BRP Can-Am Outlander 500 650 800 MAX XT Renegade 500 800 Complete Workshop Service Repair Manual 2007 2008
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🏷️ Basic Information Identification Make: BRP Brand: Can-Am Model: Outlander MAX XT / Renegade Model Variants: 500, 650, 800 Model Years: 2007, 2008 Product Type: Complete Workshop Service Repair Manual Codes Engine Codes: Rotax V-Twin (specific codes vary by displacement) Chassis Codes: Outlander (XT/MAX), Renegade (specific chassis codes may apply based on sub-model) 👋 Introduction Market Position Segment: High-performance All-Terrain Vehicles (ATVs) and Side-by-Side (SxS) like platforms. Target Audience: Recreational riders, utility users, and professional service centers requiring in-depth technical information. Competitive Analysis Competitors: Polaris Sportsman/RZR, Yamaha Grizzly/Rhino, Arctic Cat Prowler/TRV. Key Differentiators: Rotax V-Twin engine performance, Visco-Lok differential, often advanced suspension geometry. Key Features Platform Versatility: Covers both the Outlander (utility/rec) and Renegade (sport/rec) lines, and MAX (2-up) variants. Comprehensive Coverage: Addresses the needs of owners and technicians for detailed repair and maintenance across multiple configurations. 📋 Manual Details Coverage Areas Vehicle Coverage: Can-Am Outlander 500, Outlander 650, Outlander 800, Outlander MAX 500, Outlander MAX 650, Outlander MAX 800, Renegade 500, Renegade 800 Year Coverage: 2007, 2008 Page Count Estimated Page Count: Over 1000 pages (typical for complete workshop manuals covering multiple models and years) Manual Type Type: Workshop Service Repair Manual Purpose: Comprehensive repair, maintenance, and troubleshooting guide for technicians and experienced DIY users. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair procedures, specifications, and overhaul for Rotax V-twin engines (500cc, 650cc, 800cc). Fuel System: Fuel injection system (EFI), fuel pump, injectors, pressure regulator, throttle body, fuel tank, lines. Ignition System: Ignition coils, spark plugs, CDI unit, sensors. Cooling System: Radiator, coolant, water pump, thermostat, fan, hoses, lines. Exhaust System: Muffler, catalytic converter (if applicable), exhaust pipes, heat shields. Transmission: CVT transmission, drive clutch, driven clutch, belt replacement, gearcase (front and rear differentials), lubrication. Drivetrain: Driveshafts (front and rear), U-joints, CV joints, wheel hubs, propeller shafts. Suspension: Front and rear suspension systems, A-arms, shocks, springs, bushings, linkages, adjustment procedures. Brakes: Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake rotors, bleeding procedures. Steering: Handlebar steering, tie rods, steering rack, bushings, alignment, power steering (if equipped). Electrical System: Wiring diagrams, charging system (stator, rectifier/regulator), battery, starter motor, lighting, switches, fuses, relays, ECU/ECM diagnostics. Body And Frame: Frame inspection and repair, body panels, fenders, racks, seats, plastic components, decals. Accessories: Installation and troubleshooting for common factory accessories (e.g., winches, windshields). Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, valve adjustments, coolant flushes, brake fluid replacement, belt inspection/replacement, lubrication points. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation. Repair: Step-by-step instructions for component removal, installation, and repair for all covered systems. Overhaul: Complete engine and transmission overhaul procedures, including torque specifications and clearances. Diagnosis: Detailed diagnostic flowcharts and procedures for electrical, fuel, and mechanical systems. Technical Depth Depth: Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, electrical diagnostics, and frame work. User Level: Professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format Type: PDF (Portable Document Format) Searchable Text: Yes (typically, depending on the PDF conversion quality) Print Quality Resolution: High (suitable for clear viewing of diagrams and text) Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC V-twin (Rotax) Displacements: 499cc (500), 650cc (650), 799.8cc (800) Performance Horsepower Approx 500: ~30-35 HP (Varies by tuning and year) Horsepower Approx 650: ~50-55 HP (Varies by tuning and year) Horsepower Approx 800: ~60-65 HP (Varies by tuning and year) Torque Specs: Detailed torque specifications for critical engine components (e.g., cylinder head bolts, connecting rods, crankshaft) found within the manual. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Delphi system (typical) Fuel Type: Unleaded gasoline, minimum 87 octane 🔧 Transmission Standard Type: Continuously Variable Transmission (CVT) with engine braking Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Optional Options: No primary optional transmissions for these models; CVT is standard. Features Clutches: Primary (Drive) clutch and Secondary (Driven) clutch with detailed service and adjustment procedures. Differential Lock: Visco-Lok front differential, typically with manual engage/disengage for 2WD/4WD. Gearcase Oil: Specific gear oil type (e.g., SAE 80W-90 hypoid gear oil) and capacity detailed in the manual. 📐 Dimensions Exterior Length Approx: 86-97 inches (varies by model and year) Width Approx: 46-48 inches (varies by model and year) Height Approx: 45-50 inches (varies by model and year) Weights Dry Weight Approx: 570-700 lbs (varies by model and engine size) Towing Capacity: Typically 1,300 lbs (refer to specific model specs in manual for exact rating). Rack Capacity Front: Typically 90 lbs Rack Capacity Rear: Typically 180 lbs (Outlander), potentially higher for MAX variants. 🛡️ Safety Features Ratings Safety Standards: Adherence to relevant ATV safety standards (e.g., ANSI/SVIA guidelines), though specific formal 'ratings' are less...
On-board diagnostics port for connection to diagnostic tools (details on access and usage provided).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or annually. (Specific interval provided in manual based on usage).
Air Filter Cleaning:
Every 50 hours or as needed, depending on operating conditions. Replacement intervals vary.
Spark Plug Service:
Recommended inspection every 100 hours, replacement as needed (specific plug part numbers and gap in manual).
Transmission Oil Change:
Typically every 200 hours or annually. (Specific interval provided in manual).
Fluid Specifications
Engine Oil:
Specific viscosity and API rating (e.g., SAE 0W-40 Synthetic or as recommended by BRP for specific ambient temperatures). Refer to manual for exact specification, e.g., BRP's own XPS oil.
Coolant:
BRP proprietary coolant or equivalent OAT antifreeze/coolant, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Gearcase Oil:
SAE 80W-90 hypoid gear oil, meeting API GL-4 or GL-5 specifications (verify in manual).
Known Issues
Cvt Belt Wear:
Premature wear can occur with aggressive riding or improper belt alignment; manual covers inspection and replacement.
Electrical Connectors:
Corrosion or loose connections can cause intermittent faults; manual provides wiring diagrams for diagnosis.
Suspension Bushings:
Wear in A-arm and shock bushings can lead to play and steering issues; manual details replacement procedures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bombardier Recreational Products (BRP), a Canadian company with a long history in powersports and aerospace.
Model Evolution
Outlander Line:
The Outlander line was introduced in 2003, evolving into a benchmark for utility and recreational ATVs, with the introduction of the 2-up MAX variant and larger displacement engines throughout the mid-2000s.
Renegade Line:
The Renegade line debuted in 2007, combining the off-road prowess of the Outlander with a more sporty, performance-oriented chassis and suspension setup, targeting aggressive trail riding.
Production
Manufacturing Location:
Primarily manufactured by BRP in Canada (e.g., Valcourt, Quebec).
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Can-Am ATVs of this era were generally well-regarded for their performance, power, and chassis design, often receiving positive reviews in powersports publications.
Ratings
Reliability Ratings:
Owner satisfaction and reliability vary by model and maintenance, but the core Rotax engines are generally robust when properly maintained. The manual is key to ensuring this.