2013 Can-Am Outlander 500/650/800R/1000 & Renegade 500/800R/1000 Service Manual (P/N 219 100 651)

• Covers 2013 Can-Am Outlander 500, 650, 800R, and 1000 models alongside Renegade 500, 800R, and 1000 series.
• Engine removal and installation, leak-down testing, cylinder-head repair, crankshaft and crankcase service, valve-clearance adjustment, and camshaft timing are covered.
• CVT and gearbox service includes drive and driven pulley disassembly, one-way bearing inspection, and separate gearbox/4x4 coupling chapters for 500/650/800R and 1000 models.
• Fuel-system pressure testing and injector diagnosis are backed by B.U.D.S. fault-code procedures, CAN communication checks, and closed-throttle/idle-actuator resets.
• Equipped-model coverage addresses Dynamic Power Steering (DPS) torque-offset resets and replacement-unit programming, plus Air Controlled Suspension (ACS) leak testing and component diagnosis.
• Brake-system pressure validation, manual and vacuum bleeding, wheel-bearing replacement, and front suspension-arm and rear trailing-arm service support chassis repair.
• Full-vehicle wiring diagrams, connector pin-location views, harness routing and splice locations, and system-specific troubleshooting charts support electrical fault tracing.

Model Coverage and Manual Identification

This BRP-authored workshop manual is a 645-page PDF, manual reference 219 100 651, with a 2012 copyright. Outlander coverage includes standard and MAX chassis, applicable DPS and XT configurations, XT-P 800R/1000 models, and the MAX 1000 LTD. Renegade coverage includes X xc 800R and 1000 variants. Engine identification tables distinguish Rotax 490, 660, 810, and 1010 engine types corresponding to the 500, 650, 800R, and 1000 designations.

Engine and Drivetrain Repair

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.

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 Shop References

Four large-format wiring sheets cover the G2 General System and Europe System, with dedicated DPS System, Brake System, and ACS System (LTD) circuits. The Fuel System Diagnostic Flow Chart helps distinguish pressure-supply faults from electrical problems. Brake circuit layouts distinguish Outlander and Renegade configurations and CE versions.

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).

Specification Highlights and Shop Maintenance

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.

This documentation is intended for professional reference. 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.