Can-Am Outlander 800R 2009 2010 Repair Service Manual
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🏷️ Basic Information Identification Make: Can-Am Model: Outlander 800R Model Year: 2009, 2010 Product Type: Workshop Service Manual Codes Oem Manual Code: Not Specified (Industry Standard) 👋 Introduction Market Position Market Segment: Performance-oriented utility ATV (All-Terrain Vehicle). Competitive Analysis Competitors: Polaris Sportsman 800, Arctic Cat Thundercat 1000, Yamaha Grizzly 700, Suzuki KingQuad 750. Key Features Performance Focus: Known for its powerful V-twin engine, advanced suspension, and robust build for demanding off-road use. Target Audience: Enthusiasts, farmers, hunters, and recreational riders requiring a powerful and capable utility ATV. Manual Value Proposition Value For Mechanics: Essential resource for mechanical technicians, providing the in-depth knowledge required for accurate servicing and repairs. 📋 Manual Details Coverage Areas Coverage: Comprehensive coverage for 2009 and 2010 Can-Am Outlander 800R models, including all sub-variants and configurations. Page Count Page Count: Estimated 800+ pages (typical for this type of comprehensive manual). Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul of the Rotax 800cc V-twin engine, including fuel injection, ignition, lubrication, cooling, and exhaust systems. Transmission Drivetrain: Complete coverage of the CVT transmission, final drive, driveshafts, differentials (front and rear), and Visco-Lok system diagnostics and repair. Suspension Steering: Detailed procedures for front and rear suspension (independent dual A-arm, trailing arm), shocks, springs, steering linkage, hub assemblies, and wheel bearings. Brakes: Front and rear brake system diagnostics, caliper overhaul, rotor replacement, hydraulic system bleeding, parking brake adjustments, and ABS system information (if applicable). Electrical Electronics: Comprehensive wiring diagrams, troubleshooting guides for the electrical system, battery, charging system (alternator/stator, rectifier/regulator), starter motor, lighting, instrumentation, and EFI control module. Body Frame: Body panel removal and installation, seat, rack, and fairing maintenance, frame inspection and repair guidelines. Cooling System: Radiator, fan, thermostat, coolant hose inspection and replacement, coolant type and capacity specifications. Fuel System: Fuel pump, injectors, fuel filter replacement, fuel tank servicing, pressure testing. Procedures Included Preventative Maintenance: Scheduled maintenance intervals, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain/belt adjustments (if applicable), brake fluid flushes, and general inspections. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts, error code interpretation for EFI system. Repair Rebuild: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all major systems. Component Special Procedures: Specific torque specifications for critical fasteners, timing procedures, valve clearance adjustments, clutch adjustments, and special tool requirements. Technical Depth Depth Of Coverage: Highly detailed, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic fluid checks to complete engine and transmission rebuilds. Diagnostic Capability: Includes diagnostic flowcharts, component testing procedures, and information on using diagnostic tools (e.g., BUDS system, though specific BUDS usage might be in specialized documentation). 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans, ensuring clear diagrams, schematics, and text. Optimized for digital viewing and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchability: Text-searchable PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 4-stroke V-twin, liquid-cooled, SOHC, 8 valves Displacement: 799.9 cc Bore X Stroke: 92 mm x 75 mm Compression Ratio: 9.6:1 Performance Horsepower Estimate: Approximately 71 hp (specifications may vary slightly by year and tuning). Torque Estimate: Approximately 56 lb-ft (specifications may vary slightly by year and tuning). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with 54mm throttle body. Fuel Type: Unleaded gasoline, minimum 87 octane. Ignition Ignition System: Magneto, electronic ignition with high-output coils. Lubrication Oil Type Specification: SAE 10W-40 Synthetic ATV Oil meeting API GL-4 specifications (refer to manual for exact OEM spec). Example: XPS Synthetic 4T 10W-40. Oil Capacity: Approximately 2.2 L (with filter change). Cooling System Cooling Medium: Ethylene Glycol based antifreeze and water mixture (50/50). Coolant Capacity: Approximately 3.5 L. 🔧 Transmission Standard Transmission Type: CVT (Continuously Variable Transmission) with rapid engagement clutch. Transmission Gearing: High, Low, Neutral, Reverse, Park. Drive Select: 2WD/4WD with Visco-Lok front differential. Features Clutch Type: CVT with secondary roller cam clutch. Gear Reduction Ratios: High/Low gear reduction ratios specified in manual for precise adjustments and diagnostics. Fluid Specifications Cvt Fluid: Refer to manual for specific CVT fluid type (e.g., XPS Synthetic CVT Fluid or equivalent meeting Can-Am specifications). 📐 Dimensions Exterior Length: Approximately 217.2 cm (85.5 in) Width: Approximately 116.8 cm (46 in) Height: Approximately 104.1 cm (41 in) Wheelbase: Approximately 131.5 cm (51.8 in) Weights Dry Weight: Approximately 294 kg (648 lbs) Ground Clearance: Approximately 27.9 cm (11 in) Cargo Rack Capacity Front: 100 kg (220 lbs) Rack Capacity Rear: 200 kg (440 lbs) Towing Towing Capacity: 590 kg (1,300 lbs) Tires Front Tire Size: 25 x 8-12 Rear Tire Size: 25 x 10-12 Wheels Wheel Bolt Pattern: 4x137 mm (Industry Standard for Can-Am ATVs)...
