2010 Can-Am Outlander 500, Outlander 500 XT, Outlander 650, Outlander650 XT, Outlander 800, Outlander 800 XT shop manual

Product Information

Table of Contents

Safety Notice

• VIII

Introduction

• IX
  • General Information
  • Vehicle Information
  • Engine Emissions Information
  • Self-Locking Fasteners Procedure
  • Loctite Application Procedure
  • Tightening Torques
  • Manual Information

01 Maintenance

• 01
  • Maintenance Chart
  • Maintenance Chart
  • Preseason Preparation
  • Preseason Preparation
  • Storage Procedures
  • Fuel Stabilizer
  • Engine Lubrication
  • Rags Installation
  • Coolant Density
  • Drive and Driven Pulleys Protection
  • Vehicle Cleaning
  • Vehicle Protection
  • Special Procedures
  • Turn Over
  • ATV Immersion

02 Troubleshooting

• 11
  • Troubleshooting Chart
  • Electrical System
  • Cooling System
  • Magneto System
  • Lubrication
  • Cylinder and Head
  • Crankshaft
  • Gearbox
  • Coupling Unit
  • CVT
  • Engine General

03 Engine and Gearbox (V490/V660/V810)

• 25
  • Engine Removal and Installation
  • General
  • Procedures
    • Engine Removal
    • Engine Installation
    • Engine Mount Replacement
  • Air Intake System
  • General
  • Procedures
    • Air Filter
    • Air Filter Housing
    • Restrictor
  • Exhaust System
  • General
  • Procedures
    • Front Exhaust Pipe
    • Muffler
    • "Y" Exhaust Pipe
    • Fuel Tank Protector

04 Lubrication System

• 45
  • Components
  • Engine Lubrication
  • General
  • Maintenance
    • Engine Oil
  • Inspection
    • Engine Oil Pressure
  • Procedures
    • Oil Filter
    • Oil Pressure Switch (OPS)
    • Engine Oil Pressure Regulator
    • Oil Pump
    • Engine Oil Strainer

05 Cooling System

• 55
  • General
  • Inspection
    • Cooling System Leak Test
  • Maintenance
    • Coolant Replacement
  • Procedures
    • Thermostat
    • Radiator Cap
    • Radiator
    • Coolant Tank
    • Coolant Temperature Sensor (CTS)
    • Radiator Fan Relay (R1)
    • Radiator Fan
    • Water Pump Housing
    • Water Pump Impeller
    • Water Pump Shaft and Seals

06 Magneto System

• 71
  • General
  • Procedures
  • Magneto Cover
  • Stator
  • Rotor
  • Sprag Clutch
  • Sprag Clutch Gear
  • Starter Drive Gears

07 Intake Manifold, Cylinder Head and Cylinder

• 79
  • General
  • Maintenance
    • Valve Adjustment
  • Inspection
    • Leak Test
  • Procedures
    • Intake Manifold
    • Valve Cover
    • Timing Chain Tensioner
    • Camshaft Timing Gear
    • Rocker Arm
    • Timing Chain
    • Cylinder Head
    • Camshaft
    • Valve Spring
    • Valve
    • Valve Guide
    • Cylinder
    • Piston
    • Piston Rings

08 Bottom End

• 113
  • General
  • Procedures
  • Engine Drive Shaft
  • PTO Cover Oil Seal
  • PTO Cover
  • Drive Gears
  • Timing Chain
  • Timing Chain Guide
  • Crankcase
  • Crankshaft

09 Gearbox and 4x4 Coupling Unit

• 135
  • General
  • Maintenance
    • Gearbox Oil Change
  • Procedures
    • Gearbox Position Indicator Switches
    • 4WD Indicator Switch
    • Oil Seals
    • Actuator
    • Output Shaft and Coupling Mechanism
    • Gearbox

10 Shifter

• 167
  • General
  • Procedures
  • Transmission Lever
  • Link Rod
  • Shifting Plate

04 Engine Management (V490/V660/V810)

• 173
  • Overview
  • Operating Principle
    • Air Induction
    • Fuel System
    • Electrical System
    • Engine Management System
    • Electronic Fuel Injection
    • Ignition
    • Engine Modes of Operation
    • Monitoring System
    • Diagnostic Mode
    • Engine Management System Flow Chart
  • EMS Diagnostic
  • General
    • Fault Codes
    • Fault Code Table

03 Adjustment and Repair Procedures

• 193
  • General
  • Fuel System
  • Electrical System
  • Basic Adjustments
  • Idle Speed
  • Throttle Cable
  • Closed Throttle and Idle Actuator Reset
  • Ignition Timing
  • Repair Procedures
  • Main Relay (R2)
  • Diode (ECM)
  • Engine Control Module (ECM)
  • Fuel Injector
  • Fuel Rail
  • Throttle Body
  • Throttle Position Sensor (TPS)
  • Idle Bypass Valve (IBV)
  • Camshaft Position Sensor (CPS)
  • Crankshaft Position Sensor (CPS)
  • Manifold Air Pressure and Temperature Sensor (MAPTS)
  • Coolant Temperature Sensor (CTS)

05 Fuel System

• 219
  • Fuel Tank and Fuel Pump
  • General
  • Inspection
    • Fuel Tank Leak Test
    • Fuel Pressure Test
  • Procedures
    • Fuel Hose and Oetiker Clamps
    • In-line Fuel Filter
    • Fuel Tank
    • Fuel Pump
  • Fuel System Diagnostic Flow Chart

06 Electrical System

• 231
  • Communication Tools and B.U.D.S. Software
  • Communication Tools
    • Multi-Purpose Interface (MPI)
    • Multi-Purpose Interface-2 (MPI-2)
    • B.U.D.S. Software
  • Ignition System
  • General
  • Procedures
    • Ignition Switch
    • Engine Run/Stop Switch
    • Ignition Coil
    • Spark Plug
  • Charging System
  • General
  • Procedures
    • Voltage Regulator/Rectifier
    • Stator
    • Battery
    • Main Ground

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