How to Bleed & Replace Brake Fluid on a 2010 Can-Am Outlander 800R XT

Shop parts for a 2010 Can-Am Outlander 800R XT ATV.

This MotoSport procedural guide walks you through safely replacing the brake fluid and bleeding the brakes on a 2010 Can-Am Outlander 800R XT (MMY: CAN_AM;OL800RXT;2010). Follow the steps exactly, use proper PPE, and keep the work area clean to avoid contamination of the braking system.

What you’ll need

  • DOT 4 brake fluid (new, sealed container)
  • Clear hose that fits bleed nipples
  • Catch bottle or container
  • Brake-bleeder syringe or hand pump (recommended)
  • Wrenches to fit bleed nipples (usually 8 mm)
  • Clean rags and isopropyl alcohol
  • Torque wrench (for caliper hardware if removed)
  • Gloves & eye protection
  • Jack or ramps and stands (ATV stabilized on level surface)

Safety & model notes

  • Brake fluid is hygroscopic and corrosive to paint & rubber. Avoid spills; clean immediately with water & soap.
  • 2010 Outlander 800R XT typically uses DOT 4. Confirm by checking the master cylinder cap markings before starting.
  • If your machine is equipped with an electrical parking-brake or ABS-style module, consult a dealer; this guide assumes a standard hydraulic system without electronic brake modulation.
  • MotoSport recommends replacing fluid every 12 months or sooner if fluid is dark or contaminated.

Preparation

  1. Park ATV on level ground, engage park/gear, and secure so it cannot roll. Remove front storage panel if needed to access master cylinder.
  2. Clean the master-cylinder cap area to prevent dirt entering the reservoir when opened.
  3. Remove the master-cylinder cap and diaphragm; note fluid level and color. If fluid is very dark, proceed with full flush.
  4. Identify the bleed nipples on each caliper. On the Outlander 800R XT you’ll have a front dual-caliper setup and a rear caliper(s) depending on configuration — treat each caliper individually.

Bleeding order principle

Always bleed from the caliper farthest from the master cylinder first, progressing to the nearest. If unsure which is farthest, use the standard approach: rear passenger (farthest), rear driver, front right, front left (closest), or simply identify the longest hydraulic line and use that caliper first. The key rule: farthest to nearest to avoid trapping air.

Replace fluid & bleed step-by-step

  1. Top up master reservoir with DOT 4 brake fluid to the MAX line. Keep the cap loosely in place to limit contamination.
  2. Start at the farthest caliper. Attach clear hose to bleed nipple and place other end in a catch bottle partially filled with fresh fluid to prevent air being drawn back.
  3. Have an assistant slowly pump the brake lever/pedal several times and hold it down. With lever/pedal held, open the bleed nipple about 1/4 turn to allow fluid & air out. Close the nipple before the assistant releases the lever. Repeat until clear, bubble-free fluid emerges.
  4. After every few cycles, check and top the master reservoir to keep it from running dry. Never let it empty while any line is open.
  5. Tighten bleed nipple to snug after finishing each caliper. Do not overtighten; typically 8 mm wrench fit should be firm. Clean any spilled fluid immediately.
  6. Move to the next caliper following the far-to-near order and repeat the process until all calipers show clear fluid with no air bubbles.
  7. For a more thorough flush, use a brake-bleeder syringe or pressure/vacuum bleeder: connect to reservoir, push new fluid through system until old fluid is fully replaced and clear at each caliper.
  8. When finished, top reservoir to the MAX mark, reinstall cap & diaphragm, and clean all components.

Final checks & break-in

  • With ATV on stands, press the brake lever/pedal several times to confirm a firm, consistent feel. If spongy, re-bleed the affected circuit.
  • Check for leaks at bleed nipples, caliper fittings, and hose connections after pumping and after a short test ride.
  • Dispose of old brake fluid per local hazardous-waste rules; do not pour down drains.
  • Perform a controlled low-speed test ride to bed the brakes. Avoid hard braking for the first few miles while pads & rotors seat.

Maintenance tips specific to the 2010 Outlander 800R XT

  • Stock brake hoses on 2010 models can harden with age. Inspect flex hoses for cracks, swelling, or bulging during the service; replace if any deterioration is found.
  • Caliper pistons can corrode if fluid has been neglected. If caliper pistons are sticky or don’t return smoothly, remove and service or replace calipers to prevent uneven pad wear.
  • Master-cylinder reservoir plastic can become brittle. Check for hairline cracks around the cap and base — replace the reservoir assembly if found to avoid sudden leaks.
  • MotoSport recommends replacing rubber seals and washers on bleed nipples when the system is opened for a full flush to ensure leak-free service.
  • If your Outlander shows intermittent low brake lever travel after bleeding, suspect air trapped in ABS or internal lines — professional inspection is advised.

Troubleshooting

  • If a caliper continues to eject air: inspect for a cracked hose or loose banjo fitting. Replace any suspect hydraulic components.
  • If the lever/pedal remains soft after proper bleeding: re-check the reservoir level, and consider bench-bleeding a replacement master cylinder if internal seals are compromised.
  • If brakes grab excessively after new fluid: ensure pads are properly bedded and that rotors & pads are clean and free of fluid contamination.

Following this MotoSport procedure will restore a clean hydraulic system and reliable brake performance on your 2010 Can-Am Outlander 800R XT. When in doubt or if the system includes electronic brake components, consult a qualified technician or your dealership for model-specific diagnostics.

Related Shopping Categories

Shop Brake Fluid for a 2010 Can-Am Outlander 800R XT ATV.

Shop Brake Bleeders for a 2010 Can-Am Outlander 800R XT ATV.

Shop Brake Pads for a 2010 Can-Am Outlander 800R XT ATV.

Shop Brake Lines for a 2010 Can-Am Outlander 800R XT ATV.

Shop Brake Tools for a 2010 Can-Am Outlander 800R 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.