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Can-Am Outlander Series 500 Service Manual
2008 can-am
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Table Of Contents
505-
- Contents
- Table of Contents
- Troubleshooting
- Bookmarks
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2
Table of Contents
Table of Contents
-
2
Table of Contents
-
9
Safety Notice
-
10
General Information
-
11
Vehicle Information
-
11
Engine Emissions Information
-
11
Model Number
-
11
Vehicle Identification Number (VIN)
-
12
Self-Locking Fasteners Procedure
-
12
Loctite Application Procedure
-
12
Owner Responsibility
-
12
ERA Emission Regulations
-
13
Stud in Blind Holes
-
13
Preassembled Parts
-
13
Adjusting Screw
-
14
Stripped Thread Repair
-
14
Gasket Compound
-
14
Standard Thread Repair
-
14
Repair of Small Holes/Fine Threads
-
15
Tightening Torques
-
15
Mounting on Shaft
-
15
Case-In Components
-
15
Mounting with a Press
-
16
Fastener Grade/Torque
-
20
Maintenance Chart
-
24
Preseason Preparation
-
26
Storage Procedures
-
26
Fuel Stabilizer
-
26
Engine Lubrication
-
26
Rags Installation
-
27
Coolant Density
-
27
Drive and Driven Pulleys Protection
-
27
Vehicle Cleaning
-
27
Vehicle Protection
-
28
Special Procedures
-
28
Service Products
-
28
Turn over
-
28
ATV Immersion
-
30
Troubleshooting Chart
-
30
Starter Does Not Turn
-
31
Starter Turns, but Does Not Crank the Engine
-
31
Starter Motor Keeps Running
-
31
High Engine Operating Temperature
-
32
Battery Not Charging or Charging Voltage Inadequate
-
33
Low or no Oil Pressure/High Oil Consumption
-
33
Oil Contamination
-
34
Unusual Engine Noise And/Or Vibration
-
34
Oil Contamination on Cylinder And/Or Head
-
34
Unusual Engine Noise And/Or Vibrations
-
34
Unusual Gearbox Noise And/Or Vibrations
-
35
Gear Indication Fails
-
35
Gear(S) Is (Are) Hard to Shift
-
37
Wheel Drive Indication Fails
-
37
Wheel Drive Does Not Engage or Disengage
-
37
Unusual Acceleration Behavior
-
38
Engine Maximum RPM Is too High and Top Speed Is Not Reached
-
38
Drive Pulley Noise in Idle Speed
-
38
Drive Pulley Noise When Accelerating/Decelerating
-
39
Vibrations Originating from Drive Pulley
-
39
Vibrations Originating from Driven Pulley
-
39
Pulley's Do Not Down/Up Shift Properly
-
39
Belt Glazed Excessively or Having Baked Appearance
-
40
Belt Worn Excessively in Top Width
-
40
Belt Disintegration
-
40
Cracks between Cogs
-
40
Engine Cranks but Fails to Start
-
41
Engine Does Not Start
-
41
Engine Hard to Start
-
41
Engine Suddenly Turns off
-
42
Engine Backfires
-
43
Engine Does Not Offer Maximum Power And/Or Does Not Reach Maximum Operating RPM
-
45
Engine Removal and Installation
-
45
Service Tools
-
46
Engine Removal
-
46
Vehicle and Engine Preparation
-
52
Engine Installation
-
52
Final Assembly Procedure
-
53
Engine Mount Replacement
-
55
Air Intake System
-
56
Air Filter Housing
-
57
Air Filter Removal
-
57
Air Filter Housing Removal
-
59
Air Filter Housing Installation
-
59
Restrictor Removal
-
59
Restrictor Installation
-
61
Exhaust System
-
62
Front Exhaust Pipe Inspection
-
62
Front Exhaust Pipe Removal
-
62
Front Exhaust Pipe Installation
