How to Bleed & Replace Brake Fluid on a 2019 Can-Am Outlander 850 XT
Shop parts for a 2019 Can-Am Outlander 850 XT ATV.
Overview
This step-by-step guide from MotoSport shows how to drain, flush, and bleed the brake system on a 2019 Can-Am Outlander 850 XT (MMY). Procedures are written for the stock hydraulic system using DOT 4 brake fluid. Follow dealer torque specs for fasteners and wear appropriate PPE. Work on a level surface with the engine off and parking brake applied.
What you'll need
- DOT 4 brake fluid (fresh, unopened)
- Brake bleeder wrench or correct-size open wrench
- Clear plastic tubing & catch bottle
- Turkey baster or suction tool to remove old fluid from reservoir
- Clean lint-free rags and brake cleaner
- Torque wrench for caliper/banjo bolts
- Gloves and eye protection
- Optional: vacuum bleeder or pressure bleeder
Safety & model-specific notes
- Use DOT 4 only. DOT 5 is silicone-based and incompatible.
- The Outlander 850 XT may include Dynamic Power Steering & ABS-related components on some trims. If your unit has ABS, be careful not to introduce air into ABS valves by keeping reservoir levels steady and following the sequence below. Consult the vehicle service manual for ABS purging procedures if a complete ABS module bleed is required.
- The master cylinder reservoir is located near the handlebars. Keep the cap and diaphragm clean to avoid contamination.
- Brake lines and banjo fittings on the Outlander are aluminum/steel with crush washers. Replace crush washers when removing banjo bolts.
- Avoid spilling brake fluid on painted surfaces — it damages paint. Clean spills immediately with water and brake cleaner.
Preparation
- Park on level ground and secure the machine. Remove front/rear storage racks if needed for access.
- Clean the reservoir cap area to prevent contamination when opened.
- Remove the reservoir cap and diaphragm. Use a turkey baster to remove old fluid to below the minimum mark. Do not let the cap remain off for long periods.
- Raise wheels as required so calipers are accessible and to make sure no pistons extend under gravity while bleeding.
Drain and replace fluid (recommended full flush)
- Fill the reservoir with fresh DOT 4 fluid to the "max" mark.
- Locate bleed nipples on each caliper. Fit clear tubing over nipple and place the other end into a catch bottle partially filled with fresh fluid to avoid sucking air back in.
- Start with the wheel farthest from the master cylinder. On the Outlander 850 XT this is typically the rear caliper, then the front calipers with the caliper furthest from the master cylinder next, then the closest. Rule of thumb: farthest to nearest.
- Have an assistant slowly pull the brake lever/pedal several times and hold it on the last pull. Open the bleed nipple ~1/4 turn to allow fluid to flow into the tube until flow slows, then close the nipple before the lever/pedal is released. Repeat until clear fluid with no air bubbles appears and the lever/pedal feels firm.
- Keep the reservoir topped between cycles to prevent air entry. Never run the reservoir dry.
- After each caliper is done, tighten bleed nipple to spec and wipe fittings. Replace crush washers on banjo bolts if removed and torque to spec.
- Once all calipers are bled, pump the lever/pedal to confirm a firm feel. Check fluid level and top to "max", then reinstall cap and diaphragm cleanly.
Using a vacuum or pressure bleeder
Both tools speed the job and reduce assistant needs. When using a device, attach to the reservoir (pressure) or bleed nipple (vacuum) and follow manufacturer instructions. Continue to follow the farthest-to-closest sequence and ensure reservoir level never runs low.
Inspect & finish
- Check for leaks at bleeder nipples, banjo bolts, and hose connections after a short test ride.
- Inspect brake pads, rotors, and hose condition. Replace any hoses showing cracks or swelling; replace pads if thickness is below spec.
- Properly dispose of used brake fluid per local regulations.
- Record date, mileage, and fluid type in maintenance log. MotoSport recommends changing brake fluid every 12 months or sooner if water contamination is suspected.
Troubleshooting
- Spongy lever after bleeding: repeat bleed sequence making sure no air entered the reservoir and bleeder nipples are fully seated when closed.
- Persistent soft pedal with ABS: an ABS module purge may be necessary — consult a dealer-level procedure or MotoSport service tech for module-specific steps.
- Brake dragging after bleed: check caliper piston return, guide pins, and hose condition that could cause hydraulic lock.
Parts & maintenance tips for the 2019 Outlander 850 XT
- Keep spare crush washers and bleeder cap plugs on hand when servicing brakes.
- Stock OEM caliper bolts & banjo hardware are torque-sensitive; use new washers and proper torque to avoid leaks.
- If your Outlander has the Rotax engine cooling vents or accessory mounts common on the XT, remove accessory panels carefully to access rear brake lines.
- MotoSport recommends inspecting the Dynamic Power Steering reservoir and belts as part of regular service intervals since heavy steering loads can mask brake feel changes.
After finishing the bleed and confirming no leaks, test the brakes at low speed in a safe area to ensure proper operation before normal use.
Related Shopping Categories
Shop Brake Fluid for a 2019 Can-Am Outlander 850 XT ATV.
Shop Brake Bleeders for a 2019 Can-Am Outlander 850 XT ATV.
Shop Brake Pads for a 2019 Can-Am Outlander 850 XT ATV.
Shop Brake Lines for a 2019 Can-Am Outlander 850 XT ATV.
Shop Brake Tools for a 2019 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.