Table Of Contents - Can-Am Outlander Series 500 Service Manual

Table of Contents

Table Of Contents2
Safety Notice9
General Information10
Vehicle Information11
Engine Emissions Information11
Model Number11
Vehicle Identification Number (Vin)11
Self-Locking Fasteners Procedure12
Loctite Application Procedure12
Owner Responsibility12
Era Emission Regulations12
Stud In Blind Holes13
Preassembled Parts13
Adjusting Screw13
Stripped Thread Repair14
Gasket Compound14
Standard Thread Repair14
Repair Of Small Holes/Fine Threads14
Tightening Torques15
Mounting On Shaft15
Case-In Components15
Mounting With A Press15
Fastener Grade/Torque16
Maintenance Chart20
Preseason Preparation24
Storage Procedures26
Fuel Stabilizer26
Engine Lubrication26
Rags Installation26
Coolant Density27
Drive And Driven Pulleys Protection27
Vehicle Cleaning27
Vehicle Protection27
Special Procedures28
Service Products28
Turn Over28
Atv Immersion28
Troubleshooting Chart30
Starter Does Not Turn30
Starter Turns, But Does Not Crank The Engine31
Starter Motor Keeps Running31
High Engine Operating Temperature31
Battery Not Charging Or Charging Voltage Inadequate32
Low Or No Oil Pressure/High Oil Consumption33
Oil Contamination33
Unusual Engine Noise And/Or Vibration34
Oil Contamination On Cylinder And/Or Head34
Unusual Engine Noise And/Or Vibrations34
Unusual Gearbox Noise And/Or Vibrations34
Gear Indication Fails35
Gear(S) Is (Are) Hard To Shift35
Wheel Drive Indication Fails37
Wheel Drive Does Not Engage Or Disengage37
Unusual Acceleration Behavior37
Engine Maximum Rpm Is Too High And Top Speed Is Not Reached38
Drive Pulley Noise In Idle Speed38
Drive Pulley Noise When Accelerating/Decelerating38
Vibrations Originating From Drive Pulley39
Vibrations Originating From Driven Pulley39
Pulley's Do Not Down/Up Shift Properly39
Belt Glazed Excessively Or Having Baked Appearance39
Belt Worn Excessively In Top Width40
Belt Disintegration40
Cracks Between Cogs40
Engine Cranks But Fails To Start40
Engine Does Not Start41
Engine Hard To Start41
Engine Suddenly Turns Off41
Engine Backfires42
Engine Does Not Offer Maximum Power And/Or Does Not Reach Maximum Operating Rpm43
Engine Removal And Installation45
Service Tools45
Engine Removal46
Vehicle And Engine Preparation46
Engine Installation52
Final Assembly Procedure52
Engine Mount Replacement53
Air Intake System55
Air Filter Housing56
Air Filter Removal57
Air Filter Housing Removal57
Air Filter Housing Installation59
Restrictor Removal59
Restrictor Installation59
Exhaust System61
Front Exhaust Pipe Inspection62
Front Exhaust Pipe Removal62
Front Exhaust Pipe Installation62
Muffler Removal63
Muffler Installation63
"Y" Exhaust Pipe Removal63
"Y" Exhaust Pipe Installation63
Fuel Tank Protector Removal64
Fuel Tank Protector Installation64
Lubrication System65
Lubrication System Components66
Engine Oil68
Recommended Oil68
Engine Oil Viscosity68
Engine Oil Level Verification68
Engine Oil Pressure69
Oil Filter Removal69
Oil Pressure Switch (Ops)70
Oil Filter Inspection70
Oil Filter Installation70
Oil Pressure Switch Activation70
Engine Oil Pressure Regulator71
Oil Pressure Switch Removal71
Oil Pressure Switch Installation71
Oil Pump Removal72
Oil Pump Inspection72
Oil Pump Installation73
Engine Oil Strainer Removal74
Engine Oil Strainer Cleaning And Inspection74
Reed Valve Removal74
Reed Valve Inspection74
Cooling System Service Tools75
Radiator76
Water Pump77
Cooling System Leak Test78
