2012 Can-Am Outlander/Renegade 800/1000 Series Shop Manual (P/N 219 100 542)

This 779-page PDF set is centered on BRP P/N 219 100 542, the factory 2012 Shop Manual for Can-Am Outlander (1-UP) and Renegade 800R/1000 ATVs built on the SST G2 chassis. The repair coverage is 2012 only; it is not a 2013 manual and does not provide Outlander MAX repair procedures. BRP states that this edition was primarily published for mechanics and technicians already familiar with BRP service procedures. Many operations also assume the specified special tools and access to MPI-2/B.U.D.S. diagnostics.

• Factory model identification: Outlander 800R, engine type 810 (2HCA and 2JCA–2JCF); Outlander 1000, type 1010 (5LCA, 5TCA–5TCH, and 5TCJ); Renegade 800R, type 810 (4BCA–4BCC and 4DCA); and Renegade 1000, type 1010 (4GCA and 5VCA–5VCC).
• Engine repair coverage runs from removal, installation, and mount replacement through air intake, exhaust, oil-pressure diagnosis, cooling-system service, and magneto work. Internal procedures address cylinder heads, camshafts, valves and guides, cylinders, pistons, rings, timing chains, crankcases, drive gears, and crankshafts.
• CVT and gearbox chapters cover belt inspection and replacement, drive- and driven-pulley disassembly and reassembly, clutch inspection, and the CVT air guide. Separate 800R and 1000 gearbox/4x4 coupling sections document the applicable sensors or switches, actuator, oil seals, internal teardown, inspection, assembly, and shifter service.
• EFI and electronic diagnosis covers the engine-management system, CAN communication, MPI-2 and B.U.D.S. use, monitoring functions, fault-code diagnosis, closed-throttle and idle-actuator resets, ECM and injector tests, throttle-body sensors, fuel-tank leak testing, fuel-pressure testing, pump service, and fuel-system troubleshooting charts.
• Electrical, driveline, and chassis work includes power distribution, grounds, harness routing and splice locations, ignition, charging, starting, D.E.S.S. key programming, front and rear drive shafts, front differential and rear final drive, propeller-shaft U-joints, DPS diagnosis and torque-offset reset, steering alignment, suspension, brake-pressure validation, calipers, master cylinder, and model-specific body removal.
• Diagram support includes General System, Brake Systems, DPS System, and Europe System wiring diagrams, along with connector identification and power-distribution views. Exploded assemblies are backed by component-specific torque data, pressure-test specifications, capacities, wear limits, clearances, and electrical test values.
• Included reference material: a 65-page 2011–12 Flat Rate Time Schedule identified by document code VTF2012-001.FM, 13 one-page 2012 model specification sheets, and a 97-page Genuine Parts/Accessories/Riding Gear catalog. These supplements broaden the reference material but do not extend the Shop Manual’s repair coverage to every model they mention.

800R/1000 Differences and Required Tooling

The 800R transmission chapter uses gearbox-position indicator switches and an output-shaft coupling mechanism, while the 1000 chapter documents the vehicle-speed sensor and gearbox-position sensor arrangement. Outlander and Renegade body sections are also separated, and CE-market lighting, turn-signal, hazard, horn, and Europe-system wiring information is clearly identified.

Factory tool callouts name the equipment needed before a repair begins. Diagnostic hardware includes the MPI-2 interface card P/N 529 036 018 and cable P/N 710 000 851. Engine, CVT, and steering work references the camshaft timing tool P/N 529 036 231, crankshaft TDC position tool P/N 529 036 201, clutch puller P/N 529 035 746, and steering alignment tool P/N 529 036 059.

Assembly Cautions and Known Scan Gap

The front and rear camshafts are not interchangeable; reversing them during assembly can damage the engine. The water-pump seal section also warns that incorrect rotary-seal installation can break the plastic water-pump gear. CVT pulley work involves stored spring force, while brake and steering repairs directly affect vehicle control, so the manual’s cautions and the complete applicable subsection should be reviewed before disassembly. The drive-pulley chapter specifically reserves those repairs for an authorized Can-Am dealer because its subcomponent installation and assembly tolerances require strict adherence to the factory procedure.

The full file contains 779 PDF pages: the 602-page BRP Shop Manual, the 65-page flat-rate schedule, 13 specification sheets, the 97-page catalog, one third-party introductory page, and one blank page. Printed Shop Manual pages 554–555 are absent from the scan; the gap falls within the Outlander technical-specification section.