-
63
Muffler Removal
-
63
Muffler Installation
-
63
"Y" Exhaust Pipe Removal
-
63
"Y" Exhaust Pipe Installation
-
64
Fuel Tank Protector Removal
-
64
Fuel Tank Protector Installation
-
65
Lubrication System
-
66
Lubrication System Components
-
68
Engine Oil
-
68
Recommended Oil
-
68
Engine Oil Viscosity
-
68
Engine Oil Level Verification
-
69
Engine Oil Pressure
-
69
Oil Filter Removal
-
70
Oil Pressure Switch (OPS)
-
70
Oil Filter Inspection
-
70
Oil Filter Installation
-
70
Oil Pressure Switch Activation
-
71
Engine Oil Pressure Regulator
-
71
Oil Pressure Switch Removal
-
71
Oil Pressure Switch Installation
-
72
Oil Pump Removal
-
72
Oil Pump Inspection
-
73
Oil Pump Installation
-
74
Engine Oil Strainer Removal
-
74
Engine Oil Strainer Cleaning and Inspection
-
74
Reed Valve Removal
-
74
Reed Valve Inspection
-
75
Cooling System Service Tools
-
76
Radiator
-
77
Water Pump
-
78
Cooling System Leak Test
-
79
Coolant Replacement
-
79
Recommended Coolant
-
79
Draining the System
-
79
Refilling the System
-
80
Thermostat Removal
-
81
Radiator Cap
-
81
Coolant Tank
-
81
Thermostat Installation
-
81
Radiator Installation
-
82
Coolant Temperature Sensor (CTS)
-
82
Radiator Fan Relay (R1)
-
82
Relay Installation
-
82
Relay Operation Test
-
83
Radiator Fan Operation
-
84
Radiator Fan Test
-
85
Water Pump Housing
-
85
Radiator Fan Removal
-
85
Water Pump Housing Removal
-
85
Radiator Fan Installation
-
86
Water Pump Impeller
-
86
Water Pump Shaft and Seals
-
86
Water Pump Housing Inspection
-
86
Water Pump Housing Installation
-
88
Shaft/Seal Installation
-
91
Magneto System
-
93
Magneto Cover Removal
-
93
Magneto Cover Inspection and Cleaning
-
93
Magneto Cover Installation
-
94
Stator Removal
-
94
Stator Inspection
-
94
Stator Installation
-
95
Rotor Removal
-
95
Rotor Inspection
-
95
Rotor Installation
-
96
Sprag Clutch Removal
-
96
Sprag Clutch Inspection
-
96
Sprag Clutch Installation
-
97
Sprag Clutch Gear Removal
-
97
Sprag Clutch Gear Inspection
-
97
Starter Drive Gears
-
97
Sprag Clutch Gear Installation
-
98
Gear Removal
-
98
Gear Inspection
-
98
Gear Installation
-
99
Intake Manifold, Cylinder Head and Cylinder
-
100
Intake Manifold
-
101
Cylinder Head No.1
-
102
Cylinder Head No.2
-
103
Cylinders and Pistons
-
104
Maintenance
-
104
Valve Adjustment
-
104
Valve Clearance
-
105
Leak Test Inspection
-
107
Intake Manifold Removal
-
108
Valve Cover Removal
-
108
Intake Manifold Inspection
-
108
Intake Manifold Installation
-
109
Timing Chain Tensioner Removal
-
109
Timing Chain Tensioner Inspection
-
109
Timing Chain Tensioner Installation
-
110
Camshaft Timing Gear Removal
-
110
Camshaft Timing Gear Inspection
-
110
Camshaft Timing Gear Installation
-
112
Rocker Arm Removal
-
112
Rocker Arm Inspection
-
113
Timing Chain
-
113
Rocker Arm Installation
-
113
Rocker Arm Shaft
-
114
Cylinder Head Removal
-
114
Cylinder Head Inspection
-
115
Camshaft
-
115
Cylinder Head Installation
-
115
Camshaft Timing
-
116
Camshaft Timing Cylinder 2
-
117
Camshaft Timing Cylinder 1
-
119
Camshaft Inspection
-
120
Valve Spring Removal
-
120
Camshaft Installation
-
121
Valve Spring Inspection