Coolant Replacement79
Recommended Coolant79
Draining The System79
Refilling The System79
Thermostat Removal80
Radiator Cap81
Coolant Tank81
Thermostat Installation81
Radiator Installation81
Coolant Temperature Sensor (Cts)82
Radiator Fan Relay (R1)82
Relay Installation82
Relay Operation Test82
Radiator Fan Operation83
Radiator Fan Test84
Water Pump Housing85
Radiator Fan Removal85
Water Pump Housing Removal85
Radiator Fan Installation85
Water Pump Impeller86
Water Pump Shaft And Seals86
Water Pump Housing Inspection86
Water Pump Housing Installation86
Shaft/Seal Installation88
Magneto System91
Magneto Cover Removal93
Magneto Cover Inspection And Cleaning93
Magneto Cover Installation93
Stator Removal94
Stator Inspection94
Stator Installation94
Rotor Removal95
Rotor Inspection95
Rotor Installation95
Sprag Clutch Removal96
Sprag Clutch Inspection96
Sprag Clutch Installation96
Sprag Clutch Gear Removal97
Sprag Clutch Gear Inspection97
Starter Drive Gears97
Sprag Clutch Gear Installation97
Gear Removal98
Gear Inspection98
Gear Installation98
Intake Manifold, Cylinder Head And Cylinder99
Intake Manifold100
Cylinder Head No.1101
Cylinder Head No.2102
Cylinders And Pistons103
Maintenance104
Valve Adjustment104
Valve Clearance104
Leak Test Inspection105
Intake Manifold Removal107
Valve Cover Removal108
Intake Manifold Inspection108
Intake Manifold Installation108
Timing Chain Tensioner Removal109
Timing Chain Tensioner Inspection109
Timing Chain Tensioner Installation109
Camshaft Timing Gear Removal110
Camshaft Timing Gear Inspection110
Camshaft Timing Gear Installation110
Rocker Arm Removal112
Rocker Arm Inspection112
Timing Chain113
Rocker Arm Installation113
Rocker Arm Shaft113
Cylinder Head Removal114
Cylinder Head Inspection114
Camshaft115
Cylinder Head Installation115
Camshaft Timing115
Camshaft Timing Cylinder 2116
Camshaft Timing Cylinder 1117
Camshaft Inspection119
Valve Spring Removal120
Camshaft Installation120
Valve Spring Inspection121
Valve Spring Installation121
Valve Removal122
Valve Inspection122
Valve Stem Seal122
Valve Stem Diameter122
Valve Installation123
Valve Face And Seat123
Valve Seat Contact Width123
Valve Guide Removal124
Valve Guide Inspection124
Valve Guide Installation124
Cylinder Removal125
Cylinder Inspection125
Cylinder Taper In Diameter125
Cylinder Installation126
Cylinder Out Of Round126
Piston Removal126
Piston Inspection127
Piston/Cylinder Clearance127
Piston Pin Diameter128
Connecting Rod/Piston Pin Clearance128
Piston Installation129
Connecting Rod Small End Diameter129
Piston Rings131
Ring Removal131
Ring Inspection131
Ring Installation131
Bottom End133
Engine Drive Shaft134
Crankcase And Pto Cover135
Crankshaft136
Oil Seal Removal137
Engine Drive Shaft Removal137
Engine Drive Shaft Inspection137
Engine Drive Shaft Installation138
Pto Cover Oil Seal Removal139
Pto Oil Seal Inspection139
Pto Oil Seal Installation139
Pto Cover Removal139
Pto Cover Inspection140
Plain Bearing Replacement Procedure140
Plain Bearing Removal140
Pto Cover Installation141
Plain Bearing Installation141
Drive Gears Removal142
Drive Gears Inspection142
Drive Gear Installation142
Timing Chain Removal (Magneto Side)143
Timing Chain Removal (Pto Side)143
Timing Chain Inspection143
Timing Chain Installation143
Timing Chain Guide144
Chain Guide Inspection144
Chain Guide Installation144
Crankcase Disassembly144
Crankcase Cleaning145
Crankcase Inspection145
Oil Strainer145
