How to Bleed and Replace Brake Fluid on a 2016 Can-Am Outlander 850 DPS

Shop parts for a 2016 Can-Am Outlander 850 DPS ATV.

This MotoSport.com guide gives a step-by-step, model-specific procedure to safely flush and bleed the brake system on a 2016 Can-Am Outlander 850 DPS. Follow safety precautions, use the correct fluids, and note the DPS- and model-related tips below.

Tools & Materials

  • DOT 4 brake fluid (Do not use DOT 5 silicone)
  • Brake bleeder kit (vacuum or pressure) or a clear hose & wrench for manual two-person bleeding
  • Clean catch bottles and rags
  • Socket set, box wrenches, and torque wrench
  • Vehicle lift or jack & stands for safe access
  • Brake cleaner and a small brush
  • Disposable gloves & safety glasses

Safety & Prep

  • Work on a level surface; secure the machine with the parking brake and wheel chocks.
  • Wear eye protection and gloves; brake fluid is corrosive to paint.
  • Clean the master reservoir cap area before opening to avoid contamination.
  • Have fresh DOT 4 fluid ready; only use one unopened container to avoid contamination.

Model-Specific Notes for the 2016 Outlander 850 DPS

  • The Outlander 850 DPS uses hydraulic disc brakes; factory recommendation is DOT 4 fluid. Do not mix DOT 4 with DOT 5.
  • The DPS stands for Dynamic Power Steering; the steering system uses separate hydraulic fluid and is unrelated to the brake system. Do not confuse reservoirs or fluids.
  • Some 2016 Outlanders were equipped with ABS as an option. If your machine has ABS, an ABS bleed/cycle step may be required to fully purge air from the modulator. See the ABS section below.
  • Master cylinder reservoir is mounted behind the handlebar area; access requires removing the small trim panel on some machines.

Step-by-Step Brake Fluid Replacement & Bleed

1. Prepare the Reservoir

  • Remove the reservoir cap and diaphragm. Clean the area.
  • Siphon out old fluid until the reservoir is mostly empty but leave a small amount to prevent drawing air into the master cylinder.
  • Top with fresh DOT 4 fluid to the correct level and reinstall the cap loosely to limit contamination.

2. Wheel & Caliper Access

  • Raise the ATV and remove wheels as needed to access calipers and bleed nipples.
  • Locate bleed nipples on each caliper and clean them.

3. Bleeding Order

Bleed in the sequence farthest from the master cylinder to nearest. Typical order:

  1. Rear passenger side (if applicable/farthest)
  2. Rear driver side
  3. Front passenger side
  4. Front driver side (nearest)

4. Bleed Procedure (Two-Person Manual)

  1. One person pumps the brake lever/pedal several times and holds steady pressure.
  2. Other person opens the bleed nipple 1/4 turn until fluid runs clear and bubbles stop, then close nipple before the lever/pedal is released.
  3. Repeat until no air bubbles appear and the pedal/lever feels firm. Keep the reservoir topped with fresh fluid during the entire process to avoid drawing air into the master cylinder.

4b. Bleed Procedure (Vacuum or Pressure Kit)

  • Attach the vacuum/pressure kit per tool instructions to the bleed nipple or reservoir.
  • Operate tool until clear, bubble-free fluid flows and pedal/lever firmness is restored, following the same farthest-to-nearest sequence.

5. ABS-Equipped Machines

  • If your Outlander has ABS, air can be trapped in the ABS modulator. After conventional bleeding, the ABS unit may need to be cycled to purge internal air. This often requires activating the ABS pump via a diagnostic tool or following a specific ignition/brake pedal cycling routine in the service manual. If you cannot cycle the ABS, take it to a shop that can run the ABS purge or use a scan tool.

6. Final Checks

  • With all bleed nipples closed and torqued to snug (do not over-torque), top the reservoir to the proper level and reinstall the cap and diaphragm.
  • Reinstall wheels and torque axle/wheel fasteners to factory specs.
  • Check lever/pedal firm feel at rest; there should be no sponginess.
  • Test ride in a safe area at low speed, applying brakes progressively to confirm operation and parking brake engagement if applicable.

Torque & Fastener Notes

  • Caliper bolt torque varies by model; tighten to a firm setting per service manual if available. If unsure, tighten to a medium torque and recheck after test ride.

Troubleshooting

  • Persistent spongy pedal after bleeding usually indicates remaining air, a leaking fitting, or an internal master cylinder issue.
  • If fluid immediately foams or becomes cloudy, stop and replace with fresh unopened DOT 4 fluid.
  • If brake fluid leaks onto painted surfaces, rinse immediately with water and clean; brake fluid will damage paint.

Disposal & Maintenance Intervals

  • Collect used brake fluid and dispose of it according to local hazardous-waste rules.
  • Replace brake fluid every 2 years or sooner if contaminated or if you use the machine in wet/harsh environments.

Performing a thorough brake fluid replacement and bleed will restore braking performance and safety. If you encounter ABS complications or suspect internal brake-component wear, contact a qualified technician.

Related Shopping Categories

Shop Brake Fluid for a 2016 Can-Am Outlander 850 DPS ATV.

Shop Brake Bleeders for a 2016 Can-Am Outlander 850 DPS ATV.

Shop Brake Pads for a 2016 Can-Am Outlander 850 DPS ATV.

Shop Brake Lines for a 2016 Can-Am Outlander 850 DPS ATV.

Shop Brake Tools for a 2016 Can-Am Outlander 850 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.