BOMBARDIER ROTAX 800 V 810 ATV Engine Service Repair Workshop Manual 2006

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The 2006 Can-Am Outlander 800, powered by the Rotax 800 V 810 engine, was a premium all-terrain vehicle designed for demanding recreational and utility use. This model featured a powerful...

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Typ: Atv

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Art.-Nr: 132195

Stichworte: 2006 800 V 810 Atv Bombardier Rotax

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Beschreibung

The 2006 Can-Am Outlander 800, powered by the Rotax 800 V 810 engine, was a premium all-terrain vehicle designed for demanding recreational and utility use. This model featured a powerful 800cc V-twin, 4-stroke engine with electronic fuel injection, delivering impressive horsepower and torque for its class. Its robust chassis and advanced suspension system were engineered to handle challenging off-road terrain, making it a capable machine for towing, hauling, and spirited riding. The Outlander line, with its established heritage of performance and innovation, represented a significant benchmark in the high-performance ATV market of its time. This comprehensive workshop service repair manual in English provides detailed guidance for all models and repairs, covering every aspect from basic maintenance to complex overhauls. It includes in-depth procedures for the engine, transmission, drivetrain, suspension, braking, electrical, fuel, cooling, and steering systems, as well as bodywork and chassis. The manual also covers routine maintenance checks, diagnostic troubleshooting, repair procedures, rebuild instructions, and various system adjustments. Designed for professional technicians and experienced DIY mechanics, this manual serves as an essential resource for maintaining the optimal performance, reliability, and longevity of your 2006 Can-Am Outlander 800.

🏷️ Basic Information

Identification

Make:

Bombardier (Can-Am)

Model:

Outlander 800 V 810

Year:

Engine Type:

V-Twin, 4-Stroke

Codes

Engine Code Designation:

Rotax 800 V 810

👋 Introduction

Market Position

Positioning:

The 2006 Bombardier Rotax 800 V 810 engine powered high-performance ATVs, positioned as premium off-road vehicles for serious recreational riders and utility users. This engine represented a significant power upgrade for its class.

Competitive Analysis

Competitors 2006:

Competed directly with other large-displacement V-twin ATVs from manufacturers like Polaris (Sportsman 800), Arctic Cat (650 V-Twin), and Yamaha (Grizzly 660, though single cylinder).

Key Features

Engine Highlights:

Powerful 800cc V-twin engine, advanced fuel injection system (EFI), robust chassis and suspension for challenging terrain, capable of significant towing and hauling.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Page Count

Estimated Page Count:

Likely 500+ pages (typical for comprehensive service manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, including: cylinder head assembly, piston, connecting rods, crankshaft, valve train, lubrication system, cooling system, fuel injection system, ignition system, starting system, emissions control.

Transmission System:

Automatic transmission (CVT), including: belt inspection and replacement, clutch system (drive and driven), gearbox maintenance and repair, fluid specifications and change intervals.

Drivetrain System:

Front and rear drive shafts, constant velocity (CV) joints, differentials (front and rear), driveshaft U-joints, wheel hubs, bearing maintenance and replacement.

Suspension System:

Front and rear suspension components, including: A-arms, shock absorbers, springs, bushings, steering knuckles, wheel alignment specifications, adjustment procedures.

Braking System:

Hydraulic braking system, including: brake fluid specifications, bleeding procedures, caliper overhaul, master cylinder repair, brake pad and rotor replacement, parking brake mechanism.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition system, wiring diagrams, diagnostic codes, sensors, switches, fuses, relays.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, throttle body, electronic fuel injection (EFI) control module.

Cooling System:

Radiator, cooling fan, thermostat, water pump, coolant specifications and capacities, flushing and refilling procedures.

Steering System:

Handlebar assembly, steering column, tie rods, steering rack or gearbox, lubrication, adjustment procedures.

Bodywork And Chassis:

Frame inspection and repair, body panel removal and installation, seat, fenders, racks, skid plates.

Procedures Included

Maintenance Procedures:

Routine maintenance checks, oil changes, filter replacements, spark plug inspection and replacement, coolant flushes, lubrication points, pre-ride inspections.

Diagnostic Procedures:

Troubleshooting common problems, diagnostic trouble codes (DTCs), testing electrical components, fuel system diagnostics, compression testing, vacuum testing.

Repair Procedures:

Step-by-step repair instructions for all major systems, including detailed disassembly and reassembly sequences, torque specifications, special tool requirements.

Rebuild Procedures:

Complete engine and transmission rebuild procedures, including parts replacement guidelines and critical tolerances.

Adjustment Procedures:

Carburetor or fuel injection adjustments, valve lash adjustments, brake adjustments, clutch adjustments, suspension adjustments.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance and troubleshooting to complete engine rebuilds and advanced diagnostics.

Target Audience:

Professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Searchability

Searchable Text:

Yes (typically searchable PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Manufacturer:

Rotax (Bombardier Recreational Products)

Engine Configuration:

V-Twin, 800cc class

Engine Design:

4-stroke, SOHC, liquid-cooled

Bore X Stroke:

Typically around 82 mm x 75 mm (exact specs may vary slightly by specific model variant within 2006).

