2014 Can Am Commander 800R 1000 UTV Repair Manual

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the 2014 Can-Am ™ Commander ™ as described in the model list in the INTRODUCTION. This SHOP MANUAL SUPPLEMENT must be used in conjunction with the 2013 CAN-AM COMMANDER SHOP MANUAL (P/N 219 100 661). Refer to this manual when a particular system is not covered in this supplement. This edition was primarily published to be used by technicians who are already familiar with all service procedures relating to BRP products. Technicians should attend training courses given by BRPTI. Please note that the instructions will apply only if proper hand tools and special service tools are used. The contents of this manual depicts parts and procedures applicable to the particular product at the time of writing. Service and warranty bulletins may be published to update the content of this manual. Dealer modifications that were carried out after manufacturing of the product, whether or not authorized by BRP, are not included. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or ex- act replicas of the parts. The use of BRP parts is most strongly recom- mended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. This manual emphasizes particular information de- noted by the following wording and symbols: WARNING Indicates a potential hazard that, if not avoided, could result in serious injury or death. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates an instruction which, if not followed, could result in severe damage to vehicle components or other property. NOTE: Indicates supplementary information required to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understand- ing of the information will promote its correct use. Always use common shop safety practices. It is understood that this manual may be trans- lated into another language. In the event of any discrepancy, the English version shall prevail. BRP disclaims liability for all damages and/or in- juries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. IV tmr2012-002

INTRODUCTION INTRODUCTION This shop manual covers the following BRP made 2014 Can-Am side-by-side vehicles. COMMANDER YEAR ENGINE MODEL MODEL NUMBER SERIAL NUMBER STD 6CEA, 6CEB, 6CEC DPS 6TEA, 6TEB 800R XT 6DEA, 6DEB, 6DEC STD 6AEA, 6AEB DPS 6PEA XT 6BEA, 6BEB, 6BED, 6BEE, 6BEF, 6BEG, 6BEH XT-P 6EEA, 6EEB, 6EEC 2014 1000 LTD 6GEA, 6GEB, 6GED All The information and component/system descrip- tions contained in this manual are correct at time of writing. BRP however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Due to late changes, there may be some differ- ences between the manufactured product and the description and/or specifications in this document. BRP reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. tmr2012-002 V

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SERVICE TOOLS INDEX BACKLASH MEASUREMENT TOOL (P/N 529 035 665) Page: 78, 92 CV BOOT CLAMP PLIER (P/N 529 036 120) Page: 77, 89 CV JOINT EXTRACTOR (P/N 529 036 005) Page: 77, 89 DIGITAL INDUCTION TACHOMETER (P/N 529 014 500) Page: 42 ECM ADAPTER TOOL (P/N 529 036 166) Page: 45, 56, 58–61 FLUKE 115 MULTIMETER (P/N 529 035 868) Page: 45, 51, 56, 59–60, 121, 124 OETIKER PLIERS (P/N 295 000 070) Page: 53, 149 PINION NUT SOCKET (P/N 529 036 274) Page: 94 SPANNER SOCKET (P/N 529 035 649) Page: 80 STEERING ALIGNMENT TOOL (P/N 529 036 059) Page: 99, 113 TRANSMISSION ADJUSTMENT TOOL (P/N 529 036 252) Page: 20 1

Section 01 MAINTENANCE Subsection 01 (BREAK-IN INSPECTION) BREAK-IN INSPECTION This vehicle should be serviced after the first 10 hours or 300 km (200 mi) of operation, whichever comes first, by an authorized Can-Am dealer. The break-in inspection is very important and must not be ne- glected. To clear the MAINTENANCE SOON reminder message in the multifunction gauge, refer to LIGHTS, GAUGE AND ACCESSORIES subsection. REPLACE ADJUST TIGHTEN LUBRICATE CLEAN BREAK-IN INSPECTION CHART INSPECT ENGINE Engine oil and filter X Valve clearance X X Engine Air Filter X Engine seals X Engine mounting fasteners X Exhaust system X COOLING SYSTEM Radiator/cooling system leak (leak test) X X FUEL SYSTEM Fuel lines, fuel rails, connections, check valves and fuel tank leak test X ELECTRICAL SYSTEM Battery connections X CVT TRANSMISSION CVT air inlet/outlet X X CVT air filter X X GEARBOX Gearbox oil X Vehicle speed sensor X DRIVE SYSTEM Front differential/rear final drive oil X Front differential/rear final drive (seals and vents) X Front and rear propeller shaft joints X X tmr2013-003 7

Section 01 MAINTENANCE Subsection 01 (BREAK-IN INSPECTION) REPLACE ADJUST TIGHTEN LUBRICATE CLEAN BREAK-IN INSPECTION CHART INSPECT WHEEL Wheel nuts/studs X X Wheel bearings X X Wheel beadlock (X model) X STEERING SYSTEM Steering system (column, bearing, etc.) X Front wheel alignment X BRAKES Brake fluid X OCCUPANT RESTRAINT SYSTEM Seat belts X Side nets X BODY/CHASSIS Cage fasteners X Upper and lower tailgates latches X Seats latch X 8 tmr2013-003

Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance is the owner's responsibility. The vehicle should be serviced as per the maintenance schedule. The following message appears in the gauge after every 50 hours of operation, to remind you of maintenance requirements: MAINTENANCE SOON. To erase message, refer to MULTIFUNCTION GAUGE (LCD) or MULTIFUNCTION GAUGE (ANALOG/DIGITAL) subsections. The maintenance schedule does not exempt the pre-ride inspection. WARNING Failure to properly maintain the vehicle according to the maintenance schedule and procedures can make it unsafe to operate. EVERY 750KM (500MI) OR 25 HOURS OF OPERATION (WHICHEVER COMES FIRST) Replace engine air filter (when riding in severe conditions) Clean the CVT air inlet/outlet Inspect and clean the CVT air filter Inspect the brake pads Tighten the wheel lug nuts Inspect the drive shaft boots and protectors Inspect passenger grab handles condition Inspect hitch condition Inspect driver and passenger seat latch operation Inspect tailgates latch operation LTD models only; inspect and clean the ACS compressor air filter (service more often if required under severe use such as dusty area, sand, snow, wet or muddy conditions) Tighten cage fasteners EVERY 1 500 KM (1,000 MI) OR 50 HOURS OF OPERATION (WHICHEVER COMES FIRST) Replace the engine air filter (when riding in normal conditions) Verify battery condition Inspect the front differential/rear final drive oil level Inspect the drive shaft joints condition Inspect the front/rear propeller shaft joint condition Grease the front/rear propeller shaft joints Inspect the tie rod ends Inspect shock absorbers for any leaks Lubricate shock absorber spherical bearings (XT-P and LTD models) Inspect and lubricate front suspension arms Inspect brake fluid level LTD models only; replace the ACS compressor air filter (service more often if required under severe use such as dusty area, sand, snow, wet or muddy conditions) Clean exhaust area tmr2014-006 1

Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) EVERY 3 000KM (2,000MI) OR 100 HOURS OF OPERATION OR 1 YEAR (WHICHEVER COMES FIRST) Inspect seat belts (check for any damages and proper operation) Inspect side nets (check for any damages and they must buckle properly) Replace the engine oil and filter Inspect and adjust the valve clearance Inspect and clean the muffler spark arrester Check engine coolant strength Inspect throttle body Clean the fuel pump pre-filter Inspect the fuel pump pressure Replace fuel vent breather filter Inspect the drive belt Inspect, clean and lubricate the drive and driven pulleys (including the one-way bearing) Inspect the gearbox oil level and condition Inspect wheel bearings Inspect the steering system (column, bearing, etc.) Inspect and clean the brake system Inspect frame for any damage Replace rear final drive oil Inspect centrifugal levers and rollers of drive pulley LTD models only; inspect ACS shock absorbers hoses and fittings 2 tmr2014-006

Subsection 02 (PERIODIC MAINTENANCE SCHEDULE) EVERY 6 000KM (4,000MI) OR 200 HOURS OF OPERATION OR 2 YEARS (WHICHEVER COMES FIRST) Replace the engine coolant Verify the cooling system and proceed with a cooling system leak test and a pressure cap test Verify the fuel system and perform a leak test Replace spark plugs Replace the front differential oil Replace gearbox oil Clean the vehicle speed sensor Replace the brake fluid tmr2014-006 3

Section 01 MAINTENANCE Subsection 03 (PERIODIC MAINTENANCE PROCEDURES) PERIODIC MAINTENANCE PROCEDURES SERVICE TOOLS Description Part Number Page TEST CAP ...................................................................................... 529 035 991 ........................................... 20 VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ..................................... 20, 31 SERVICE PRODUCTS Description Part Number Page BRAKE FLUID................................................................................ 293 600 131 ........................................... 31 BRP PREMIXED COOLANT .......................................................... 219 700 362 ........................................... 15 COSMO RUBBER GREASE .......................................................... 293 550 055 ........................................... 30 LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 25 SUSPENSION GREASE ................................................................. 293 550 033 ........................................... 29 XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......................... 293 600 121 ........................................... 14 XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) ......................... 293 600 112 ........................................... 14 XPS BRAKES AND PARTS CLEANER ........................................... 219 701 705 ..................................... 24, 30 XPS SYNTHETIC GEAR OIL (75W 140) ........................................ 293 600 140 ..................................... 24, 27 XPS SYNTHETIC GEAR OIL (75W 90) .......................................... 293 600 043 ........................................... 26 XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 30 GENERAL This subsection provides: – Fluid level verifications – Maintenance procedures. The following systems should be serviced according to the PERIODIC MAINTENANCE SCHED- ULE. PROCEDURES ENGINE (AIR INTAKE SYSTEM) Air Filter Replacement NOTICE Never modify the air intake system. Otherwise, engine performance degradation or damage can occur. The engine is calibrated to operate specifically with these components. Air Filter Replacement Guideline Air filter replacement should be adjusted according to riding conditions as it is critical to ensure proper engine performance and life span. Air filter replacement frequency must be in- creased for the following dusty conditions: – Riding on dry sand – Riding on dry dirt covered surfaces – Riding on dry gravel roads or similar conditions. NOTE: Riding in a group in these conditions would increase even more the air filter replacement requirement. Air Filter Removal Remove service cover. tmo2011-001-225_a 1. Service cover Release clamps and remove air filter housing cover. tmr2013-005 11

2014 Can Am Commander 800R 1000 UTV Repair Manual

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