2012 Can Am Commander 800: The Ultimate Owner'S Survival Guide

There’s a reason you still see so many of them on the trails. The 2012 Can-Am Commander 800 is a legendary machine—a true workhorse with a playful side that carved out a new space in the side-by-side world. You probably love its punchy Rotax V-twin engine and its versatile, dual-level cargo box.

But you also know that owning a machine of this vintage means being its primary caretaker. You’ve likely wondered how to tackle that strange noise, prevent a common failure, or just keep it running as strong as it did a decade ago. It can feel like a constant battle against time and trail abuse.

We promise this comprehensive guide will be your go-to resource. We’re going to break down everything you need to know, from diagnosing the most common problems to performing essential maintenance and even choosing the smartest upgrades. This is more than just a manual; it’s a collection of hard-won knowledge from the garage and the trail.

In this ultimate 2012 Can-Am Commander 800 guide, we’ll cover common issues and their fixes, a detailed maintenance schedule, smart performance mods, and best practices to keep your rig tearing up the dirt for years to come. Let’s get wrenching.

Understanding Your 2012 Can-Am Commander 800: More Than Just a Machine

Before we dive into the nuts and bolts, let’s appreciate what makes this machine special. When it launched, the Commander blended utility and sport performance in a way few others had. Its 71-horsepower, 800cc Rotax engine was a powerhouse, and features like the Visco-Lok front differential offered real off-road capability.

The benefits of the 2012 Can-Am Commander 800 are still relevant today. It boasts a stout frame, a comfortable cabin for its time, and that unique, industry-first dual-level cargo bed that’s perfect for separating tools from coolers.

Knowing its strengths and weaknesses is the first step to becoming a true expert owner. It’s a powerful, capable rig, but it has its quirks—quirks we’re about to help you master.

Common Problems with 2012 Can-Am Commander 800 (And How to Fix Them)

Every machine has an Achilles’ heel. For the Commander 800, a few known issues tend to pop up. Don’t worry—most are manageable for a DIY mechanic with the right tools and knowledge. Here are some 2012 Can-Am Commander 800 tips for tackling them head-on.

Overheating and Cooling System Woes

One of the most frequent complaints is overheating, especially on slow, technical trails. The radiator’s location makes it a magnet for mud and debris.

The Symptom: The temp gauge climbs into the red, you see steam, or the engine fan runs constantly.
The Fix: Start with the simple stuff. Thoroughly clean your radiator fins after every muddy ride. Use a garden hose (not a high-pressure washer, which can bend the fins) to spray from the back towards the front.
Pro Tip: Check your coolant level before every ride. If it’s low, you may have a leak. Inspect hoses for cracks or loose clamps. For persistent issues, consider a radiator relocate kit to move it to a higher, cleaner position.

The Infamous “Limp Mode”

Limp mode is the machine’s way of protecting itself, but it’s incredibly frustrating. It cuts power and limits your speed, often at the worst possible time.

The Symptom: The machine suddenly loses power and won’t exceed a low RPM or speed. The check engine light is likely on.
The Fix: This can be triggered by many things. Common culprits include a faulty brake pressure switch (the machine thinks you’re pressing the brake and gas at the same time) or a bad throttle position sensor (TPS). You’ll need an OBD-II scanner with a Can-Am adapter to pull the specific fault code.

Drive Belt Durability and CVT Care

The CVT drive belt is a wear item, but premature failure can leave you stranded. Heat is the number one killer of belts.

The Symptom: A smell of burning rubber, loss of power, or a loud bang followed by a complete loss of drive.
The Fix: Always use low gear when driving under 20 mph, towing, or climbing steep hills. This keeps the CVT clutches engaged properly and reduces belt slippage and heat. Inspect your belt for glazing, cracks, or missing cogs every 50 hours.
Must-Have Tool: A good quality CVT belt-changing tool. Always carry a spare belt and the tools to change it on the trail. We recommend an OEM BRP belt or a heavy-duty aftermarket one from a brand like Gates.

Electrical Gremlins: Battery & Stator Issues

Weak starting, dim lights, or a dead machine can often be traced to the electrical system. The stock battery isn’t known for its longevity.

The Symptom: Slow cranking, accessories cutting out, or the machine won’t start at all.
The Fix: Test your battery first. A multimeter should read around 12.6 volts when off and over 13.5 volts when the engine is running. If the running voltage is low, your stator might be failing—a known issue on these models. Upgrading to a quality AGM battery is a smart first step.

The Essential 2012 Can-Am Commander 800 Care Guide

The best way to fix problems is to prevent them. A solid maintenance routine is non-negotiable. Following these 2012 Can-Am Commander 800 best practices will save you headaches and money down the road.

Your Regular Maintenance Checklist

Consistency is key. Break your maintenance into simple, regular checks.

