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2011 commander 800R
Can-Am 2011 commander 800R - User Manual
423 pages
Manual
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2
Table of Contents
Main Page
Table of Contents
4
Safety Notice
12
Engine Identification Number (EIN)
13
Introduction
13
Vehicle Information
13
VIN Decal Description
13
Hoisting the Vehicle
14
Rear of Vehicle
14
Engine Emissions Information
15
Owner Responsibility
15
Transporting the Vehicle
15
Manual Information
16
Manual Layout
16
Manual Procedures
16
Fastener Grade/Torque
19
Tightening Torque
19
Application Procedure
20
Fastener Information
20
Self-Locking Fasteners Procedure
20
Threadlocker Application for Blind Holes
20
Threadlocker Application for an Adjustment Screw
21
Threadlocker Application for Pre-Assembled Parts
21
Threadlocker Application for Stud Installation in Blind Holes
21
Application for Stripped Thread Repair
22
Gasket Compound Application
22
Mounting with a Press
22
Standard Thread Repair
22
Threadlocker Application for Case-In Components
23
Service Tools Index
24
Fuse Box
25
Maintenance
28
Break-In Inspection
28
Periodic Maintenance Schedule
30
Periodic Maintenance Procedures
32
Air Filter Replacement
32
General
32
Air Filter Installation
33
Muffler Spark Arrester Cleaning and Inspection
33
Engine Oil Level Verification
34
Engine Oil and Filter
35
Engine Oil Change
35
Engine Oil Filter Replacement
35
Oil Filter Removal
35
Engine Coolant Level Verification
36
Oil Filter Installation
36
Recommended Engine Coolant
36
Cooling System Draining
37
Engine Coolant Replacement
37
Engine Coolant Specific Gravity Check
37
Cooling System Drain Plug Torque
38
Radiator Hose Clamp
38
Bleed Screw Installation
39
Cooling System Bleeding
39
Cooling System Inspection
40
Coolant Expansion Tank Vents
41
Cooling System Leak Test
41
Cvt Air Filter Cleaning
42
Engine Valve Clearance Adjustment
42
Pressure Cap Test
42
Valve Clearance
42
CVT Air Filter
43
Cvt Air Inlet/Outlet Cleaning
43
Drive Belt Inspection
43
Drive Pulley, Driven Pulley and One-Way Bearing Maintenance
43
Gearbox Oil Level Verification
44
Gearbox Oil Replacement
44
Battery Inspection
45
Fuel Pump Prefilter Cleaning
45
Fuel Pump Pressure Test
45
Fuel System Inspection
45
Fuel Tank Vent Breather Filter Replacement
45
Spark Plug Replacement
45
Throttle Body Inspection
45
Front Differential Oil Level Verification
46
Front Differential Oil Replacement
46
Vehicle Speed Sensor (Vss) Cleaning
46
Drive Shaft Boot and Protector (Visual Inspection)
47
Rear Final Drive Oil Level Verification
47
Rear Final Drive Oil Replacement
47
Drive Shaft Joint Inspection
48
Propeller Shaft U-Joint Condition
48
Propeller Shaft U-Joint Lubrication
48
Shock Absorber Inspection
48
Shock Absorber Spherical Bearing Lubrication
48
Steering System Inspection
48
Wheel Bearing Inspection
48
Wheel Lug Nut Torque Check
48
Front Suspension Arm Lubrication
49
Spherical Bearing Lubrication
49
Brake Disc
50
Brake Fluid Replacement
50
Brake Pads
50
Brake System Inspection and Cleaning
50
Bleeding Procedure Using a Vacuum Pump
51
Brake Fluid Bleeding
51
Brake Fluid Filling
51
Manual Bleeding Procedure
51
Bleeder Torque
52
Passenger Handhold Condition
52
Tow Hitch Inspection
52
Preseason Preparation
54
Engine Internal Lubrication
56
Fuel System Protection
56
Storage
56
Storage Oil
56
Battery Removal
57
Chassis Lubrication
57
Drive System
57
Vehicle Cleaning
57
Rolled over Vehicle
58
Special Procedures
58
