Can-Am Commander 800R/1000 UTV 2013 Service Manual Set (P/N 219 100 661)

The Shop Manual provides repair procedures, while the model-specific parts books support component identification before work begins. The Flat Rate Time Manual adds warranty labor allowances; the Operator’s Guide covers controls, maintenance, and safe operation.

Use the Supplement-IS booklet with the corresponding base parts catalog. Its model listings identify parts-reference coverage. The Shop Manual is specific to 2013; only the exhaust-area cleaning addendum also covers 2011–2013 vehicles.

PDF Search, Bookmarks and Wiring Detail

Text search and navigation: Shop procedures have OCR text, and parts lists and operator instructions are also searchable. Embedded bookmarks link the publications and many subsections. Some cover and illustration text, including the CE wiring sheet, is not searchable. Small wiring labels are readable when enlarged.

Supplied as one printable, 1,167-page PDF. The publication totals above already include the original covers, blank and note pages, supplementary catalog material, and the two-page addendum.

Engine Rebuilds, Driveline Service and Electronic Diagnosis

These selected coverage highlights outline the main workshop content. Additional topics include muffler spark-arrester inspection and wheel and tire service.

• Engine repair: Step-by-step removal and installation, cylinder-head and bottom-end service, piston and ring inspection, valve adjustment, and timing-chain procedures.

• Cooling and lubrication: Oil-pressure diagnosis, cooling-system leak testing, coolant replacement and bleeding, and water-pump shaft, seal, and drive-gear service.

• CVT and driveline: Belt replacement, drive and driven pulley disassembly, one-way clutch maintenance, gearbox and 4x4 coupling diagnosis, and shifter adjustment.

• Electronic diagnosis: EMS, CAN, EFI, iTC, and D.E.S.S. troubleshooting, with B.U.D.S./MPI-2 communication, sensor tests, component activation, and module initialization.

• Steering and suspension: Alignment, DPS load testing and torque-offset reset, front and rear suspension service, and LTD Air Controlled Suspension diagnosis.

• Brakes and chassis: Brake-pressure validation, master-cylinder and caliper removal and inspection, pad and disc checks, bleeding, body panels, cargo box, cage, and frame.

• Workshop references: Exploded assembly views, illustrated parts lists, wiring diagrams, connector information, troubleshooting charts, torque specifications, fluid data, and wear limits.

The Shop Manual was written for mechanical technicians already familiar with BRP service procedures and assumes access to the specified hand tools and special service tools.

Maintenance and Internal Engine Work

Break-in inspection and periodic maintenance are supplemented by seasonal storage, preseason preparation, and procedures for rolled-over or submerged vehicles.

Cylinder leak-down guidance distinguishes intake-valve leakage, exhaust-valve leakage, head-gasket faults, and piston or ring wear. This gives the technician a basis for identifying the affected area before teardown.

Internal repair coverage includes rocker arms, camshafts, valve guides, cylinders, pistons and rings, crankcase separation, plain-bearing inspection, and crankshaft measurement and assembly. Model-specific instructions distinguish the 810 and 1010 engines, including their timing-chain tensioner arrangements.

Tool references include engine lifting tool 529 036 022, camshaft timing tool 529 036 231, and crankshaft locking bolt 529 035 617. The camshaft instructions explain why mixing components between the two cylinder assemblies can damage the engine.

Water-Pump Seals and Cooling-System Diagnosis

Cooling coverage extends to the housing, impeller, shaft, rotary seal, and drive gears. The seal procedures identify rotary-seal pusher plate 529 036 130 and distinguish work performed with the engine assembled from work requiring disassembly.

Incorrect rotary-seal installation can break the plastic water-pump drive gear, while an omitted thrust washer can cause a seal leak. These cautions accompany the relevant procedures.

CVT, Gearbox and Final-Drive Service

Pulley service includes roller and bushing inspection, with clutch holder 529 036 238 and clutch puller 529 035 746 identified in the tool references. BRP specifies that drive-pulley repairs must be performed by an authorized Can-Am dealer.

Gearbox coverage includes internal disassembly, oil seals, the 4x4 actuator, vehicle-speed sensor (VSS), and gearbox-position sensor (GBPS). Specific shaded coupling components are non-serviceable and require gearbox replacement.

Front and rear drive sections cover differentials, propeller shafts, U-joints, drive shafts, CV boots, hubs, and wheel bearings. The Visco-Lok pump and carrier are replacement assemblies rather than an internally rebuildable pump.

B.U.D.S., Module Setup and Electrical Fault Tracing

The diagnostic chapters connect fault codes with live monitoring, sensor measurements, and actuator tests. Setup work includes ignition-key programming, replacement-gauge registration, ECM data entry and first initialization, and GBPS reset after specified component replacements.

These procedures require the applicable B.U.D.S. software and diagnostic hardware. References include ECM adapter 529 036 166, MPI-2 diagnostic cable 710 000 851, and MPI-2 interface card 529 036 018. Starting and charging circuits, gauge functions, wiring harnesses, and connector repair are also covered.

Visual references include the engine lubrication circuit, fuel-system diagnostic flow chart, cooling-fan troubleshooting chart, power-distribution diagram, DPS system diagram, and ACS system diagram. General-system wiring and harness views add connector and pin-identification detail.

DPS, LTD Air Suspension and Brake Service

DPS procedures link steering alignment and component replacement to the required torque-offset reset. The manual also explains how external magnetism and static discharge can affect the torque sensor and steering behavior.

LTD ACS coverage includes pneumatic hoses, release and solenoid valves, the suspension control module, relay, compressor, and B.U.D.S. leak and component tests. Suspension repair extends to trailing arms and the anti-sway bar.

Brake work includes fluid replacement, vacuum and manual bleeding, and master-cylinder rod adjustment. Rack-and-pinion service is limited to boots and tie-rod ends; the internal assembly is not serviceable.

Work on a Commander can involve a raised vehicle, spring-loaded CVT components, hot cooling and exhaust systems, pressurized fuel or ACS circuits, and live electrical testing. Follow the factory safety notices, support the vehicle correctly, isolate electrical power in the specified order, and release system pressure before repair.

A Preview of Injector and Thermostat Test Data

For both engines, injector resistance is specified at 11.4–12.6 Ω at 20°C (68°F). The EFI section pairs this specification with connector-pin assignments, activation tests, leak checks, and fuel-pressure-drop testing.

The cooling specifications distinguish thermostat operation by engine: opening begins at 65°C (149°F), with full opening at 75°C (167°F) for the 800R and 88°C (190°F) for the 1000.