2013-2014 Can-Am Outlander/Outlander X mr/Renegade ATVs OEM Service & Repair Manual

2013 Shop Manual Outlander TM 500/650/800R/1000 Renegade TM 500/800R/1000 Outlander TM X mr 650/1000

Table of Contents Technical Specifications Outlander Series (500/650/800R/1000) p 5 Outlander Series X mr (650/1000) p 21 Renegade Series (500/800R/1000) p 32 Safety Notice and Introduction Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 44 Outlander Series X mr (650/1000) p 55 Service Tools Index (all models) p 58 Break-In Inspection (all models) p 60 Periodic Maintenance Schedule (all models) p 61 Periodic Maintenance Procedures (all models) p 65 Storage Procedure (all models) p 89 Special Procedures (all models) p 93 Engine Removal and Installation (all models) p 95 Air Intake System Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 102 Outlander Series X mr (650/1000) p 107 Exhaust System (all models) p 111 Lubrication System (all models) p 116 Cooling System Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 127 Outlander Series X mr (650/1000) p 148 Magneto System (all models) p 170 Intake Manifold (all models) p 180 Top End (all models) p 182 Timing Chain (all models) p 208 Bottom End (all models) p 219 Continuously Variable Transmission (CVT) Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 242 Outlander Series X mr (650/1000) p 265 Gearbox and 4x4 Coupling Unit 500/650/800R models p 288 1000 models p 319 Shifter (all models) p 345 Engine Management System (all models) p 350 Electronic Fuel Injection (EFI) (all models) p 454 Fuel Tank and Fuel Pump (all models) p 478 Power Distribution and Grounds (all models) p 498 Wiring Harness and Connectors (all models) p 501 Ignition, Charging, and Starting Systems (all models) p 529 Lights, Gauge, and Accessories (all models) p 549 Front and Rear Drives (all models) p 572 Wheels and Tires Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 596 Outlander Series X mr (650/1000) p 600 Steering System Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p 603 Outlander Series X mr (650/1000) p 618

Table of Contents (Continued) Dynamic Power Steering (DPS) (all models) p 630 Front Suspension (all models) p 656 Rear Suspension (all models) p 663 Air Controlled Suspension (ACS) Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p673 Outlander Series X mr (650/1000) p696 Brakes Outlander (500/650/800R/1000) and Renegade Series (500/800R/1000) p719 Outlander Series X mr (650/1000) p737 Body Outlander Series p 750 Outlander Series X mr p 776 Renegade Series p 799 Frame p 811 Wiring Diagrams p 814 Additional Information and Bulletins p 823

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) OUTLANDER SERIES (500/650/800R/1000) SERVICE PRODUCTS Description Part Number Page CV GREASE ................................................................................... 293 550 019 ........................................... 11 XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......................... 293 600 121 ............................................. 5 XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) ......................... 293 600 112 ............................................. 5 XPS SYNTHETIC GEAR OIL (75W 140) ........................................ 293 600 140 ....................................... 7, 11 XPS SYNTHETIC GEAR OIL (75W 90) .......................................... 293 600 043 ........................................... 11 ENGINE 500 ROTAX ® 490, 4-stroke, 2 cylinders (V-twin), liquid cooled 650 ROTAX ® 660, 4-stroke, 2 cylinders (V-twin), liquid cooled 800R ROTAX ® 810, 4-stroke, 2 cylinders (V-twin), liquid cooled Engine type 1000 ROTAX ® 1010, 4-stroke, 2 cylinders (V-twin), liquid cooled Valvetrain 4 valves/cylinder (mechanical adjustment), single over head camshaft (SOHC) with timing chain 500 650 82 mm (3.23 in) Bore 800R 1000 91 mm (3.58 in) 500 47.3 mm (1.86 in) 650 800R 61.5 mm (2.42 in) Stroke 1000 75 mm (2.95 in) 500 500 cm³ (30.5 in³) 650 650 cm³ (39.7 in³) 800R 799 cm³ (48.8 in³) Displacement 1000 976 cm³ (59.6 in³) 500 10.6:1 650 800R 10.3:1 Compression ratio 1000 10.5:1 500 650 8000 rpm Maximum HP RPM 800R 1000 7000 rpm Exhaust system Spark arrestor approved by USDA Forest Service Air filter Synthetic paper filter with foam 500 3° BTDC Intake valve opening 650 800R 1000 5° BTDC

