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Can-Am Outlander 800 2007 Series User Manual

Can-Am Outlander 800 2007 Series
504 pages
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2007 / 2008

Table of Contents

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Can-Am Outlander 800 2007 Series Specifications

General IconGeneral
BrandCan-Am
ModelOutlander 800 2007 Series
CategoryOffroad Vehicle
LanguageEnglish

Summary

Introduction

General Information

Provides an overview of the manual's content and vehicle models.

Vehicle Information

Contains specific details and identification numbers for the vehicle.

Engine Emissions Information

Details engine emissions compliance and regulatory information.

Loctite Application Procedure

Instructions for applying Loctite products during maintenance and repair.

Self-Locking Fasteners Procedure

Guidance on the correct use of self-locking fasteners.

Tightening Torques

Specifications for fastener torque values across various components.

Manual Information

Information regarding the structure and use of the service manual.

Maintenance

Maintenance Chart

Details recommended maintenance intervals and specific tasks for the vehicle.

Preseason Preparation

Procedures for preparing the ATV for the riding season.

Storage Procedures

Guidelines for properly storing the ATV during off-season periods.

Special Procedures

Covers specific procedures like ATV immersion or turnover.

Troubleshooting

Troubleshooting Chart

A guide to diagnose and resolve common vehicle issues and symptoms.

Electrical System Troubleshooting

Diagnosing and resolving problems within the electrical system.

Cooling System Troubleshooting

Steps for identifying and fixing cooling system malfunctions.

Magneto System Troubleshooting

Diagnosing and resolving issues related to the magneto system.

Lubrication Troubleshooting

Addressing problems associated with the vehicle's lubrication system.

Engine and Gearbox

Engine Removal and Installation

Procedures for removing and installing the engine and gearbox assembly.

Air Intake System

Service and maintenance for the air intake system components.

Exhaust System

Procedures for servicing and maintaining the exhaust system.

Lubrication System

Details on engine oil, filter, and pressure checks and changes.

Cooling System

Maintenance and service procedures for the cooling system.

Magneto System

Service procedures for the magneto and related components.

Intake Manifold, Cylinder Head, and Cylinder

Service procedures for the engine's top-end components.

Bottom End

Procedures for servicing the crankshaft, connecting rods, and bearings.

Gearbox and 4x4 Coupling Unit

Service and maintenance for the gearbox and 4x4 system.

Shifter

Procedures for servicing the transmission shifter mechanism.

Engine Management

Engine Management Overview

Introduction to the engine management system and its components.

Operating Principle

Explains the basic function and interaction of engine management systems.

Air Induction System

Details on the air intake, filter, and throttle body functions.

Throttle Body

Information on the throttle body and its role in engine control.

Fuel System

Overview of the fuel system's components and operation.

Electrical System

Explanation of the vehicle's electrical system and communication links.

Engine Control Module (ECM)

Details on the ECM's function in controlling engine operations.

EMS Diagnostic

Procedures for diagnosing engine management system faults.

Fault Codes

Lists and explains diagnostic fault codes for the EMS.

Adjustment and Repair Procedures

Service Tools

Lists specialized tools for engine management procedures.

Service Products

Lists recommended products and their part numbers for repairs.

General Engine Management Procedures

General guidelines and warnings for engine management system work.

Fuel System Procedures

Maintenance and repair of the fuel system components.

Electrical System Procedures

Troubleshooting and repair of the vehicle's electrical system.

Basic Adjustments

Procedures for adjusting idle speed and throttle cable.

Throttle Body

Removal, installation, and adjustment of the throttle body.

Throttle Position Sensor (TPS)

Testing and replacement of the TPS sensor.

Idle Bypass Valve (IBV)

Information and testing procedures for the Idle Bypass Valve.

Crankshaft Position Sensor (CPS)

Testing and replacement of the CPS sensor.

Camshaft Position Sensor

Testing and replacement of the camshaft position sensor.

MAPTS Sensor

Testing and replacement of the MAPTS sensor.

Coolant Temperature Sensor (CTS)

Testing and replacement of the CTS sensor.

Fuel Tank and Fuel Pump

Fuel System Service Tools

Lists necessary tools for fuel system maintenance and repair.

General Fuel System Information

Safety precautions and general procedures for fuel system work.

