Can-Am Outlander Series 500 Service Manual

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CAN-AM OUTLANDER SERIES 500 SERVICE

MANUAL
Table of Contents
Table of Contents
Safety Notice
General Information
Vehicle Information
Engine Emissions Information
Model Number
Vehicle Identification Number (VIN)
Self-Locking Fasteners Procedure
Loctite Application Procedure
Owner Responsibility
ERA Emission Regulations
Stud in Blind Holes
Preassembled Parts
Adjusting Screw
Stripped Thread Repair
Gasket Compound
Standard Thread Repair
Repair of Small Holes/Fine Threads
Tightening Torques
Mounting on Shaft
Case-In Components
Mounting with a Press
Fastener Grade/Torque
Maintenance Chart
Preseason Preparation
Storage Procedures
Fuel Stabilizer
Engine Lubrication
Rags Installation
Coolant Density
Drive and Driven Pulleys Protection
Vehicle Cleaning
Vehicle Protection
Special Procedures
Service Products
Turn Over
ATV Immersion
Troubleshooting Chart
Starter Does Not Turn
Starter Turns, But Does Not Crank the Engine
Starter Motor Keeps Running
High Engine Operating Temperature
Battery Not Charging or Charging Voltage Inadequate
Low or No Oil Pressure/High Oil Consumption
Oil Contamination
Unusual Engine Noise And/Or Vibration
Oil Contamination on Cylinder and/or Head
Unusual Engine Noise and/or Vibrations
Unusual Gearbox Noise and/or Vibrations
Gear indication fails
Gear(s) is (are) hard to shift
Wheel Drive Indication Fails
Wheel Drive Does Not Engage or Disengage
Unusual Acceleration Behavior
Engine Maximum RPM Is Too High and Top Speed is Not Reached
Drive Pulley Noise in Idle Speed
Drive Pulley Noise When Accelerating/Decelerating
Vibrations originating from drive pulley
Vibrations originating from driven pulley
Pulley's Do Not Down/Up Shift Properly
Belt Glazed Excessively or Having Baked Appearance
Belt Worn Excessively In Top Width
Belt Disintegration
Cracks Between Cogs
Engine Cranks But Fails to Start
Engine Does Not Start
Engine Hard to Start
Engine Suddenly Turns Off
Engine Backfires
Engine Does Not Offer Maximum Power And/Or Does Not Reach
Maximum Operating RPM
Engine Removal and Installation
Service Tools
Engine Removal
Vehicle and Engine Preparation
Engine Installation
Final Assembly Procedure
Engine Mount Replacement
Air Intake System
Air Filter Housing
Air Filter Removal
Air Filter Housing Removal
Air Filter Housing Installation
Restrictor Removal
Restrictor Installation
Exhaust System
Front Exhaust Pipe Inspection
Front Exhaust Pipe Removal
Front Exhaust Pipe Installation
Muffler removal
Muffler Installation
"Y" Exhaust Pipe Removal
"Y" Exhaust Pipe Installation
Fuel Tank Protector Removal
Fuel Tank Protector Installation
Lubrication System
Lubrication System Components
Engine Oil
Recommended Oil
Engine Oil Viscosity
Engine Oil Level Verification
Engine Oil Pressure
Oil Filter Removal
Oil Pressure Switch (OPS)
Oil Filter Inspection
Oil Filter Installation
Oil Pressure Switch Activation
Engine Oil Pressure Regulator
Oil Pressure Switch Removal
Oil Pressure Switch Installation
Oil Pump Removal
Oil Pump Inspection
Oil Pump Installation
Engine Oil Strainer Removal
Engine Oil Strainer Cleaning and Inspection
Reed Valve Removal
Reed Valve Inspection
Cooling System Service Tools
Radiator
Water Pump
Cooling System Leak Test
Coolant Replacement
Recommended Coolant
Draining the System
Refilling the System
Thermostat Removal
Radiator Cap
Coolant Tank
Thermostat Installation
Radiator Installation
Coolant Temperature Sensor (CTS)
Radiator Fan Relay (R1)
Relay Installation
Relay Operation Test
Radiator Fan Operation
Radiator Fan Test
Water Pump Housing
Radiator Fan Removal
Water Pump Housing Removal
Radiator Fan Installation
Water Pump Impeller
Water Pump Shaft and Seals
Water Pump Housing Inspection
