How to Bleed and Replace Brake Fluid on a 2016 Can-Am Outlander 650 DPS
Shop parts for a 2016 Can-Am Outlander 650 DPS ATV.
This MotoSport guide walks you step-by-step through safely flushing and bleeding the hydraulic brakes on a 2016 Can-Am Outlander 650 DPS. Procedures are written specifically for this MMY (make, model, year) to help preserve brake performance, protect components, and keep your ride reliable.
Safety & prep
- Work on a level surface with the engine off, key removed, and the parking brake engaged (if equipped).
- Wear nitrile gloves and eye protection. Brake fluid (DOT 4) is hygroscopic and will damage paint, plastics, and rubberwipe spills immediately.
- Use DOT 4 brake fluid only. Do not mix DOT 5 (silicone) with DOT 4 or DOT 3.
- Have new brake fluid, a bleed kit (vacuum pump or clear tubing & bottle), a turkey baster or syringe for removing old fluid from reservoirs, a small wrench for bleeder screws, and a torque wrench for fasteners.
- Park vehicle so you can access both front and rear calipers. Lift wheels off the ground for easier access if needed.
What you need to know about the 2016 Outlander 650 DPS
- The DPS designation refers to Dynamic Power Steering — it does not change brake fluid type or routine bleed procedure, but take care not to spill brake fluid on power steering components or steering rack boots.
- The Outlander 650 uses separate master cylinder reservoirs for front and rear brakes. Bleed each circuit independently.
- Hydraulic calipers are conventional single/double piston designs; caliper bleeder screw locations are on the caliper bodies and typically point upward or outward. Identify each before starting.
- ABS is not standard on most 2016 Outlander 650 DPS models. If your unit has an ABS module, consult an authorized dealer for ABS-specific bleed procedures to avoid air trapping in the module.
- Inspect brake lines and hoses for cracking or swelling. Replace any suspect lines before bleeding.
Overview of bleed sequence
Always bleed from the caliper furthest from the corresponding master cylinder first, then move to the next-furthest, finishing with the closest caliper. For this Outlander:
- Front circuit (handlebar master): bleed the right-front caliper first if it is furthest from the master, then left-front. Verify layout on your machine — if the machine is symmetrical, choose the caliper farthest from the master cylinder outlet.
- Rear circuit (rear master): bleed the rear caliper(s) by starting with the furthest rear caliper from the rear master, then the closer caliper.
Step-by-step: drain, replace & bleed
- Remove the reservoir caps for the front and rear master cylinders. Clean around caps to avoid contamination.
- Using a turkey baster or syringe, remove as much old fluid from each reservoir as possible. Dispose of old fluid responsibly.
- Top reservoirs with fresh DOT 4 fluid but do not overfill. Keep caps loosely in place to minimize contamination and limit air entry.
- Start with the circuit furthest from the master cylinder. Attach clear tubing over the bleeder screw and the other end into a clean bottle partially filled with fresh fluid to prevent air being drawn back in. If using a handheld vacuum bleed pump, attach per tool instructions.
- Have an assistant slowly pump the brake lever/pedal several times then hold pressure (or follow vacuum pump method). Open the bleeder screw 1/4 to 1/2 turn until fluid runs out into the tubing. Close the screw before the assistant releases pressure. Repeat until fluid runs clear and free of bubbles.
- Keep the master reservoir topped with fresh fluid during the entire process. Never let the reservoir run dry or you will introduce air into the system and prolong the job.
- Work through the bleed sequence: furthest caliper → next furthest → nearest caliper. For single-caliper systems just focus on that caliper last.
- After bleeding each caliper, ensure the bleeder screw is tightened to the specified snugness. Avoid over-torquing; consult your service manual for exact fastener torque values or tighten to a firm stop and then a small additional fraction of a turn.
- When bleeding is complete for both circuits, top reservoir fluid to the full mark and reinstall caps. Operate brake lever & pedal to confirm firm feel with no sponginess. If soft, repeat bleeding sequence.
- Wash any spilled fluid with water immediately and dry painted/plastic surfaces. Replace and properly dispose of contaminated rags and old fluid.
Common issues & troubleshooting
- Spongy lever/pedal after bleeding: likely air remaining or reservoir ran dry. Repeat bleed, ensuring continuous fluid feed.
- Persistent leaks: inspect bleeder screw, banjo fittings, and hoses. Replace worn crush washers or seals as needed.
- Brake drag after bleeding: check caliper pistons for free movement, ensure caliper bolts are torqued correctly, and check pads for correct seating.
- Contaminated brake pads: if significant fluid reached the pads, replace them; contaminated pads cause reduced stopping power.
Maintenance tips specific to your Outlander 650 DPS
- Change brake fluid every 1-2 years depending on water exposure and riding conditions. Fresh fluid preserves braking performance and caliper internals.
- When servicing brakes, inspect front/rear brake hose routing near the DPS rack and steering linkages to prevent chafing or fluid contact with power steering parts.
- Keep a small spare bottle of DOT 4 in your tool kit for top-offs on remote rides; store sealed and away from moisture.
- After any brake service, perform a slow test ride in a safe area to confirm braking performance before full-speed use.
Parts & replacement items to consider
- DOT 4 brake fluid (fresh, unopened)
- Replacement bleeder screws and crush washers
- Brake pads (inspect and replace if contaminated or worn)
- Rubber hoses if cracked or showing age
- Caliper rebuild kits if pistons or seals are leaking
Following this MotoSport-specific guide will keep the braking system on your 2016 Can-Am Outlander 650 DPS operating safely and reliably. If you encounter ABS or other unexpected hardware, or if the braking feel does not improve after repeated proper bleeding, consult a certified Can-Am technician.
Related Shopping Categories
Shop Brake Fluid for a 2016 Can-Am Outlander 650 DPS ATV.
Shop Brake Bleeders for a 2016 Can-Am Outlander 650 DPS ATV.
Shop Brake Pads for a 2016 Can-Am Outlander 650 DPS ATV.
Shop Brake Lines for a 2016 Can-Am Outlander 650 DPS ATV.
Shop Brake Tools for a 2016 Can-Am Outlander 650 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.