Fuel System Inspection

Procedures for inspecting fuel system components for leaks or damage.

Fuel System Diagnostic Flow Chart

A flowchart to help diagnose fuel system issues.

Electrical System

Communication Tools and Software

Information on diagnostic tools and software for vehicle communication.

Ignition System

Procedures for testing and servicing the ignition system components.

Charging System

Maintenance and troubleshooting for the vehicle's charging system.

Starting System

Procedures for diagnosing and servicing the starting system.

Digitally Encoded Security System (DESS)

Information on DESS programming and troubleshooting.

Lights, Gauges, and Accessories

Service and troubleshooting for lighting, instrument gauges, and accessories.

Continuously Variable Transmission (CVT)

Service Tools

Lists specialized tools for CVT maintenance and repair.

Service Products

Lists recommended products for CVT service.

Drive Belt

Procedures for inspecting, removing, and installing the drive belt.

Drive Pulley

Service procedures for the drive pulley assembly.

Driven Pulley

Maintenance and disassembly of the driven pulley.

CVT Air Guide

Removal and inspection of the CVT air guide.

Front Drive

Service Tools

Lists specialized tools for front drive system service.

Service Products

Lists recommended products for front drive system maintenance.

Tires and Wheels

Procedures for tire replacement and wheel hub service.

Wheel Hub

Service procedures for removing and installing the wheel hub.

Front Drive Shaft

Procedures for removing and installing the front drive shaft.

Drive Shaft Boot

Service procedures for the drive shaft boot.

Front Differential

Maintenance and service procedures for the front differential.

Rear Drive

Service Tools

Lists specialized tools for rear drive system service.

Service Products

Lists recommended products for rear drive system maintenance.

Tires and Wheels

Procedures for tire replacement and wheel hub service.

Wheel Hub Inspection

Inspection procedures for the wheel hub and wear ring.

Differential Protector Removal

Procedure for removing the differential protector.

Drive Shaft

Procedures for removing and installing the drive shaft.

Propeller Shaft U-Joint

Service procedures for the propeller shaft U-joint.

Rear Differential

Maintenance and service procedures for the rear differential.

Steering System

Service Tools

Lists specialized tools for steering system maintenance.

Service Tools - Other Supplier

Lists tools from other suppliers for steering system service.

Service Products

Lists recommended products for steering system maintenance.

Handlebar Cover

Procedures for removing and installing the handlebar cover.

Handlebar Grip

Procedures for removing and installing handlebar grips.

Handlebar

Procedures related to the handlebar, including brake and throttle controls.

Steering Column

Service procedures for the steering column components.

Steering Column Bearing

Procedures for servicing the steering column bearing.

Tie-Rod

Service procedures for the tie-rod assembly.

Knuckle

Procedures for removing and installing steering knuckles.

Wheel Bearing

Procedures for inspecting and replacing wheel bearings.

Multifunction Switch

Testing and replacement of the multifunction switch.

Throttle Handle

Procedures for adjusting and servicing the throttle handle.

Steering Alignment

Procedures for checking and adjusting vehicle steering alignment.

Front Suspension

Service Tools

Lists specialized tools for front suspension service.

Service Products

Lists recommended products for front suspension maintenance.

Shock Absorber and Spring

Procedures for removing and installing shock absorbers and springs.

Lower Suspension Arm

Procedures for servicing the lower suspension arm components.

Lower Ball Joint

Procedures for servicing and replacing lower ball joints.

Upper Suspension Arm

Procedures for servicing the upper suspension arm components.

Upper Ball Joint

Procedures for servicing and replacing upper ball joints.

Rear Suspension

Service Tools

Lists specialized tools for rear suspension service.

Service Products

Lists recommended products for rear suspension maintenance.

Trailing Arm

Procedures for removing and installing the trailing arm.

Trailing Arm Bearings

Procedures for servicing and replacing trailing arm bearings.

Front and Rear Brakes

Service Tools

Lists specialized tools for brake system service.

Service Products

Lists recommended products for brake system maintenance.

Brake Fluid

Procedures for checking and replacing brake fluid.

Parking Brake

Information on the operation and maintenance of the parking brake.

Hydraulic Brakes

General information about the hydraulic brake system.

