How to Bleed & Replace Brake Fluid on a 2016 Can-Am Outlander 850 X MR

Shop parts for a 2016 CAN_AM OL850XMR ATV.

Overview: This MotoSport proprietary guide walks through replacing the brake fluid and bleeding the hydraulic brakes on the 2016 Can-Am Outlander 850 X MR. The Outlander 850 X MR is a performance mud-oriented machine; mud, water crossings and heavy use accelerate pad & fluid degradation. Use fresh DOT 4 brake fluid unless your owner’s manual specifies otherwise. Always follow safe lifting and wheel support practices.

Tools & Supplies

  • Fresh DOT 4 brake fluid (clear, unopened)
  • Brake bleeder kit or clear tubing & catch bottle
  • Turkey baster or fluid siphon
  • Box-end wrenches for bleed nipples (typically 8mm or 10mm)
  • Torque wrench and appropriate sockets
  • Clean rags, brake cleaner and catch pan
  • Jack or lift and axle stands; wheel chocks
  • Disposable gloves & eye protection

Model Notes & Preparation

  • The Outlander 850 X MR uses hydraulic disc brakes front and rear. The front master cylinder reservoir is at the handlebars; the rear master cylinder reservoir is near the frame/engine area. Reservoir access may require removing plastic panels or the front rack for full visibility.
  • Because this model is mud-focused, inspect calipers, lines and banjo fittings for embedded debris and corrosion before bleeding. Replace damaged lines or corroded fittings rather than relying on a bleed alone.
  • Brake pad wear is often accelerated by mud & water. Check pad thickness, rotor scoring and banjo bolt crush washers when refilling fluid.
  • If you suspect ABS or electronic braking components on your machine, do not open any electronic modules — consult the dealer. Most 2016 Outlander 850 X MR units have conventional hydraulic brakes, but confirm visually.

Safety First

  • Work on a cool machine; avoid hot rotors.
  • Protect painted surfaces from spilled fluid — DOT fluids damage paint.
  • Keep the master cylinder reservoir cap area clean to avoid contamination.
  • Never mix DOT 4 with DOT 5 (silicone) fluids.

Step 1 – Remove Old Fluid from Reservoirs

  1. Park ATV on level ground, chock wheels, and lift so wheels can rotate freely.
  2. Clean around reservoir caps. Remove caps and diaphragms. Cover openings with clean rags to prevent dirt entry.
  3. Use a turkey baster or siphon to remove as much old fluid as possible from both front and rear reservoirs. Dispose of used fluid properly.

Step 2 – Inspect System

  1. Inspect hoses, banjo bolts and calipers for leaks or corrosion. Replace any questionable hardware and new crush washers for banjo bolts when reassembling.
  2. Check brake pads and rotors. If pads are thin or rotors are deeply scored, service those items before bleeding.

Step 3 – Refill Reservoirs

  1. Pour fresh DOT 4 into each reservoir, filling to the recommended level but not overfilling. Keep caps nearby but not sealed yet so air can escape during bleed.

Step 4 – Bleeding Sequence — MotoSport Recommended

MotoSport recommends bleeding from the caliper farthest from its master cylinder to the nearest. Typical ATV sequence: rear caliper(s) first then front calipers. Work one circuit at a time (rear circuit, then front circuit).

  1. Attach clear tubing to the rear caliper bleed nipple; place other end in a catch bottle partially filled with fresh fluid to prevent air re-entry.
  2. Have an assistant slowly depress and hold the brake pedal (rear) or you can use a pressure bleeder set to the master cylinder if available.
  3. Open the bleed nipple about 1/4 turn. Brake fluid and bubbles will flow into the tubing. Close the nipple before the assistant releases the pedal. Repeat until clear, bubble-free fluid appears.
  4. Keep the reservoir topped during the sequence to prevent drawing air into the master cylinder.
  5. Torque bleed nipple to spec snugness once finished. Repeat for the other rear caliper if applicable.
  6. Move to the front calipers: bleed the caliper farthest from the front master cylinder first, then the next. Follow the same pump-open-close routine, keeping reservoirs topped.

Step 5 – Benchmarks & Checks

  • Brake lever/pedal should feel firm and consistent. If sponginess remains after several bleed attempts, inspect lines and master cylinders for internal leaks or master cylinder failure.
  • After bleeding, clean any spilled fluid and reinstall reservoir diaphragms and caps.
  • Seat wheels and torque wheel fasteners to manufacturer specs. Check caliper bolts to proper torque values.

Step 6 – Final Road/Test Checks

  • Lower the machine, remove chocks and perform a low-speed brake test in a safe area to confirm firm braking and no leaks.
  • Retorque any banjo bolts after first short ride if you replaced crush washers or fittings.
  • Monitor fluid level over the next few rides — a rapid drop indicates a leak.

MotoSport Tips Specific to the X MR Owner

  • After riding in deep mud or water, flush and replace brake fluid more frequently; contaminated fluid shortens system life and reduces boiling point.
  • Inspect and flush calipers if mud has packed into the piston boots. A caliper rebuild kit is inexpensive insurance on a mud-focused machine.
  • When replacing banjo bolts, always use new crush washers. Hand-tighten then torque to spec and recheck after initial use.
  • If you use a pressure bleeder, set pressure modestly — excessive pressure can damage seals.
  • Keep extra DOT 4 on hand at the trailhead; a quick top-off prevents air ingestion after remote repairs.

Troubleshooting

  • Persistent spongy lever/pedal: repeat bleeding, inspect lines for swelling, inspect master cylinder internals.
  • Brake fade after heavy braking: consider higher boiling-point fluid or check for glazed pads/overheated rotors.
  • Brake drag after bleeding: ensure caliper pistons are free and sliders move; clean and lubricate guide pins where applicable.

Performing a full brake fluid replacement and bleed at regular intervals keeps your Outlander 850 X MR safe and responsive in extreme conditions. For OEM-spec replacement hardware and service parts, visit MotoSport to find parts and service gear tailored to your ride.

Related Shopping Categories

Shop Brake Fluid for a 2016 CAN_AM OL850XMR ATV.

Shop Brake Bleeders for a 2016 CAN_AM OL850XMR ATV.

Shop Brake Pads for a 2016 CAN_AM OL850XMR ATV.

Shop Brake Lines for a 2016 CAN_AM OL850XMR ATV.

Shop Brake Tools for a 2016 CAN_AM OL850XMR 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.