2016 Can-Am Outlander MAX 650 XT Service & Repair Manual
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SAFETY NOTICE
SAFETY NOTICE
This shop manual supplement has been prepared
as a guide to correctly service and repair the 2016
Can-Am
™
Outlander ATVs as described in the
model list in the INTRODUCTION.
This edition was primarily published to be used
by mechanics and 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 in this manual
will apply only if proper hand tools and special ser-
vice 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.
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.
It is understood that certain modifications may
render use of the ATV illegal under existing fed-
eral, provincial and state regulations.
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 ve-
hicle components or other property.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understanding
of the information will promote its correct use.
Always observe common shop safety practice.
Unless otherwise noted, the engine must be
stopped and the key must be removed prior to
perform any services.
Torque wrench tightening specifications must be
strictly adhered to. Use the torque values and ser-
vice products as in the exploded views or in the
procedures when noted.
Locking devices when removed must be replaced
(e.g.: locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).
Hoses, cables and locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
When ordering parts always refer to the specific
model PARTS CATALOGS.
We strongly recommend that any services be car-
ried out and/or verified by a highly skilled profes-
sional mechanic.
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 con-
tents of this publication.
vmr2016-104 I
INTRODUCTION
INTRODUCTION
This shop manual supplement covers the follow-
ing BRP made 2016 Can-Am Outlander and Out-
lander MAX Series vehicles.
MODEL OPTION PACKAGE
DPS
PRO Outlander 570
XT
DPS
Outlander Max 570
XT
STD
DPS
PRO
XT
Outlander 650
XTP
STD
DPS
PRO
XT
Outlander Max 650
XTP
STD
DPS
XT
Outlander 850
XTP
DPS
XT Outlander Max 850
XTP
DPS
XT Outlander 1000R
XTP
DPS
LTD
PRO
XT
Outlander Max 1000R
XTP
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. 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, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)
vmr2012-002-002_a
TYPICAL
1. VIN (Vehicle Identification Number) location
A VIN (Vehicle Identification Number) decal is lo-
cated under the seat, and another on the forward
RH side of the lower frame member. A vin num-
ber is also stamped on the frame in this area.
VIN Decal Description
vmo2008-011-094_a
TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL
1. VIN (Vehicle Identification Number)
2. Manufacturing date and model number
II vmr2016-104
INTRODUCTION
vmr2015-005-003_a
TYPICAL — VEHICLE SERIAL NUMBER DECAL ON RH SIDE
OF FRAME
1. VIN (Vehicle Identification Number)
2. Vehicle manufacturing date and model number
ENGINE IDENTIFICATION
NUMBER (EIN)
vmr2016-005-001_a
LH SIDE OF 570 ENGINE
1. EIN (Engine Identification Number)
tmr2011-002-002_a
TYPICAL - RH SIDE OF OTHER ENGINES
1. Engine Identification Number (EIN)
ENGINE EMISSIONS
INFORMATION
MANUFACTURER'S
RESPONSIBILITY
Manufacturers of engines must determine the
exhaust emission levels for each engine horse-
power family and certify these engines with
the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.
DEALER RESPONSIBILITY
When servicing any vehicle that carry an emis-
sions control information label, adjustments must
be kept within published factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes.
OWNER RESPONSIBILITY
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone else to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EMISSION REGULATIONS
The vehicle you are servicing may have been
certified to applicable emission regulations in
your country or state. Not as an exhaustive list;
this may include standards for engine exhaust
emissions, crankcase emissions, permeation
emissions and evaporative emissions. Servic-
ing procedures in this manual must be strictly
followed in order to keep the vehicle within the
factory specifications. Failure to follow servicing
vmr2016-104 III
INTRODUCTION
procedures in this manual may lead a vehicle to
be out of compliance with applicable emission
regulations.
When servicing any vehicle; adjustments must be
kept within published factory specifications. Re-
placement or repair of any emission related com-
ponent must be executed in a manner that main-
tains emission levels within the applicable certifi-
cation standards. Nobody is allowed to modify the
engine in any manner that would alter the horse-
power or allow emission levels to exceed their
predetermined factory specifications. Exceptions
include manufacturer’s prescribed changes.
The owner/operator is required to have engine
maintenance performed to maintain emission lev-
els within the prescribed certification standards.
