How to Bleed and Replace Brake Fluid on a 2021 Can-Am Outlander 650 DPS
Shop parts for a 2021 Can-Am Outlander 650 DPS ATV.
This MotoSport-exclusive guide walks you through replacing and bleeding the brake fluid on a 2021 Can-Am Outlander 650 DPS. Follow these steps precisely for safe, reliable braking. If you are not comfortable with brake work, contact a qualified tech.
What you need
- DOT 4 brake fluid (fresh, unopened)
- Clear plastic hose and graduated bottle or bleeder kit
- Wrench set (including the bleeder nipple wrench sizes)
- Phillips/flat screwdrivers, pliers
- Catch container, shop rags, gloves and eye protection
- Torque wrench (for reassembly)
- Service manual for torque specs and reservoir locations
Safety & model notes for the 2021 Outlander 650 DPS
- Brake reservoirs: The 2021 Outlander 650 DPS typically has separate reservoirs for front and rear circuits. Verify reservoir locations before starting – usually under the front handlebar cover for front and near the rear brake master cylinder.
- Brake fluid type: Use DOT 4 only. Do not mix with mineral oil or DOT 5. Keep fluid sealed until use.
- Power steering & electronics: DPS electronics are separate from brake hydraulics, but take care routing hoses and avoid spilling fluid on plastic surfaces or electrical connectors. Brake fluid is corrosive to paint and plastics.
- Parking brake: Release the parking brake and put the ATV on a stable stand with wheels off the ground for safe wheel access.
- Caliper hardware: Inspect caliper pins, slides and banjo fittings. Replace crush washers when loosening banjo bolts if disturbed.
Preparation
- Work on a level surface, engine off, ignition off and key removed.
- Clean the master cylinder reservoir caps to prevent contamination.
- Remove enough old fluid from reservoirs with a syringe so you can add fresh fluid during the procedure without overflowing.
- Top up reservoirs with fresh DOT 4 to the recommended level, but do not overfill.
Bleeding order and general principle
Bleed starting with the wheel farthest from the master cylinder and finish with the closest. Typical order for Outlander 650 DPS (confirm visually for your machine):
- Rear brake caliper (if rear is furthest)
- Right front caliper
- Left front caliper
- Finish at the caliper closest to the master cylinder
The goal is to purge air by pushing fluid from the master cylinder through each caliper to the bleeder nipple, collecting expelled fluid in a container.
Manual (two-person) bleeding method
- Have an assistant slowly pump the brake lever or pedal several times and hold steady pressure.
- Open the bleeder nipple slightly with the correct wrench until fluid and air bubbles appear, then tighten the nipple while your assistant maintains pressure.
- Have the assistant release the lever/pedal. Repeat until no air bubbles appear and the fluid runs clear.
- Keep reservoir topped during the entire process to avoid drawing air into the master cylinder.
- Move to the next caliper following the bleeding order.
- When finished, ensure bleeder nipples are tightened to the specified torque in the service manual and clean up any spilled fluid immediately.
One-person vacuum or pressure-bleed method
- Attach a vacuum pump to the bleeder nipple or use a pressure-bleeder on the master cylinder reservoir per the manufacturer instructions.
- Operate the pump and open each bleeder until clear fluid runs without bubbles, then close the bleeder and move to the next wheel.
- Monitor reservoir level closely and refill with fresh DOT 4 as needed.
Flush and replace full system fluid
- For a full fluid replacement, repeatedly draw old fluid from the reservoir and top with fresh DOT 4 between bleeding passes until fluid expelled from each caliper is clean and new.
- Be methodical: front and rear circuits must be fully flushed separately if reservoirs are separate.
Final checks
- Confirm firm lever/pedal feel with no sponginess. If spongy, re-bleed until solid.
- Check for leaks at bleeder nipples, banjo bolts and hose connections after cycling the brakes hard a few times.
- Torque banjo bolts and caliper mounting bolts to service manual specs. Replace crush washers if removed.
- Wash any spill areas with water immediately and dry; brake fluid can damage paint and plastics.
- Dispose of old brake fluid properly at a hazardous-waste facility.
Inspection items unique to this model
- Caliper condition: Inspect for seal leakage and pad wear; Outlander 650 DPS pads typically wear faster if ridden in wet/muddy conditions common to ATV use.
- ABS or stability systems: If your unit is equipped with electronic brake aids, do not introduce air into system components beyond standard bleed points; consult your service manual or MotoSport tech support for model-specific instructions.
- Brake hose routing: Ensure hoses are free from chafing against racks or frame, especially near the steering and swingarm pivots unique to the Outlander design.
- Dynamic Power Steering interference: When working under handlebars, avoid disconnecting DPS wiring or sensors; secure any moved covers correctly on reassembly.
Troubleshooting
- Persistent sponginess: Check master cylinder for internal leaks, and inspect caliper pistons for corrosion or sticking.
- Continued air ingress: Inspect reservoir cap vent and seals; ensure cap is clean and venting correctly.
- Brake drag after bleeding: Check caliper pistons returned fully and caliper slide pins are lubricated and free.
When to seek professional service
If you encounter leaking master cylinder seals, damaged calipers, persistent air that cannot be purged, or any electronic brake system faults, stop and let a certified technician handle repairs.
Regularly replacing brake fluid every 1-2 years or sooner if contaminated preserves braking performance and protects hydraulic components on your Outlander 650 DPS. Use this MotoSport-specific procedure as your shop reference and consult your service manual for torque values and any model-specific illustrations.
Related Shopping Categories
Shop Brake Fluid for a 2021 Can-Am Outlander 650 DPS ATV.
Shop Brake Bleeders for a 2021 Can-Am Outlander 650 DPS ATV.
Shop Brake Pads for a 2021 Can-Am Outlander 650 DPS ATV.
Shop Brake Lines for a 2021 Can-Am Outlander 650 DPS ATV.
Shop Brake Tools for a 2021 Can-Am Outlander 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.