2013 2014 can am renegade & outlander service manual
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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
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A complete service manual is available for the 2013-2014 Can-Am Outlander (all models), Outlander L (all models), Renegade (all models), and Outlander XMR. These manuals are essential resources for both professional mechanics and DIY enthusiasts, providing detailed technical information for maintenance, repair, and troubleshooting.