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) 500 34° ABDC 650 800R 45° ABDC Intake valve closing 1000 60° ABDC 500 39° BBDC 650 50° BBDC Exhaust valve opening 800R 1000 55° BBDC 500 2° ATDC 650 0° ATDC Exhaust valve closing 800R 1000 5° ATDC Intake 0.06 mm to 0.14 mm (.0024 in to .0055 in) Valve clearance Exhaust 0.11 mm to 0.19 mm (.0043 in to .0075 in) New 4.966 mm to 4.980 mm (.1955 in to .1961 in) Intake Service limit 4.930 mm (.1941 in) New 4.956 mm to 4.970 mm (.1951 in to .1957 in) Valve stem diameter Exhaust Service limit 4.930 mm (.1941 in) New 0.005 mm (.0002 in) Valve out of round Intake and exhaust Service limit 0.06 mm (.0024 in) New 4.998 mm to 5.018 mm (.1968 in to .1976 in) Valve guide diameter Service limit 5.050 mm (.1988 in) New 40.81 mm (1.607 in) Valve spring free length Service limit 39.00 mm (1.535 in) New 1.05 mm to 1.35 mm (.041 in to .053 in) Intake Service limit 1.8 mm (.071 in) New 1.25 mm to 1.55 mm (.049 in to .061 in) Valve seat contact width Exhaust Service limit 2 mm (.079 in) New 12.036 mm to 12.050 mm (.4739 in to .4744 in) Rocker arm bore diameter Service limit 12.060 mm (.4748 in) New 12.000 mm to 12.018 mm (.4724 in to .4731 in) Rocker arm shaft diameter Service limit 11.990 mm (.472 in) New 81.950 mm to 81.966 mm (3.2264 in to 3.227 in) 500 650 Service limit 81.850 mm (3.2224 in) New 90.950 mm to 90.966 mm (3.5807 in to 3.5813 in) Piston diameter 800R 1000 Service limit 90.900 mm (3.5787 in) New 0.057 mm to 0.087 mm (.0022 in to .0034 in) 500 650 Service limit 0.100 mm (.0039 in) New 0.027 mm to 0.057 mm (.0011 in to .0022 in) Piston/cylinder clearance 800R 1000 Service limit 0.100 mm (.0039 in) 1 st Upper compression ring, rectangular 2 nd Lower compression ring, tapered face Piston ring type 3 rd Oil scraper ring

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) New 0.20 mm to 0.40 mm (.008 in to .016 in) Rectangular Service limit 0.60 mm (.024 in) New 0.20 mm to 0.40 mm (.008 in to .016 in) Tapered face Service limit 0.70 mm (.028 in) New 0.20 mm to 0.70 mm (.008 in to .028 in) Ring end gap Oil scraper ring Service limit 1.00 mm (.039 in) New 0.03 mm to 0.07 mm (.0012 in to .0028 in) Rectangular Service limit 0.15 mm (.0059 in) New 0.02 mm to 0.06 mm (.0008 in to .0024 in) Tapered face Service limit 0.15 mm (.0059 in) New 0.01 mm to 0.18 mm (.0004 in to .0071 in) Ring/piston groove clearance Oil scraper ring Service limit 0.25 mm (.0098 in) 500 650 82.023 mm to 82.037 mm (3.2293 in to 3.2298 in) Cylinder bore 800R 1000 New 90.993 mm to 91.007 mm (3.5824 in to 3.583 in) Maximum New 0.038 mm (.0015 in) Cylinder taper Service limit 0.090 mm (.0035 in) Maximum New 0.015 mm (.0006 in) Cylinder out of round Service limit 0.020 mm (.0008 in) New 34.959 mm to 34.975 mm (1.3763 in to 1.377 in) Timing chain side Service limit 34.950 mm (1.376 in) New 21.959 mm to 21.980 mm (.8645 in to .8654 in) Camshaft main bearing journal Spark plug side Service limit 21.950 mm (.8642 in) New 35.000 mm to 35.025 mm (1.378 in to 1.3789 in) Timing chain side Service limit 35.040 mm (1.3795 in) New 22.000 mm to 22.021 mm (.8661 in to .867 in) Camshaft main bearing journal bore Spark plug side Wear limit 22.040 mm (.8677 in) New 31.830 mm to 32.030 mm (1.2531 in to 1.261 in) 500 Service limit 31.810 mm (1.2524 in) New 32.11 mm to 32.31 mm (1.2642 in to 1.272 in) 650 Service limit 32.09 mm (1.2634 in) New 32.890 mm to 33.090 mm (1.2949 in to 1.3028 in) 800R Service limit 32.870 mm (1.2941 in) New 32.960 mm to 33.160 mm (1.2976 in to 1.3055 in) Intake valve 1000 Service limit 32.940 mm (1.2969 in) New 31.830 mm to 32.030 mm (1.2531 in to 1.261 in) 500 Service limit 31.810 mm (1.2524 in) New 31.940 mm to 32.140 mm (1.257 in to 1.265 in) 650 Service limit 32.090 mm (1.2634 in) New 32.950 mm to 33.150 mm (1.2972 in to 1.3051 in) 800R Service limit 32.930 mm (1.2965 in) New 32.860 mm to 33.060 mm (1.2937 in to 1.3016 in) Camshaft lobe Exhaust valve 1000 Service limit 32.840 mm (1.2929 in) vmr2012-045 3