Known for its powerful V-twin engine, advanced suspension, and robust build for demanding off-road use.
Target Audience:
Enthusiasts, farmers, hunters, and recreational riders requiring a powerful and capable utility ATV.
Manual Value Proposition
Value For Mechanics:
Essential resource for mechanical technicians, providing the in-depth knowledge required for accurate servicing and repairs.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive coverage for 2009 and 2010 Can-Am Outlander 800R models, including all sub-variants and configurations.
Page Count
Page Count:
Estimated 800+ pages (typical for this type of comprehensive manual).
Manual Type
Manual Type:
Repair Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul of the Rotax 800cc V-twin engine, including fuel injection, ignition, lubrication, cooling, and exhaust systems.
Transmission Drivetrain:
Complete coverage of the CVT transmission, final drive, driveshafts, differentials (front and rear), and Visco-Lok system diagnostics and repair.
Suspension Steering:
Detailed procedures for front and rear suspension (independent dual A-arm, trailing arm), shocks, springs, steering linkage, hub assemblies, and wheel bearings.
Brakes:
Front and rear brake system diagnostics, caliper overhaul, rotor replacement, hydraulic system bleeding, parking brake adjustments, and ABS system information (if applicable).
Electrical Electronics:
Comprehensive wiring diagrams, troubleshooting guides for the electrical system, battery, charging system (alternator/stator, rectifier/regulator), starter motor, lighting, instrumentation, and EFI control module.
Body Frame:
Body panel removal and installation, seat, rack, and fairing maintenance, frame inspection and repair guidelines.
Cooling System:
Radiator, fan, thermostat, coolant hose inspection and replacement, coolant type and capacity specifications.
Scheduled maintenance intervals, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain/belt adjustments (if applicable), brake fluid flushes, and general inspections.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts, error code interpretation for EFI system.
Repair Rebuild:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all major systems.
Component Special Procedures:
Specific torque specifications for critical fasteners, timing procedures, valve clearance adjustments, clutch adjustments, and special tool requirements.
Technical Depth
Depth Of Coverage:
Highly detailed, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic fluid checks to complete engine and transmission rebuilds.
Diagnostic Capability:
Includes diagnostic flowcharts, component testing procedures, and information on using diagnostic tools (e.g., BUDS system, though specific BUDS usage might be in specialized documentation).
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, ensuring clear diagrams, schematics, and text. Optimized for digital viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchability:
Text-searchable PDF for quick information retrieval.
Approximately 71 hp (specifications may vary slightly by year and tuning).
Torque Estimate:
Approximately 56 lb-ft (specifications may vary slightly by year and tuning).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with 54mm throttle body.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Ignition
Ignition System:
Magneto, electronic ignition with high-output coils.
Lubrication
Oil Type Specification:
SAE 10W-40 Synthetic ATV Oil meeting API GL-4 specifications (refer to manual for exact OEM spec). Example: XPS Synthetic 4T 10W-40.
Oil Capacity:
Approximately 2.2 L (with filter change).
Cooling System
Cooling Medium:
Ethylene Glycol based antifreeze and water mixture (50/50).
Coolant Capacity:
Approximately 3.5 L.
