How to Bleed and Replace Brake Fluid on a 2016 Can-Am Outlander MAX 650 DPS
Shop parts for a 2016 Can-Am Outlander MAX 650 DPS ATV.
This MotoSport-exclusive guide walks you through a safe, complete brake fluid replacement and bleeding procedure for the 2016 Can-Am Outlander MAX 650 DPS. Follow the steps exactly, use the specified fluid, and respect safety practices to maintain braking performance and system longevity.
What you need
- DOT4 brake fluid (only use fresh, unopened fluid)
- Clear vinyl hose small enough to fit over bleed nipple
- Catch bottle partially filled with used fluid to prevent air draw-back
- Bleeder wrench or correctly sized open-end wrench
- Turkey baster or fluid syringe for reservoir
- Torque wrench for fastener checks
- Clean rags, gloves, eye protection
- Optional: vacuum or pressure brake bleeder
Factory fluid & system notes for the 2016 Outlander MAX 650 DPS
- MotoSport recommends DOT4 brake fluid for this model. Do not mix DOT3 or silicone fluids with DOT4.
- The DPS model has hydraulic brakes with a single master cylinder supplying front and rear circuits; bleeding order should start with the caliper furthest from the master cylinder and finish at the closest.
- There is no factory ABS on this year/model, so standard bleeding procedures apply.
- Brake fluid is hygroscopic – replace every 1-2 years or if moisture testing indicates contamination.
Safety and prep
- Work on a level surface with the engine off, parking brake engaged, and ignition key removed.
- Wear gloves & eye protection. Brake fluid damages paint – protect bodywork or cover with rags.
- Keep reservoir cap clean. Do not allow air contamination of the system while the cap is open.
- Lift or support the Outlander securely if you need wheel access. Chock wheels if not lifted.
Step-by-step: flush and bleed
- Locate the brake fluid reservoir near the handlebars. Clean the cap area and remove the cap slowly. Note fluid level and condition.
- Use a turkey baster or syringe to remove most old fluid from the reservoir. Leave a little to avoid drawing air into the master cylinder.
- Top off reservoir with fresh DOT4 fluid. Keep the cap partially installed or covered to reduce contamination while you work.
- If you have a helper: one person will pump the lever/pedal and hold it down while the other opens and closes bleed nipples. If using a vacuum or pressure bleeder, follow tool instructions but still maintain reservoir level.
- Identify bleeding sequence. For the 2016 Outlander MAX 650 DPS, MotoSport recommends this order: rear caliper(s) first (furthest from master), then front passenger-side caliper, then front driver-side caliper (closest to master). If your bike has a different hose routing, always start at the caliper furthest from the reservoir.
- Attach clear hose to the bleed nipple and submerge the other end in a catch bottle part-filled with old fluid to prevent air re-entry.
- Have helper slowly pump the brake lever (or pedal) to build pressure, then hold. Open the bleed nipple about one-quarter turn to allow fluid/air to escape. Close nipple before the helper releases the lever. Repeat until clear, bubble-free fluid appears and lever feel is firm.
- Keep reservoir topped with fresh fluid throughout. Never let reservoir run dry during bleeding.
- Repeat step 6-8 for each caliper in the specified order. For rear dual-calipers, do the furthest rear first then the nearer rear, then front passenger, then front driver.
- After the last caliper is bled, cycle the lever several times with the engine on (if applicable) to confirm firm, consistent pressure. Re-check all bleed nipple tightness and reservoir level.
- Clean any spilled fluid and reinstall reservoir cap. Dispose of old fluid responsibly.
Tips for a successful bleed
- Work methodically and keep the reservoir at least half full during the process to prevent introducing air into the master cylinder.
- If brakes feel spongy after bleeding, repeat the sequence; trapped air commonly requires a second pass.
- A vacuum bleeder speeds the job and reduces helper error, but ensure you don't pull the reservoir dry.
- Inspect bleed nipple threads and rubber dust caps for corrosion or damage; replace if they leak or round off.
Post-service checks
- Confirm lever/pedal travel is firm and consistent. Test brakes at low speed in a safe area before riding normally.
- Check for leaks at hoses, caliper banjo bolts, and bleed nipples after a short test ride.
- Re-torque caliper mounting and banjo bolts to factory spec if you removed hardware. If unsure of torque values, consult your authorized manual or a MotoSport technician.
Model-specific maintenance notes for the 2016 Outlander MAX 650 DPS
- DPS power steering adds load to the chassis; ensure steering and brake systems are serviced per schedule to maintain stable braking feel at low speed.
- Inspect brake lines for chafing against frame or accessories common on MAX models fitted with racks or aftermarket bumpers.
- Max models are heavier and often carry two riders; maintain brake system health more frequently if you routinely carry passengers or tow loads.
- Track fluid change intervals: MotoSport advises a full brake fluid replacement every 12-24 months depending on use and exposure to wet/muddy conditions.
When to get professional help
- If you cannot achieve firm lever feel after repeated bleeding attempts.
- If you find contaminated or rapidly deteriorating fluid, warped rotors, leaking master cylinder, or damaged calipers.
- If you are uncomfortable lifting the machine or working under it safely.
Follow this MotoSport procedure to restore reliable brake performance on your 2016 Can-Am Outlander MAX 650 DPS. Regular inspection and timely fluid replacement keep stopping power strong and safe for two-up riding and utility use.
Related Shopping Categories
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Shop Brake Tools for a 2016 Can-Am Outlander MAX 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.