MotoSport Guide: How to Bleed & Replace Brake Fluid on a 2015 Can-Am Outlander 650

Shop parts for a 2015 Can-Am Outlander 650 ATV.

This MotoSport-exclusive procedure walks you through safely replacing and bleeding the brake fluid on a 2015 Can-Am Outlander 650. Follow each step carefully, wear eye protection, and avoid contaminating brake components with oil or grease.

What you’ll need

  • DOT 4 brake fluid (fresh, unopened)
  • Clear plastic tubing that fits snugly over bleed nipples
  • Catch bottle for old fluid
  • Brake bleeder kit or vacuum pump (optional but speeds work)
  • Socket set, wrench set, torque wrench
  • Clean rags, shop towels, rubber gloves
  • Replacement crush washers for banjo bolts (recommended)
  • Service manual or repair torque specs for clamp/banjo bolts

Safety & prep

  • Work on a level surface with the engine off and key removed.
  • Support the Outlander so wheels can spin freely for front caliper bleeding.
  • Protect painted surfaces from spilled fluid – brake fluid will damage paint.
  • Keep reservoir caps clean; remove caps slowly to prevent debris falling in.

Model-specific notes for the 2015 Can-Am Outlander 650

  • The Outlander 650 uses handlebar-mounted master cylinder for the front brakes and a foot pedal master/linked rear system depending on trim. Confirm which brake actuates each caliper on your unit before starting.
  • Some 2015 models may be equipped with a combined braking system (linked / ABS variants are rare on this year/model). If your unit has ABS or an electronic brake assist module, consult the service manual before pressure-bleeding & do not power-cycle the ABS pump without manufacturer procedure.
  • Banjo bolt and fitting locations are cramped – replacing crush washers at the banjo bolt seals is cheap insurance against leaks.
  • Store used fluid and contaminated rags properly — do not pour brake fluid down drains.

Step-by-step: Replace & bleed brake fluid

1. Remove old fluid from reservoir

  • Locate front master cylinder reservoir (handlebar area) and rear reservoir (under rear rack or near foot pedal, depending on model).
  • Clean the reservoir caps and surrounding area, then remove caps and diaphragms to prevent contamination.
  • Siphon old fluid into a waste container until level is low. Do not reuse old fluid.

2. Fill with fresh DOT 4

  • Top up the reservoirs with fresh DOT 4 fluid to the fill mark. Keep the cap loosely installed to minimize air entry while working.

3. Determine bleed sequence

  • Bleed the calipers starting with the wheel farthest from the master cylinder and move to the nearest. For most Outlander setups this generally means: right front, left front, then rear (confirm by tracing the brake lines on your machine).

4. Crack bleed nipple, attach tubing

  • Place clear tubing over the bleed nipple of the caliper and route into a catch bottle partially filled with used fluid to prevent air suck-back.
  • Loosen the nipple one half-turn only to prevent damage, or follow your bleeder tool instructions.

5. Pump or vacuum-bleed

  • Manual method: Have an assistant slowly squeeze the lever or pedal to build pressure, hold it, open the bleed nipple to expel fluid and air, then close the nipple before the lever/pedal is released. Repeat until clear fluid without bubbles appears. Keep reservoir topped between cycles.
  • Vacuum/pressure bleeder: Attach device and draw fluid through until clear, maintaining reservoir level. If using a pressure bleeder on the reservoir, use low pressure and monitor ABS warnings if equipped.

6. Replace crush washers & torque banjo bolts

  • Whenever you disconnect lines, replace the copper crush washers at banjo fittings. Tighten banjo bolts to the factory torque spec listed in the service manual. If you don’t have the manual, torque carefully — do not over-tighten.

7. Final checks

  • Ensure bleed nipples are closed tight and reservoirs are filled to the proper level. Reinstall diaphragms and caps securely.
  • Operate the lever and pedal several times to confirm firm, consistent feel. If you notice a spongy lever, repeat bleeding until firmness is achieved.
  • Check all lines, fittings, and calipers for leaks after a short test ride at low speed. Re-check fluid level and top as required.

Troubleshooting & tips

  • Persistent sponginess usually means remaining air or a leak. Inspect hose ends, fitting threads, and banjo bolts for seepage.
  • If uneven pressure between sides occurs, bleed that circuit again and inspect the caliper piston condition — seized pistons can mimic hydraulic problems.
  • If your Outlander has an ABS pumping module, cycle the ignition and apply the brakes per service instructions to allow the module to purge air pockets if the manufacturer specifies it.
  • Always use fresh DOT 4 fluid. Mixing fluid types degrades performance and can damage seals.

Maintenance interval

MotoSport recommends replacing brake fluid every 2 years or sooner if fluid appears dark or contaminated. Regular fluid changes protect internal seals and ensure reliable stopping power.

Final note

When in doubt, consult the Can-Am service manual for exact torque specs and any ABS-specific procedures for the 2015 Outlander 650. If you prefer, MotoSport parts and service accessories are available to help with the job.

Related Shopping Categories

Shop Brake Fluid for a 2015 Can-Am Outlander 650 ATV.

Shop Brake Bleeders for a 2015 Can-Am Outlander 650 ATV.

Shop Brake Pads for a 2015 Can-Am Outlander 650 ATV.

Shop Brake Lines for a 2015 Can-Am Outlander 650 ATV.

Shop Brake Tools for a 2015 Can-Am Outlander 650 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.