🔧 Transmission
Standard
Transmission Type:
CVT (Continuously Variable Transmission) with rapid engagement clutch.
Transmission Gearing:
High, Low, Neutral, Reverse, Park.
Drive Select:
2WD/4WD with Visco-Lok front differential.
Features
Clutch Type:
CVT with secondary roller cam clutch.
Gear Reduction Ratios:
High/Low gear reduction ratios specified in manual for precise adjustments and diagnostics.
Fluid Specifications
Cvt Fluid:
Refer to manual for specific CVT fluid type (e.g., XPS Synthetic CVT Fluid or equivalent meeting Can-Am specifications).
📐 Dimensions
Exterior
Length:
Approximately 217.2 cm (85.5 in)
Width:
Approximately 116.8 cm (46 in)
Height:
Approximately 104.1 cm (41 in)
Wheelbase:
Approximately 131.5 cm (51.8 in)
Weights
Dry Weight:
Approximately 294 kg (648 lbs)
Ground Clearance:
Approximately 27.9 cm (11 in)
Cargo
Rack Capacity Front:
100 kg (220 lbs)
Rack Capacity Rear:
200 kg (440 lbs)
Towing
Towing Capacity:
590 kg (1,300 lbs)
Tires
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheels
Wheel Bolt Pattern:
4x137 mm (Industry Standard for Can-Am ATVs)
🛡️ Safety Features
Ratings
Crash Test Data:
ATVs are not typically subjected to the same crash test ratings as passenger vehicles. Safety information focuses on proper operation and protective gear.
Active Features
Braking System:
Hydraulically activated front and rear disc brakes with perforated rotors.
Differential Lock:
Visco-Lok auto-locking front differential enhances traction in challenging terrain.
Passive Features
Roll Cage Protection:
Not applicable for this ATV model. Emphasizes operator awareness and adherence to safe riding practices.
Operator Safety
Recommended Gear:
Helmet, eye protection, gloves, long sleeves, long pants, and sturdy footwear are strongly recommended for all riders.
💡 Technology Features
Infotainment
Instrumentation:
Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, 4x4 indicator, gear indicator, and diagnostic indicators.
Driver Assistance
Traction Control:
Visco-Lok front differential acts as a form of traction enhancement by automatically locking when wheel slippage is detected.
Connectivity
Diagnostic Port:
Includes diagnostic port for connection to BUDS (BRP Utility Diagnostic System) for advanced diagnostics and module programming (BUDS software not included in this manual).
🔧 Maintenance
Service Intervals
Initial Service:
First service typically recommended around 10 hours or 1 month of operation (refer to manual for exact break-in procedure).
Routine Maintenance:
Engine oil and filter: every 100 hours or 6 months. Air filter: check every 20 hours, clean/replace as needed. Spark plugs: every 200 hours or 1 year. CVT belt inspection: every 100 hours.
Lubrication Points:
Refer to manual for specific lubrication points such as pivot points, steering components, and driveshaft U-joints (if applicable).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Specifications:
50/50 mix of permanent ethylene glycol antifreeze and distilled water.
Known Issues
Common Wear Items:
CVT belt wear, front differential (Visco-Lok) engagement issues under heavy load, suspension bushings, and wheel bearings are common wear items due to demanding use.
Electrical System Considerations:
Battery health and charging system (stator/rectifier) are critical for EFI system operation. Corrosion in electrical connectors can also be an issue.
Diagnostic Tips
Efi Troubleshooting:
The manual provides detailed steps for diagnosing EFI issues, including checking sensors, fuel pressure, and ignition timing.
📚 Vehicle History
Brand Heritage
Parent Company:
Bombardier Recreational Products (BRP), a Canadian company with a long history in powersports.
Model Evolution
Outlander Lineage:
The Outlander line has been a cornerstone of Can-Am's ATV offerings, continually evolving in performance, technology, and utility features.
Production
Manufacturing Location:
Primarily manufactured in Quebec, Canada.
Model Development Context
Outlander 800R Introduction:
The 800R model represented a significant step up in engine performance and features within the utility ATV segment, establishing Can-Am as a major player.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2009-2010 Outlander 800R are not widely documented, Can-Am ATVs have consistently received positive reviews for performance and innovation within the powersports industry.
Ratings
Consumer Reviews:
Generally well-regarded for its powerful engine and capable chassis by ATV enthusiasts and publications.