Plain Bearing Replacement146
Crankcase Assembly147
Crankshaft Locking Procedure148
Crankshaft Inspection150
Crankshaft Axial Play150
Connecting Rod Big End Axial Play150
Connecting Rod Big End Radial Play150
Crankshaft Radial Play Mag/Pto Side151
Crankshaft Assembly152
Crankshaft Radial Play (Pto Side Support Bearing)152
Crankshaft Installation153
Outlander 500153
Outlander 650 And 800153
Gearbox And 4X4 Coupling Unit155
Gearbox Components And 4X4 Coupling Mechanism156
Gearbox Housing And 4X4 Actuator Unit157
Gearbox Oil Change158
Draining Procedure158
Gearbox Position Indicator Switches Removal159
Gearbox Position Indicator Switches Installation159
4Wd Indicator Switch Removal160
4Wd Indicator Switch Test160
4Wd Indicator Switch Installation160
Oil Seals Removal160
Countershaft Oil Seal161
Shift Shaft Oil Seal161
Output Shaft Oil Seal161
Output Shaft And Countershaft Oil Seal161
Actuator Test162
Actuator Removal162
Output Shaft And Coupling Mechanism164
Output Shaft Backlash Procedure164
Coupling Sleeve Groove Width167
Coupling Fork Claw Thickness167
Gearbox Removal169
Gearbox Disassembly169
Bevel Gear Axial Clearance169
Bearing Removal In Housing173
Gearbox Inspection173
Shift Forks174
Shift Drum174
Levers174
Gears174
Width Of Shift Fork Engagement Groove175
Intermediate Gear Shaft175
Bevel Gear Adjustment176
Bevel Gear Backlash Procedure177
Bevel Gear Axial Clearance Procedure178
Bearing Installation In Housing179
Other Gearbox Components180
Shifter Service Products187
Transmission Lever188
Shifter Lever Removal188
Link Rod Removal189
Shifter Lever Inspection189
Shifter Lever Installation189
Shifting Plate190
Link Rod Inspection190
Link Rod Installation190
Shifting Plate Removal190
Shifting Plate Inspection191
Shifting Plate Installation191
Overview193
Front193
Engine Management System Overview193
Operating Principle194
Air Induction194
Fuel System194
Throttle Body194
Fuel Rail195
Fuel Pump Module195
Fuel Pressure Regulator195
Fuel Filter195
Electrical System196
Engine Control Module (Ecm)196
Power Distribution196
Engine Management System198
Electronic Fuel Injection198
Ignition198
Ecm And Vfb Interaction With The Electrical System198
Engine Modes Of Operation199
Ignition Timing199
Vehicle Speed Limiter199
Limp Home Mode199
Monitoring System200
Diagnostic Mode200
Battery Voltage Warning Device200
Low Oil Pressure Warning Device200
Engine Management System Flow Chart201
Ems Diagnostic203
On-Board Diagnostic203
Fault Codes204
Tps (Throttle Position Sensor) Faults204
Tps "Out Of Range" Fault204
Fault Code P2119204
Fault Code Table205
Adjustment And Repair Procedures213
Diagnostic Tools215
Resistance Measurement215
Ecm Connectors216
Engine Connector216
Temperature Sensor Table216
Basic Adjustments217
Idle Speed217
Throttle Cable217
Closed Throttle And Idle Actuator Reset218
Repair Procedures219
Main Relay219
D1 Diode (Ecm)219
Diode (D1) Installation219
Diode (D1) Test220
Quick Test To Validate Ecm Operation220
Ecm Power Supply And Ground Pinout220
Ecm Power Supply Verification220
If Ecm Works When Bypassing Relay222
Ecm Replacement222
Fuel Injector223
Security Exchange223
Leakage Test223
Electrical Test223
Fuel Injector Replacement225
Fuel Injector Removal225
Fuel Injector Installation225
Fuel Rail Replacement226
Fuel Rail Removal226
Fuel Rail Installation226
Mechanical Inspection227
Electrical Inspection227
Throttle Body Replacement227
Throttle Position Sensor (Tps)230
