Can-Am Outlander/Renegade 800R/1000 ATV Manual Set, 2012 (P/N 219 100 542)

Use the Shop Manual for repair methods and the flat-rate schedule for the warranty labor operations it lists. The specification sheets and catalog provide separate model and accessory references.

Repair coverage: The Shop Manual covers the listed 2012 models. It does not provide 2013 or Outlander MAX repair procedures; additional models appearing in the reference publications do not expand its repair coverage.

PDF Search, Wiring Detail and Page Gaps

Text search and diagram detail: Most repair chapters have searchable text, and embedded bookmarks open repair and reference sections. Some specification and wiring pages lack searchable text. Small wiring labels are readable when enlarged.

The set comes as one printable, 779-page PDF in English, including the publications above, one introductory page and one blank page. Printed Shop Manual pages 554–555 and flat-rate schedule pages 3–4 are absent.

From Engine Teardown to EFI Fault Finding

These highlights are a selection of the contents. Further topics include storage preparation and procedures for submerged or rolled-over vehicles.

• Engine and maintenance: Step-by-step engine removal and installation, cylinder-head and valve repair, piston/ring inspection, timing-chain service, scheduled maintenance, and valve-clearance adjustment.

• CVT and gearboxes: Belt and clutch inspection, drive- and driven-pulley disassembly and reassembly, CVT air-guide service, separate 800R/1000 gearbox and 4x4 coupling procedures, and shifter adjustment.

• EFI and fuel diagnosis: Engine-management and CAN troubleshooting, MPI-2/B.U.D.S. fault-code diagnosis, ECM and injector tests, throttle-body sensors, fuel-tank leak testing, and fuel-pump service.

• Electrical systems: Ignition, charging and starting tests, D.E.S.S. key programming, power distribution, grounds, harness routing, splice locations, connector identification, and wiring diagrams.

• Driveline: Front and rear drive-shaft service, propeller shafts and U-joints, front differential and rear final-drive disassembly, inspection, and gear adjustment.

• Steering and suspension: DPS diagnosis and torque-offset reset, steering alignment, wheel-bearing replacement, shock and suspension-arm service, trailing arms, and anti-sway-bar procedures.

• Brakes and body: Hydraulic brake diagnosis, pressure validation and bleeding, caliper and master-cylinder work, disc/pad inspection, and separate Outlander/Renegade body-removal sections.

BRP wrote this edition primarily for mechanics and technicians already familiar with its service procedures; electronic diagnosis also requires the specified equipment and access to MPI-2/B.U.D.S.

Internal Engine Work and Assembly Cautions

Engine coverage includes mount replacement, air intake, exhaust, oil-pressure diagnosis, lubrication-system service and magneto work. Internal procedures extend to valve guides, cylinders, crankcases, drive gears and crankshafts, supported by exploded assemblies, component-specific torques, wear limits and clearances.

Cooling-system chapters cover thermostat and radiator checks, fan-circuit diagnosis, and water-pump service.

Assembly details: The front and rear camshafts differ; mixing them up can damage the engine. Incorrect water-pump rotary-seal installation can break the plastic pump-drive gear.

800R/1000 Gearbox Differences and CVT Limits

The 800R chapter covers gearbox-position indicator switches and the output-shaft coupling mechanism. The 1000 chapter documents the vehicle-speed sensor and gearbox-position sensor arrangement, including position-sensor initialization.

Drive-pulley repairs: The manual assigns these repairs to authorized Can-Am dealers because subcomponent installation and assembly tolerances require strict adherence to the specified procedures.

CVT pulley springs store force, while brake and steering repairs affect vehicle control. Review the applicable cautions and complete subsection before disassembly.

EFI Tests and Circuit References

Fuel-pressure and injector tests support fault isolation by distinguishing pressure-supply problems from leakage after shutdown. B.U.D.S. coverage includes monitoring functions, closed-throttle and idle-actuator resets, and ECM replacement setup. Replacement DPS units also require the applicable software and initialization.

Diagram references: General System, Brake Systems, DPS System and Europe System wiring diagrams accompany power-distribution views and the Fuel System Diagnostic Flow Chart. CE-market lighting, turn-signal, hazard and horn circuits are identified separately.

Factory Diagnostic and Service Tools

Diagnostic tool references identify the MPI-2 interface card P/N 529 036 018 and cable P/N 710 000 851.

Timing work calls for the camshaft timing tool P/N 529 036 231 and crankshaft TDC position tool P/N 529 036 201. CVT and steering procedures reference the clutch puller P/N 529 035 746 and steering alignment tool P/N 529 036 059.

Sample Valve-Clearance and Fuel-Pressure Data

For both 800R and 1000 engines, the valve-adjustment section specifies intake clearance of 0.06–0.14 mm and exhaust clearance of 0.11–0.19 mm with the engine cold.

For the covered EFI systems, the fuel-pressure specification is 350 kPa (51 PSI) in static and dynamic testing.