🏷️ Basic Information

Make:

Can-Am

Model:

Outlander / Renegade

Product Type:

Service Manual / Repair Manual

Product Name:

Can-Am Outlander / Renegade Service Manual Repair 2008-2009 PDF Download

Model Years Covered:

2008, 2009

👋 Introduction

Category:

Performance Recreational Utility ATVs

Target Audience:

Can-Am ATV owners, DIY mechanics, professional ATV technicians, service departments.

Competitors:

Polaris Sportsman/Scrambler, Arctic Cat Alterra/Wildcat, Yamaha Grizzly/Kodiak, Suzuki KingQuad.

Coverage:

Covers both Outlander and Renegade models, encompassing multiple engine displacements and model years from a critical early generation.

Detail Level:

Factory-level detail, ensuring accuracy for all repair and maintenance procedures.

Utility:

Essential resource for owners and technicians performing routine maintenance, complex repairs, or performance modifications.

📋 Manual Details

Vehicle Models Covered:

Can-Am Outlander 500, Outlander 650, Outlander 800, Renegade 500, Renegade 650, Renegade 800

Estimated Page Count:

Extensive (factory manual typical 500+ pages, specific count not provided but implied by 'complete tear down and rebuild')

Type:

Factory Service Manual / Repair Manual

Language:

English (standard for factory manuals unless specified)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine teardown, rebuild, inspection, diagnosis, valve adjustments, piston/ring replacement, cylinder head service, crankshaft and connecting rod service.

Engine Fuel System:

Fuel injection system diagnosis and repair, fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter replacement.

Ignition System:

Ignition coil testing, spark plug service, CDI unit diagnosis, wiring diagrams for ignition components.

Cooling System:

Radiator service, coolant flush and fill, water pump inspection and replacement, thermostat operation, fan control.

Transmission Drivetrain:

CVT system (Clutch replacement, belt inspection and replacement, primary and secondary clutch service), gearbox inspection and repair, driveshaft, U-joints, differentials (front and rear).

Electrical System:

Battery testing and maintenance, charging system (stator, rectifier/regulator), starter motor service, lighting system, accessory wiring, fuse and relay identification and testing.

Braking System:

Brake caliper service, brake pad replacement, brake line inspection and replacement, master cylinder service, brake fluid flush and bleed procedures, parking brake adjustment.

Suspension Steering:

Front and rear suspension component inspection, shock absorber service/replacement, ball joint replacement, tie rod end replacement, steering column and rack diagnosis and repair, wheel alignment specifications.

Body Chassis:

Frame inspection, body panel removal and installation, plastic component repair, seat removal, rack and luggage system installation/removal.

Controls:

Handlebar controls, throttle cable adjustment, brake lever service, foot pedal adjustments.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant checks, brake checks, tire pressure, battery care.

Troubleshooting:

Diagnostic charts and flowcharts for common problems, symptom-based troubleshooting guides for engine, electrical, and drivetrain issues.

Repair:

Detailed step-by-step instructions for disassembly, repair, and reassembly of all major components and systems.

Technical Specifications:

Torque specifications for all fasteners, engine performance data, fluid capacities, tolerances, and clearances.

Wiring Diagrams:

Complete electrical system wiring diagrams with component identification and color coding.

Parts Diagrams:

Illustrated parts diagrams for easy identification and ordering of replacement components.

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and component-level repair.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text content within the PDF for quick information retrieval.

Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding:

Not applicable (Digital Download - PDF)

Paper Type:

Not applicable (Digital Download - PDF)

⚙️ Engine Specifications

Engine Type:

V-twin, 4-stroke, SOHC, 8-valve (Rotax V-Twin Engine Family)

Engine Displacement:

Available in 500cc, 650cc, and 800cc variants.

Bore X Stroke 500Cc:

Approximately 70 mm x 64 mm (specific to Rotax 500)

Bore X Stroke 650Cc:

Approximately 72 mm x 65.2 mm (specific to Rotax 650)

Bore X Stroke 800Cc:

Approximately 78 mm x 61.2 mm (specific to Rotax 800)

Horsepower 500Cc:

Approx. 36 HP (27 kW)

Horsepower 650Cc:

Approx. 45 HP (33.5 kW)

Horsepower 800Cc:

Approx. 58 HP (43 kW)

Fuel Delivery:

Electronic Fuel Injection (EFI) with Keihin throttle body (specific size varies by displacement)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Ignition:

Magneto, high-output CDI ignition, dual spark plugs per cylinder.

