How to Bleed and Replace Brake Fluid on a 2019 Can-Am Outlander 650 DPS
Shop parts for a 2019 CAN_AM OL650DPS ATV.
This MotoSport guide walks a Do-It-Yourselfer through safely flushing, replacing, and bleeding the brake fluid on a 2019 Can-Am Outlander 650 DPS. Procedures below assume a mechanically competent owner with basic tools. If you are unsure at any step, stop and consult a professional.
Overview
Brake fluid deteriorates with moisture absorption and heat cycling. Replacing fluid restores pedal feel and reduces corrosion in the master cylinder, lines, calipers and ABS components. The 2019 Outlander 650 DPS uses sealed hydraulic disc brakes front and rear with a remote reservoir; stock fluid specification is DOT 4. Confirm with your owner's manual and follow MotoSport recommendations for quality DOT 4 brake fluid.
Tools & Materials
- DOT 4 brake fluid (new, unopened bottle)
- Brake bleeder kit or clear tubing and a catch bottle
- Hand vacuum pump bleeder or pressure bleeder (recommended)
- Wrenches for bleeder nipples (commonly 8 mm)
- Box or line wrench to avoid rounding nipples
- Shop rags, gloves, safety glasses
- Torque wrench for caliper & master cylinder fasteners
- Jack or stands to safely lift and support the ATV
- Small turkey baster or syringe (for topping reservoir)
- Brake cleaner and small container for old fluid
Safety First
- Work on a level, stable surface. Engage parking brake and remove key.
- Wear eye protection and gloves. Brake fluid is corrosive to paint.
- Keep new fluid free of contamination; do not reuse opened fluid beyond a short session.
- Dispose of used brake fluid per local regulations.
Preparation
- Park ATV, remove cargo, and clean around the master cylinder reservoir cap and bleeder nipples.
- Lift and securely support the machine so wheels can rotate and you can access each bleeder nipple.
- Identify bleed order: start with the caliper furthest from the master cylinder. Typical order for Outlander 650 DPS: right rear, left rear (if independent), right front, left front. Confirm routing visually.
- Remove the reservoir cap and diaphragm carefully. Keep debris out. Note reservoir min/max markings.
Step-by-Step – Complete Flush & Bleed
- Top reservoir with new DOT 4 brake fluid until near max. Do not overfill.
- If using a pressure bleeder: connect to reservoir according to bleeder tool instructions, pressurize to manufacturer-recommended pressure (low setting), then open each caliper bleeder in the bleed order until clear fluid flows and bubbles stop. Keep reservoir topped during the process.
- If using a hand vacuum pump or manual pump kit: attach clear tubing to the caliper bleeder nipple and submerge the other end in a catch bottle with a small amount of old fluid to prevent air entry. Have a helper slowly depress the brake lever/pedal while you open the bleeder nipple about a quarter turn. On release, close the nipple before the lever is fully released. Repeat until clear fluid with no bubbles exits and the lever feel is firm. Refill reservoir as needed.
- If performing two-person bleed without tools: one person pumps brakes slowly to build pressure and then holds steady while the other opens the bleeder. Close the nipple before the lever is released. This is less ideal for complete fluid exchange but works for bleeding air.
- To fully flush old fluid, continue cycling new fluid through each caliper until the expelled fluid is clean and free of contamination. Replace reservoir fluid as necessary to prevent drawing in air.
- Work quickly to minimize moisture uptake by the new fluid and avoid contamination of painted surfaces. Wipe any spills immediately with water first if on painted surfaces, then follow with brake cleaner as required.
- After the final caliper is bled, pump the lever/pedal until firm. Check fluid level and secure diaphragm and cap. Torque any caliper or reservoir fasteners to factory specs if disturbed.
Post-Service Checks
- Confirm lever/pedal feel is firm and consistent. If still spongy, repeat bleeding sequence and check for line leaks or a failing master cylinder.
- Inspect bleeder nipples for seepage. Torque and recheck as needed.
- Test brakes at low speed in a safe area before regular riding.
Model-Specific Notes for the 2019 Can-Am Outlander 650 DPS
- The DPS model has Dynamic Power Steering that does not change the hydraulic brake system, but take care around the EPS wiring and connectors when lifting or removing panels.
- The master cylinder is located under the front rack area on the right side near the handlebars. Clean the area before opening to avoid contamination.
- Some 2019 Outlander 650 DPS units were equipped with a combined reservoir servicing front and rear circuits. Observe the reservoir internal divider and keep fluid levels visible during bleeding to prevent air ingress into either circuit.
- Brake calipers use metric bleeder fittings; use a proper-size flare or line wrench to avoid rounding the nipple heads.
- If your machine has aftermarket accessories close to the reservoir or lines, ensure they do not interfere with proper reservoir ventilation while riding.
- Always verify DOT 4 compatibility with any replacement parts or hoses. Do not mix DOT 4 with DOT 5 silicone fluid.
Troubleshooting
- Persistent soft lever: re-check bleed order, inspect for collapsed hoses, leak paths, or a worn master cylinder.
- Air returns after bleeding: likely a hidden leak or an open fitting on return. Pressure-bleeding can help locate leaks.
- Contaminated or dark fluid returns quickly to old color: repeat full flush until new fluid runs clear.
Maintenance Interval Recommendation
MotoSport recommends replacing brake fluid every 2 years or sooner if you ride in wet, high-humidity, or heavy-use conditions. Regular checks for color and moisture-related issues will extend system life and safety.
When in doubt about torque specs, diagnostic faults, or if you encounter ABS warning lights after bleeding, consult a certified Can-Am dealer or qualified technician.
Related Shopping Categories
Shop Brake Fluid for a 2019 CAN_AM OL650DPS ATV.
Shop Brake Bleeders for a 2019 CAN_AM OL650DPS ATV.
Shop Brake Pads for a 2019 CAN_AM OL650DPS ATV.
Shop Brake Lines for a 2019 CAN_AM OL650DPS ATV.
Shop Brake Tools for a 2019 CAN_AM OL650DPS 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.