How to bleed and replace brake fluid on a 2012 Can-Am Outlander MAX 650 XT ATV

How to Bleed and Replace Brake Fluid on a 2012 Can-Am Outlander MAX 650 XT

Shop parts for a 2012 CAN_AM OLM650XT ATV.

This MotoSport guide shows step-by-step how to properly replace and bleed the brake fluid on a 2012 Can-Am Outlander MAX 650 XT. The MAX 650 XT uses two separate hydraulic circuits: a handlebar front master cylinder that serves the front brakes and a foot-operated rear master cylinder for the rear brake. Treat each circuit independently when flushing and bleeding. Use DOT 4 brake fluid unless you have an aftermarket system specifying otherwise.

Tools & supplies

• DOT 4 brake fluid (fresh, unopened)
• Clear plastic tubing that fits bleeder nipples snugly
• Bleeder bottle or clear container partially filled with fresh brake fluid
• Wrench set (usually 8mm or 10mm for bleeder screws; verify fit)
• Vacuum or pressure brake bleeder (optional but speeds the job)
• Box or open-end wrench for banjo bolts if you need to remove lines
• Clean rag, catch pan, gloves, safety glasses
• Zip ties or clamps to secure tubing

Safety reminders

• Brake fluid is corrosive to paint & plastics – protect painted surfaces and immediately clean spills.
• Work on level ground with the ATV secured; use wheel chocks.
• Never reuse old brake fluid. Keep the reservoir caps closed except when adding fluid to avoid moisture contamination.
• Dispose of old brake fluid according to local hazardous-waste rules.

Preparation

• Warm the ATV by operating it briefly. Warm fluid is less viscous and bleeds easier.
• Locate the master cylinder reservoirs: the front (handlebar) reservoir is on the right handlebar, the rear (foot) reservoir is by the footwell near the rear brake pedal.
• Clean the caps and surrounding area to prevent contamination before opening.
• Remove the reservoir caps and diaphragms; keep the reservoir topped with fresh fluid throughout the procedure to avoid drawing air into the system.

Bleeding order and strategy

Because the Outlander MAX 650 XT has separate master cylinders, bleed each circuit independently: front circuit first, then rear circuit. For each circuit, bleed calipers from the one farthest from its master cylinder to the nearest if multiple calipers are present. Keep the reservoir full the entire time.

Manual (two-person) bleed method

1. Attach clear tubing to the bleeder nipple on the farthest caliper and route into a catch bottle partially filled with clean brake fluid to prevent air from re-entering.
2. Have an assistant slowly pump the brake lever or pedal several times and then hold firm pressure.
3. Open the bleeder screw about 1/4 turn. Dark fluid and air bubbles will flow into the tube. Close the screw before the assistant releases the lever or pedal.
4. Repeat: pump, hold, open, close until only clear fluid with no bubbles comes out.
5. Move to the next caliper (if applicable) and repeat the process, always topping the master reservoir so it never runs low.
6. After the last caliper for that circuit is clear, perform a final sequence of firm lever/pedal tests with the screw closed to check for a firm feel.

Single-person vacuum or pressure bleed method

1. Connect the vacuum pump to the bleeder nipple following the pump manufacturer instructions. If using a pressure bleeder, attach to the master cylinder reservoir per the tool instructions.
2. Open the bleeder screw and operate the vacuum/pressure until fluid runs clear with no bubbles.
3. Close the bleeder screw while maintaining vacuum/pressure, then remove the tool.
4. Repeat for each caliper in the correct order, keeping the reservoir full at all times.

Tips for stubborn air or contaminated fluid

• If air persists, loosen the banjo bolt at the caliper to let trapped air escape, then retighten to spec and re-bleed. Use new copper crush washers when reassembling if the banjo has them.
• If fluid is very dark or contaminated, perform a full system flush: remove old fluid from the reservoir, add fresh fluid, then bleed until clear fluid emerges from every bleeder.
• When reusing bleeder cups or tubing, ensure they are clean. Never siphon fluid back into the reservoir.

Final checks

• Torque bleeder screws and any banjo bolts to manufacturer specs if available; if unknown, snug and avoid over-tightening to prevent stripping.
• Top reservoirs to the correct level and reinstall caps and diaphragms.
• Check brake lever and pedal firmness at rest and under load; brakes should be firm with no sponginess.
• Test ride at low speed in a safe area to confirm effective braking before normal use.

Model-specific notes for the 2012 Can-Am Outlander MAX 650 XT

• The Outlander MAX 650 XT often sees mixed-terrain, wet use. Moisture uptake in brake fluid is a common cause of spongy brakes on this model, so replace fluid every 1-2 years if used in wet/mud conditions.
• The MAX 650 has separate circuits (front handlebar & rear foot) — bleeding one does not purge the other. Always service both circuits for consistent feel.
• Inspect brake lines and hose fittings for wear or cracking at the wheel joints and near the steering linkage; movement and off-road flex can accelerate hose fatigue on this chassis.
• ABS: if your model is equipped with ABS components, avoid applying pressure to ABS modules and follow manufacturer procedures if ABS bleed is required. For non-ABS models, standard bleeding is sufficient.
• Aftermarket calipers or braided lines are common upgrades on these ATVs. If installed, check manufacturer recommendations for bleed procedures and compatible fluid types before servicing.

Maintenance schedule recommendation

• Inspect fluid level and brake operation before every ride.
• Replace brake fluid every 12-24 months depending on use and exposure to water; sooner if performance degrades.

Follow these steps and notes to ensure the braking system on your 2012 Can-Am Outlander MAX 650 XT is bled correctly and safely. If you encounter persistent issues or suspect internal master cylinder or caliper failure, consult a qualified technician.

Related Shopping Categories

Shop Brake Fluid for a 2012 CAN-AM OLM650XT ATV.

Shop Brake Bleeders for a 2012 CAN-AM OLM650XT ATV.

Shop Brake Pads for a 2012 CAN-AM OLM650XT ATV.

Shop Brake Lines for a 2012 CAN-AM OLM650XT ATV.

Shop Brake Tools for a 2012 CAN-AM OLM650XT 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.