2008–2009 Can-Am Outlander 400 EFI / XT / MAX / MAX XT ATV Service Manual (P/N 219100311)

This BRP shop manual covers the 2008–2009 Can-Am Outlander 400 EFI, Outlander 400 EFI XT, Outlander MAX 400 EFI, and Outlander MAX 400 EFI XT. It covers maintenance, fault diagnosis, mechanical repair, and electrical testing.

• Scheduled maintenance: Service charts, preseason preparation, storage procedures, lubrication checks, and special procedures for a vehicle that has overturned or been submerged.

• Engine and cooling: Engine removal and installation, cylinder-head and crankcase disassembly, valve service, oil-pump inspection, radiator testing, and water-pump shaft and seal replacement.

• CVT and gearbox: Drive-belt replacement, pulley inspection and repair, gearbox disassembly, output-shaft measurements, shifter adjustment, and gearbox position-switch testing.

• Engine management and fuel: B.U.D.S. communication, fault-code tables, ECM replacement, sensor testing, throttle resets, injector checks, and fuel-tank and pump service.

• Electrical systems: Magneto/stator, ignition, charging and starting tests, multifunction-gauge diagnostics, Vehicle Speed Sensor (VSS) checks, lighting circuits, and XT winch controls.

• Drive and chassis: The 4x4 coupling unit, front and rear differentials, steering alignment, MacPherson struts, trailing arms, brake bleeding, body panels, and frame components.

Written primarily for mechanical technicians familiar with BRP service procedures, the manual assumes workshop experience and appropriate tools. Electronic diagnostics require access to B.U.D.S. software, a PC, the Multi-Purpose Interface-2 (MPI-2), and the specified diagnostic cable.

B.U.D.S., Sensors, and Fuel-System Diagnosis

The multifunction gauge displays active faults; B.U.D.S. also retrieves stored faults that are no longer active. This distinction helps technicians investigate intermittent complaints when the gauge no longer shows the original fault. ECM replacement and gauge matching receive separate treatment.

Sensor procedures cover the Throttle Position Sensor (TPS), Manifold Absolute Pressure and Temperature Sensor (MAPTS), Coolant Temperature Sensor (CTS), Crankshaft Position Sensor (CPS), and Idle Air Control Valve (IACV). Connector assignments, temperature/resistance tables, and power-distribution diagrams support component and wiring checks.

The fuel-system diagnostic flowchart links pressure findings to pump, regulator, injector, or leakage checks. Separate pump procedures distinguish the external fuel filter on 2008 models from the nonserviceable internal filter in the 2009 pump assembly.

The IACV's sensitive drive screw can be damaged by manually moving the piston or operating the valve outside the throttle body; the manual addresses this alongside removal and resetting requirements.

Engine, Transmission, and Chassis Repair

Cylinder leak testing helps distinguish leakage through valves, piston rings, or the head gasket before disassembly. Camshaft-timing illustrations accompany valve-train service, while crankshaft inspection, bearing clearances, gearbox backlash, and shim selection extend the coverage to internal repairs.

The cooling chapter addresses radiator, thermostat, fan, and water-pump service. Its seal-installation guidance warns that hammering the water-pump rotary seal can damage its ceramic element. CVT drive-pulley repairs are specifically reserved for authorized Can-Am dealers.

Front-differential exploded views support assembly identification and inspection. Chassis procedures cover trailing-arm bearings, suspension preload, steering geometry, and brake components; the illustrated front-brake circuits distinguish the 2009 CE configuration, including its brake circuit splitter.

Repair procedures include tightening torques, wear limits, and service-product references. Introductory material explains fastener grades, tightening sequences, and Loctite application.

Follow the manual's precautions for pressurized fuel and coolant, electrical isolation, and supported vehicle lifting.

Service Bulletins and Dealer References

Appended materials address radiator expansion-bottle vent routing, throttle opening, spring applications, high-altitude calibration, battery care, and B.U.D.S. communication tools. The Outlander 400 EFI communication guidance requires MPI-2; MPI-1 is incompatible.

A bulletin clarifies that the 2009 Outlander 400 EFI has no D.E.S.S. despite incorrectly fitted decals. Predelivery inspection instructions and a bilingual warranty labor-time schedule are also included. These broader references have their own model-applicability tables; they do not expand the main repair manual's coverage.

Selected Fuel-Pressure and Valve-Clearance Specifications

These selected specifications show the service data available for the Outlander 400 EFI series. At the fuel-pump outlet, the specified pressure is 350 kPa (51 psi) with the ignition on and the run/stop switch at RUN, and again with the engine running. With the engine cold, valve clearance is 0.06–0.14 mm (0.0024–0.0055 in) at the intake and 0.11–0.19 mm (0.0043–0.0075 in) at the exhaust. The corresponding procedures explain the test conditions and interpretation.

PDF Navigation, Wiring Detail, and Included Pages

Text search and diagram viewing: The main manual has an OCR text layer, with chapter and supplement bookmarks for navigation. OCR errors and some diagram labels limit text search. The General System wiring diagram is divided across several pages; small wire and connector labels are readable when enlarged.

The download contains one printable PDF with 594 pages total: 457 pages of main-manual text, illustrations, and reference material; 10 wiring-diagram pages; 65 pages of bulletins and predelivery material; and 62 pages of the English/French flat-rate schedule. Blank pages, an accessory-promotion page, and a parts-return form are already included in these totals.