Water Pump Housing Installation
Shaft/Seal Installation
Magneto System
Magneto Cover Removal
Magneto Cover Inspection and Cleaning
Magneto Cover Installation
Stator Removal
Stator Inspection
Stator Installation
Rotor Removal
Rotor Inspection
Rotor Installation
Sprag Clutch Removal
Sprag Clutch Inspection
Sprag Clutch Installation
Sprag Clutch Gear Removal
Sprag Clutch Gear Inspection
Starter Drive Gears
Sprag Clutch Gear Installation
Gear Removal
Gear Inspection
Gear installation
Intake Manifold, Cylinder Head and Cylinder
Intake Manifold
Cylinder Head No.1
Cylinder Head No.2
Cylinders and Pistons
Maintenance
Valve Adjustment
Valve Clearance
Leak Test Inspection
Intake Manifold Removal
Valve Cover Removal
Intake Manifold Inspection
Intake Manifold Installation
Timing Chain Tensioner Removal
Timing Chain Tensioner Inspection
Timing Chain Tensioner Installation
Camshaft Timing Gear Removal
Camshaft Timing Gear Inspection
Camshaft Timing Gear Installation
Rocker Arm Removal
Rocker Arm Inspection
Timing Chain
Rocker Arm Installation
Rocker Arm Shaft
Cylinder Head Removal
Cylinder Head Inspection
Camshaft
Cylinder Head Installation
Camshaft Timing
Camshaft Timing Cylinder 2
Camshaft Timing Cylinder 1
Camshaft Inspection
Valve Spring Removal
Camshaft Installation
Valve Spring Inspection
Valve Spring Installation
Valve Removal
Valve Inspection
Valve Stem Seal
Valve Stem Diameter
Valve Installation
Valve Face and Seat
Valve Seat Contact Width
Valve Guide Removal
Valve Guide Inspection
Valve Guide Installation
Cylinder Removal
Cylinder Inspection
Cylinder Taper in Diameter
Cylinder Installation
Cylinder Out of Round
Piston Removal
Piston Inspection
Piston/Cylinder Clearance
Piston Pin Diameter
Connecting Rod/Piston Pin Clearance
Piston Installation
Connecting Rod small End Diameter
Piston Rings
Ring Removal
Ring Inspection
Ring Installation
Bottom End
Engine Drive shaft
Crankcase And PTO Cover
Crankshaft
Oil Seal Removal
Engine Drive Shaft Removal
Engine Drive shaft Inspection
Engine Drive Shaft Installation
PTO Cover Oil Seal removal
PTO Oil Seal Inspection
PTO Oil Seal Installation
PTO Cover Removal
PTO Cover Inspection
Plain Bearing Replacement Procedure
Plain Bearing Removal
PTO Cover Installation
Plain Bearing Installation
Drive Gears Removal
Drive Gears Inspection
Drive Gear Installation
Timing Chain Removal (Magneto Side)
Timing Chain Removal (PTO Side)
Timing Chain Inspection
Timing Chain Installation
Timing Chain Guide
Chain Guide Inspection
Chain Guide Installation
Crankcase Disassembly
Crankcase Cleaning
Crankcase Inspection
Oil Strainer
Plain Bearing Replacement
Crankcase Assembly
Crankshaft Locking Procedure
Crankshaft Inspection
Crankshaft Axial Play
Connecting Rod Big End Axial Play
Connecting Rod Big End Radial Play
Crankshaft Radial Play MAG/PTO Side
Crankshaft Assembly
Crankshaft Radial Play (PTO Side Support Bearing)
Crankshaft Installation
Outlander 500
Outlander 650 and 800
Gearbox And 4x4 Coupling Unit
Gearbox Components and 4x4 Coupling Mechanism
Gearbox Housing and 4x4 Actuator Unit
Gearbox Oil Change
Draining Procedure
Gearbox Position Indicator Switches Removal
Gearbox Position Indicator Switches Installation
4WD Indicator Switch Removal
4WD Indicator Switch Test
4WD Indicator Switch Installation
Oil Seals Removal
Countershaft Oil Seal
Shift Shaft Oil Seal
Output Shaft Oil Seal
Output Shaft and Countershaft Oil Seal
Actuator Test
Actuator Removal
Output Shaft and Coupling Mechanism
Output Shaft Backlash Procedure
Coupling Sleeve Groove Width
Coupling Fork Claw Thickness
Gearbox Removal
Gearbox Disassembly
Bevel Gear Axial Clearance
Bearing removal in Housing
Gearbox Inspection
Shift Forks
Shift Drum
Levers
Gears
Width of Shift Fork Engagement Groove
Intermediate Gear Shaft
