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Can-Am Outlander / Renegade 2012 800 1000 Workshop Manual

Can-Am Outlander / Renegade 2012 800 1000 Factory Workshop Manual


This is the same manual your local dealer will use when doing a repair. The manual for the Can-Am Outlander / Renegade 2012 800 1000 has detailed illustrations as well as step by step instructions. All pages are printable, so run off what you need and take it with you into the garage or workshop. These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourself as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your atv working properly. Each manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of illustrations, that guide the reader through each service and repair procedure.


Topics Covered


SAFETY NOTiCE........................................................................................................ X
INTRODUCTION........................................................................................................ XI
VEHICLE INFORMATION............................................................................................ XI
ENGINE EMISSIONS INFORMATION............................................................................. XI
MANUAL INFORMATION ........................................................................................... XII
FASTENER INFORMATION ........................................................................................ XVI
01 MAINTENANCE
01 - BREAK-IN INSPECTION......................................................................................... 7
02 - PERIODIC MAINTENANCE SCHEDULE....................................................................... 9
GENERAL ...................................................................................................... 9
MAINTENANCE SOON MESSAGE......................................................................... 9
SEVERE DUSTY CONDITIONS............................................................................. 9
MAINTENANCE SCHEDULE ................................................................................ 9
03 - PERIODIC MAINTENANCE PROCEDURES................................................................. 11
GENERAL .................................................................................................... 11
PROCEDURES........ ...... ...... ... ... .... ...... ... ... ....................... ......... ................. .... 11
ENGINE (AIR INTAKE SYSTEM) .......................................................................... 11
ENGINE (EXHAUST SYSTEM) ............................................................................ 14
ENGINE (LUBRICATION SYSTEM). .......... ......... .......... ........ ... .... ... ................ ..... ... 15
ENGINE (COOLING SYSTEM) ............................................................................ 18
ENGINE (CYLINDER HEAD) .............................................................................. 21
GEARBOX ................................................................................................. 21
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ..................................................... 23
FUEL SySTEM............................................................................................ 24
ELECTRICAL SySTEM.................................................................................... 26
DRIVE SySTEM........................................................................................... 26
CHASSIS (WHEELS AND TIRES) ......................................................................... 28
CHASSIS (STEERING SYSTEM) .......................................................................... 29
CHASSIS (SUSPENSION) ................................................................................. 29
CHASSIS (BRAKES)....................................................................................... 31
CHASSIS (BODY) ......................................................................................... 33
CHASSIS (FRAME)........................................................................................ 33
04 - PRESEASON PREPARATION................................................................................. 35
05 - STORAGE PROCEDURE....................................................................................... 37
GENERAL .................................................................................................... 37
PROCEDURES ............................................................................................... 37
FUEL SySTEM............................................................................................ 37
ENGINE ................................................................................................... 37
ELECTRICAL SySTEM.................................................................................... 38
DRIVE SySTEM........................................................................................... 38
CHASSIS .................................................................................................. 38
06 - SPECIAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GENERAL .................................................................................................... 41
WHAT TO DO IF WATER IS IN THE CVT ................................................................. 41
WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSiNG.............................................. 41
WHAT TO DO IF VEHICLE IS ROLLED OVER............................................................ 41
WHAT TO DO IF VEHICLE IS SUBMERGED IN WATER................................................. 42
02 ENGINE, CVT AND GEARBOX
01- ENGINE REMOVAL AND INSTALLATION .................................................................. 43
GENERAL .................................................................................................... 44
PROCEDURES ............................................................................................... 44
ENGINE REMOVAL ....................................................................................... 44
02 ENGINE, CVT AND GEARBOX (contd}
II
01- ENGINE REMOVAL AND INSTALLATION (contd}
PROCEDURES (contd)
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ENGINE MOUNTS REPLACEMENT ...................................................................... 49
02- AIR INTAKE SYSTEM .......................................................................................... 51
GENERAL .................................................................................................... 52
PROCEDURES............................................................................................... 52
AIR FILTER................................................................................................ 52
AIR FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
03 - EXHAUST SYSTEM............................................................................................ 57
GENERAL .................................................................................................... 58
PROCEDURES............................................................................................... 58
SPARK ARRESTER........................................................................................ 58
MUFFLER ................................................................................................. 58
HEAT SHIELD............................................................................................. 60
Y-EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HEAD PIPE (FRONT CYLINDER).......................................................................... 60
04- LUBRICATION SYSTEM....................................................................................... 63
GENERAL .................................................................................................... 66
INSPECTION................................................................................................. 66
ENGINE OIL PRESSURE.................................................................................. 66
TROUBLESHOOTING ...................................................................................... 66
PROCEDURES ............................................................................................... 67
OIL COOLER.............................................................................................. 67
OIL PRESSURE SWITCH (OPS)........................................................................... 68
ENGINE OIL PRESSURE REGULATOR................................................................... 69
OIL PUMP ................................................................................................ 70