Compression Ratio:

Approximately 9.3:1

Performance

Horsepower Rating:

Around 52-55 HP (at flywheel)

Torque Rating:

Around 48-50 lb-ft (at flywheel)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with throttle body (typically 54mm)

Fuel Type:

Unleaded gasoline (minimum 87 octane)

Lubrication

Oil Type:

SAE 10W-40 Synthetic Motorcycle Oil (meeting JASO MA or MA2 specifications)

Oil Capacity:

Approximately 2.4 Liters (2.5 US Quarts) with filter change.

Cooling

Cooling Method:

Liquid-cooled

Coolant Type:

Ethylene Glycol based antifreeze (50/50 mix with distilled water)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR8E (or equivalent)

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with engine braking

Optional

Gear Selection:

H (High), L (Low), N (Neutral), R (Reverse), P (Park)

Features

Drive Modes:

2WD / 4WD selectable (often with Visco-Lok front differential)

Transmission Fluid Type:

Specific CVT Fluid (e.g., Bombardier recommends their proprietary fluid or equivalent)

Transmission Fluid Capacity:

Approx. 0.9 Liters (0.95 US Quarts)

📐 Dimensions

Exterior

Wheelbase:

Approximately 50 inches (127 cm)

Overall Length:

Approximately 86 inches (218 cm)

Overall Width:

Approximately 46 inches (117 cm)

Overall Height:

Approximately 45 inches (114 cm)

Cargo

Front Rack Capacity:

Approximately 100 lbs (45 kg)

Rear Rack Capacity:

Approximately 200 lbs (90 kg)

Weights

Dry Weight:

Approximately 635 lbs (288 kg)

Towing Capacity:

Typically 1,300 lbs (590 kg)

Tires

Front Tire Size:

25 x 8-12

Rear Tire Size:

25 x 10-12

Wheel Bolt Pattern:

4x110mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI/SVIA standards for ATVs.

Active Features

Braking System Type:

Hydraulic disc brakes (front and rear)

Engine Braking:

Standard feature on CVT for downhill control.

Selectable 4Wd:

Provides enhanced traction in challenging conditions.

Passive Features

Lighting:

Dual 35W headlights, 35W taillight/stoplight.

Throttle Limiter:

Often implemented for newer riders or specific modes.

💡 Technology Features

Infotainment

Infotainment System:

N/A (ATVs of this era generally did not feature complex infotainment systems; focus was on utility and performance).

Driver Assistance

Driver Assistance Features:

Engine braking via CVT, selectable 2WD/4WD, basic digital display with essential indicators (speed, odometer, fuel, 4x4 indicator, etc.).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Initial Service:

Typically 20 hours or 1 month: Check oil, adjust tire pressures, inspect fasteners, check chain/belt tension.

Regular Maintenance:

Every 100 hours or 6 months: Oil and filter change, spark plug inspection, air filter cleaning/replacement, coolant level check, brake system inspection, drive belt inspection, lubrication points.

Major Service:

Every 300 hours or 18 months: Includes all regular maintenance plus: valve clearance check/adjustment, spark plug replacement, coolant flush, transmission fluid change, differential fluid change, comprehensive electrical system check.

Fluid Specifications

Engine Oil Spec:

SAE 10W-40 Synthetic Motorcycle Oil (JASO MA/MA2)

Engine Oil Capacity:

2.4 L (2.5 US qt)

Coolant Type:

50/50 Ethylene Glycol & Distilled Water

Transmission Fluid Type:

Specific CVT Fluid (e.g., BRP XPS CVT Fluid or equivalent)

Transmission Fluid Capacity:

0.9 L (0.95 US qt)

Front Differential Fluid Type:

Hypoid Gear Oil SAE 80W-90

Rear Differential Fluid Type:

Hypoid Gear Oil SAE 80W-90

Known Issues

Common Wear Items:

CVT drive belt (especially under heavy use), wheel bearings, ball joints, tie rod ends, suspension bushings, brake pads.

Potential Engine Concerns:

Overheating if cooling system is not maintained, potential for starter solenoid issues, fuel injector clogging if fuel quality is poor. Early models sometimes had oil consumption concerns.

Electrical Gremlins:

Wiring harness integrity can be a concern in harsh environments; check for corrosion or damage. Battery terminals and grounds are critical.

📚 Vehicle History

Brand Heritage

Brand History:

Bombardier Recreational Products (BRP) has a long history in motorsports and powersports, with the Can-Am brand established in 1973. BRP is renowned for innovation and performance.

Model Evolution

Outlander Lineage:

The Outlander series began in 2003, quickly establishing itself as a leading high-performance ATV. The 800cc V-twin was a significant expansion of the line, offering class-leading power and torque.

Production

Manufacturing Location:

Valcourt, Quebec, Canada

Key Milestone 2006:

The introduction and refinement of the 800cc Rotax engine marked a performance benchmark for the Outlander line, offering a substantial power increase over previous models.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the 2006 model year aren't always publicized, the Rotax 800 engine and Outlander platform were generally well-regarded for their power and capability within the ATV industry press and among consumers.