines for a 2010 Can-Am Outlander 650 ATV.

Shop Brake Tools for a 2010 Can-Am Outlander 650 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.