Tps Wear Test230
Tps Resistance Test231
Tps Input Voltage Test231
Tps Replacement231
Idle Bypass Valve (Ibv)232
Ibv Information In B.u.d.s. Software232
Ibv Resistance Test232
Ibv Visual Inspection233
Crankshaft Position Sensor (Cps)234
Cps Resistance Test234
Cps Replacement234
Camshaft Position Sensor (Caps)235
Caps Voltage Test235
Manifold Air Pressure And Temperature Sensor (Mapts)236
Caps Replacement236
Sensor Pressure Function236
Voltage Test236
Quick Test237
Sensor Temperature Function237
Resistance Test237
Mapts Replacement237
Cts Resistance Test238
Cts Replacement238
Fuel Tank And Fuel Pump239
Fuel Tank Leak Test Inspection241
Check Valve And Pressure Relief Valve242
Fuel Pressure Test244
Fuel Hose And Oetiker Clamps245
In-Line Fuel Filter245
Fuel Hose Replacement245
Oetiker Clamp Replacement245
Fuel Tank Draining246
Fuel Tank Removal246
Fuel Tank Protector247
Fuel Tank Inspection247
Fuel Tank Installation247
Fuel Pump Circuit Test248
Fuel Pump Power Supply248
Fuel Pump Ground Circuit249
Fuel Pump Removal249
Fuel Pump Installation249
Fuel System Diagnostic Flow Chart250
Communication Tools And B.u.d.s. Software251
Multi-Purpose Interface (Mpi)251
Mpi Supply251
Connections With Vehicle251
Multi-Purpose Interface-2 (Mpi-2)252
Mpi-2 Supply253
B.u.d.s. Software253
Changes In Ecm254
Ignition System255
Ignition Switch255
Switch Resistance Test255
Switch Wiring Test (Ignition Function)256
Switch Wiring Test (Dess Function)256
Engine Run/Stop Switch257
Switch Resistance Test (Ignition Function)257
Switch Resistance Test (Dess Function)257
Ignition Coil Input Voltage258
Ignition Coil Resistance Test259
Spark Plug Removal260
Troubleshooting Fouled Spark Plug260
Spark Plug Analysis260
Spark Plug Installation260
Charging System263
Magneto263
Voltage Regulator/Rectifier263
Dc Current Test With An Inductive Ammeter264
Dc Current Test With A Multimeter264
Stator266
Static Test: Continuity266
Static Test: Insulation267
Dynamic Test: Ac Voltage267
Battery Information268
Battery Troubleshooting268
Discharged Or Weak Battery268
Battery Unloaded Test268
Battery Removal269
Battery Cleaning269
Battery Inspection270
Battery Storage270
Main Ground271
Starting System273
Engine Cranking Conditions273
Ignition Switch And Engine Run/Stop Switch273
Electrical Cable And Connections273
Fuses274
D2 Diode (Starter Solenoid)274
Start Button275
Start Button Resistance Test275
Start Button Wiring Test275
Starting Solenoid276
Solenoid Signal Test277
Electric Starter278
Starter Test278
Digitally Encoded Security System (Dess)281
Dess Key Programming281
Lights, Gauge And Accessories283
Diagnostic283
Checking For Shorts Between 2 Wires283
Recommended Tools283
Electrical Connectors284
Fuses In Front Service Compartment284
Fuse Located At The Rear284
Accessory Relay (R3)285
Multifunction Gauge286
Unit Selection (Mph Vs Km/H)286
Gauge Operation286
Tachometer289
Transmission Position Display289
Fuel Level Display289
Indicator Lamps290
Multifunction Display (Normal Display Mode)290
Multifunction Display (Temporary Display Mode)291
Multifunction Display Codes/Messages291
Function Display Problems293
Fuel Level293
2/4Wd Pilot Lamp293
Hi Beam Pilot Lamp293
Multifunction Gauge Pinout294
Multifunction Gauge Removal295
Multifunction Gauge Installation295
New Multifunction Gauge Registration (Coding)295
Country Selection295
Vehicle Speed Sensor (Vss)296
Fuel Level Sender297
Multifunction Switch297
Low/Hi Beam Switch298