Pre-Ride Check (Every Single Time): Check engine oil level, coolant level, tire pressure, and brake fluid. Give the machine a quick walk-around to look for leaks or loose parts.
25-Hour Service (After Break-In & Every 25 Hours): This is your “mini” service. Change the engine oil and filter. Clean and re-oil the air filter. Inspect the CVT belt and clean out the CVT housing with compressed air.
100-Hour Service (Annually for most riders): This is the big one. Perform all the 25-hour tasks, plus: change the front and rear differential fluid, change the gearbox oil, replace the spark plugs, and grease all chassis zerks.

Fluid Essentials: Oil, Coolant, and Differential Fluid

Using the right fluids is critical. Don’t cheap out here.

Engine Oil: Use a high-quality 5W-40 synthetic oil rated for powersports engines, like XPS Synthetic Blend Oil or a reputable equivalent.
Coolant: Use a 50/50 pre-mix of ethylene glycol-based coolant designed for aluminum engines.
Differential & Gearbox: Use 75W-90 (front diff) and 75W-140 (rear diff/gearbox) synthetic gear oil.

Air Filter: Your Engine’s Lungs

A dirty air filter is a fast way to kill engine performance and cause long-term damage. In dusty conditions, you should check and clean it after every ride.

Gently tap out loose dirt, then wash with a dedicated foam filter cleaner and warm water. Let it dry completely before re-oiling with foam filter oil. Be careful not to over-oil it, as this can restrict airflow.

Smart Upgrades & Performance Mods

Ready to improve on the factory setup? These mods offer the best bang for your buck, enhancing reliability and capability. This is how to 2012 Can-Am Commander 800 ownership evolves from maintenance to personalization.

Tires & Wheels: The Foundation of Your Ride

The single best upgrade you can make. The stock tires are okay, but a good set of 6-ply or 8-ply radial tires will dramatically improve traction, reduce flats, and enhance ride quality. Choose a tread pattern that matches the terrain you ride most.

Suspension Upgrades for a Smoother Trail

The stock shocks can feel harsh. Upgrading to aftermarket shocks from brands like Elka or Fox will transform the ride, making it smoother over rough terrain and more stable at speed. If new shocks aren’t in the budget, consider a dual-rate spring kit for your stock shocks as a cost-effective improvement.

Clutch Kits: Reclaiming Lost Power

If you’ve added larger tires or ride at high altitudes, you’ve lost performance. A clutch kit, with its different springs and weights, recalibrates your CVT to account for these changes. It will improve acceleration, back-shifting, and belt life. It’s one of the most noticeable performance mods you can make.

Eco-Friendly & Sustainable 2012 Can-Am Commander 800 Best Practices

Being a responsible off-roader means protecting the trails we love. A sustainable 2012 Can-Am Commander 800 is one that’s well-maintained and used respectfully.

Proper Fluid Disposal

Never dump used oil, coolant, or gear lube on the ground or down a drain. Collect all used fluids in a sealed container and take them to your local auto parts store or municipal recycling center. Most accept them for free.

Tread Lightly Principles

This is the golden rule of off-roading. Stay on designated trails, cross streams only at designated crossings, and avoid creating new trails. Pack out everything you pack in. A quiet machine is also a more eco-friendly 2012 Can-Am Commander 800, so ensure your exhaust and spark arrestor are in good condition.

Choosing Long-Lasting, Quality Parts

Buying cheap, low-quality parts that fail quickly creates more waste. Investing in durable, well-made components means fewer replacements and less material heading to the landfill. It’s better for your wallet and the environment in the long run.

Frequently Asked Questions About the 2012 Can-Am Commander 800

What type of oil is best for a 2012 Commander 800?

The best choice is a full synthetic 5W-40 4-stroke oil specifically designed for Rotax V-twin engines or high-performance UTVs. BRP’s XPS brand is the factory recommendation, but other quality brands like Amsoil or Mobil 1 Racing 4T will also work great.

How often should I change the drive belt?

There’s no hard mileage rule, as it depends entirely on your riding style. A good rule of thumb is to inspect it every 50 hours of use and replace it proactively every 1500-2000 miles, or immediately if you see signs of excessive wear like glazing, cracking, or fraying.

What’s the top speed of a stock 2012 Commander 800?

A stock 2012 Can-Am Commander 800 can typically reach a top speed of around 65-70 mph on a flat, smooth surface. However, factors like tire size, clutch condition, and rider weight can affect the actual top speed.

Is the 2012 Commander 800 a reliable machine?

Yes, with a major caveat: it is reliable if it is properly maintained. Like any high-performance machine from that era, it requires diligent upkeep. If you stay on top of fluid changes, belt inspections, and address the common issues we’ve listed, it can be a very dependable rig for years of fun.

Your 2012 Can-Am Commander 800 is a classic piece of off-road history. By understanding its needs, staying ahead of maintenance, and making smart choices, you’re not just an owner—you’re a steward of a legendary machine. Now you have the knowledge and the confidence to keep it running strong.

Grab your tools, get your hands dirty, and get back out on the trail. Happy riding!

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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.