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.
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.
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.
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
Estimated Page Count:
Over 1000 pages (typical for complete workshop manuals covering multiple models and years)
Type:
Workshop Service Repair Manual
Purpose:
Comprehensive repair, maintenance, and troubleshooting guide for technicians and experienced DIY users.
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).
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.
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, electrical diagnostics, and frame work.
User Level:
Professional technicians and advanced DIY enthusiasts.
Engine Type:
Liquid-cooled, 4-stroke, SOHC V-twin (Rotax)
Displacements:
499cc (500), 650cc (650), 799.8cc (800)
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 Delivery:
Electronic Fuel Injection (EFI) with Delphi system (typical)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Type:
Continuously Variable Transmission (CVT) with engine braking
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Options:
No primary optional transmissions for these models; CVT is standard.
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.
Safety Standards:
Adherence to relevant ATV safety standards (e.g., ANSI/SVIA guidelines), though specific formal 'ratings' are less common than for passenger cars.
Braking System:
Hydraulic disc brakes on all wheels, often with a left-hand brake lever controlling front and rear, and a right-foot pedal for rear brake.
Differential:
Visco-Lok front differential for enhanced traction, automatically engages when wheel slip is detected.
Frame Construction:
Steel frame designed for torsional rigidity and durability.
Operator Protection:
Handlebar with knuckle guards, ergonomic seating position.
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).
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).
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.
Manufacturer:
Bombardier Recreational Products (BRP), a Canadian company with a long history in powersports and aerospace.
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.
Manufacturing Location:
Primarily manufactured by BRP in Canada (e.g., Valcourt, Quebec).