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) ENGINE (CONT'D) New 42.016 mm to 42.040 mm (1.6542 in to 1.6551 in) Crankshaft main bearing journal diameter (MAG/PTO side) Service limit 42.000 mm (1.6535 in) Crankshaft radial play (MAG/PTO side) Service limit 0.07 mm (.0028 in) New 34.004 mm to 34.020 mm (1.3387 in to 1.3394 in) Crankshaft bearing journal diameter (in PTO cover) Service limit 33.998 mm (1.3385 in) Crankshaft radial play (PTO cover bearing) Service limit 0.10 mm (.0039 in) New 0.200 mm to 0.500 mm (.0079 in to .0197 in) Crankshaft axial play Service limit 0.600 mm (.0236 in) New 35.064 mm to 35.080 mm (1.3805 in to 1.3811 in) 500 Service limit 35.050 mm (1.3799 in) New 40.009 mm to 40.025 mm (1.5752 in to 1.5758 in) 650 800R Service limit 39.990 mm (1.5744 in) New 41.986 mm to 42.010 mm (1.653 in to 1.6539 in) Crankshaft pin diameter 1000 Service limit 41.967 mm (1.6522 in) Crankshaft deflection MAG/PTO side New 0.050 mm (.002 in) Crankcase plain bearing MAG/PTO side Service limit 42.100 mm (1.6575 in) PTO cover plain bearing Service limit 34.120 mm (1.3433 in) 500 35.150 mm (1.384 in) 650 800R 40.100 mm (1.579 in) Connecting rod big end diameter 1000 Service limit 42.100 mm (1.6575 in) Connecting rod big end radial play Service limit 0.09 mm (.0035 in) 500 650 800R 0.200 mm to 0.500 mm (.008 in to .02 in) 1000 New 0.250 mm to 0.550 mm (.0098 in to .0217 in) Connecting rod big end axial play 500 650 800R 1000 Service limit 0.600 mm (.024 in) New 18.010 mm to 18.020 mm (.7091 in to .7094 in) 500 Service limit 18.060 mm (.711 in) New 20.010 mm to 20.020 mm (.7878 in to .7882 in) 650 800R Service limit 20.060 mm (.7898 in) New 22.010 mm to 22.020 mm (.8665 in to .8669 in) Connecting rod small end diameter 1000 Service limit 22.050 mm (.8681 in) New 17.996 mm to 18.000 mm (.7085 in to .7087 in) 500 Service limit 17.980 mm (.708 in) New 19.996 mm to 20.000 mm (.7872 in to .7874 in) 650 800R Service limit 19.980 mm (.787 in) New 21.996 mm to 22.000 mm (.866 in to .866 in) Piston pin diameter 1000 Service limit 21.980 mm (.8654 in) Connecting rod/piston pin clearance (radial play) Service limit 0.080 mm (.0031 in) 4 vmr2012-045