Bevel Gear Adjustment
Bevel Gear Backlash Procedure
Bevel Gear Axial Clearance Procedure
Bearing Installation in Housing
Other Gearbox Components
Shifter Service Products
Transmission Lever
Shifter Lever Removal
Link Rod Removal
Shifter Lever Inspection
Shifter Lever Installation
Shifting Plate
Link Rod Inspection
Link Rod Installation
Shifting Plate Removal
Shifting Plate Inspection
Shifting Plate Installation
Overview
Front
Engine Management System Overview
Operating Principle
Air Induction
Fuel System
Throttle Body
Fuel Rail
Fuel Pump Module
Fuel Pressure Regulator
Fuel Filter
Electrical System
Engine Control Module (ECM)
Power Distribution
Engine Management System
Electronic Fuel Injection
Ignition
ECM and VFB interaction with the Electrical System
Engine Modes of Operation
Ignition Timing
Vehicle Speed Limiter
Limp Home Mode
Monitoring System
Diagnostic Mode
Battery Voltage Warning Device
Low Oil Pressure Warning Device
Engine Management System Flow Chart
EMS Diagnostic
On-Board Diagnostic
Fault Codes
TPS (Throttle Position Sensor) Faults
TPS "Out of Range" Fault
Fault Code P2119
Fault Code Table
Adjustment and Repair Procedures
Diagnostic Tools
Resistance Measurement
ECM Connectors
Engine Connector
Temperature Sensor Table
Basic Adjustments
Idle Speed
Throttle Cable
Closed Throttle and Idle Actuator Reset
Repair Procedures
Main Relay
D1 Diode (ECM)
Diode (D1) Installation
Diode (D1) Test
Quick Test to Validate ECM Operation
ECM Power Supply and Ground Pinout
ECM Power Supply Verification
If ECM Works when Bypassing Relay
ECM Replacement
Fuel Injector
Security Exchange
Leakage Test
Electrical Test
Fuel Injector Replacement
Fuel Injector Removal
Fuel Injector Installation
Fuel Rail Replacement
Fuel Rail Removal
Fuel Rail Installation
Mechanical Inspection
Electrical Inspection
Throttle Body Replacement
Throttle Position Sensor (TPS)
TPS Wear Test
TPS Resistance Test
TPS Input Voltage Test
TPS Replacement
Idle Bypass Valve (IBV)
IBV Information in B.U.D.S. Software
IBV Resistance Test
IBV Visual Inspection
Crankshaft Position Sensor (CPS)
CPS Resistance Test
CPS Replacement
Camshaft Position Sensor (CAPS)
CAPS Voltage Test
Manifold Air Pressure And Temperature Sensor (Mapts)
CAPS Replacement
Sensor Pressure Function
Voltage Test
Quick Test
Sensor Temperature Function
Resistance Test
MAPTS Replacement
CTS Resistance Test
CTS Replacement
Fuel Tank and Fuel Pump
Fuel Tank Leak Test Inspection
Check Valve and Pressure Relief Valve
Fuel Pressure Test
Fuel Hose and Oetiker Clamps
In-Line fuel Filter
Fuel Hose Replacement
Oetiker Clamp Replacement
Fuel Tank Draining
Fuel Tank Removal
Fuel Tank Protector
Fuel Tank Inspection
Fuel Tank Installation
Fuel Pump Circuit Test
Fuel Pump Power Supply
Fuel Pump Ground Circuit
Fuel Pump Removal
Fuel Pump Installation
Fuel System Diagnostic Flow Chart
Communication Tools and B.U.D.S. Software
Multi-Purpose Interface (MPI)
MPI Supply
Connections with Vehicle
Multi-Purpose Interface-2 (MPI-2)
MPI-2 Supply
B.U.D.S. Software
Changes in ECM
Ignition System
Ignition Switch
Switch Resistance Test
Switch Wiring Test (Ignition Function)
Switch Wiring Test (DESS Function)
Engine Run/Stop Switch
Switch Resistance Test (Ignition Function)
Switch Resistance Test (DESS function)
Ignition Coil Input Voltage
Ignition Coil Resistance Test
Spark Plug Removal
Troubleshooting Fouled Spark Plug
Spark Plug Analysis
Spark Plug Installation
Charging System
Magneto
Voltage Regulator/Rectifier
DC Current Test with an Inductive Ammeter
DC Current Test with a Multimeter
Stator
Static Test: Continuity
Static Test: Insulation
Dynamic Test: AC Voltage
Battery Information
Battery Troubleshooting
Discharged or Weak Battery
Battery Unloaded Test
Battery Removal
Battery cleaning
