Let’s agree on something: the 2012 Can-Am Outlander 800 is an absolute beast. That Rotax V-twin engine has a sound and a fury that still turns heads on the trail, and its rugged chassis can take a beating. But keeping a high-performance machine of this era in peak condition requires more than just gas and go; it demands a bit of know-how and a willingness to get your hands dirty.
We promise this comprehensive guide will give you the confidence and expert insights you need. We’re pulling back the curtain on the essential maintenance, common issues, and smart upgrades that separate a tired-out quad from a trail-dominating legend. This isn’t just a manual; it’s your roadmap to reliability and performance.
In this article, you’ll get a complete 2012 Can-Am Outlander 800 guide. We’ll walk through a bulletproof maintenance schedule, diagnose the most frequent problems you might encounter, explore performance mods that actually work, and share some pro tips to keep your Outlander running strong for years to come. Let’s get started.
Why the 2012 Can-Am Outlander 800 is Still a Trail Legend
Even a decade later, this machine holds a special place in the hearts of off-roaders. It hit the sweet spot of power, handling, and rugged utility that few ATVs of its time could match. The benefits of the 2012 Can-Am Outlander 800 are still relevant today.
At its core is the legendary 71-horsepower, 799cc Rotax V-twin engine. It delivers incredible torque right off the line, making it a monster for climbing hills, powering through deep mud, and towing heavy loads. It’s not just about raw power; the delivery is smooth and predictable.
Can-Am paired that engine with a revolutionary chassis for its time. The Surrounding Spar Technology (SST) G1 frame provided a lower center of gravity and better torsional rigidity than traditional tube frames. This, combined with its independent rear suspension, gives the Outlander a surprisingly plush and stable ride over rough terrain.
Key Features That Stand the Test of Time
- Visco-Lok Front Differential: An automatic locking differential that transfers power to the wheel with the most grip without you having to flip a switch.
- Dynamic Power Steering (DPS): The tri-mode system provides variable assistance, making steering effortless at low speeds and stable at high speeds.
- Versatility: Whether you need a workhorse for the farm or a high-speed trail machine for the weekend, the Outlander 800 is more than capable.
The Essential 2012 Can-Am Outlander 800 Care Guide
Consistent maintenance is the single most important factor in keeping your ATV reliable. Following these 2012 Can-Am Outlander 800 best practices will prevent small issues from becoming expensive, trail-ending failures. Think of this as your essential care guide.
Pre-Ride Inspection: Your 5-Minute Lifesaver
Before every single ride, take five minutes to do a quick walk-around. It’s the cheapest insurance you can get. A simple method to remember is T-CLOCS.
- T – Tires & Wheels: Check for proper inflation (typically 5-7 PSI for trail riding), look for cuts or punctures, and ensure lug nuts are snug.
- C – Controls & Cables: Test your throttle for smooth operation. Check brake levers and fluid levels. Ensure steering is responsive.
- L – Lights & Electrics: Test your headlights (high and low beams), taillights, and brake lights.
- O – Oil & Fluids: Check the engine oil level. Give a quick glance at the coolant reservoir and brake fluid master cylinder. Look for any drips or leaks underneath.
- C – Chassis & Suspension: Look for loose bolts, cracked welds, or damaged parts. Check your CV boots for any rips or tears, as this can quickly destroy a CV joint.
Engine and Drivetrain Maintenance
The heart of your machine needs regular attention. Don’t skip these crucial fluid changes.
Engine Oil & Filter: Change the oil and filter every 50 hours or at least once a season. Use a quality synthetic 5W-40 oil designed for powersports engines, like BRP’s own XPS Synthetic Blend Oil. You’ll need an 8mm Allen for the drain plug and a 17mm socket for the oil filter cover.
Air Filter: This is your engine’s first line of defense against dust and dirt. Check it after every dusty ride. A foam filter can be cleaned with filter cleaner and re-oiled, while a paper filter should be replaced when dirty. A clogged air filter is a major cause of power loss.
Gearbox & Differentials: Change the front differential, rear differential, and gearbox fluids every 100 hours or annually. Use the recommended 75W-90 or 75W-140 synthetic gear oil. This is a simple drain-and-fill job that prevents costly gear failure.
Chassis and Suspension Care
A little grease goes a long way. The chassis takes a huge amount of abuse, and these simple steps are critical.
Use a grease gun to hit all the zerk fittings on your A-arms, sway bars, and other pivot points. This pushes out water and dirt, keeping your suspension moving freely. While you’re there, grab a wheel and check for play by pushing and pulling on it—excessive movement can indicate a worn wheel bearing or ball joint.
Common Problems with the 2012 Can-Am Outlander 800 (And How to Fix Them)
No machine is perfect. Knowing the common problems with 2012 Can-Am Outlander 800 models helps you diagnose issues quickly and get back on the trail. Here’s what to watch out for.
Overheating Issues
The big V-twin generates a lot of heat, especially in slow, technical riding or mud. If your temperature light is flashing, stop immediately.
- The Cause: The most common culprit is a radiator caked in mud. The second is a faulty radiator fan or relay.
