How to Bleed and Replace Brake Fluid on a 2016 Can-Am Outlander 650

Shop parts for a 2016 Can-Am Outlander 650 ATV.

This MotoSport guide gives step-by-step, model-specific instructions to safely replace and bleed the brake fluid on a 2016 Can-Am Outlander 650 (MMY CAN_AM;OL650;2016). Follow these directions carefully to maintain braking performance and avoid damage to brake components.

Special notes for the 2016 Can-Am Outlander 650 owner

  • The Outlander 650 uses a hydraulic braking system that typically requires DOT 4 brake fluid – verify the master cylinder cap stamping or the owner's manual before purchasing fluid.
  • Some 2016 Outlander packages include ABS and/or shared master cylinder layouts; if your machine has ABS, do not introduce air into ABS components. Consult your dealer or MotoSport parts if you suspect ABS involvement.
  • Brake reservoir(s) are located at the handlebar for the front brake and near the rear brake pedal for the rear system on many models – confirm layout on your bike before starting.
  • Use new crush washers on banjo bolts when re-installing caliper lines; reuse increases leak risk.
  • Keep the work area clean and cover painted surfaces when removing fluid to avoid damage from brake fluid's corrosive properties.

Tools & materials

  • DOT 4 brake fluid (fresh, unopened)
  • Brake bleeder kit or clear tubing and a catch bottle
  • Wrench set (commonly 8-12 mm for bleed nipples and banjo bolts)
  • Torque wrench (for return of banjo bolts & caliper hardware)
  • Rubber gloves, shop rags, and safety glasses
  • Jack or stands to stabilize the ATV (if needed)
  • New crush washers for banjo bolts

Preparation

  1. Park the Outlander on level ground; engage park/parking brake and remove the key.
  2. Clean around the master cylinder ports, reservoir caps, and calipers to keep dirt out of the system.
  3. Remove the reservoir cap(s) and diaphragm pad. Wipe out any residue with a lint-free cloth.
  4. Inspect brake lines, calipers, hoses, and master cylinder for leaks or damage. Replace any worn parts before proceeding.
  5. Open the new brake fluid container only when ready to pour to avoid contamination.

Bleeding strategy & sequence

Always bleed the caliper furthest from the master cylinder first and work toward the nearest. For most Outlander configurations that means:

  • If a single master cylinder services all brakes: bleed the rear caliper furthest from the reservoir first, then the other rear/front calipers finishing with the caliper closest to the master cylinder.
  • If separate front/rear reservoirs exist: treat each circuit independently and use the same furthest-to-nearest approach for each circuit.

Step-by-step — replace fluid and bleed

  1. Top off the reservoir with fresh DOT 4 fluid. Keep the cap loosely in place to minimize contamination.
  2. Attach clear tubing to the caliper bleed nipple and route the other end into a catch bottle partially filled with fresh fluid. Submerge the tube end in fluid to prevent air being drawn back in.
  3. Have an assistant slowly depress and hold the brake lever or pedal. Open the bleed nipple with the appropriate wrench to allow fluid and air to escape. Close the nipple before the assistant releases the lever or pedal. Repeat until clear, bubble-free fluid flows and no air appears. Maintain reservoir level above the minimum the entire time.
  4. Work through each caliper in the planned sequence. After each caliper is bled, tighten the bleed nipple to spec (hand-tight plus a small quarter-turn; check factory torque if available).
  5. If the master cylinder begins to feel spongy even after calipers are bled, bench-bleed the master cylinder: remove it if necessary, mount in a vise, and use short tubing from the outlet ports back into the reservoir. Cycle the piston slowly until no bubbles appear. Reinstall and re-bleed calipers if needed.
  6. After the final caliper is bled, pump the brake lever/pedal firmly several times to seat the system. Check for firm lever/pedal action and confirm no leaks at fittings.
  7. Top off the reservoir to the maximum mark, reinstall the diaphragm and cap, and wipe any spilled fluid from the ATV immediately.
  8. Replace any banjo bolt crush washers with new ones and torque banjo bolts to factory specification. If torque specs aren't known, tighten to a safe moderate torque and check for leaks under pressure during a short test ride.

Post-bleed checks

  • Inspect all bleeder nipples & banjo connections for leaks with the system pressurized.
  • Confirm brake lever and pedal feel is firm and consistent; allow a short slow-speed test ride in a safe area to verify braking performance before hard use.
  • Dispose of old brake fluid properly at an approved recycling facility; do not pour down drains or on the ground.

Troubleshooting

  • Persistent sponginess: there may still be air in the system or a leak. Re-check connections and re-bleed. If ABS is present, consult MotoSport parts or your dealer for ABS-safe bleeding procedure.
  • New leaks after bleeding: immediately re-tighten fittings and replace damaged crush washers or lines.
  • Brake fade after fluid change: ensure you used the correct fluid type. DOT 4 is hygroscopic; old fluid absorbs moisture and reduces boiling point – replacement restores performance.

Maintenance tips & MotoSport recommendations

  • Replace brake fluid every 1-2 years or sooner if you ride in wet or dusty conditions.
  • Always use high-quality DOT 4 brake fluid and new crush washers on reassembly.
  • If your Outlander has factory ABS or other electronic braking aids, verify whether special service steps or an ABS bleed tool are required.
  • Keep a maintenance log with fluid change dates and mileage to protect resale value and ensure safe operation.

Following this MotoSport-specific procedure will keep the braking system on your 2016 Can-Am Outlander 650 safe and responsive. If you encounter ABS complications, persistent problems, or hardware failures, contact MotoSport for parts or professional service recommendations.

Related Shopping Categories

Shop Brake Fluid for a 2016 Can-Am Outlander 650 ATV.

Shop Brake Bleeders for a 2016 Can-Am Outlander 650 ATV.

Shop Brake Pads for a 2016 Can-Am Outlander 650 ATV.

Shop Brake Lines for a 2016 Can-Am Outlander 650 ATV.

Shop Brake Tools for a 2016 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.