Brake Fluid Reservoir

Procedures for maintaining the brake fluid reservoir.

Rear Brake Fluid Reservoir

Procedures for maintaining the rear brake fluid reservoir.

Brake Hoses

Inspection and replacement procedures for brake hoses.

Brake Pedal

Procedures for servicing the brake pedal.

Front Master Cylinder

Procedures for servicing the front master cylinder.

Rear Master Cylinder

Procedures for servicing the rear master cylinder.

Caliper

Procedures for servicing the brake caliper.

Brake Pads

Procedures for inspection and replacement of brake pads.

Brake Disc

Procedures for inspecting and replacing brake discs.

Body

Service Tools

Lists specialized tools for bodywork and frame maintenance.

Outlander Series Body Parts

Exploded view and part identification for Outlander body components.

Seat

Procedures for removing and installing the vehicle seat.

Central Panel

Procedures for removing and installing the central panel.

Dash Board

Procedures for removing and installing the dashboard.

Side Panel

Procedures for removing and installing side panels.

Footrest

Procedures for removing and installing footrests.

Inner Fender

Procedures for removing and installing inner fenders.

Heavy Duty Bumper

Procedures for removing and installing heavy duty bumpers.

Front Bumper/Front Skid Plate

Procedures for removing and installing front bumper and skid plate.

Fender

Procedures for removing and installing fenders.

Fender Support

Procedures for removing and installing fender supports.

Frame

Footrest Support

Procedures for removing and installing footrest supports.

Battery Support

Procedures for removing and installing battery supports.

Hitch

Procedures for removing and installing the hitch.

Recovery Hook

Procedures for removing and installing the recovery hook.

Outlander Series Technical Specifications

Engine Specifications

Technical data for the engine, including bore, stroke, and compression.

Valve Specifications

Specifications for valve timing, stem diameter, and clearances.

Coolant Specifications

Information on coolant type and capacity.

Electrical System Specifications

Data on battery, ignition, magneto, and lighting systems.

Fuel System Specifications

Specifications for fuel delivery, pump, and tank capacity.

Drive Train Specifications

Specifications for front/rear drive, CV joint grease, and propeller shaft grease.

Transmission Specifications

Specifications for the CVT, including belt width and pulley dimensions.

Steering Specifications

Specifications for steering system components like turning radius.

Suspension Specifications

Data on suspension travel, shock absorbers, and spring free length.

Brakes Specifications

Specifications for brake fluid, calipers, pads, and discs.

Tires and Wheels Specifications

Information on tire pressure, size, and wheel dimensions.

Loading Capacity

Specifications for weight limits, rack capacity, and towing capacity.

Material Specifications

Details on the materials used for various vehicle components.

Renegade Models Technical Specifications

Engine Specifications

Technical data for Renegade engine models.

Gearbox Specifications

Technical data for the Renegade gearbox.

Cooling System Specifications

Data on coolant type and capacity for Renegade models.

Electrical System Specifications

Specifications for electrical systems on Renegade models.

Fuel System Specifications

Specifications for fuel system components on Renegade models.

Drive Train Specifications

Specifications for drive train components on Renegade models.

Transmission Specifications

CVT and steering specifications for Renegade models.

Suspension Specifications

Data on suspension for Renegade models.

Brakes Specifications

Specifications for brakes on Renegade models.

Tires and Wheels Specifications

Tire and wheel data for Renegade models.

Loading Capacity

Loading capacities for Renegade models.

Material Specifications

Material details for Renegade models.

Electrical Connectors and Wiring Diagrams

Service Tools

Lists specialized tools for electrical connector service.

Service Tools - Other Supplier

Lists tools from other suppliers for electrical connector service.

Deutsch Connectors

Procedures for removing and disassembling Deutsch connectors.

Connector Disassembly

Steps for safely disassembling electrical connectors.

ECM Connectors

Identification and service of ECM connectors.

Terminal Removal

Procedures for safely removing terminals from connectors.

Terminal Crimping (Kostal)

Instructions for crimping new terminals using specific tools.

Multifunction Speedometer Connector

Procedures for disconnecting and connecting the multifunction speedometer.

Battery and Starter Cable Terminals

Procedures for preparing and attaching terminals to cables.

Wiring Diagrams

Explanation of wiring diagram conventions and color codes.

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