Can-Am Outlander & Renegade ATV Service Manual, 2013 (P/N 219 100 651)

This BRP-authored workshop manual covers 2013 Can-Am Outlander 500/650/800R/1000, including MAX models, and Renegade 500/800R/1000. It carries P/N 219 100 651 and a 2012 copyright. Equipped-model coverage includes applicable DPS and XT configurations, XT-P 800R/1000 models, the MAX 1000 LTD, and Renegade X xc 800R/1000 variants.

PDF Search, Wiring Detail and Page Count

Text search and wiring detail: Service text is searchable across the main workshop sections, although some figure labels and the four large-format wiring sheets are not text-searchable. There are no embedded PDF bookmarks. Small wiring labels require zooming; pin numbers, connector references, and wire-color codes are readable in enlarged views.

One printable 645-page PDF in English, including the cover and front matter, four Notes pages, and four large-format wiring sheets.

Engine, CVT and Electronic System Service

These selected service topics illustrate the manual’s coverage rather than reproduce its full contents. Other sections address beadlock-wheel service and winch-circuit testing.

• Engine repair: Step-by-step engine removal and installation, leak-down testing, cylinder-head repair, crankshaft and crankcase service, valve-clearance adjustment, and camshaft timing.

• CVT and gearbox: Drive and driven pulley disassembly, one-way bearing inspection, and separate gearbox/4x4 coupling chapters for 500/650/800R and 1000 models.

• EFI diagnosis: Fuel-pressure testing and injector diagnosis, B.U.D.S. fault-code procedures, CAN communication checks, and closed-throttle/idle-actuator resets.

• DPS and ACS: Equipped-model procedures for steering torque-offset resets, replacement DPS programming, and Air Controlled Suspension leak testing and component diagnosis.

• Brakes and suspension: Brake-system pressure validation, manual and vacuum bleeding, wheel-bearing replacement, and front suspension-arm and rear trailing-arm service.

• Electrical fault tracing: Vehicle wiring diagrams, connector pin-location views, harness routing and splice locations, and system-specific troubleshooting charts.

BRP primarily wrote this manual for mechanics and technicians already familiar with its service procedures; the work assumes proper hand tools and special service tools.

Engine Repair and Cooling-System Differences

Internal engine coverage extends to valve-guide replacement, piston-ring inspection, and crankcase plain-bearing replacement. Lubrication diagnosis covers the oil pump, pressure regulator, and oil cooler fitted to 800R/1000 engines.

Cooling sections distinguish the 1000’s in-line thermostat from the cylinder-head-mounted arrangement on 500/650/800R engines. Water-pump procedures separate seal replacement on an assembled engine from shaft replacement requiring engine disassembly.

The manual specifically warns that incorrect rotary-seal installation can break the water-pump shaft’s plastic drive gear.

Gearbox and Final-Drive Service Limits

The 1000 gearbox chapter documents gearbox position sensor (GBPS) re-zeroing after replacement of the gearbox, shift drum, sensor, or ECM. Its exploded view also identifies nonserviceable components whose failure requires gearbox replacement.

Front differential and rear final-drive procedures cover backlash and bearing-preload adjustment, with separate work on CV joints, boots, and propeller-shaft U-joints. The Visco-Lok shear pump is not serviceable; differential service should not be confused with rebuilding that sealed unit.

EFI, Electronic Controls and Equipped Chassis

ECM replacement coverage includes transferring vehicle data, D.E.S.S. key programming, and the required initialization work. Replacement multifunction-gauge setup is also documented.

Electrical repair sections cover throttle-position and manifold pressure/temperature sensor testing, stator continuity and insulation checks, charging-system output, and starter-solenoid voltage-drop diagnosis.

Programming and specified electronic tests require B.U.D.S. software and the MPI-2 interface; the PDF provides the procedures, not the diagnostic equipment. Connector instructions explain how direct probing of the ECM harness connector can enlarge terminals and cause intermittent contact faults.

For LTD suspension faults, the ACS chapter separates compressor, solenoid-valve, module, and pressure-transducer testing. It also covers air-hose replacement and shock-absorber inspection.

Separate Outlander and Renegade body chapters describe module and panel removal, including MAX-specific passenger and luggage components.

Wiring Diagrams and Workshop References

The G2 General System and Europe System wiring sheets are supplemented by dedicated DPS System, Brake System, and ACS System (LTD) circuits. Brake circuit layouts distinguish Outlander and Renegade configurations and CE versions.

The Fuel System Diagnostic Flow Chart helps distinguish pressure-supply faults from electrical problems before repair work is selected.

The five-page illustrated service-tool index gives part numbers and procedure references, including the camshaft timing tool (P/N 529 036 231), clutch puller (P/N 529 035 746), and ECM adapter tool (P/N 529 036 166).

Reference material includes torque tables, fluid capacities, wear limits, clearance specifications, and electrical test values. Break-in inspection checklists and periodic maintenance schedules address normal use and severe dusty conditions. Air-intake and exhaust service, storage, preseason preparation, and procedures for rollover or water immersion are included.

Mechanical training and proper equipment are needed for brake, pressurized-fuel, and rotating-CVT work; BRP specifies that drive-pulley repairs be performed by an authorized Can-Am dealer.

Fuel-Pressure and Piston-Clearance Examples

The fuel-system test specifies 350 ± 10 kPa at a supply voltage of 12 ± 0.1 V, with pressure assessed in static and running tests. The accompanying diagnostic material distinguishes rapid from slow pressure loss after shutdown.

For internal engine inspection, new piston-to-cylinder clearance is 0.057–0.087 mm on 500/650 engines and 0.027–0.057 mm on 800R/1000 engines. Separate service limits accompany these model-specific new-part specifications.