How to Bleed and Replace Brake Fluid on a 2016 Can-Am Outlander 850 XT
Shop parts for a 2016 Can-Am Outlander 850 XT ATV.
This MotoSport-exclusive guide walks you through a complete, safe brake fluid flush and bleed for a 2016 Can-Am Outlander 850 XT. Procedures cover both front and rear hydraulic systems, recommended fluids, tools, and model-specific notes every owner should know.
Safety & prep
- Work on a level surface, engine off, key removed. Block wheels and engage parking brake.
- Wear nitrile gloves and eye protection. Brake fluid is corrosive to paint & plastics; protect bodywork and clean spills immediately.
- Use DOT 4 brake fluid only. Do not mix with DOT 3/5.1 unless DOT 4 is compatible; always follow fresh DOT 4 from a sealed container.
Tools & materials
- DOT 4 brake fluid (fresh sealed bottle)
- Clear plastic hose and catch bottle
- Wrenches for bleeder screws (commonly 8mm; bring a small set 7-10mm)
- 7mm-10mm hex/Allen for caliper bolts if removing pads (if needed)
- Bleeder kit or handheld vacuum pump (optional)
- Rags, isopropyl alcohol for cleanup, and torque wrench
Model notes for the 2016 Outlander 850 XT
- The 2016 Outlander 850 XT uses hydraulic disc brakes with separate master cylinders for front (handlebar lever) and rear (foot lever). Bleeding must be done per circuit — treat front and rear independently.
- If your unit is equipped with Dynamic Power Steering (DPS), steering play will not affect the brake system but secure handlebar position while bleeding the front master cylinder.
- Inspect brake hose routing near swingarm and suspension for chafing or cracks common on high-hour units; replace any soft or bulged hoses before pressure bleeding.
- Check pad wear and rotor condition while bleeding. Uncommon but important: contaminated pads from leaking caliper seals require pad replacement and caliper service.
Overview of the bleed sequence
Bleed each hydraulic circuit separately. For each circuit, follow the farthest-to-closest caliper rule relative to the master cylinder: start with the caliper farthest from its master cylinder and finish with the nearest.
Step-by-step — Front brake system
- Locate the front brake fluid reservoir on the right handlebar. Clean cap area thoroughly with a rag and isopropyl alcohol. Remove cap and diaphragm, keeping contaminants out.
- Top reservoir to the MAX mark with DOT 4. Keep the level high throughout the procedure to avoid drawing air into the master cylinder.
- Raise the front end so the wheels can turn freely or place on a stable stand. Identify which caliper is farthest from the front master cylinder (typically the opposite side from the reservoir/mounting arrangement).
- Fit clear hose over the caliper bleeder nipple; submerge the other end in a catch bottle partially filled with old fluid to prevent air re-entry.
- With a helper: have helper slowly pull and hold the front brake lever, open the bleeder screw about 1/4 turn to allow fluid to flow, then close the screw before the helper releases the lever. Repeat until clear, bubble-free fluid flows and no air is visible. Keep reservoir topped off between cycles.
- Repeat for the other front caliper (closest last). After final caliper, squeeze lever to confirm firm lever feel. If spongy, repeat cycles until firm.
- Clean bleeder screws and torque to manufacturer spec; reinstall reservoir diaphragm and cap. Wipe any spilled fluid immediately.
Step-by-step — Rear brake system
- Locate the rear brake master cylinder and reservoir (usually on the frame near the foot brake pedal). Clean around the cap and open it.
- Top reservoir with DOT 4. Raise the rear or position so the wheel can spin freely.
- Attach clear hose to the rear caliper bleeder. Place the free hose end in a catch bottle.
- Use the same pump-and-hold or helper-pump method: pump the foot pedal, hold pressure, open the bleeder screw, close before releasing pedal. Repeat until fluid runs clear and bubble-free. Keep the reservoir topped off.
- Verify pedal feel; a firm pedal indicates success. If pedal remains soft, repeat bleeding until firm.
- Torque bleeder and any removed hardware to spec; reinstall reservoir cap and clean area.
One-man vacuum or pressure bleeding alternative
If you work solo, use a vacuum bleeder on each caliper or a pressurized reservoir bleeder on the master cylinder. Follow the tool manufacturer directions. Even with vacuum methods, maintain proper fluid level in the master cylinder to avoid introducing air.
Final checks & post-bleed tasks
- Confirm reservoir fluid level at proper mark after everything is tightened. Cap and diaphragm must be sealed correctly.
- Bounce suspension and operate controls to purge trapped air. Re-check fluid level and top if needed.
- Road-test slowly in a safe area at low speed to verify braking performance and pedal/lever firmness. Reinspect for leaks after the test ride.
- Properly dispose of old fluid per local regulations. Do not reuse old brake fluid.
Troubleshooting
- Persistent soft lever/pedal: check master cylinder internal seals, calipers for seized pistons, or flexible hoses swelling under pressure. Replace faulty components before re-bleeding.
- Air keeps returning: inspect for loose banjo bolts, cracked hose ends, or hairline leaks at bleed nipples. Tighten/replace as needed.
Maintenance tips specific to the Outlander 850 XT
- Service interval: inspect brake fluid and system annually or every 12 months; replace fluid every 2 years if exposed to heavy use or water contamination.
- After aggressive trail use in wet conditions, check fluid for discoloration. Brown or cloudy fluid indicates moisture contamination — flush immediately.
- Keep a small spare bottle of DOT 4 in your toolkit for topping off on extended trail trips, but keep it sealed until use.
- When replacing pads or calipers, inspect and, if needed, replace copper crush washers on banjo fittings to prevent leaks.
Performing a complete fluid replacement and bleed on your 2016 Can-Am Outlander 850 XT restores braking performance and extends component life. If you encounter persistent issues after following this MotoSport guide, consult a qualified ATV technician for diagnostic service.
Related Shopping Categories
Shop Brake Fluid for a 2016 Can-Am Outlander 850 XT ATV.
Shop Brake Bleeders for a 2016 Can-Am Outlander 850 XT ATV.
Shop Brake Pads for a 2016 Can-Am Outlander 850 XT ATV.
Shop Brake Lines for a 2016 Can-Am Outlander 850 XT ATV.
Shop Brake Tools for a 2016 Can-Am Outlander 850 XT 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.