How to bleed and replace brake fluid on a 2012 Can-Am Outlander MAX 500
Shop parts for a 2012 Can-Am Outlander MAX 500 ATV.
Tools & supplies you need:
- DOT 4 brake fluid (do not mix DOT 3 & DOT 5)
- clear plastic tubing and catch bottle
- bleeder wrench set (metric), flare-nut or box-end style
- handheld vacuum/pressure bleeder or syringe (optional)
- clean rags, gloves, safety glasses
- jack or ramps and stands to safely support the machine
- shop manual or notes for valve locations and recommended procedures
Model-specific notes for the 2012 Can-Am Outlander MAX 500 (MMY OLM500):
- The Outlander MAX 500 uses hydraulic disc brakes with separate master cylinders for the handlebar (front) and foot lever (rear). Each reservoir must be serviced independently.
- Factory systems typically specify DOT 4 fluid; confirm the reservoir cap label before beginning. Do not introduce DOT 5 (silicone) fluid.
- There is no rider-facing ABS module on most 2012 Outlander 500 models, but hydraulic proportioning or combined braking features may be present. If your unit has a brake pressure sensor or electronic module, consult the service manual before using a pressure bleeder.
- Brake line fittings and bleeder screws are metric. If a fitting is seized, apply penetrating oil and use proper-size wrenches to avoid rounding.
Preparation
- Park on level ground, engage parking brake, remove the key, and disconnect the battery negative terminal if you will be working near electronics.
- Lift & securely support the front and/or rear of the ATV so wheels can turn or hang freely if the procedure requires pumping the calipers.
- Clean the reservoir caps & surrounding area to prevent contamination. Remove the caps and diaphragm; expose the brake fluid level but don't let dirt fall in.
- Inspect brake lines, hoses, calipers, and pads for wear or leaks. Replace worn parts before bleeding fluid.
General bleeding principle
Always keep the master cylinder reservoir topped with fresh DOT 4 fluid during the entire bleed to avoid introducing air. Work from the caliper farthest from the master cylinder toward the closest caliper. For each circuit (front handlebar circuit and rear foot circuit), follow the furthest-first sequence.
Recommended bleed sequence (typical for quad with separate front & rear masters)
- Rear master (foot lever) circuit: bleed the rear caliper first (furthest from the rear master if there are multiple rear calipers), then any secondary rear caliper.
- Front master (handlebar) circuit: bleed the front calipers starting with the caliper farthest from the handlebar master cylinder, then the next closest.
- If your MAX 500 has dual front calipers on each side or a combined system, identify the correct order by tracing the brake line from the master cylinder.
Step-by-step bleed using manual pump or syringe method
- Place clear tubing over the caliper bleeder screw; submerge the other end in a small catch bottle partially filled with old fluid. This prevents air from being drawn back in.
- Open the bleeder screw about 1/4 turn. Do not remove it completely.
- Have an assistant slowly pull the brake lever or press the foot pedal until firm pressure is felt, then hold it. For hand lever front master, you can use a lever clamp to hold position between pumps if bleeding single-handedly.
- While the lever/pedal is held, open the bleeder screw slightly to allow fluid and air to flow into the tubing. Close the bleeder before the lever/pedal is released.
- Repeat pump/open/close cycles until clear, bubble-free fluid exits and you see no air in the tubing. Keep reservoir topped with fresh DOT 4 fluid throughout.
- Torque bleeder screws snugly when finished; wipe off any spilled fluid immediately. Brake fluid can damage paint and plastics.
Step-by-step bleed using a vacuum or pressure bleeder
- Follow the bleeder tool manufacturer instructions. If using a vacuum hand pump, attach tubing to the bleeder screw and draw until fluid flows cleanly without bubbles.
- If using a pressure bleeder on the master cylinder reservoir, set pressure low and open each caliper bleeder in the same far-to-near order until fluid runs clear. Do not over-pressurize the system.
- Monitor reservoir level carefully and do not allow it to run dry.
Flushing and replacing all fluid
- To fully replace old fluid, repeat bleeding until the fluid exiting the bleeders matches the fresh fluid color. It may take several reservoir refills to completely purge old fluid.
- Dispose of old brake fluid per local hazardous-waste regulations.
Post-bleed checks
- With the ATV on stands, apply the brake forcefully to confirm a firm pedal/lever feel and no movement in lever free-play beyond specs.
- Check for leaks at reservoir, lines, banjo bolts, and bleeder screws after pressurizing the system.
- Reinstall reservoir caps and diaphragms, reconnect the battery if disconnected, and test brakes at low speed in a safe area before normal riding.
Safety & maintenance tips
- Brake fluid is hygroscopic — it absorbs moisture over time. Replace fluid every 1-2 years or per the service schedule to prevent corrosion and boiling under heavy use.
- If the brake lever/pedal never firms up or you get a soft spongy feel after multiple bleeds, inspect master cylinders, calipers, and lines for internal seals or collapsed hoses that may require replacement.
- Use only DOT-specified fluid. Mixing different types (DOT 3/DOT 4 are compatible; DOT 5 is not) can damage the system.
- If any bleeder screw or fitting is rounded, replace it. Never apply excessive heat or force to stuck bleeders without proper tools and technique.
Final reminder
For any uncertainty about braking-system repairs on the 2012 Can-Am Outlander MAX 500, refer to the factory service manual or contact a certified technician. Proper braking function is critical to your safety.
Related Shopping Categories
Shop Brake Fluid for a 2012 Can-Am Outlander MAX 500 ATV.
Shop Brake Bleeders for a 2012 Can-Am Outlander MAX 500 ATV.
Shop Brake Pads for a 2012 Can-Am Outlander MAX 500 ATV.
Shop Brake Lines for a 2012 Can-Am Outlander MAX 500 ATV.
Shop Brake Tools for a 2012 Can-Am Outlander MAX 500 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.