ENGINE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REED VALVE.............................................................................................. 73
05 - COOLING SYSTEM . .-.......................................................................................... 75
GENERAL .................................................................................................... 80
PROCEDURES ............................................................................................... 80
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RADIATOR COOLING FAN RELAY (R1 ).. .. .. .. . .. .. .. .. . .. . .. .. .. .. . .. .. .. .. .. . .. .. . .. .. .. .. .. .. .. .. .. .. . 82
RADIATOR COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
WATER PUMP HOUSING................................................................................. 85
WATER PUMP IMPELLER................................................................................ 86
WATER PUMP SHAFT, ROTARY SEAL AND OIL SEAL .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 86
WATER PUMP GEARS .................................................................................... 93
06 - MAGNETO SYSTEM........................................................................................... 97
GENERAL .................................................................................................... 99
PROCEDURES ............................................................................................... 99
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
STATOR .................................................................................................. 100
ROTOR ................................................................................................... 103
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SPRAG CLUTCH GEAR .................................................................................. 106
STARTER DRIVE GEARS................................................................................. 106
07- TOP END ........................................................................................................ 107
GENERAL ................................................................................................... 112
INSPECTION ................................................................................................ 112
LEAK TEST ............................................................................................... 112
02 ENGINE, CVT AND GEARBOX (contd)
07 - TOP END (contd)
TABLE OF CONTENTS
PROCEDURES .............................................................................................. 114
INTAKE MANIFOLD...................................................................................... 114
VALVE COVER ........................................................................................... 115
ROCKER ARM........................................................................................... 116
CYLINDER HEAD........................................................................................ 118
CAMSHAFT. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 120
VALVE SPRINGS......................................................................................... 122
VALVES ................................................................................................... 124
VALVE GUiDES........................................................................................... 126
CyLINDER ............................................................................................... 127
PISTON .................................................................................................. 129
PISTON RINGS........................................................................................... 133
08 - TIMING CHAIN ................................................................................................ 135
GENERAL................................................................................................... 137
TROUBLESHOOTING..................................................................................... 137
PROCEDURES.............................................................................................. 137
TIMING CHAIN TENSIONERS ........................................................................... 137
CAMSHAFT TIMING GEARS............................................................................ 139
TIMING CHAIN........................................................................................... 143
TIMING CHAIN GUIDE (TENSIONER SIDE) ............................................................. 145
09 - BOTTOM END ................................................................................................. 147
GENERAL ................................................................................................... 151
PROCEDURES .............................................................................................. 151
ENGINE DRIVE SHAFT .................................................................................. 151
FRONT OIL SEAL (ENGINE DRIVE SHAFT) ............................................................. 153
REAR OIL SEAL (ENGINE DRIVE SHAFT) ............................................................... 153
PTO COVER OIL SEAL .................................................................................. 153
PTO COVER .............................................................................................. 154
DRIVE GEARS........................................................................................... 156
CRANKCASE .............................................................................................. 157
CRANKSHAFT ............................................................................................ 161
10 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT)................................................... 171
GENERAL................................................................................................... 174
PROCEDURES .............................................................................................. 174
CVT COVER .............................................................................................. 174
DRIVE BELT.............................................................................................. 175
DRIVE PULLEy........................................................................................... 176
DRIVEN PULLEy......................................................................................... 184
CVT AIR GUiDE.......................................................................................... 193
11 - GEARBOX AND 4X4 COUPLING UNIT (800R) ........................................................... 195
GENERAL................................................................................................... 198
OVERViEW............................................................................................... 198
TROUBLESHOOTING..................................................................................... 198
PROCEDURES .............................................................................................. 198
GEARBOX POSITION INDICATOR SWiTCHES.......................................................... 198
4WD INDICATOR SWiTCH.............................................................................. 200
GEARBOX OIL SEALS ................................................................................... 200
ACTUATOR .............................................................................................. 202
OUTPUT SHAFT AND COUPLING MECHANiSM....................................................... 205
GEARBOX ................................................................................................ 210
12 - GEARBOX AND 4X4 COUPLING UNIT (1000) ............................................................ 229
GENERAL................................................................................................... 231
GEARBOX OVERViEW ................................................................................... 231
02 ENGINE, CVT AND GEARBOX (contd)
12- GEARBOX AND 4X4 COUPLING UNIT (1000) (contd)
TROUBLESHOOTING ..................................................................................... 231
PROCEDURES .............................................................................................. 232
VEHICLE SPEED SENSOR (VSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
GEARBOX POSITION SENSOR (GBPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4WD INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
GEARBOX OIL SEALS................................................................................... 238