Submerged Vehicle
58
Engine Removal and Installation
60
Engine Removal
61
ENGINE, CVT and GEARBOX (Cont'D)
61
Vehicle and Engine Preparation
61
Lifting Engine
62
Vehicle Speed Sensor
62
Engine Installation
63
Engine Mount Installation
63
Engine Mount Removal
63
Final Assembly
63
Air Intake System
64
Air Filter Housing
65
Air Filter Housing Removal
66
Exhaust System
68
Muffler
69
Muffler Inspection
69
Muffler Removal
69
Spark Arrester
69
Exhaust Pipe
70
Exhaust Pipe Inspection
70
Exhaust Pipe Removal
70
Head Pipe
70
Rear Cylinder
71
Rear Head Pipe Inspection
71
Rear Head Pipe Installation
71
Rear Head Pipe Removal
71
Lubrication System
72
Engine Lubrication Circuit
74
Engine Oil Pressure
75
Low or no Oil Pressure
75
High Oil Consumption
76
Oil Contamination
76
Oil Cooler Inspection
76
Oil Cooler Installation
76
Engine Oil Pressure Regulator
77
Oil Pressure Switch
77
Oil Pressure Switch Activation
77
Oil Pressure Switch Removal
77
Oil Pressure Regulator Inspection
78
Oil Pressure Regulator Installation
78
Oil Pump
78
Oil Pump Removal
78
Oil Pump Inspection
79
Engine Oil Strainer
80
Oil Pump Final Test
80
Oil Pump Installation
80
Oil Strainer Removal
80
Oil Strainer Cleaning and Inspection
81
Oil Strainer Installation
81
Reed Valve
81
Reed Valve Installation
81
Cooling System
82
Radiator
83
General
87
Procedures
87
Thermostat
87
Thermostat Removal
87
Radiator Inspection
89
Radiator Removal
89
Thermostat Installation
89
Thermostat Test
89
Coolant Temperature Sensor (Cts)
90
Radiator Cooling Fan Relay (R1)
90
Radiator Installation
90
Relay Installation
90
Radiator Cooling Fan
91
Radiator Cooling Fan Operation
91
Relay Continuity Test
91
Radiator Cooling Fan Fuse Location
92
Radiator Cooling Fan Test
92
Radiator Cooling Fan Removal
93
Water Pump Housing
93
Water Pump Housing Inspection
93
Water Pump Housing Removal
93
Water Pump Housing
94
Water Pump Impeller
94
Water Pump Impeller Installation
94
Water Pump Shaft and Seals
94
Oil Seal
96
Rotary Seal
96
Rotary Seal and Oil Seal Installation
96
Magneto System
104
General
106
Magneto Cover
106
Magneto Cover Access in Vehicle
106
Magneto Cover Inspection and Cleaning
106
Magneto Cover Removal
106
Procedures
106
Stator
107
Stator Connector Access
107
Stator Static Test
107
Rotor
108
Stator Inspection
108
Stator Installation
108
Stator Removal
108
Stator Static Test Insulation
108
Rotor Inspection
109
Rotor Installation
109
Sprag Clutch
110
Sprag Clutch Removal
110
Sprag Clutch Gear
111
Sprag Clutch Gear Removal
111
Sprag Clutch Inspection
111
Sprag Clutch Installation
111
Sprag Clutch Gear Installation
112
Starter Drive Gear Inspection
112
Starter Drive Gear Installation
112
Starter Drive Gears
112
Top End
114
Intake Manifold
115
Cylinder Head No. 1
116
Cylinder Head No. 2
117
Cylinders and Pistons
118
General
119
Inspection
119
Leak Test
119
Preparation
119
Diagnosis
121
Intake Manifold Removal
121
Procedures
121
Intake Manifold Installation
122
Valve Cover Inspection
122
Valve Cover Installation
122
Valve Cover Removal
122
Rocker Arm Removal
123
Rocker Arm Bore Diameter
124
Rocker Arm Inspection
124
Rocker Arm Installation
124
Rocker Arm Shaft
124
Cylinder Head
125
Cylinder Head Access
125
Cylinder Head Inspection
126
Cylinder Head Installation
126
Camshaft Removal
127
Camshaft Inspection
128
Camshaft Journal
128
Camshaft Lobe
128
Camshaft Installation
129
Valve Spring Removal
129
Valve Springs
129
Valve Spring Free Length
130
Valve Spring Inspection
130