-
121
Valve Spring Installation
-
122
Valve Removal
-
122
Valve Inspection
-
122
Valve Stem Seal
-
122
Valve Stem Diameter
-
123
Valve Installation
-
123
Valve Face and Seat
-
123
Valve Seat Contact Width
-
124
Valve Guide Removal
-
124
Valve Guide Inspection
-
124
Valve Guide Installation
-
125
Cylinder Removal
-
125
Cylinder Inspection
-
125
Cylinder Taper in Diameter
-
126
Cylinder Installation
-
126
Cylinder out of Round
-
126
Piston Removal
-
127
Piston Inspection
-
127
Piston/Cylinder Clearance
-
128
Piston Pin Diameter
-
128
Connecting Rod/Piston Pin Clearance
-
129
Piston Installation
-
129
Connecting Rod Small End Diameter
-
131
Piston Rings
-
131
Ring Removal
-
131
Ring Inspection
-
131
Ring Installation
-
133
Bottom End
-
134
Engine Drive Shaft
-
135
Crankcase and PTO Cover
-
136
Crankshaft
-
137
Oil Seal Removal
-
137
Engine Drive Shaft Removal
-
137
Engine Drive Shaft Inspection
-
138
Engine Drive Shaft Installation
-
139
PTO Cover Oil Seal Removal
-
139
PTO Oil Seal Inspection
-
139
PTO Oil Seal Installation
-
139
PTO Cover Removal
-
140
PTO Cover Inspection
-
140
Plain Bearing Replacement Procedure
-
140
Plain Bearing Removal
-
141
PTO Cover Installation
-
141
Plain Bearing Installation
-
142
Drive Gears Removal
-
142
Drive Gears Inspection
-
142
Drive Gear Installation
-
143
Timing Chain Removal (Magneto Side)
-
143
Timing Chain Removal (PTO Side)
-
143
Timing Chain Inspection
-
143
Timing Chain Installation
-
144
Timing Chain Guide
-
144
Chain Guide Inspection
-
144
Chain Guide Installation
-
144
Crankcase Disassembly
-
145
Crankcase Cleaning
-
145
Crankcase Inspection
-
145
Oil Strainer
-
146
Plain Bearing Replacement
-
147
Crankcase Assembly
-
148
Crankshaft Locking Procedure
-
150
Crankshaft Inspection
-
150
Crankshaft Axial Play
-
150
Connecting Rod Big End Axial Play
-
150
Connecting Rod Big End Radial Play
-
151
Crankshaft Radial Play MAG/PTO Side
-
152
Crankshaft Assembly
-
152
Crankshaft Radial Play (PTO Side Support Bearing)
-
153
Crankshaft Installation
-
153
Outlander 500
-
153
Outlander 650 and 800
-
155
Gearbox and 4X4 Coupling Unit
-
156
Gearbox Components and 4X4 Coupling Mechanism
-
157
Gearbox Housing and 4X4 Actuator Unit
-
158
Gearbox Oil Change
-
158
Draining Procedure
-
159
Gearbox Position Indicator Switches Removal
-
159
Gearbox Position Indicator Switches Installation
-
160
4WD Indicator Switch Removal
-
160
4WD Indicator Switch Test
-
160
4WD Indicator Switch Installation
-
160
Oil Seals Removal
-
161
Countershaft Oil Seal
-
161
Shift Shaft Oil Seal
-
161
Output Shaft Oil Seal
-
161
Output Shaft and Countershaft Oil Seal
-
162
Actuator Test
-
162
Actuator Removal
-
164
Output Shaft and Coupling Mechanism
-
164
Output Shaft Backlash Procedure
-
167
Coupling Sleeve Groove Width
-
167
Coupling Fork Claw Thickness
-
169
Gearbox Removal
-
169
Gearbox Disassembly
-
169
Bevel Gear Axial Clearance
-
173
Bearing Removal in Housing
-
173
Gearbox Inspection
-
174
Shift Forks
-
174
Shift Drum
-
174
Levers
-
174
Gears
2007 / 2008
Table ofContents
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Table of Contents
-
2
Table of Contents
-
9
Safety Notice
-
10
General Information
-
11
Vehicle Information
-
11
Engine Emissions Information
-
11
Model Number
-
11
Vehicle Identification Number (VIN)
-
12
Self-Locking Fasteners Procedure
-
12
Loctite Application Procedure
-
12
Owner Responsibility
-
12
ERA Emission Regulations
-
13
Stud in Blind Holes
-
13
Preassembled Parts
-
13
Adjusting Screw
-
14
Stripped Thread Repair
-
14
Gasket Compound
-
14
Standard Thread Repair
-
14
Repair of Small Holes/Fine Threads
-
15
Tightening Torques
-
15
Mounting on Shaft
-
15
Case-In Components
-
15
Mounting with a Press
-
16
Fastener Grade/Torque
-
20
Maintenance Chart
-
24
Preseason Preparation
-
26
Storage Procedures
-
26
Fuel Stabilizer
-
26
Engine Lubrication
-
26
Rags Installation
-
27
Coolant Density
-
27
Drive and Driven Pulleys Protection
-
27
Vehicle Cleaning
-
27
Vehicle Protection
-
28
Special Procedures
-
28
Service Products
-
28
Turn over
-
28
ATV Immersion
-
30
Troubleshooting Chart
-
30
Starter Does Not Turn
-
31
Starter Turns, but Does Not Crank the Engine
-
31
Starter Motor Keeps Running
-
31
High Engine Operating Temperature
-
32
Battery Not Charging or Charging Voltage Inadequate
-
33
Low or no Oil Pressure/High Oil Consumption
-
33
Oil Contamination
-
34
Unusual Engine Noise And/Or Vibration
-
34
Oil Contamination on Cylinder And/Or Head
-
34
Unusual Engine Noise And/Or Vibrations
-
34
Unusual Gearbox Noise And/Or Vibrations
-
35
Gear Indication Fails
-
35
Gear(S) Is (Are) Hard to Shift
-
37
Wheel Drive Indication Fails
-
37
Wheel Drive Does Not Engage or Disengage
-
37
Unusual Acceleration Behavior
-
38
Engine Maximum RPM Is too High and Top Speed Is Not Reached
-
38
Drive Pulley Noise in Idle Speed
-
38
Drive Pulley Noise When Accelerating/Decelerating
-
39
Vibrations Originating from Drive Pulley
-
39
Vibrations Originating from Driven Pulley
-
39
Pulley's Do Not Down/Up Shift Properly
-
39
Belt Glazed Excessively or Having Baked Appearance
-
40
Belt Worn Excessively in Top Width
-
40
Belt Disintegration
-
40
Cracks between Cogs
-
40
Engine Cranks but Fails to Start
-
41
Engine Does Not Start
-
41
Engine Hard to Start
-
41
Engine Suddenly Turns off
-
42
Engine Backfires
-
43
Engine Does Not Offer Maximum Power And/Or Does Not Reach Maximum Operating RPM
-
45
Engine Removal and Installation
-
45
Service Tools
-
46
Engine Removal
-
46
Vehicle and Engine Preparation
-
52
Engine Installation
-
52
Final Assembly Procedure
-
53
Engine Mount Replacement
-
55
Air Intake System
-
56
Air Filter Housing
-
57
Air Filter Removal
-
57
Air Filter Housing Removal
-
59
Air Filter Housing Installation
-
59
Restrictor Removal
-
59
Restrictor Installation
-
61
Exhaust System
-
62
Front Exhaust Pipe Inspection
-
62
Front Exhaust Pipe Removal
-
62
Front Exhaust Pipe Installation
-
63
Muffler Removal
-
63
Muffler Installation
-
63
"Y" Exhaust Pipe Removal
-
63
"Y" Exhaust Pipe Installation
-
64
Fuel Tank Protector Removal
-
64
Fuel Tank Protector Installation
-
65
Lubrication System
-
66
Lubrication System Components
-
68
Engine Oil
-
68
Recommended Oil
-
68
Engine Oil Viscosity
-
68
Engine Oil Level Verification
-
69
Engine Oil Pressure