GEARBOX................................................................................................ 240
13- SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
GENERAL................................................................................................... 256
PROCEDURES .............................................................................................. 256
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
SHIFT ROD ............................................................................................... 257
SHIFT PLATE ............................................................................................. 258
03 ELECTRONIC MANAGEMENT SYSTEMS
01 -ENGINE MANAGEMENT SYSTEM (EMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
GENERAL................................................................................................... 262
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
02 - CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
GENERAL................................................................................................... 263
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
03 - COMMUNICATION TOOLS AND B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
GENERAL................................................................................................... 265
TROUBLESHOOTING ..................................................................................... 265
DIAGNOSTIC TIPS....................................................................................... 265
PROCEDURES .............................................................................................. 266
MULTI-PURPOSE INTERFACE-2 (MPI-2)................................................................. 266
B.U.D.S................................................................................................... 267
04- DIAGNOSTIC SYSTEM AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
GENERAL................................................................................................... 271
MONITORING SYSTEM ................................................................................. 271
FAULT CODES ........................................................................................... 272
FAULT CODE DIAGNOSTIC.............................................................................. 276
FAULT CODE TABLE..................................................................................... 280
04 fuel system
IV
01 - ELECTRONIC FUEL INJECTION (EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
GENERAL................................................................................................... 299
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
ADJUSTMENT ............................................................................................. 300
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
CLOSED THROTTLE AND IDLE ACTUATOR RESET.................................................... 301
TROUBLESHOOTING ..................................................................................... 302
DIAGNOSTIC TIPS....................................................................................... 302
PROCEDURES .............................................................................................. 302
ENGINE CONTROL MODULE (ECM) .................................................................... 302
FUEL INJECTOR......................................................................................... 307
FUEL RAIL............................................................................................... 309
THROTILE CABLE ....................................................................................... 310
THROTILE BODY ........................................................................................ 311
THROTILE POSITION SENSOR (TPS) ................................................................... 314
IDLE AIR CONTROL VALVE (IACV) ...................................................................... 316
04 FUEL SYSTEM (contd)
01 -ELECTRONIC FUEL INJECTION (EFI) (contd)
PROCEDURES (contd)
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 317
MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR (MAPTS) ......................... 318
CTS (COOLANT TEMPERATURE SENSOR) ............................................................. 321
02 - FUEL TANK AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
GENERAL................................................................................................... 325
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
INSPECTION ................................................................................................ 326
FUEL TANK LEAK TEST .................................................................................. 326
FUEL SYSTEM PRESSURE TEST........................................................................ 327
TROUBLESHOOTING..................................................................................... 329
FUEL SYSTEM DIAGNOSTIC FLOW CHART............................................................ 329
PROCEDURES.............................................................................................. 330
FUEL HOSE AND OETIKER CLAMPS ................................................................... 330
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
FUEL PUMP ............................................................................................. 334
FUEL PUMP PREFILTER (STRAINER) . .. .. . .. .. .. . .. .. .. .. . .. . .. .. .. .. .. .. .. . .. .. . .. .. .. .. .. . .. . .. .. .. .. 338
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
FUEL TANK VENT VALVES ............................................................................... 340
05 ELECTRICAL SYSTEM
01 - POWER DISTRIBUTION AND GROUNDS................................................................. 343
GENERAL................................................................................................... 343
POWER DISTRIBUTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
FUSE BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
FUSE BOX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
GROUNDS ............................................................................................... 345
02- WIRING HARNESS AND CONNECTORS .................................................................. 347
GENERAL................................................................................................... 347
CONNECTOR ABBREVIATION DESCRIPTION .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . 347
WIRING HARNESS ARRANGEMENT.................................................................... 349
WIRING HARNESS ROUTING ........................................................................... 351
WIRING HARNESS SPLICE LOCATION .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 361
PROCEDURES .............................................................................................. 367
DEUTSCH CONNECTORS............................................................................... 367
PACKARD CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
PACKARD CONNECTOR (MULTIFUNCTION GAUGE} ................................................... 368
MOLEX CONNECTOR ................................................................................... 370
FURUKAWA CONNECTOR .............................................................................. 372
BATIERY AND STARTER CABLE TERMINALS.......................................................... 373
03 - IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
GENERAL................................................................................................... 375
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
TROUBLESHOOTING ..................................................................................... 375
DIAGNOSTIC GUIDELINES.............................................................................. 375
PROCEDURES .............................................................................................. 376
IGNITION SWITCH....................................................................................... 376
EMERGENCY ENGINE STOP SWITCH .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 376
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
SPARK PLUG............................................................................................. 380
04 - CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
GENERAL................................................................................................... 381
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
DRIVE SYSTEM
CHASSIS
TECHNICAL SPECIFICATIONS
WIRING DIAGRAMS



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