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) LUBRICATION SYSTEM Type Wet sump. Replaceable cartridge oil filter Oil filter BRP Rotax paper type, replaceable Engine oil pressure Minimum 300 kPa (44 PSI) at 6000 RPM Capacity (oil change with filter) 2.0 L (2.1 qt (U.S. liq.)) Engine oil Recommended For the summer season, use XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) (P/N 293 600 121). For the winter season, use XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) (P/N 293 600 112). If not available, use a 5W40 motor oil that meets the requirements for API service classification SG, SH or SJ COOLING SYSTEM Type Ethyl glycol/water mix (50% coolant, 50% water). Use premixed coolant sold by BRP (P/N 219 700 362) or coolant specifically designed for aluminum engines 500/650/800R 3.4 L (.9 U.S. gal.) Coolant Capacity 1000 3.5 L (.9 U.S. gal.) Starts to open 65°C (149°F) Thermostat Fully open 75°C (167°F) Radiator cap opening pressure 110 kPa (16 PSI) TRANSMISSION Type CVT (Continuously Variable Transmission) Engagement RPM 1650 ± 100 RPM Drive belt width Service limit 30.00 mm (1.181 in) New 13.70 mm to 13.80 mm (.539 in to .543 in) Governor cup roller outer diameter Service limit 13.20 mm (.52 in) New 8.05 mm to 8.15 mm (.317 in to .321 in) Governor cup roller inner diameter Service limit 9.00 mm (.354 in) New 6.078 mm to 6.100 mm (.239 in to .24 in) Centrifugal lever pivot bolt diameter Service limit 6.000 mm (.236 in) New 6.035 mm to 6.078 mm (.2376 in to .2393 in) Centrifugal lever bore diameter Service limit 6.200 mm (.244 in) New 6.113 mm to 6.171 mm (.241 in to .243 in) Drive pulley sliding half centrifugal lever pivot bolt bore diameter Service limit 6.300 mm (.248 in) vmr2012-045 5

Section 01 TECHNICAL SPECIFICATIONS Subsection 01 (OUTLANDER SERIES (500/650/800R/1000)) TRANSMISSION (CONT’D) New 55.000 mm to 55.040 mm (2.165 in to 2.167 in) Drive pulley sliding half large bushing Service limit 55.200 mm (2.173 in) New 32.000 mm to 32.040 mm (1.26 in to 1.261 in) Drive pulley sliding half small bushing Service limit 32.200 mm (1.268 in) 500 650 85 mm (3.346 in) Drive pulley spring free length 800R 1000 Service limit 105 mm (4.134 in) Drive pulley spring free squareness Service limit 4 mm (.157 in) New 9.2 mm to 9.4 mm (.362 in to .37 in) Spring sleeve length Service limit 9.0 mm (.354 in) New 30.060 mm to 30.100 mm (1.183 in to 1.185 in) Driven pulley sliding half bushing Service limit 30.200 mm (1.189 in) New 30.060 mm to 30.100 mm (1.183 in to 1.185 in) Driven pulley sliding fixed bushing Service limit 30.200 mm (1.189 in) Torque gear on driven pulley Service limit 7.500 mm (.295 in) 500 190 mm (7.48 in) Driven pulley spring free length 650 800R 1000 Service limit 125 mm (4.921 in) Driven pulley spring free squareness Service limit 3.8 mm (.15 in) GEARBOX Type Dual range (HI-LO) with park, neutral and reverse Angle Drive Subtransmission 32/13 = 2.462 High 35/28 = 1.250 Low 43/20 = 2.150 500 650 Reverse 31/14 = 2.214 Angle Drive Subtransmission 32/13 = 2.462 High 34/29 = 1.173 Low 43/20 = 2.150 800R Reverse 31/14 = 2.214 Angle Drive Subtransmission 37/15 = 2.467 Intermediate 45/44 = 1.023 High 37/33 = 1.121 Low 44/19 = 2.316 Gear Ratios 1000 Reverse 34/12 = 2.833 High 3,078 Low 5,293 500 650 Reverse 5,545 High 2,886 Low 5.292 800R Reverse 5,541 High 2,829 Low 5,842 Overall Gear Ratios 1000 Reverse 7,148 6 vmr2012-045

2013-2014 Can-Am Outlander/Outlander X mr/Renegade ATVs OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed