2006 Can Am Outlander 800 Xt - The Ultimate Owner'S & Buyer'S Guide

Let’s be honest. You’ve either got a 2006 Can Am Outlander 800 XT sitting in your garage, or you’re thinking about getting one. You know it was a beast in its day—a true game-changer that put massive V-twin power on the map for utility ATVs. It’s a legend for a reason.

But you also know that a machine this old, with this much power, comes with its own set of quirks and needs. You’re probably wondering how to keep it running strong, what to watch out for, and how to get the most out of it without breaking the bank.

We promise this is the only guide you’ll need. We’re going to break down everything from the ground up. In this deep dive, we’ll cover the common problems (and their fixes), a complete DIY maintenance checklist, smart performance mods, and a no-nonsense buyer’s guide for those looking to join the club. Let’s get wrenching.

Why the 2006 Can-Am Outlander 800 XT Still Rips: A Look Back

Before we get into the nuts and bolts, it’s worth remembering why this machine is so special. When BRP (Bombardier Recreational Products) dropped this ATV, it sent shockwaves through the industry. The competition was still focused on big single-cylinder engines.

Can-Am, on the other hand, stuffed a massive 800cc Rotax V-twin engine into a utility quad chassis. This wasn’t just an engine; it was a statement. It delivered a level of torque and horsepower that was simply unheard of at the time, making it the undisputed king of the trail.

Key Features That Defined a Legend

Understanding the core components helps you appreciate what you’re working on. The benefits of the 2006 Can Am Outlander 800 XT were baked right into its design.

The Rotax 800 V-Twin Engine: This is the heart of the beast. It’s a liquid-cooled, SOHC, 8-valve engine that provides incredible low-end grunt and a thrilling top-end rush. It’s the reason these quads are still so much fun.
TTI Rear Suspension: The Trailing Torsional Independent rear suspension was another BRP innovation. It allows the wheels to travel straight up and down, which keeps the machine stable and predictable in rough terrain.

* Visco-Lok Front Differential: This is an automatic-locking front diff. When it senses one front wheel slipping, it progressively transfers power to the wheel with more traction. No buttons to push, it just works.
* The XT Package: This was the premium trim. The “XT” added crucial upgrades right from the factory, including a heavy-duty front bumper, a 2,500 lb. Warn winch, and cast-aluminum wheels.

Common Problems with the 2006 Can-Am Outlander 800 XT (And How to Fix Them)

No machine is perfect, especially one approaching two decades of service. Knowing the common failure points is half the battle. This section is your field guide to the most frequent issues you might encounter.

Electrical Gremlins: The Voltage Regulator

If there’s one Achilles’ heel on these early V-twin Can-Ams, it’s the charging system. The stock voltage regulator is notorious for overheating and failing. When it goes, it can either stop charging the battery or, worse, overcharge it and cook your battery and ECU.

Symptoms: The battery keeps dying, the pod display flickers or goes blank, headlights are dim or surge brightly, or you smell a “rotten egg” smell from the battery boiling.
The Fix: Do not replace it with another stock OEM unit. The aftermarket has solved this problem. Look for a modern MOSFET-style regulator (like those from Rick’s Motorsport Electrics or RMStator). Many owners also relocate the regulator to an area with better airflow, like up on the radiator support, to help it run cooler.

Frame and Chassis Weak Points

That big V-twin produces a lot of torque, which puts stress on the frame over time. Hard riding, big tires, and jumps can accelerate wear and lead to cracks.

Where to Look: Grab a bright flashlight and get down on the ground. The most common crack location is on the frame tubes near the rear differential mounts. Also, check all A-arm mounting points and the front differential support bracket.
The Fix: If you find a small crack, you can often stop-drill the end of it and have a competent welder repair it. For prevention, consider adding a frame gusset kit. These kits reinforce the known weak spots before they become a problem.

Drivetrain Wear and Tear

Power has to go somewhere. The drivetrain on the Outlander 800 is robust, but it’s not invincible. Regular inspection is key.

CV Boots and Axles: The rubber CV boots protect the constant velocity joints in your axles. A single tear can let in dirt and water, quickly destroying the joint. Check them before every ride for rips or cracks. If you catch a torn boot early, you can just replace the boot. If you hear a “clicking” sound when turning, the joint is likely shot, and you’ll need a new axle.
U-Joints: The front and rear driveshafts have U-joints that can wear out, causing a vibration or clunking sound. Grab the driveshaft and try to twist it or move it up and down. Any play means it’s time for a replacement.

Your Essential 2006 Can-Am Outlander 800 XT Care Guide: A DIY Maintenance Checklist

Consistent maintenance is the secret to longevity. This isn’t just about fixing things when they break; it’s about preventing them from breaking in the first place. This is a core part of our 2006 can am outlander 800 xt best practices.

Follow this checklist to keep your machine trail-ready. Always consult your owner’s manual for specific fluid types and capacities.

Engine Oil and Filter: Change the oil and filter every 25-30 hours of use, or at least once a season. Use a quality synthetic 5W-40 oil rated for wet clutches, like Amsoil Formula 4-Stroke or XPS Synthetic Blend.
Air Filter: This is your engine’s lungs. Clean and re-oil your foam air filter after every dusty ride. A clogged filter robs power and can let dirt into your engine.
Coolant: Check the coolant level in the overflow bottle before each ride. Every couple of years, perform a full flush and fill with a quality ethylene glycol-based coolant.
Differential Fluids: The front and rear differentials need their fluid changed annually. Use a synthetic 75W-90 gear oil for the front and 75W-140 for the rear.
Brake System: Check your brake fluid level and pad thickness regularly. If the fluid looks dark and murky, it’s time to bleed the system with fresh DOT 4 brake fluid.
Grease Points: Get out your grease gun! Grease all the zerk fittings on the A-arms, steering components, and driveshaft yokes every 10-15 hours. This pushes out water and dirt.

For a truly sustainable 2006 can am outlander 800 xt ownership plan, always collect and dispose of used fluids properly. Most auto parts stores will accept used oil and coolant for free recycling, which is the most eco-friendly 2006 can am outlander 800 xt practice.

Unlocking More Power: Smart Performance Mods

The stock 800 has plenty of power, but who doesn’t want a little more? Here’s how to wake up your Outlander without sacrificing reliability. This is a quick “how to 2006 can am outlander 800 xt” performance guide.

The Holy Trinity of ATV Mods

For the best bang for your buck, you’ll want to address the clutch, exhaust, and fuel system together.

Clutch Kit: If you’ve added bigger, heavier tires, a clutch kit is not optional. It recalibrates your CVT to handle the extra load, restoring lost acceleration and preventing belt slip. Brands like Dalton and EPI make excellent, easy-to-install kits.
Slip-On Exhaust: A quality slip-on exhaust from a company like HMF or Big Gun can improve sound, shed a few pounds, and free up a couple of horsepower.
Fuel Controller: When you change the airflow with an exhaust, you need to adjust the fuel to match. A “plug-and-play” fuel controller like a Power Commander or EJK tuner allows you to add fuel, preventing a lean condition that can damage your engine.

Off-Road Setup: Best Practices for Trail Dominance

Getting your machine dialed in for the trail is just as important as engine maintenance. Here are a few essential 2006 can am outlander 800 xt tips for off-road performance.

Tires and Tire Pressure: The single best upgrade you can make. A good 6-ply or 8-ply radial tire will dramatically improve traction and puncture resistance. For general trail riding, start with 5-7 PSI and adjust from there.
Skid Plates: The underside of your ATV is vulnerable. A full set of aluminum or UHMW (Ultra-High Molecular Weight plastic) skid plates will protect your engine, differentials, and A-arms from rocks and stumps.
Winch Maintenance: Your XT came with a winch, so make sure it works! Periodically unspool the cable, check for frays (especially with steel cable), and spool it back in tightly. Check the electrical connections for corrosion.

Buyer’s Guide: What to Look For Before Buying a Used 2006 Outlander 800 XT

Found a good deal on a used one? Awesome! But go in with your eyes open. This complete 2006 can am outlander 800 xt guide for buyers will help you avoid buying someone else’s headache.

Pre-Purchase Inspection Checklist

Cold Start: Insist on seeing the machine started cold. Watch for excessive smoke or strange noises. A healthy Rotax 800 fires up quickly and settles into a smooth, albeit loud, idle.
Check the 4WD: With the engine running, switch it into 4WD. You should hear a distinct “clunk” as the actuator engages. Drive it forward slowly with the handlebars turned to make sure the front wheels are pulling.
Frame Inspection: Perform the frame check mentioned in the “Common Problems” section. A cracked frame is a major red flag.
Fluids Check: Pull the oil dipstick. Is the oil milky (a sign of water/coolant)? Does the coolant look clean? Dark, sludgy fluids suggest neglect.
Feel for Play: Grab each wheel at the top and bottom and try to wiggle it. Any significant play could mean bad ball joints or wheel bearings. Do the same for the handlebars to check for worn tie rod ends.
Ask for Records: The best seller is one who has kept maintenance records. It shows the machine was cared for.

Frequently Asked Questions About the 2006 Can Am Outlander 800 XT

What kind of oil is best for a 2006 Can Am Outlander 800 XT?

The best choice is a high-quality synthetic 5W-40 4-stroke oil that is rated for wet clutches (JASO MA/MA2). Brands like Amsoil, Maxima, and BRP’s own XPS oil are all excellent options.

How fast can a 2006 Outlander 800 go?

A stock 2006 Outlander 800 XT in good running condition can typically reach a top speed of around 70-75 mph. However, its real strength is its blistering acceleration, not its top speed.

Are these ATVs reliable?

They can be very reliable if they are well-maintained. Due to their age and known issues like the voltage regulator and potential frame stress, they require a diligent owner. If you stay on top of the maintenance outlined in this guide, it can be a trusty trail companion for years to come.

What’s the first sign of a bad voltage regulator?

Often, the first sign is intermittent weirdness with the digital display pod. It might flicker, reset, or show odd symbols. This is because it’s the first component to react to inconsistent voltage from a failing regulator. If you see this, check your battery voltage with a multimeter while the engine is running. It should be between 13.5 and 14.5 volts. Anything higher or lower points to a charging system problem.

The 2006 Can Am Outlander 800 XT is a modern classic. It’s a powerful, capable, and incredibly fun machine that represents a major milestone in ATV history. Yes, it has its quirks, but every one of them is well-documented and fixable by a careful DIY mechanic.

By understanding its weaknesses and committing to a solid maintenance routine, you can ensure this legendary quad provides thrills for many more seasons. So get your tools ready, follow this guide, and keep that V-twin roaring. Stay safe out there and have a blast on the trails!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.