How to Bleed & Replace Brake Fluid on a 2015 Can-Am Outlander MAX 800R DPS

Shop parts for a 2015 Can-Am Outlander MAX 800R DPS ATV.

This quick, MotoSport-proprietary guide walks you through safely flushing and bleeding the hydraulic brakes on a 2015 Can-Am Outlander MAX 800R DPS. Follow all safety cautions, use the correct fluid, and keep the reservoir capped to prevent contamination. If you’re unsure at any step, stop and contact a qualified technician.

What you need

  • DOT 4 brake fluid (fresh, unopened)
  • Clear hose to fit bleeder nipples
  • Small catch bottle or jar
  • Brake-fluid syringe or vacuum bleeder or pressure bleeder
  • Clean rags and isopropyl alcohol
  • Box wrench set (sized for bleeder nipples and banjo bolts)
  • Torque wrench (recommended for banjo bolts)
  • Gloves and eye protection
  • Service manual or a phone with the model page for torque specs & sequence (keep nearby)

Important model notes for the 2015 Outlander MAX 800R DPS

  • The 800R MAX has Dynamic Power Steering (DPS). DPS electronics can be sensitive to low battery voltage – keep the battery charged during long bleeding sessions to avoid loss of assist.
  • This model typically uses DOT 4 hydraulic fluid. Do not mix with DOT 5 (silicone) fluids.
  • Use new copper crush washers when removing banjo bolts on calipers to prevent leaks.
  • If you notice spongy brakes after bleeding, check master-cylinder seals, caliper pistons, and flexible hoses for internal collapse or contamination — these are common failure points on higher-mileage machines.

Safety first

  • Work on a flat, stable surface; chock rear wheels.
  • Wear gloves & eye protection. Brake fluid damages paint & plastics; wipe spills immediately with isopropyl alcohol.
  • Never reuse drained brake fluid.

Step-by-step bleed & fluid replacement

1. Prep

  • Park ATV on level ground and switch engine off. Remove seat or panel to access the brake master-cylinder reservoir. Clean around cap before opening to keep contaminants out.
  • Remove reservoir cap and diaphragm; cover with a clean rag to minimize dirt entry.
  • Top the reservoir with fresh DOT 4 fluid to the fill line. Do not overfill.

2. Decide bleeding method

  • Vacuum or pressure bleeding is fastest and reduces aeration risk. A syringe method or manual two-person pump-and-hold works fine if you don’t have tools.

3. Bleed order (recommended)

Bleed wheels from the one farthest from the master cylinder toward the nearest. On the Outlander MAX 800R DPS the recommended order is usually:

  1. Rear right
  2. Rear left
  3. Front right
  4. Front left

Confirm with your service manual if you have any doubt.

4. Bleeding technique – vacuum or pressure bleeder

  • Attach clear hose to bleeder nipple and place other end into catch bottle partially filled with fresh fluid to prevent air re-entry.
  • If using a pressure bleeder, pressurize reservoir per tool instructions (usually low pressure). Open bleeder nipple and allow fluid to flow until clear, bubble-free fluid appears. Close nipple while flow stops, then move to next caliper.
  • Maintain reservoir level above minimum throughout; top with fresh fluid as needed.

5. Bleeding technique – manual (two-person)

  • One person slowly depresses brake pedal several times then holds it down. Second person opens bleeder nipple briefly to let fluid and air escape, then closes nipple before pedal is released. Repeat until fluid runs clear and pedal feel is firm.
  • Keep reservoir topped between cycles.

6. Single-point syringe method (one-person)

  • Use a syringe to remove old fluid from the reservoir and refill with fresh DOT 4. Connect a vacuum syringe to the bleeder nipple and pull fluid through while pumping the lever slowly to cycle fresh fluid through until clear.

7. Final checks

  • When all wheels are clear of air, tighten bleeder nipples to spec (snug then torque to factory spec if known). Replace any banjo bolt crush washers and torque banjo bolts to the specified value.
  • Top reservoir to max line, reinstall cap and diaphragm, and wipe any spilled fluid.
  • Test brake lever and pedal feel with the ATV still supported. Brakes should feel firm. With ATV on ground, perform a low-speed brake test in a safe area.

Troubleshooting

  • Persistent spongy pedal after correct bleeding: suspect internal hose collapse, contaminated caliper seals, or master-cylinder issues.
  • Rapid fluid loss or leaks: inspect banjo bolt washers, caliper seals, hose fittings, and master-cylinder reservoir for cracks.
  • If DPS assist drops or electrical errors appear, check battery voltage and connectors; some electrical systems can be affected during long service sessions.

Maintenance tips

  • Replace brake fluid every 1-2 years or sooner if you ride in wet/harsh conditions.
  • Always use DOT 4 and store sealed fluid away from moisture.
  • Keep a record of fluid changes and note any component replacements (hoses, calipers, master cylinder).

Following this MotoSport-exclusive procedure will help ensure safe, reliable braking on your 2015 Can-Am Outlander MAX 800R DPS. If any step feels beyond your comfort level, have a qualified shop complete the job.

Related Shopping Categories

Shop Brake Fluid for a 2015 Can-Am Outlander MAX 800R DPS ATV.

Shop Brake Bleeders for a 2015 Can-Am Outlander MAX 800R DPS ATV.

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Shop Brake Lines for a 2015 Can-Am Outlander MAX 800R DPS ATV.

Shop Brake Tools for a 2015 Can-Am Outlander MAX 800R DPS 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.