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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

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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

loading

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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

2007 renegade series 500 2008 outlander series 500 2008 outlander series 650 2008 renegade series 800 2008 outlander series 800 2008 renegade series 500

Posted by: rowenawhapt1951esz.blogspot.com

Source: https://www.manualslib.com/manual/805236/Can-Am-Outlander-Series-500.html

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