Valve Spring Installation
130
Valve Inspection
131
Valve Removal
131
Valve Stem Seal
131
Valves
131
Intake Valve
132
Valve Installation
132
Valve Stem Diameter
132
Valve Guide Inspection
133
Valve Guide Installation
133
Valve Guide Removal
133
Cylinder
134
Cylinder Installation
135
Cylinder out of Round
135
Cylinder Taper in Diameter
135
Piston Installation
136
Piston Measurement
136
Piston Removal
136
Connecting Rod/Piston Pin Clearance
137
Piston Pin Diameter
137
Connecting Rod Small End Diameter
138
Engine Type
138
Lower Compression Ring
139
Piston Rings
139
Ring Inspection
139
Ring Removal
139
Oil Scraper Ring
140
Ring End Gap
140
Ring Installation
140
Timing Chain
142
Engine Lacks Acceleration or Power
144
General
144
Procedures
144
Timing Chain Tensioners
144
Troubleshooting
144
Unusual Engine Noise or Vibration
144
Timing Chain Tensioner Adjustment
145
Timing Chain Tensioner Inspection
145
Timing Chain Tensioner Installation
145
Camshaft Timing Gear Inspection
146
Camshaft Timing Gear Installation
146
Camshaft Timing Gear Removal
146
Camshaft Timing Gears
146
Camshaft Timing
147
Camshaft Timing Cylinder 2
148
Camshaft Timing Cylinder 1
150
Timing Chain Guide (Tensioner Side)
151
Timing Chain Removal
151
Timing Chain Removal PTO Side
151
Timing Chain Inspection
152
Timing Chain Installation
152
Timing Chain Guide
153
Timing Chain Guide Inspection
153
Timing Chain Guide Removal
153
Bottom End
154
Engine Drive Shaft
155
Crankcase and PTO Cover
156
Crankshaft
157
Engine Drive Shaft Removal
158
General
158
Oil Seal Replacement
158
Procedures
158
Engine Drive Shaft Inspection
159
Engine Drive Shaft Installation
159
PTO Cover Oil Seal
160
PTO Oil Seal Inspection
160
PTO Oil Seal Installation
160
PTO Oil Seal Removal
160
PTO Cover
161
PTO Cover Installation
161
PTO Cover Removal
161
Plain Bearing Installation
162
Plain Bearing Removal
162
Drive Gear Removal
163
Drive Gears
163
Breather Gear
164
Crankcase
164
Crankcase Disassembly
164
Drive Gears Inspection
164
Crankcase Cleaning
166
Crankcase Inspection
166
Oil Strainer
166
Plain Bearing Installation
167
Crankcase Assembly
168
Crankshaft Locking
168
Connecting Rod Big End Axial Play
170
Crankshaft Axial Play
170
Crankshaft Inspection
170
Connecting Rod Big End Radial Play
171
Crankshaft Radial Play MAG/PTO Side
171
Crankshaft Assembly
172
Crankshaft Journal Diameter
172
Crankshaft Radial Play
172
Crankshaft Installation
174
Continuously Variable Transmission
176
CVT Cover
179
CVT Cover Access
179
CVT Cover Draining
179
CVT Cover Removal
179
CVT Cover Installation
180
Drive Belt Installation
180
Drive Belt Removal
180
Drive Pulley Removal
181
First Locking Method
181
Second Locking Method
181
Drive Pulley Disassembly
182
Drive Pulley Removal Continuation
182
Governor Cup
182
Sliding Sheave
183
Drive Pulley Cleaning
184
Fixed Sheave
184
Bushings
185
Drive Pulley Inspection
185
Roller and Slider Shoe
185
Roller Outer Diameter
185
Centrifugal Lever Bore Diameter
186
Sliding Sheave Large Bushing
186
Clutch Spring Squareness
187
One-Way Clutch
187
Sliding Sheave Small Bushing
187
Spring
187
Drive Pulley Installation
188
Driven Pulley
189
Driven Pulley Removal
189
Driven Pulley Disassembly
190
Driven Pulley Cleaning
191
Driven Pulley Inspection
191
Bushing Bore Diameter
192
Bushings Bore Diameter
192
Wear on Teeth both Sides
192
Driven Pulley Assembly
193
Spring Free Length
193
Wear on Contact Surface
193
Width on Top Surface
193
Driven Pulley Installation
194
