Can-Am Outlander 500/650/800 & Renegade 500/800 – 2008 ATV Service Manual (P/N 219 100 273)

The 2008 Can-Am factory shop manual (P/N 219 100 273) covers the Outlander 500/650/800 and Renegade 500/800 series with Rotax V490, V660, and V810 engines, including the listed MAX, XT, and Ltd variants.

PDF Bookmarks and Wiring Detail

Navigation and small labels: PDF text search is not available. Embedded bookmarks link to major sections, service subsections, specifications, and wiring groups. Small wiring labels require zooming, and larger diagrams continue across consecutive pages.

One printable English PDF contains 504 pages, including the original cover, 18 preliminary pages, 19 blank separator pages, and one repeated troubleshooting page.

Rotax Engine, EFI, and Drivetrain Service

These selected service topics show the manual’s repair and diagnostic scope. Other covered subjects include XT winch testing and frame-welding precautions.

• Engine repair: Step-by-step engine removal and installation, cylinder-head service, valve adjustment, camshaft timing, piston inspection, crankcase separation, and crankshaft-bearing replacement.

• Cooling and lubrication: Cooling-system leak testing and bleeding, thermostat and radiator-fan diagnosis, water-pump shaft and seal replacement, oil-pressure testing, and oil-pump inspection.

• EFI diagnosis: Fault-code tables, injector and sensor tests, fuel-pressure checks, throttle-body replacement, and closed-throttle and idle-actuator resets.

• Electrical and DESS: Ignition, charging, and starting-system tests; Digitally Encoded Security System key programming; multifunction-gauge diagnosis; connector views; and wiring diagrams.

• CVT and gearbox: Drive-belt replacement, drive and driven pulley disassembly, one-way clutch inspection, internal gearbox service, and 4x4 coupling-unit diagnosis.

• Front and rear drive: Differential teardown, backlash and preload adjustment, drive-shaft boot replacement, and propeller-shaft U-joint service.

• Steering, suspension, and brakes: Steering alignment, wheel-bearing and ball-joint replacement, trailing-arm bearing service, master-cylinder and caliper repair, and brake bleeding.

Written primarily for mechanical technicians already familiar with BRP service procedures, this manual assumes the proper hand tools and special service equipment are available.

Maintenance and Internal Engine Work

The maintenance chart ties scheduled inspections to the relevant service sections. Preseason preparation, storage procedures, rollover checks, and separate short- and long-duration immersion procedures address work beyond routine oil and filter changes.

Engine sections distinguish front and rear cylinder components and engine-specific piston installation details. Exploded views show component orientation alongside assembly torques, supporting reassembly of the cooling, fuel, and brake systems.

The timing-chain section warns that incorrect tensioner adjustment can cause severe engine damage.

Water-pump service: Shaft and seal replacement requires engine removal but no crankcase split. Coolant and oil leaks are distinguished at the indicator hole; replacement instructions cover both seals together and a new shaft with the rotary seal.

B.U.D.S., Fuel-System Tests, and DESS

The engine-management system flow chart, fault-code table, fuel-system diagnostic flow chart, engine-connector pinout, and temperature-sensor chart connect symptoms to circuit and component checks. Injector, TPS, idle bypass valve, CPS, CAPS, MAPTS, and coolant-temperature sensor tests provide more detail than a code list alone.

B.U.D.S. procedures require a PC and an MPI or MPI-2 interface. The text covers component activation, ECM data transfer, required resets after replacement, and DESS key programming; further software-function details are referred to B.U.D.S. Help.

Terminal protection: The specified ECM adapter (P/N 420 277 010) supports probing without enlarging connector terminals, which can create intermittent electrical faults. Follow the manual’s precautions for pressurized fuel and electrical isolation.

CVT Diagnosis and Differential Setup

The hard-shifting chart considers idle control, linkage, one-way clutch lubrication, and friction-washer wear alongside internal gearbox faults. This gives technicians a way to assess related systems before committing to gearbox disassembly.

Gearbox and differential chapters explain shim selection, backlash measurements, and bearing preload. The manual specifies drive-pulley repairs for authorized Can-Am dealers and identifies the drive pulley puller (P/N 529 035 746).

Chassis Variants and Wiring References

Front-suspension procedures distinguish the Outlander 500 strut layout from the double A-arm arrangements on the larger Outlanders and Renegades. Rear suspension coverage includes torsion-bar and trailing-arm bearing work; brake chapters distinguish model-specific layouts and bleeding requirements.

Wiring sheets are labeled for Renegade 800 and Outlander 500/650/800. General-system diagrams accompany separate charging, starting, injection/ignition, distribution, and accessory circuits.

Examples of Valve Clearances and Fuel Test Data

For the covered Rotax engines, the valve-adjustment section specifies cold clearances of 0.06–0.14 mm at the intake valves and 0.11–0.19 mm at the exhaust valves.

The fuel-pump outlet pressure test specifies 350 kPa (51 PSI) with the ignition on, the run/stop switch in RUN, and a fully charged battery. The accompanying diagnosis distinguishes rapid from slow pressure loss.