Override Switch298
12-Volt Auxiliary Power Outlet299
12-Volt Auxiliary Power Outlet Test299
12-Volt Power Outlet Removal299
12-Volt Power Outlet Installation299
Headlamp Test300
Headlamp Bulb Replacement300
Headlamp Beam Aiming302
Headlamp Adjustment302
Taillight Bulb Replacement303
Winch Test303
Winch Motor303
Voltage Supply To Switch303
Winch Control Switch304
Winch Relay304
Winch Removal305
Winch Installation305
D5 And D6 Diodes (Winch Relay)306
Winch Control Switch Removal306
Winch Control Switch Installation306
Continuously Variable Transmission (Cvt)309
Drive Belt Removal311
Drive Pulley312
Drive Belt Inspection312
Drive Belt Installation312
Drive Pulley Removal313
Drive Pulley Disassembly314
Sliding Sheave315
Fixed Sheave315
Drive Pulley Cleaning315
Drive Pulley Inspection316
Drive Pulley Governor Cup316
Drive Pulley Roller And Slider Shoe316
Centrifugal Lever Bore Diameter317
Centrifugal Lever Pivot Bolt Bore Diameter317
Sliding Sheave Large Bushing317
Drive Pulley Assembly318
Sliding Sheave Small Bushing318
Spring Free Length318
Spring Sleeve Length318
Friction Washer319
Driven Pulley Removal320
Bushings Bore Diameter322
Bushing Bore Diameter322
Wear On Teeth Both Sides322
Width On Top Surface323
Wear On Contact Surface323
Clutch Spring Squareness323
Cvt Air Guide Removal325
Cvt Air Guide Inspection325
Cvt Air Guide Installation325
Front Drive327
Tires And Wheels329
Wheel Hub Removal329
Wheel Hub Inspection330
Wheel Hub Installation330
Front Drive Shaft Removal330
Drive Shaft Inspection331
Drive Shaft Installation331
Drive Shaft Boot Inspection332
Drive Shaft Boot Removal332
Drive Shaft Boot Installation332
Front Differential Oil Level332
Front Differential Oil Change333
Front Differential Removal333
Front Differential Inspection334
Front Differential Disassembly334
Ring Gear Carrier/Ring Gear334
Pinion Gear334
Ring Gear Adjustment335
Backlash335
Front Propeller Shaft Removal336
Front Propeller Shaft Inspection337
Front Propeller Shaft Installation337
Propeller Shaft U-Joint Removal337
Propeller Shaft U-Joint Installation337
Rear Drive339
Differential Protector Removal342
Differential Protector Installation342
Drive Shaft Removal342
Rear Propeller Shaft343
Steering System351
Handlebar Grip Removal353
Handlebar Grip Installation353
Handlebar Cover Removal353
Handlebar Cover Installation353
Handlebar Inspection354
Handlebar Installation354
Steering Column Removal354
Steering Column Inspection354
Steering Column Bearing Removal355
Steering Column Installation355
Tie-Rod355
Tie-Rod Removal356
Tie-Rod Installation356
Knuckle Removal356
Knuckle Inspection358
Wheel Bearing Inspection358
Wheel Bearing Removal358
Wheel Bearing Installation359
Multifunction Switch Removal359
Throttle Handle Removal359
Multifunction Switch Installation360
Handle Brake Removal360
Handle Brake Hose Removal360
Steering Alignment360
Front Suspension363
Shock Absorber And Spring Removal367
Shock Absorber And Spring Disassembly368
Shock Absorber And Spring Inspection368
Lower Suspension Arm Protector Removal369
Lower Suspension Arm Protector Installation369
Lower Suspension Arm Inspection369
Lower Suspension Arm Removal369
Lower Suspension Arm Installation370
Lower Ball Joint Removal371
Lower Ball Joint Installation371
Upper Suspension Arm Lubrication372
Upper Suspension Arm Inspection372
Upper Suspension Arm Removal372
Upper Suspension Arm Installation373
Upper Suspension Arm Bracket Removal373
