Can-Am Outlander 500 800R 1000 2013-2016 Service Manual

The Outlander is Can-Am’s flagship utility ATV, offered through these years with a choice of Rotax V-twin engines: the 500, 650, 800R and 1000. All of them sit on the Surrounding Spar Technology (SST) G2 frame and use a continuously variable transmission, with trims that include the base Outlander, DPS, XT, XT-P and the two-up MAX. DPS models add Tri-Mode Dynamic Power Steering, and the XT adds aluminum underbelly protection plates. A Visco-Lok QE auto-locking front differential gives selectable 2WD or 4WD, and a multifunction digital gauge shows speed, tach, odometer, trip and hour meters, diagnostics and gear position. The 2015 Outlander 1000R X mr is the biggest-displacement mud ATV Can-Am designed to that point.

All four engines are liquid-cooled, SOHC, 8-valve (four valves per cylinder) Rotax V-twins with electronic fuel injection, with a 46mm throttle body and two Siemens VDO injectors. Displacement is 499.6cc on the 500 (82 x 47mm bore and stroke, about 40 hp and 42 Nm), 649.6cc on the 650 (82 x 62mm), 799.9cc on the 800R (91 x 62mm, about 71 hp and 73 Nm) and 976cc on the 1000 (91 x 75mm). The CVT has a sub-transmission with high, low, park, neutral and reverse, and the drive is shaft-driven.

The double A-arm front suspension and the rear torsional trailing-arm independent suspension give about 9 inches of travel at the front and 9.3 inches at the rear. Braking is dual 214mm ventilated front discs with hydraulic twin-piston calipers and a single 214mm rear disc. The XT runs 26x8-12 front and 26x10-12 rear tires, and the engine has an engine braking function. The Outlander measures about 86 inches long, 46 inches wide and 44 inches high, with a 51-inch (1,295mm) wheelbase, a 34.5-inch (877mm) seat height and 11 inches (279mm) of ground clearance. The MAX two-up models are longer, with a 59-inch wheelbase.

The racks carry 100 lbs at the front and 200 lbs at the rear, with 5.7 gallons (21.4 litres) of rear storage, and towing capacity is 1,300 lbs (590 kg). The fuel tank holds 5.4 gallons (20.5 litres). Dry weights in 2013 were about 713 lbs (324 kg) for the 500, 726 lbs (330 kg) for the 650, 729 lbs (331 kg) for the 800R and 759 lbs (345 kg) for the 1000 DPS.

This factory service manual covers the procedures, torque specs, and diagrams needed to keep a Can-Am Outlander 500 800R 1000 running the way it was built to.