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

• Set of BRP publications for the 2013 Can-Am Commander 800R and 1000, centered on the 493-page Shop Manual P/N 219 100 661 for the 810 and 1010 engines; companion references separate STD, DPS, XT, X, LTD, and Supplement-IS configurations.
• Covers engine removal and installation, cylinder leak-down diagnosis, valve-train and cylinder-head service, timing-chain work, piston and cylinder inspection, crankcase separation, crankshaft checks, and water-pump shaft and seal repair.
• Details CVT belt and cover service, drive and driven pulley inspection and rebuild, one-way clutch maintenance, gearbox and 4x4 coupling diagnosis, shifter adjustment, and front and rear drive repair.
• Provides EMS, CAN, EFI, iTC, D.E.S.S., and B.U.D.S./MPI-2 diagnostics, including module communication, key programming, sensor and actuator testing, ECM initialization, gearbox-position sensor reset, and fault-code diagnosis.
• Documents steering alignment, DPS torque-offset reset and load testing, suspension service, LTD Air Controlled Suspension diagnosis, brake pressure validation, caliper and master-cylinder repair, and brake bleeding.
• Includes exploded assembly views, illustrated parts breakdowns, wiring and power-distribution sheets, connector information, troubleshooting charts, component torque data, fluid specifications, wear limits, and electrical test values.

1,167-page PDF set: 493-page Shop Manual; 62-page Flat Rate Time Manual; 123-page BRP Genuine Parts, Accessories & Riding Gear catalog; 102-page 800R STD/DPS/XT parts manual; 106-page 1000 STD/DPS/XT/X parts manual; 104-page 1000 LTD parts manual; 18-page Supplement-IS parts booklet; 157-page Operator’s Guide; and a 2-page exhaust-area cleaning addendum. The repair manual itself is the first 493 pages and is specific to 2013; only the two-page exhaust-area addendum also covers 2011–2013 vehicles. The remaining documents add parts, warranty labor, operator, and safety references. Shop Manual P/N 219 100 661 and Operator’s Guide cover number 219 000 963 identify the two main publications.

Factory Repair Coverage

Maintenance coverage starts with the break-in inspection and periodic schedule, then moves through fluid and filter service, valve adjustment, CVT care, storage, preseason preparation, and procedures for rolled-over or submerged vehicles.

The Shop Manual’s introduction assigns the Commander 800R to the 810 engine and the Commander 1000 to the 1010 engine. Its service chapters use model-specific callouts where the cooling layout, component access, engine measurements, or installation details differ. The companion parts and flat-rate publications further distinguish STD, DPS, XT, X, LTD, and Supplement-IS builds, helping the technician select repair information before work begins.

Engine coverage runs well beyond routine maintenance. It addresses removal and installation, oil-pressure diagnosis, cooling-system pressure and leak testing, water-pump housing, impeller, shaft, rotary seal and drive gears, magneto and sprag clutch service, cylinder leak-down testing, rocker arms, camshafts, cylinder heads, valves and guides, cylinders, pistons and rings, timing chains and tensioners, crankcase disassembly, plain-bearing inspection, and crankshaft measurement and assembly. Service-tool references include the engine lifting tool 529 036 022, camshaft timing tool 529 036 231, crankshaft locking bolt 529 035 617, and rotary-seal pusher plate 529 036 130.

The drivetrain chapters cover drive-belt replacement, drive and driven pulley disassembly, roller and bushing checks, one-way clutch maintenance, gearbox oil seals and disassembly, the 4x4 actuator, VSS and GBPS testing, shifter adjustment, differentials, propeller shafts, U-joints, drive shafts, CV boots, hubs, and wheel bearings. The gearbox view also marks specific shaded 4x4-coupling parts as non-serviceable, requiring gearbox replacement for those failures. Tool references include clutch holder 529 036 238, clutch puller 529 035 746, and the related pullers and seal installers.

Electronic Diagnosis and Chassis Systems

The electronic sections explain the ECM-controlled engine management system, CAN communication, intelligent throttle control, EFI, starting and charging circuits, D.E.S.S. security, gauge functions, wiring harnesses, and connector repair. MPI-2 and B.U.D.S. coverage supports fault-code work, live monitoring, component activation, ignition-key programming, replacement-gauge registration, ECM data entry, first initialization, GBPS reset, DPS torque-offset reset, and ACS leak and component tests. The tool index identifies the ECM adapter 529 036 166, MPI-2 diagnostic cable 710 000 851, and MPI-2 interface card 529 036 018.

Chassis repair includes rack-and-pinion removal, tie-rod and knuckle service, steering alignment, DPS diagnosis, front and rear suspension, trailing arms, anti-sway bar, LTD ACS pneumatic and electrical components, brakes, body panels, cargo box, cage, and frame. The brake chapter covers inspection, pressure validation, master cylinder and caliper work, pad and disc checks, fluid replacement, and vacuum or manual bleeding.

Representative 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, backed by general-system, harness, and connector-pin information.

Manual warnings identify several deeper repair risks. The two cylinder camshafts are not interchangeable; mixing their components can damage the engine. Incorrect water-pump rotary-seal installation can damage the plastic drive gear, while an omitted thrust washer can create a seal leak. The DPS torque sensor is sensitive to magnetism and static discharge, so magnetized tools or arc welding near the unit can alter steering behavior and prevent a correct offset reset.

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.