The owner/operator is allowed and should not
allow anyone else to modify the engine in any
manner that would alter the horsepower or allow
emissions levels to exceed their predetermined
factory specifications.
MANUAL INFORMATION
MANUAL PROCEDURES
Many of the procedures in this manual are inter-
related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained.
WARNING
Unless otherwise specified, the engine
should be turned OFF and cold for all main-
tenance and repair procedures.
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
vmr2012-002-001_a
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be
different from the ones of the parts catalogs.
When ordering parts always refer to the specific
model PARTS CATALOGS.
NOTICE
Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropri-
ate PARTS CATALOG to obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
rect fasteners could cause damage to the vehi-
cle.
MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various subsections,
and again, each subsection has one or more divi-
sions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.
IV vmr2016-104
INTRODUCTION
Typical_iso_2008_en
vmr2016-104 V
INTRODUCTION
typical_txt_2008_en
VI vmr2016-104
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, cotter pins, etc.).
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw in all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE
Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: Whenever possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
FASTENER GRADE/TORQUE
FASTENER
SIZE
5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4
1.5 – 2 N•m
(13 – 18 lbf•in)
2.5 – 3 N•m
(22 – 27 lbf•in)
3.5 N•m - 4 N•m
(31 lbf•in - 35 lbf•in)
4 N•m - 5 N•m
(35 lbf•in - 44 lbf•in)
M5
3 N•m - 3.5 N•m
(27 lbf•in - 31 lbf•in)
4.5 N•m - 5.5 N•m
(40 lbf•in - 49 lbf•in)
7 N•m - 8.5 N•m
(62 lbf•in - 75 lbf•in)
8 N•m - 10 N•m
(71 lbf•in - 89 lbf•in)
M6
6.5 N•m - 8.5 N•m
(58 lbf•in - 75 lbf•in)
8 N•m - 12 N•m
(71 lbf•in - 106 lbf•in)
10.5 – 15 N•m
(93 – 133 lbf•in)
16 N•m (142 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
vmr2016-104 VII
INTRODUCTION
FASTENER INFORMATION
NOTICE
Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENER
PROCEDURE
A00A6LA
TYPICAL — SELF-LOCKING FASTENER
The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to properly clean a
threaded hole, then use a solvent. Allow the sol-
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper
adhesion of the product used for locking the fas-
tener.
LOCTITE
®
THREADLOCKER
APPLICATION PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind
Holes
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
VIII vmr2016-104
INTRODUCTION
4. Apply several drops along the threaded hole
and at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud
Installation in Blind Holes
lmr2007-040-005_a
1. On stud threads
2. On threads and in the hole
3. On retaining nut threads
1. Clean threads (stud and hole) with solvent.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads and allow to dry.
3. Apply 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
NOTE: To avoid a hydro lock situation, do not ap-
ply too much Loctite.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
Threadlocker Application for
Pre-Assembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
1. Clean bolts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces.
5. Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Threadlocker Application for an
Adjustment Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
vmr2016-104 IX
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The Can-Am Outlander MAX 650 XT Service & Repair Manual is an essential resource for professional technicians and do-it-yourself mechanics alike. This complete official full factory service repair manual provides comprehensive guidance for repairing and maintaining the Can-Am Outlander MAX 650 XT.
Featuring easy-to-read text sections, high-quality diagrams, and step-by-step instructions, this manual covers all aspects of the machine, offering detailed insights for efficient repairs. Whether you're a professional mechanic or a DIY enthusiast, this manual equips you with the knowledge needed to make informed decisions about maintaining and repairing the Can-Am Outlander MAX 650 XT.
Upon purchase, you will receive instant access to the manual in either .PDF or .OVA file format, allowing you to start your repairs without any waiting or shipping delays. The manual includes critical specifications, illustrations, maintenance procedures, disassembly and assembly instructions, cleaning and reinstalling procedures, and much more.
With the ability to zoom in and out, this manual provides a user-friendly experience for all versions of Windows and Mac. It does not require any additional software and is delivered instantly upon purchase, ensuring a hassle-free experience.
In summary, the Can-Am Outlander MAX 650 XT Service & Repair Manual is a valuable resource that empowers both professional technicians and DIY enthusiasts to effectively maintain and repair the Can-Am Outlander MAX 650 XT.