CVT Air Guide Inspection
195
CVT Air Guide Installation
195
CVT Air Guide Removal
195
Gearbox and 4X4 Coupling Unit
196
Gearbox Components and 4X4 Coupling Mechanism
197
Gear Indication Fails
198
Gear(S) Is (Are) Hard to Shift
198
Gearbox Overview
198
Unusual Gearbox Noise And/Or Vibrations
198
VSS Access
199
VSS Circuit Protection
199
VSS Input Voltage Test
199
VSS Location
199
GBPS Reset
200
VSS Installatoin
200
VSS Removal
200
GBPS Access
201
GBPS Communication Link Continuity Test
201
Multimeter Probe Positions
201
4WD Indicator Switch
202
4WD Indicator Switch Access
202
4WD Indicator Switch Test
202
GBPS Removal
202
Actuator
203
Actuator Access
203
Actuator Installation
203
Actuator Removal
203
Gearbox Oil Seal Replacement
204
Gearbox Oil Seals
204
Shift Drum Shaft Oil Seal
205
Shift Shaft Oil Seal
205
Gearbox Removal
206
Output Shaft Oil Seal
206
Gearbox Disassembly
207
Gearbox Left Cover
207
Position for Soft Hammer
207
Index Lever and Index Washer
208
Main Shaft and Shift Forks
208
Gearbox Right Cover
210
Shift Shaft and Shift Drum
210
Output Shaft and 4X4 Coupling Mechanism
211
Countershaft
212
Gearbox Bearings
212
Bearings
213
Diameter Free Pinion
213
Free Pinions
213
Gearbox Inspection
213
Bearing Pin Outer Diameter
214
Countershaft Bearing Journals
214
CVT Side
214
Width of Shift Fork Engagement
214
Bearing Journal CVT/MAG Side
215
Free Pinion Bearing
215
Main Shaft
215
Shift Fork Claw Thickness
215
Coupling Fork
216
Coupling Sleeve Groove Width
216
Gearbox Assembly
216
Sealing Compound Application
218
Shift Lever
223
Shifter Cable
224
Engine Management System
228
Diagnostic Mode
229
Fuel System
229
Limp Home Mode
229
Monitoring System
229
Communication Tools and B.U.D.S.
232
Diagnostic Tips
232
Status Lights
232
USB Light
232
Missing Module
233
Module List
233
No Vehicle Detected
233
Connecting the PC to the Vehicle
234
Diagnostic Connector Location
234
Mpi-2
234
MPI-2 Power
234
B.U.D.S. Software
235
How to Establish Communication Using B.U.D.S. Software
235
Electronic Modules Updates
236
Writing Changes
237
Diagnostic System and Fault Codes
238
Pilot Lamps
238
Active Fault Codes
239
Fault Codes
239
Inactive Fault Codes
239
Occurred Fault Codes
239
Analog/Digital Gauge
240
LCD Gauge
241
Park Brake
242
Specific Faults
242
TAS Fault
242
TPS Fault
242
Intelligent Throttle Control
244
Normal/Sport Modes
244
Performance Key
244
System Main Features
244
Override Switch
245
Seat Belt Switch
245
Sport/Normal Switch
245
Throttle Accelerator
245
TAS Failure
246
TAS Test with B.u.D.s
246
TAS Wire Information
246
Air Filter
248
EFI Sensors
248
Electronic Fuel Injection (Efi)
248
General
248
System Description
248
Adjustment
249
Fuel Injectors
249
Fuel Rail
249
Idle Speed
249
Diagnostic Tips
250
ECM First Initialization
250
Engine Control Module (Ecm)
250
Procedures
250
Quick Test to Validate ECM Operation
250
Troubleshooting
250
ECM Access
251
ECM Connector Identification
251
Continuity Test of ECM Ground Circuits
252
ECM Adapter Tool
252
ECM Power Supply Test
252
ECM Removal
252
ECM Automated Data Transfer
253
ECM Installation
253
ECM Replacement
253
ECM Manual Data Entry
254
Fuel Injector
256
Fuel Injector Leak Test
258
Fuel Injector Resistance Test
258
Fuel Injector Input Voltage Test
259
Fuel Injector Installation
260
Fuel Rail Removal
260
Fuel Rail Installation
261
Throttle Body
261
Throttle Body Description
261
Throttle Body Access
262
Throttle Body Cleaning
262
Throttle Body Installation
262
Throttle Position Sensor (Tps)
263
Throttle Position Sensor Initialization
263
TPS Resistance Test
264
TPS Wear Test
264
Crankshaft Position Sensor (Cps)
265
Manifold Air Pressure and Temperature Sensor (Mapts)
266
Cts (Coolant Temperature Sensor)
269
Fuel Tank and Fuel Pump
272
General
274
System Description
274
Fuel Pump Pressure Test
275
Fuel Tank Leak Test
275
Inspection
275
Fuel System Diagnostic Flow Chart
278
Troubleshooting
278
Fuel Hose and Oetiker Clamps
279
Fuel Tank
279
Procedures
279
Fuel Tank Inspection
280
Fuel Tank Installation
280
Fuel Pump Input Voltage Test
281
Fuel Pump Quick Test
281
Fuel Level Sender
285
Fuel Tank Vent Valve
286
Electrical System
288
Fuse Box 2
288
General
288
Power Distribution Diagram
288
Controller Area Network (Can)
290
General
290
System Description
290
Diagnostic Guidelines
292
General
292
Ignition System
292
System Description
292
Troubleshooting
292
Ignition Coil
293
Ignition Switch
293
Procedures
293
Spark Plug
294
Charging System Output
296
General
296
Inspection
296
System Description
296
PROCEDURES (Cont'D)
306
Console Switches
308
Lights, Gauge and Accessories
308
Switches Access
308
Switches Removal and Installation
308
Multifunction Gauge Circuit Protection
309
Multifunction Gauge Installation
309
Multifunction Gauge Removal
309
Multifunction Gauge Wire Identification
309
Front Drive
318
Rear Drive
328
Wheel Hub Inspection
331
Wheel Hub Installation
331
Wheel Hub Removal
331
Drive Shaft Boot
332
Drive Shaft Inspection
332
Drive Shaft Installation
332
Drive Shaft Removal
332
Propeller Shaft U-Joints
333
Rear Final Drive
334
Chassis
338
General
338
Procedures
338
Wheels and Tires
338
Wheels
340
Steering System
342
Adjustment
344
General
344
Steering Alignment
344
Diagnostic Tips
346
Procedures
346
Steering Column
346
Steering Wheel
346
Troubleshooting
346
Rack and Pinion
348
Tie-Rod Ends
348
Knuckles
349
Wheel Bearings
349
Front Suspension
352
General
353
Procedures
353
Shock Absorber
353
Springs
353
Shock Absorber Bushings
354
Upper Suspension Arm
355
Ball Joints
356
Lower Suspension Arm
356
Suspension Arm Bushings
356
Rear Suspension
358
General
359
Procedures
359
Rear Suspension
359
Shock Absorbers
359
Shock Absorber Bushings
360
Springs
360
Anti-Sway Bar
361
Trailing Arm
361
Brakes
364
Brake System Pressure Validation
366
General
366
Inspection
366
Brake Light Switch
368
Master Cylinder
368
Procedures
368
Brake Pads
370
Caliper
370
Brake Disc
371
Body
372
Upper Console
374
Lower Console
382
Lateral Console Panels
383
Glove Box Removal and Installation
384
Cargo Box
386
Cargo Box Tilt Release Mechanism
387
Cargo Box Support
388
Upper Tail Gate
389
Lower Tail Gate
390
Adjustment
392
Cargo Box Adjustments
392
General
392
Cargo Box
394
Cargo Box Gas Shock
394
Procedures
394
Frame
396
Cage
399
General
399
Procedures
399
Frame
400
Commander 800R and 1000
402
Technical Specifications
402
General
412
Wiring Diagram Codes
412
Wiring Diagram Information
412
Wiring Diagram Location
412
Connector Information
414
Deutsch Connectors
414
General
414
Connector Information
415
Deutsch Connectors
415
Packard Connectors
416
Packard Connector (Multifunction Gauge)
417
Molex Connector
418
Battery and Starter Cable Terminals
421
Furukawa Connector
421
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Can-Am 2011 commander 800R Specifications
General
Brand
Can-Am
Model
2011 commander 800R
Category
Utility Vehicle
Language
English
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