Battery Inspection
Battery Storage
Main Ground
Starting System
Engine Cranking Conditions
Ignition Switch and Engine Run/Stop Switch
Electrical Cable and Connections
Fuses
D2 Diode (Starter solenoid)
Start button
Start Button Resistance Test
Start Button Wiring Test
Starting Solenoid
Solenoid Signal Test
Electric Starter
Starter Test
Digitally Encoded Security System (DESS)
DESS key Programming
Lights, Gauge and Accessories
Diagnostic
Checking for Shorts Between 2 Wires
Recommended Tools
Electrical Connectors
Fuses in Front Service Compartment
Fuse located at the Rear
Accessory Relay (R3)
Multifunction Gauge
Unit Selection (MPH vs km/h)
Gauge Operation
Tachometer
Transmission Position Display
Fuel Level Display
Indicator Lamps
Multifunction Display (Normal Display Mode)
Multifunction Display (temporary display mode)
Multifunction Display Codes/Messages
Function Display Problems
Fuel Level
2/4WD Pilot Lamp
HI Beam Pilot Lamp
Multifunction Gauge Pinout
Multifunction Gauge Removal
Multifunction Gauge Installation
New Multifunction Gauge Registration (coding)
Country Selection
Vehicle Speed Sensor (VSS)
Fuel Level Sender
Multifunction Switch
Low/hi Beam Switch
Override Switch
12-Volt Auxiliary Power Outlet
12-Volt Auxiliary Power Outlet Test
12-Volt Power Outlet Removal
12-Volt Power Outlet Installation
Headlamp Test
Headlamp Bulb Replacement
Headlamp Beam Aiming
Headlamp Adjustment
Taillight bulb replacement
Winch test
Winch motor
Voltage supply to switch
Winch Control Switch
Winch Relay
Winch Removal
Winch Installation
D5 and D6 Diodes (Winch Relay)
Winch Control Switch removal
Winch Control Switch Installation
Continuously Variable Transmission (CVT)
Drive Belt Removal
Drive Pulley
Drive Belt Inspection
Drive Belt Installation
Drive Pulley Removal
Drive Pulley Disassembly
Sliding Sheave
Fixed Sheave
Drive Pulley Cleaning
Drive Pulley Inspection
Drive Pulley Governor Cup
Drive Pulley Roller and Slider Shoe
Centrifugal Lever Bore Diameter
Centrifugal lever Pivot Bolt Bore diameter
Sliding Sheave Large Bushing
Drive Pulley Assembly
Sliding Sheave Small Bushing
Spring Free Length
Spring Sleeve Length
Friction Washer
Driven Pulley Removal
Bushings Bore Diameter
Bushing Bore Diameter
Wear on Teeth Both Sides
Width On Top Surface
Wear On Contact Surface
Clutch Spring Squareness
CVT Air Guide Removal
CVT Air Guide Inspection
CVT Air Guide Installation
Front Drive
Tires and Wheels
Wheel Hub Removal
Wheel Hub Inspection
Wheel Hub Installation
Front Drive Shaft Removal
Drive Shaft Inspection
Drive Shaft Installation
Drive Shaft Boot Inspection
Drive Shaft Boot Removal
Drive Shaft Boot Installation
Front Differential Oil Level
Front Differential Oil Change
Front Differential Removal
Front Differential Inspection
Front Differential Disassembly
Ring gear carrier/Ring Gear
Pinion Gear
Ring Gear Adjustment
Backlash
Front Propeller Shaft Removal
Front Propeller Shaft Inspection
Front Propeller Shaft Installation
Propeller Shaft U-Joint Removal
Propeller Shaft U-Joint Installation
Rear Drive
Differential Protector Removal
Differential Protector Installation
Drive Shaft Removal
Rear Propeller Shaft
Steering System
Handlebar Grip Removal
Handlebar Grip Installation
Handlebar Cover Removal
Handlebar Cover Installation
Handlebar Inspection
Handlebar Installation
Steering Column Removal
Steering Column Inspection
Steering Column Bearing Removal
Steering Column Installation
Tie-Rod
Tie-Rod Removal
Tie-Rod Installation
Knuckle Removal
Knuckle Inspection
Wheel Bearing Inspection
Wheel Bearing Removal
Wheel Bearing Installation
Multifunction Switch Removal
Throttle Handle Removal
Multifunction Switch Installation
Handle Brake Removal
Handle Brake Hose Removal
Steering Alignment
Front Suspension
Shock Absorber and Spring Removal