Upper Suspension Arm Bracket Inspection374
Upper Suspension Arm Bracket Installation374
Upper Ball Joint Inspection374
Upper Ball Joint Removal374
Upper Ball Joint Installation375
Rear Suspension377
Rear Shock Removal379
Rear Shock Disassembly379
Rear Shock Inspection380
Rear Shock Assembly And Installation380
Torsion Bar Removal380
Torsion Bar Inspection381
Torsion Bar Installation381
Trailing Arm Removal381
Trailing Arm Inspection382
Trailing Arm Installation382
Trailing Arm Bearings Inspection382
Trailing Arm Bearings Removal382
Trailing Arm Bearings Installation384
Front And Rear Brakes385
Hydraulic Brakes System389
Parking Brake389
Brake Recommended Fluid389
Brake Fluid Level389
Brake Fluid Replacement390
Brake Fluid Draining390
Brake Fluid Filling And Bleeding390
With A Vacuum Pump390
Rear Brake Light Switch Inspection391
Rear Brake Light Switch Test391
Rear Brake Light Switch Removal392
Rear Brake Light Switch Installation392
Front Brake Light Switch Inspection392
Parking Brake Mechanism Removal392
Front Brake Light Switch Installation393
Brake Lever Removal393
Brake Lever Installation393
Front Master Cylinder Removal393
Front Master Cylinder Disassembly394
Front Master Cylinder Assembly394
Front Master Cylinder Installation394
Rear Master Cylinder Removal394
Rear Master Cylinder Disassembly395
Rear Master Cylinder Inspection And Lubrication395
Rear Master Cylinder Assembly395
Rear Master Cylinder Installation396
Caliper Removal396
Caliper Disassembly397
Caliper Inspection397
Caliper Assembly397
Brake Pads Removal397
Brake Pads Installation398
Brake Disc Inspection399
Brake Disc Removal399
Brake Disc Installation400
Brake Pedal Removal400
Brake Pedal Installation400
Brake Hoses Inspection400
Brake Hoses Removal401
Brake Hoses Installation401
Body403
Outlander Series Body Parts (Front View)404
Outlander Series Body Parts (Rear View)405
Outlander Series Body Parts (Side View)406
Outlander Series Seat407
Outlander Series Xt Package408
Renegade Models Body Parts (Front View)409
Renegade Models Body Parts (Rear View)410
Renegade Models Body Parts (Side View)411
Renegade Models Seat412
Vehicle Care413
Plastic Rivet413
Decal Removal413
Decal Installation413
Seat Removal414
Seat Installation415
Seat Cover Replacement415
Central Panel Removal415
Central Panel Installation416
Dash Board Removal416
Side Panel Removal416
Side Panel Installation416
Footrest Removal417
Inner Fender Removal417
Inner Fender Installation417
Bumper Removal417
Bumper Installation418
Front Bumper/Front Skid Plate/Front Fascia Removal418
Luggage Rack Removal419
Luggage Rack Installation419
Fender Removal419
Fender Installation421
Fender Support Removal422
Fender Support Installation422
Frame423
Footrest Support Removal425
Footrest Support Inspection425
Battery Support Removal425
Battery Support Installation426
Hitch Removal426
Hitch Installation426
Hook Removal426
Hook Inspection427
Hook Installation427
Frame Cleaning427
Frame Welding427
Technical Specifications429
Outlander Series429
Renegade Models439
Deutsch Connectors449
Removal From Engine Connector Bracket449
Connector Disassembly449
Terminal Removal451
Terminal Crimping (Kostal)452
Multifunction Speedometer Connector453
Battery And Starter Cable Terminals454
Crimping454
Wiring Diagrams457
Wiring Connectors Coding457
Wire Colors457
Wire Gauge457
Wire Location In Connector458
Distribution System459
Injection/Ignition System461
Cooling System463