🔧 Transmission

Type:

CVT (Continuously Variable Transmission) with engine braking

Transmission Modes:

High, Low, Neutral, Reverse, Park

Transmission Type:

Not applicable (CVT is standard)

Clutch System:

Primary (Drive) and Secondary (Driven) clutches

Drivetrain:

Selectable 2WD/4WD with Visco-Lok auto-locking front differential, or Tri-Mode Dynamic Power Steering (DPS) models.

Gear Reduction:

Includes high and low gear reduction ranges for optimal torque and speed.

📐 Dimensions

Length Approx:

Outlander: 86 in (218.4 cm) / Renegade: 82 in (208.3 cm) (varies slightly by model/trim)

Width Approx:

46 in (116.8 cm)

Height Approx:

45 in (114.3 cm)

Dry Weight Approx:

520 - 590 lbs (236 - 268 kg) depending on model and configuration.

Towing Capacity:

1,300 lbs (590 kg)

Rack Capacity Front:

120 lbs (54.4 kg)

Rack Capacity Rear:

240 lbs (109 kg)

🛡️ Safety Features

Crash Test Ratings:

Not applicable (ATVs are not subject to typical automotive crash testing standards)

Braking:

Hydraulic disc brakes (front and rear), dual-level traction control (on select models), engine braking.

Steering:

Dynamic Power Steering (DPS) available on select models for reduced steering effort.

Lighting:

Dual 35W halogen headlights, 55W projector-beam headlight, LED taillight.

Chassis Design:

Surround rider design with footwells, hand guards (standard on Renegade). Frame integrity for off-road use.

💡 Technology Features

Display Features:

Digital instrument cluster displaying speed, RPM, odometer, trip meters, fuel level, gear indicator, 4x4 indicator, etc.

Steering Assist:

Dynamic Power Steering (DPS) on select models for improved rider comfort and control.

Traction Control:

Dual-level traction control system available on some premium trims.

Diagnostic Port:

Standard diagnostic connector for accessing fault codes and real-time data via compatible tools.

Headlight Technology:

Halogen and projector-beam headlight configurations for optimal visibility.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km or 12 months (refer to manual for specific conditions).

Air Filter Cleaning:

Inspect every 1,000 km or 6 months; clean or replace as needed, more frequently in dusty conditions.

Spark Plug Replacement:

Refer to manual for specific interval, typically around 200-300 hours or 3,000-5,000 km.

Brake Fluid Flush:

Every 2 years or as recommended by manual.

Engine Oil:

SAE 5W-40 Synthetic (refer to manual for exact spec, e.g., XPS Synthetic 5W-40).

Engine Oil Capacity:

Approximately 2.1 US qt (2 L) (check dipstick/site glass).

Coolant:

Ethylene glycol based antifreeze (50/50 mix with distilled water recommended, e.g., XPS Antifreeze/Coolant).

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Differential Fluid Front:

Hypoid Gear Oil SAE 80W-90 (specific to Visco-Lok system).

Differential Fluid Rear:

Hypoid Gear Oil SAE 80W-90.

Transmission Clutch Fluid:

Not applicable for sealed CVT system; specialized lubrication for internal components addressed in manual.

Cvt Belt Wear:

Premature CVT belt wear can occur with aggressive riding or improper clutch maintenance. Manual details inspection and replacement.

Viscolok Issues:

Potential for Visco-Lok front differential to stick or not engage properly if fluid is contaminated or worn. Manual covers diagnosis.

Electrical Connectors:

Corrosion or loose connections on some electrical components can lead to intermittent issues. Manual provides troubleshooting steps.

Cooling System Leaks:

Minor leaks from hoses or clamps are possible, especially under stress. Regular checks are important.

📚 Vehicle History

Manufacturer:

BRP (Bombardier Recreational Products), parent company of Can-Am.

Can Am Atv Legacy:

Can-Am has a long history in motorsports and off-road vehicle development, known for performance and innovation.

Outlander Introduction:

The Outlander line was introduced as a versatile utility and recreational ATV, evolving over years with various engine sizes and features.

Renegade Introduction:

The Renegade was introduced as a sport-utility ATV, blending the power and features of the Outlander with a more performance-oriented chassis and styling.

Manufacturing Location:

Primarily manufactured in Valcourt, Quebec, Canada.

🏆 Awards & Recognition

Industry Acclaim:

Can-Am ATVs of this era generally received positive reviews for their powerful engines and advanced features, competing strongly in the performance ATV market.

Consumer Satisfaction:

Consistent strong performance in consumer satisfaction surveys for the Can-Am Outlander and Renegade lines, particularly regarding power and handling.

Emission Standards:

Meets relevant EPA and CARB emission standards for ATVs of its model years.