Shock Absorber and Spring Disassembly
Shock Absorber and Spring Inspection
Lower Suspension Arm Protector Removal
Lower Suspension Arm Protector Installation
Lower Suspension Arm Inspection
Lower Suspension Arm Removal
Lower Suspension Arm Installation
Lower Ball Joint Removal
Lower Ball Joint Installation
Upper suspension arm lubrication
Upper suspension arm inspection
Upper suspension arm removal
Upper suspension arm installation
Upper suspension arm bracket removal
Upper suspension arm bracket inspection
Upper suspension arm bracket installation
Upper Ball Joint Inspection
Upper Ball Joint Removal
Upper Ball Joint Installation
Rear suspension
Rear Shock Removal
Rear Shock Disassembly
Rear Shock Inspection
Rear Shock Assembly and Installation
Torsion Bar Removal
Torsion Bar inspection
Torsion Bar installation
Trailing Arm Removal
Trailing Arm Inspection
Trailing Arm Installation
Trailing Arm Bearings Inspection
Trailing Arm Bearings Removal
Trailing Arm Bearings Installation
Front and Rear Brakes
Hydraulic Brakes System
Parking Brake
Brake Recommended Fluid
Brake Fluid Level
Brake Fluid Replacement
Brake Fluid Draining
Brake Fluid Filling and Bleeding
With a Vacuum pump
Rear Brake Light Switch Inspection
Rear Brake Light Switch Test
Rear Brake Light Switch Removal
Rear Brake Light Switch Installation
Front Brake Light Switch inspection
Parking Brake Mechanism Removal
Front Brake Light Switch Installation
Brake Lever Removal
Brake Lever installation
Front Master Cylinder removal
Front Master Cylinder Disassembly
Front Master Cylinder Assembly
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Disassembly
Rear Master Cylinder Inspection and Lubrication
Rear Master Cylinder Assembly
Rear Master Cylinder Installation
Caliper Removal
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Brake Pads Removal
Brake Pads Installation
Brake Disc Inspection
Brake Disc Removal
Brake Disc Installation
Brake Pedal Removal
Brake Pedal Installation
Brake Hoses Inspection
Brake Hoses Removal
Brake Hoses Installation
Body
Outlander Series Body Parts (Front View)
Outlander Series Body Parts (Rear View)
Outlander Series Body Parts (Side View)
Outlander Series Seat
Outlander Series XT Package
Renegade Models Body Parts (Front View)
Renegade Models Body Parts (Rear View)
Renegade Models Body Parts (Side View)
Renegade Models Seat
Vehicle Care
Plastic Rivet
Decal Removal
Decal Installation
Seat Removal
Seat Installation
Seat Cover Replacement
Central Panel Removal
Central Panel Installation
Dash Board Removal
Side Panel Removal
Side Panel Installation
Footrest Removal
Inner Fender Removal
Inner Fender Installation
Bumper Removal
Bumper Installation
Front Bumper/Front Skid Plate/Front Fascia Removal
Luggage Rack Removal
Luggage Rack Installation
Fender Removal
Fender Installation
Fender support removal
Fender support installation
Frame
Footrest Support Removal
Footrest Support Inspection
Battery Support Removal
Battery Support installation
Hitch Removal
Hitch Installation
Hook Removal
Hook inspection
Hook installation
Frame Cleaning
Frame Welding
Technical Specifications
Outlander Series
Renegade Models
Deutsch Connectors
Removal from Engine Connector Bracket
Connector Disassembly
Terminal Removal
Terminal Crimping (Kostal)
Multifunction Speedometer Connector
Battery and Starter Cable Terminals
Crimping
Wiring Diagrams
Wiring Connectors Coding
Wire Colors
Wire Gauge
Wire Location in Connector
Distribution System
Injection/Ignition System
Cooling System
2007 / 2008
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Can-Am Outlander Series 500 Service Manual

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CAN-AM OUTLANDER SERIES 500 SERVICE

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