How to bleed and replace brake fluid on a 2012 Can-Am DS450

Shop parts for a 2012 Can-Am DS450 ATV.

This MotoSport proprietary guide walks you through a full brake-fluid service on the 2012 Can-Am DS450 – tools, fluid selection, step-by-step bleeding and replacement, model-specific notes, inspection points, and troubleshooting tips. Follow all safety steps and wear eye protection and gloves. Brake fluid is corrosive to paint and rubber.

What youll need

  • DOT 4 brake fluid (fresh, unopened)
  • Clear plastic tubing that fits tightly over bleed nipples
  • Clean catch bottle or jar with a small amount of old fluid to prevent air draw-back
  • Brake bleeder wrench or appropriately-sized open wrench
  • Turkey-baster, syringe, or fluid transfer pump (optional but recommended)
  • Shop rags, brake-clean, and a small brush
  • New crush washers for banjo bolts (recommended) and replacement bleed nipple caps
  • Torque wrench for reinstalling fasteners

Brake fluid & service interval

The DS450 uses DOT 4 brake fluid. Replace fluid every 1-2 years or sooner if exposed to water, heavy use, or contamination. Always use fresh, unopened fluid and never mix DOT 4 with DOT 5 silicone fluid.

Pre-service checks specific to the 2012 Can-Am DS450

  • Park bike on level surface and secure. Turn handlebars straight ahead to access master cylinder reservoirs.
  • Identify master cylinders: front brake lever reservoir (right handlebar) and rear brake pedal reservoir (usually near the frame/engine area).
  • Inspect brake lines for cracks, swelling, or dry-rot. Replace any compromised hoses before bleeding.
  • Inspect calipers and pads for wear – excessive pad wear may require caliper removal for pad replacement before new fluid is installed.
  • Have replacement crush washers for the banjo bolts on the calipers & master cylinder lines; the DS450 commonly uses copper crush washers that should be replaced any time a banjo bolt is disturbed.

Preparation

  • Clean the reservoir caps and surrounding area thoroughly to prevent dirt entry.
  • Remove reservoir caps and diaphragms gently. Keep caps and diaphragms aside on a clean rag.
  • Top reservoirs with fresh DOT 4 fluid to just below the fill mark – do not overfill.
  • Position catch container low so gravity helps when bleeding the calipers.
  • If the bike has ABS or a pressure-modulating unit, consult a dealer – DS450 is typically non-ABS, but verify before aggressive bleeding procedures.

Bleed sequence and method

Perform bleeding in this order: front brake(s) first, then rear. On bikes with multiple front calipers, bleed the caliper furthest from the master cylinder first. For the DS450 single-front setup bleed the front, then the rear.

1. Bench-bleed master reservoir (optional but recommended)

  • Use a syringe or turkey-baster to remove as much old fluid from the reservoir as possible.
  • Refill with fresh DOT 4. Pump the front lever slowly while observing fluid movement; this helps purge large air pockets from the master assembly before opening caliper nipples.

2. Front brake bleeding

  • Fit clear tubing over the caliper bleed nipple; place the other end into the catch bottle partially filled with old fluid to create a liquid seal and prevent air re-entry.
  • Loosen the bleed nipple a half-turn. Do not remove completely.
  • With an assistant, squeeze the front brake lever slowly and hold, open the bleed nipple until fluid flows, then close the nipple. Release the lever. Repeat until fluid leaving the tubing is clear and bubble-free.
  • Keep master reservoir topped during the process so it never goes below the minimum level.
  • Tighten the bleed nipple to spec for that fitting or snug plus a small fraction of a turn; replace and tighten banjo bolt with new crush washers to factory torque if you removed the line.

3. Rear brake bleeding

  • Same process as the front. Fit tubing to the rear caliper bleed nipple and catch fluid. Pump the rear brake pedal while an assistant opens and closes the nipple as fluid runs clear.
  • Some rear reservoirs sit low & may need the motorcycle on the center stand or a service stand so the reservoir is above the caliper level to aid gravity bleeding.

4. Final topping and checks

  • Once both circuits are clear, top reservoirs to the correct level, reinstall diaphragms and caps, and make sure caps are sealed.
  • Clean any spilled fluid from painted surfaces immediately with brake-clean; inspect for leaks at banjo bolts and bleed nipples.
  • Pump the brake lever and pedal several times to build firm pressure before riding. Both should feel firm and not spongy.
  • Test brakes at low speed in a safe area before normal operation.

Torque and hardware notes

  • Replace crush washers on banjo bolts every time the hydraulic line is disturbed. Copper washers deform to seal and once used they may not seal again reliably.
  • Use a calibrated torque wrench for banjo bolts and caliper fasteners where a torque value is available in your service manual. If you do not have a factory torque value, nip fasteners to a firm, even torque and then verify braking function – avoid over-tightening which can strip threads or crush lines.

Common problems and troubleshooting

  • Persistent spongy lever/pedal: repeat bleeding and ensure reservoirs never ran dry; inspect for air ingress points or soft/swollen hoses.
  • Fluid leaks after bleeding: re-check nipple and banjo bolt sealing surfaces and replace crush washers; tighten to proper spec.
  • Brake drag after bleeding: check caliper pistons for proper retraction, pads for binding on pins, and hose routing that may cause pressure if kinked.
  • Discolored or dark fluid immediately after service: indicates contamination; flush again until fluid runs clear.

Disposal and final care

  • Dispose of old brake fluid according to local hazardous-waste regulations. Do not pour down drains.
  • Record date and mileage of service in maintenance log. Recommend next replacement interval at 12-24 months depending on use and environment.

Model-specific reminders for the 2012 Can-Am DS450 owner

  • DS450 hydraulic fittings can be accessed with the handlebars straight and bike on a center or rear stand; this improves reservoir orientation for bleeding.
  • Watch for fuel-line routing and plastics near the rear master reservoir when working near the frame; fluid spills will damage plastic and paint.
  • The DS450 uses compact master-cylinder reservoirs – keep fluid level monitored carefully during bleeding to avoid introducing air.
  • If your bike has aftermarket handlebars or lever guards, ensure lever travel is unobstructed during bleeding and testing.

Performing a proper brake-fluid replacement and bleed restores brake performance and safety. If you encounter stubborn air, persistent leaks, or ABS-related concerns, consult a qualified technician or MotoSport service pros.

Related Shopping Categories

Shop Brake Fluid for a 2012 Can-Am DS450 ATV.

Shop Brake Bleeders for a 2012 Can-Am DS450 ATV.

Shop Brake Pads for a 2012 Can-Am DS450 ATV.

Shop Brake Lines for a 2012 Can-Am DS450 ATV.

Shop Brake Tools for a 2012 Can-Am DS450 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.