-
69
Oil Filter Removal
-
70
Oil Pressure Switch (OPS)
-
70
Oil Filter Inspection
-
70
Oil Filter Installation
-
70
Oil Pressure Switch Activation
-
71
Engine Oil Pressure Regulator
-
71
Oil Pressure Switch Removal
-
71
Oil Pressure Switch Installation
-
72
Oil Pump Removal
-
72
Oil Pump Inspection
-
73
Oil Pump Installation
-
74
Engine Oil Strainer Removal
-
74
Engine Oil Strainer Cleaning and Inspection
-
74
Reed Valve Removal
-
74
Reed Valve Inspection
-
75
Cooling System Service Tools
-
76
Radiator
-
77
Water Pump
-
78
Cooling System Leak Test
-
79
Coolant Replacement
-
79
Recommended Coolant
-
79
Draining the System
-
79
Refilling the System
-
80
Thermostat Removal
-
81
Radiator Cap
-
81
Coolant Tank
-
81
Thermostat Installation
-
81
Radiator Installation
-
82
Coolant Temperature Sensor (CTS)
-
82
Radiator Fan Relay (R1)
-
82
Relay Installation
-
82
Relay Operation Test
-
83
Radiator Fan Operation
-
84
Radiator Fan Test
-
85
Water Pump Housing
-
85
Radiator Fan Removal
-
85
Water Pump Housing Removal
-
85
Radiator Fan Installation
-
86
Water Pump Impeller
-
86
Water Pump Shaft and Seals
-
86
Water Pump Housing Inspection
-
86
Water Pump Housing Installation
-
88
Shaft/Seal Installation
-
91
Magneto System
-
93
Magneto Cover Removal
-
93
Magneto Cover Inspection and Cleaning
-
93
Magneto Cover Installation
-
94
Stator Removal
-
94
Stator Inspection
-
94
Stator Installation
-
95
Rotor Removal
-
95
Rotor Inspection
-
95
Rotor Installation
-
96
Sprag Clutch Removal
-
96
Sprag Clutch Inspection
-
96
Sprag Clutch Installation
-
97
Sprag Clutch Gear Removal
-
97
Sprag Clutch Gear Inspection
-
97
Starter Drive Gears
-
97
Sprag Clutch Gear Installation
-
98
Gear Removal
-
98
Gear Inspection
-
98
Gear Installation
-
99
Intake Manifold, Cylinder Head and Cylinder
-
100
Intake Manifold
-
101
Cylinder Head No.1
-
102
Cylinder Head No.2
-
103
Cylinders and Pistons
-
104
Maintenance
-
104
Valve Adjustment
-
104
Valve Clearance
-
105
Leak Test Inspection
-
107
Intake Manifold Removal
-
108
Valve Cover Removal
-
108
Intake Manifold Inspection
-
108
Intake Manifold Installation
-
109
Timing Chain Tensioner Removal
-
109
Timing Chain Tensioner Inspection
-
109
Timing Chain Tensioner Installation
-
110
Camshaft Timing Gear Removal
-
110
Camshaft Timing Gear Inspection
-
110
Camshaft Timing Gear Installation
-
112
Rocker Arm Removal
-
112
Rocker Arm Inspection
-
113
Timing Chain
-
113
Rocker Arm Installation
-
113
Rocker Arm Shaft
-
114
Cylinder Head Removal
-
114
Cylinder Head Inspection
-
115
Camshaft
-
115
Cylinder Head Installation
-
115
Camshaft Timing
-
116
Camshaft Timing Cylinder 2
-
117
Camshaft Timing Cylinder 1
-
119
Camshaft Inspection
-
120
Valve Spring Removal
-
120
Camshaft Installation
-
121
Valve Spring Inspection
-
121
Valve Spring Installation
-
122
Valve Removal
-
122
Valve Inspection
-
122
Valve Stem Seal
-
122
Valve Stem Diameter
-
123
Valve Installation
-
123
Valve Face and Seat
-
123
Valve Seat Contact Width
-
124
Valve Guide Removal
-
124
Valve Guide Inspection
-
124
Valve Guide Installation
-
125
Cylinder Removal
-
125
Cylinder Inspection
-
125
