How to bleed and replace brake fluid on a 2020 Can-Am Outlander 650 DPS

Shop parts for a 2020 CAN_AM OL650DPS ATV.

This MotoSport guide covers step-by-step instructions to safely replace and bleed the hydraulic brake system on a 2020 Can-Am Outlander 650 DPS. Follow all safety precautions, use the correct fluid, and work methodically to keep your brakes reliable.

Overview & model notes

  • Model specifics: 2020 Can-Am Outlander 650 DPS uses hydraulic disc brakes with a front dual-caliper setup and a rear single caliper (varies by trim). DPS denotes Dynamic Power Steering; the steering system is separate from the brake system but adds weight and can change handling characteristicsbe cautious when testing after service.
  • Brake fluid spec: Use DOT 4 brake fluid unless the owner's manual specifies otherwise. DOT 4 is hygroscopic; replace on schedule and do not mix with DOT 5 silicone fluid.
  • Maintenance interval: Replace brake fluid every 12-24 months depending on use and exposure to water. Replace sooner if fluid is dark or contaminated.
  • ABS note: If your machine is equipped with any electronic braking aids, follow manufacturer cautions. Most Outlander 650 DPS models have conventional hydraulic brakes without complex ABS modules, but consult your manual if unsure.

Tools & materials

  • DOT 4 brake fluid (fresh, unopened)
  • Clear plastic tubing that fits snugly over bleed nipples
  • Clean catch bottle or reservoir for old fluid
  • Combination wrench set (bleed nipple size commonly 8 mm or 10 mm)
  • Vacuum bleeder or hand pump (optional but speeds the job)
  • Brake cleaner, shop towels, and gloves
  • Torque wrench for caliper bolts (recommended)
  • Floor jack or ATV stands to safely elevate machine
  • Eye protection and brake fluid-safe paint or plastic to protect painted surfaces

Safety and prep

  • Work on a flat, stable surface. Place transmission in park and set the parking brake if applicable.
  • Chock wheels and put the ATV on stands so wheels can rotate freely.
  • Cover bodywork and painted surfaces where brake fluid may drip; DOT 4 will damage paint.
  • Wear gloves and eye protection. Dispose of old fluid properlydo not pour down drains.
  • Keep the brake fluid reservoir cap closed as much as possible to limit moisture entry.

Locate master cylinder & reservoir

On the Outlander 650 DPS, the front master cylinder and reservoir are mounted on the handlebar near the right-hand grip. The rear reservoir may be combined or a separate remote reservoir depending on factory plumbing. Confirm which reservoir feeds which calipers before starting. Inspect hoses and fittings for damage.

Procedure: full fluid replacement and bleed

  1. Initial inspection: Check hose condition, caliper mounting bolts, and pad thickness. Replace worn pads or damaged components before bleeding.
  2. Clean reservoir cap area to prevent contamination. Remove cap and diaphragm carefully. Siphon out old fluid from the reservoir with a turkey baster or suction tool until mostly empty but do not let air into the master cylinder for long periods.
  3. Top reservoir with fresh DOT 4 fluid. Keep the reservoir level between MIN and MAX during the procedure.
  4. Identify bleed order: start with the caliper farthest from the master cylinder, then proceed toward the closest. Common sequence: rear caliper first (farthest), then passenger/front-right, then driver/front-left if applicable. If plumbing differs, use farthest-to-nearest relative to the reservoir location.
  5. Attach clear tubing to the bleed nipple and submerge the other end in a small amount of clean fluid inside a catch bottle to prevent air backflow.
  6. Open the bleed nipple ~1/4 turn. Have an assistant slowly depress the brake lever or pedal until firm, hold it, then open the nipple to let fluid and air escape. Close the nipple before the lever/pedal is released. Repeat until only clear fluid with no bubbles runs out, topping the reservoir frequently.
  7. If using a vacuum bleeder, attach it to the caliper bleed nipple and open the nipple while the vacuum tool runs. Keep reservoir topped and follow tool instructions. Vacuum or pressure bleeding is faster and reduces the need for an assistant.
  8. Move to the next caliper in the sequence. Repeat the bleed procedure for each caliper until all lines are clear and lever/pedal feel is firm. Maintain reservoir level above the MIN line throughout.
  9. After final caliper is bled, pump the lever/pedal several times and recheck for sponginess. If spongy, repeat bleeding sequence focusing on stubborn lines.
  10. Close all bleed nipples, wipe away any spilled fluid, reinstall the reservoir diaphragm and cap, and torque any fasteners to spec if known. Spin each wheel and confirm calipers are functioning normally.
  11. Test ride cautiously at low speed to verify braking performance before riding normally.

Bench bleeding the master cylinder (recommended for new master or after long dry time)

  1. If you remove the master cylinder, bench-bleed it first with supplied fittings or a small tubing looped from outlet ports back into the reservoir.
  2. Use a screwdriver or bleeding tool to slowly actuate the piston until no air bubbles appear in the reservoir return lines.
  3. Reinstall and then bleed the calipers as above.

Troubleshooting

  • Persistent spongy lever/pedal: likely trapped air or contaminated master cylinder. Re-bleed, bench-bleed master cylinder, or inspect hoses for collapse.
  • Leaking bleed nipple or hose: replace damaged parts; do not drive with leaks.
  • Brake drag after bleeding: check caliper pistons for proper retraction and pad clearance; check routing for pinched lines.

Final checks & tips

  • Use only DOT 4 (or spec shown in your manual) and never mix with DOT 5 silicone fluid.
  • Label the service date on the reservoir or in your maintenance log. Replace fluid again at recommended intervals or after heavy water exposure.
  • If you're unsure of the bleed order because the plumbing was modified, trace hoses from the reservoir to calipersalways farthest-to-nearest.
  • Keep spare bleed nipples and suitable crush washers on hand if you suspect corrosion or leaks.
  • If brakes remain unsatisfactory after correct bleeding, consult a MotoSport service specialist or certified technician.

Following this MotoSport procedure will restore a firm, reliable brake feel on your 2020 Can-Am Outlander 650 DPS. Proper fluid selection, cleanliness, and methodical bleeding ensure safe stopping performance.

Related Shopping Categories

Shop Brake Fluid for a 2020 CAN_AM OL650DPS ATV.

Shop Brake Bleeders for a 2020 CAN_AM OL650DPS ATV.

Shop Brake Pads for a 2020 CAN_AM OL650DPS ATV.

Shop Brake Lines for a 2020 CAN_AM OL650DPS ATV.

Shop Brake Tools for a 2020 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.