How to Bleed and Replace Brake Fluid on a 2012 Can-Am Outlander 800R XT

Shop parts for a 2012 Can-Am Outlander 800R XT ATV.

This MotoSport guide walks you through a complete, safe brake fluid replacement and bleeding procedure tailored for the 2012 Can-Am Outlander 800R XT (MMY CAN_AM;OL800RXT;2012). Follow these steps to restore braking performance, protect hydraulic components, and avoid contamination. Read all steps before starting and work in a well-ventilated, clean area.

What you need

  • DOT 4 brake fluid (fresh, high-quality)
  • Brake bleeder kit or clear tubing and a catch bottle
  • Turkey baster or fluid siphon
  • Clean funnel and gloves
  • Shop rags and brake-clean spray
  • 10 mm and 8 mm wrenches (bleeder and banjo/line bolts may vary)
  • Torque wrench (recommended)
  • Jack and stands or ramps to support the ATV safely
  • Assistant (recommended) or a vacuum/pressure bleeder

Model-specific notes for the 2012 Outlander 800R XT

  • The Outlander 800R XT uses a hydraulic disc brake system with separate front and rear calipers. Many units are non-ABS; if your machine has ABS components, follow manufacturer guidance for ABS module bleeding or use a diagnostic tool to cycle the pump while bleeding.
  • Front calipers are conventional twin-piston units mounted on the lower fork legs. Rear caliper is mounted on the swingarm. Bleeder nipples are accessible but may require clearing of dirt and protective caps.
  • Banjo bolts for brake lines often use crush washers. Replace crush washers whenever removing the banjo fitting to avoid leaks.
  • Brake line routing on the XT model includes protective sleeves near pivot points. Inspect lines for abrasion, cracking, or swelling while replacing fluid.
  • Typical system fluid capacity is small per circuit; plan to change all fluid in the system by flushing each caliper and the master cylinder reservoir.

Safety first

  • Park on level ground, engage parking brake, and block wheels. Securely support the ATV with recommended stands.
  • Brake fluid damages paint and plastics. Wipe spills immediately and use catch containers.
  • DOT brake fluid is hygroscopic. Never reuse drained fluid or top up from partially used containers.

Step 1 Prepare the machine

  • Clean around the master cylinder reservoir cap and bleeder nipples to prevent contamination.
  • Raise wheels as needed for access. Remove wheels only if necessary to access calipers safely.
  • Open the reservoir cap and remove the diaphragm/cover. Use a clean funnel to prevent dirt ingress.
  • If the fluid is dark or contaminated, use a turkey baster to remove most old fluid from the reservoir before topping with fresh DOT 4.

Step 2 Bleeding order

Bleed farthest caliper from the master cylinder first, then move to the nearest. On most Outlander layouts the common sequence is:

  • Rear caliper (farthest)
  • Front passenger-side caliper
  • Front driver-side caliper (closest)

Step 3 Manual two-person bleed (recommended)

  1. Have your assistant slowly depress the brake lever/pedal several times and hold it down (do not pump).
  2. Open the bleeder nipple at the selected caliper about a 1/4 turn with a wrench. Attach clear tubing to capture fluid into a bottle partially filled with some fresh fluid to avoid drawing air back in.
  3. Allow fluid and air to flow until the stream is steady and free of bubbles, then close the bleeder while the lever/pedal is still held down.
  4. Release the lever/pedal and top up the master reservoir immediately. Repeat at the same caliper until no air appears, then move to the next caliper following the bleed sequence.
  5. Never let the reservoir level drop below the minimum while bleeding; topping up prevents air entry to the master cylinder.

Step 4 One-person vacuum or pressure bleeding

  • Attach a vacuum bleeder to each bleeder in sequence or use a pressure bleeder on the reservoir per tool instructions.
  • Operate the tool to draw fluid through each caliper until clear fluid flows with no bubbles, following the bleed order described earlier.

Step 5 Master cylinder flushing

  • Once all calipers are bled, cycle the lever/pedal and open the reservoir to allow fresh fluid to displace any remaining old fluid in the master cylinder. Drain until the outgoing fluid is clear.
  • Top the reservoir to the correct level, reinstall the diaphragm and cap, and secure it.

Step 6 Final checks

  • Torque banjo bolts and line fittings to the recommended tightness for your replacement parts; replace crush washers if removed. If you don't have exact torque specs on hand, tighten to a snug, manufacturer-recommended setting and verify there are no leaks during testing.
  • Clean all fluid residue and inspect for leaks while an assistant applies and holds the brakes at various pressures.
  • Verify firm lever/pedal feel. If spongy, re-bleed until firm.
  • Test ride at low speed in a safe area to confirm braking performance before normal use.

Maintenance intervals & best practices

  • Replace brake fluid every 1-2 years or sooner if contaminated or if you operate the ATV in wet / harsh conditions.
  • Inspect lines, fittings, calipers, pads, and rotors whenever changing fluid. Replace worn pads and damaged lines immediately.
  • Store brake fluid sealed and discard any fluid that becomes cloudy or discolored.

Troubleshooting

  • Persistent spongy brakes: repeat bleeding, inspect reservoir for contamination, and check for compressible components (old hoses or damaged seals).
  • Fluid leaks: tighten fittings, replace crush washers, or replace damaged hoses/calipers.
  • ABS-equipped unit issues: if equipped, follow the ABS system bleeding procedure specific to the unit (cycle pump via diagnostic tool if required) or consult a dealer if ABS cannot be purged of air.

Following this MotoSport-specific procedure ensures a complete brake fluid replacement and reliable bleeding for the 2012 Can-Am Outlander 800R XT. If you're unsure about ABS procedures, torque specs, or spot a hydraulic component failure, have a certified technician inspect the system.

Related Shopping Categories

Shop Brake Fluid for a 2012 Can-Am Outlander 800R XT ATV.

Shop Brake Bleeders for a 2012 Can-Am Outlander 800R XT ATV.

Shop Brake Pads for a 2012 Can-Am Outlander 800R XT ATV.

Shop Brake Lines for a 2012 Can-Am Outlander 800R XT ATV.

Shop Brake Tools for a 2012 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.