Cylinder Taper in Diameter
-
126
Cylinder Installation
-
126
Cylinder out of Round
-
126
Piston Removal
-
127
Piston Inspection
-
127
Piston/Cylinder Clearance
-
128
Piston Pin Diameter
-
128
Connecting Rod/Piston Pin Clearance
-
129
Piston Installation
-
129
Connecting Rod Small End Diameter
-
131
Piston Rings
-
131
Ring Removal
-
131
Ring Inspection
-
131
Ring Installation
-
133
Bottom End
-
134
Engine Drive Shaft
-
135
Crankcase and PTO Cover
-
136
Crankshaft
-
137
Oil Seal Removal
-
137
Engine Drive Shaft Removal
-
137
Engine Drive Shaft Inspection
-
138
Engine Drive Shaft Installation
-
139
PTO Cover Oil Seal Removal
-
139
PTO Oil Seal Inspection
-
139
PTO Oil Seal Installation
-
139
PTO Cover Removal
-
140
PTO Cover Inspection
-
140
Plain Bearing Replacement Procedure
-
140
Plain Bearing Removal
-
141
PTO Cover Installation
-
141
Plain Bearing Installation
-
142
Drive Gears Removal
-
142
Drive Gears Inspection
-
142
Drive Gear Installation
-
143
Timing Chain Removal (Magneto Side)
-
143
Timing Chain Removal (PTO Side)
-
143
Timing Chain Inspection
-
143
Timing Chain Installation
-
144
Timing Chain Guide
-
144
Chain Guide Inspection
-
144
Chain Guide Installation
-
144
Crankcase Disassembly
-
145
Crankcase Cleaning
-
145
Crankcase Inspection
-
145
Oil Strainer
-
146
Plain Bearing Replacement
-
147
Crankcase Assembly
-
148
Crankshaft Locking Procedure
-
150
Crankshaft Inspection
-
150
Crankshaft Axial Play
-
150
Connecting Rod Big End Axial Play
-
150
Connecting Rod Big End Radial Play
-
151
Crankshaft Radial Play MAG/PTO Side
-
152
Crankshaft Assembly
-
152
Crankshaft Radial Play (PTO Side Support Bearing)
-
153
Crankshaft Installation
-
153
Outlander 500
-
153
Outlander 650 and 800
-
155
Gearbox and 4X4 Coupling Unit
-
156
Gearbox Components and 4X4 Coupling Mechanism
-
157
Gearbox Housing and 4X4 Actuator Unit
-
158
Gearbox Oil Change
-
158
Draining Procedure
-
159
Gearbox Position Indicator Switches Removal
-
159
Gearbox Position Indicator Switches Installation
-
160
4WD Indicator Switch Removal
-
160
4WD Indicator Switch Test
-
160
4WD Indicator Switch Installation
-
160
Oil Seals Removal
-
161
Countershaft Oil Seal
-
161
Shift Shaft Oil Seal
-
161
Output Shaft Oil Seal
-
161
Output Shaft and Countershaft Oil Seal
-
162
Actuator Test
-
162
Actuator Removal
-
164
Output Shaft and Coupling Mechanism
-
164
Output Shaft Backlash Procedure
-
167
Coupling Sleeve Groove Width
-
167
Coupling Fork Claw Thickness
-
169
Gearbox Removal
-
169
Gearbox Disassembly
-
169
Bevel Gear Axial Clearance
-
173
Bearing Removal in Housing
-
173
Gearbox Inspection
-
174
Shift Forks
-
174
Shift Drum
-
174
Levers
-
174
Gears
Troubleshooting
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Summary of Contents for Can-Am Outlander Series 500
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This manual is also suitable for:
Outlander series 650 Renegade series 800 2007 outlander series 500 2007 outlander series 650 2007 renegade series 800 2007 outlander series 800 ... Show all
Posted by: rowenawhapt1951esz.blogspot.com
Source: https://www.manualslib.com/manual/805236/Can-Am-Outlander-Series-500.html