2009 Can-Am Outlander & Renegade 500/650/800 Service Manual (P/N 219 100 273)

Built for full shop work rather than operator-level maintenance, this set combines repair, diagnosis, overhaul, adjustment, and reference material for the covered BRP V-twin ATVs. BRP states that the service publications were prepared primarily for mechanical technicians already familiar with its procedures; the B.U.D.S., internal-engine, and special-tool work therefore assumes professional shop skills and equipment.

• Model coverage: Covers 2008 Outlander 500, 650, and 800 models in standard, XT, MAX, MAX XT, and MAX 800 Limited configurations where listed, plus Renegade 500 and 800. The 2009 supplement covers the corresponding 500/650/800R EFI line and adds the Renegade 800R X; both introductions provide year-specific BRP model-number tables.
• Document makeup: 736 PDF pages total - compiled title page: 1; 2008 Shop Manual P/N 219 100 273: 503; 2009 Shop Manual Supplement: 110; English 2009 ATV Technical Update Book P/N 219 100 309: 118; separate 2009 wiring-diagram sheets: 4. The base volume also carries BRP publishing-process code vmr2008-040.
• Engine and gearbox repair: Details V490, V660, and V810 engine removal and installation, lubrication and cooling-system testing, magneto and starter-drive service, cylinder-head and timing work, piston and crankshaft inspection, crankcase service, gearbox overhaul, 4x4 coupling work, and shifter adjustment.
• Electronic diagnosis and fuel service: Covers B.U.D.S. with MPI/MPI-2 communication, fault-code diagnosis, ECM and sensor testing, closed-throttle and idle-actuator reset, DESS key programming, fuel-pressure and tank-leak tests, and injector, fuel-rail, throttle-body, and fuel-pump repair.
• CVT, driveline, and chassis procedures: Includes drive-belt and pulley service, front and rear differentials, propeller shafts and U-joints, half shafts and boots, steering alignment, wheel bearings, suspension arms and trailing-arm bearings, hydraulic brakes, body panels, and frame work.
• Year-specific updates: Distinguishes the 2009 800R from the earlier 800 H.O. build and documents early/late MY2008 rear half-shaft and boot designs, revised coolant-reservoir venting, and 2009 XT/Limited vent-tube routing.
• Diagrams and specifications: Provides engine-management and fuel-system flow charts, fault-code tables, connector and pin-location views, gearbox/4x4 exploded views, full-page wiring diagrams, torque tables, capacities, pressure-test data, wear limits, clearances, and electrical test specifications.

V-Twin Engine and Gearbox Work

The V-twin chapters move well beyond routine service. They cover the air intake and exhaust, oil pump and pressure-control components, radiator and water-pump assemblies, stator and rotor, sprag clutch, valve train, camshaft timing, cylinders, pistons, crankshaft, PTO cover, drive gears, and internal gearbox assemblies. Factory procedures include removal, disassembly, inspection, leak and pressure testing, reassembly, installation, adjustment, and final checks, supported by exploded views and component-specific service data.

B.U.D.S. and Electrical Diagnosis

The engine-management material traces EFI operation from inputs and sensors through the ECM, injectors, ignition, monitoring modes, and limp-home strategy. Dedicated electrical chapters cover the charging and starting systems, ignition switch, relays, multifunction gauge, speed and fuel-level senders, lighting, winch circuits, and DESS troubleshooting. Named references include the Engine Management System Flow Chart, Fault Code Table, Fuel System Flow Chart, Deutsch and ECM connector views, and 2008-2009 Outlander and Renegade wiring sheets, including CE/Europe variants.

2009 Supplement and Running Changes

The 2009 supplement is not a stand-alone manual; BRP directs the reader back to the 2008 volume for systems not repeated. Its revised material covers the 800R air filter, camshaft inspection data, gearbox-position and AWD switches, fuel injectors and throttle cable, fuel tank/pump/level sensor, stator, rear torsion bar and trailing arm, brakes, body components, and year-specific specifications. The update book adds parts-compatibility detail, including three rear half-shaft/boot generations whose individual components are not interchangeable, plus the 800R injector O-ring and gasket-kit distinction. It also contains broader dealer and other-model material, so not all 118 pages apply specifically to these V-twin ATVs.

Special Tools and Repair Cautions

Tool references identify equipment such as the engine lifting tool P/N 529 036 022, MPI-2 interface P/N 529 036 018, drive-pulley puller P/N 529 035 746, and trailing-arm bearing installer/remover P/N 529 035 920. The manual warns that incorrect indexing of the PTO-cover plain bearing can block its oil feed and damage the engine, while sealant on a gearbox/AWD switch plunger can make the switch malfunction. Fuel-system, brake, CVT, and engine-removal work should be performed with the ATV secured and the manual's pressure-release, electrical-isolation, and lifting precautions observed.