- The Fix: Thoroughly clean your radiator from the backside, pushing dirt and debris out the front. Use a garden hose, not a high-pressure washer that can bend the delicate fins. To test the fan, you can often apply 12V directly to its leads. If the fan spins, the problem is likely the relay or temperature sensor.
Electrical Gremlins and DPS Faults
Sudden power steering failure or weird check engine lights are often electrical. Don’t panic; start with the basics.
- The Cause: A weak or dying battery is the #1 cause of strange electrical issues on these machines. Corroded battery terminals or a faulty voltage regulator are also common suspects.
- The Fix: Use a multimeter to check your battery voltage. A healthy battery should read about 12.6V at rest and 13.5-14.5V when the engine is running. If the voltage doesn’t rise when running, your charging system (stator or voltage regulator) needs attention. Clean all battery and ground connections with a wire brush until they shine.
Drivetrain Noises and Issues
Clicks, whines, and clunks from the drivetrain are signs that something needs your attention.
- The Cause: A loud clicking sound when turning is the classic sign of a worn-out CV joint. A slipping or jerky feeling on takeoff often points to a worn CVT belt. A clunk when shifting from park to drive can be worn U-joints on the driveshafts.
- The Fix: Inspect your CVT belt for glazing, cracks, or flat spots. Replacing a belt is a straightforward DIY job. If a CV boot is torn, it’s best to replace the entire axle assembly, as dirt has likely already contaminated the joint. You can check for U-joint play by grabbing the driveshaft and trying to twist it.
Smart Performance Mods: Getting More from Your 800
The Outlander 800 is powerful out of the box, but a few smart upgrades can tailor it perfectly to your riding style. Here are a few 2012 Can-Am Outlander 800 tips for effective modifications.
Clutch Kits: The Best Bang-for-Your-Buck Upgrade
If you’ve added larger, heavier tires or you primarily ride in thick mud or at high altitudes, a clutch kit is a must. A kit from a reputable brand like EPI or Dalton includes different springs and weights to change how your CVT engages.
This allows the engine to get into its powerband more quickly and holds it there, improving acceleration and back-shifting. It’s the best way to regain the power you lost from adding bigger tires.
Tires and Wheels
The right set of tires can completely transform your machine. Don’t just go for the biggest, most aggressive tire you can find. Consider your primary terrain.
- All-Terrain: For general trail riding, a 6-ply tire like the Maxxis Bighorn 2.0 offers a great balance of traction, durability, and smooth ride.
- Mud: If you live in the muck, a dedicated mud tire like the ITP Cryptid or SuperATV Assassinator is what you need. Be aware they ride rough on hardpack.
- Rock Crawling: Look for a tough, 8-ply radial tire with a flexible carcass and a rounded profile, like the Pro Armor Crawler XG.
Sustainable Riding and Off-Road Best Practices
Being a responsible rider ensures we have trails to enjoy for years to come. A sustainable 2012 Can-Am Outlander 800 is one that’s well-maintained and ridden with respect for the environment.
Tire Pressure is Everything
One of the easiest how to 2012 Can-Am Outlander 800 tips is mastering tire pressure. Lowering your pressure to 4-5 PSI on the trail increases the tire’s footprint, providing massive gains in traction and a smoother ride. Just remember to air back up to road pressure if you ride on pavement.
An Eco-Friendly Approach
Being an eco-friendly 2012 Can-Am Outlander 800 owner is simple. Always pack out what you pack in. Stay on designated trails to prevent erosion. When performing maintenance, capture all used fluids like oil and coolant and take them to an auto parts store or local facility for proper recycling. A well-tuned engine also burns cleaner, so regular maintenance is good for both your ATV and the environment.
Frequently Asked Questions About the 2012 Can-Am Outlander 800
What kind of oil does a 2012 Can-Am Outlander 800 take?
The recommended engine oil is a 5W-40 synthetic or synthetic-blend oil specifically formulated for powersports engines. BRP’s XPS brand is the factory choice, but other high-quality brands like Mobil 1 Racing 4T or Amsoil Formula 4-Stroke are excellent alternatives.
How much horsepower does the 2012 Outlander 800 have?
The 2012 Can-Am Outlander 800R, with its 799.9cc Rotax V-twin engine, produces approximately 71 horsepower. This was a class-leading figure at the time and is still highly competitive today.
Is the 2012 Can-Am Outlander 800 a reliable ATV?
Yes, when properly maintained, it is a very reliable machine. Like any high-performance vehicle, it requires regular fluid changes and inspections. The most common issues, like overheating and electrical faults, are often preventable with proactive maintenance discussed in this guide.
What should I look for when buying a used one?
Check for signs of abuse. Look for a bent frame, cracked plastics, and torn CV boots. Check the fluid levels and condition—dark, milky oil is a red flag. Ask for maintenance records. Start it cold and listen for any unusual engine noises. Test the 4WD system and power steering to ensure they engage correctly.
Your 2012 Can-Am Outlander 800 is an incredible machine with a ton of potential. By understanding its needs, addressing its common weak spots, and performing regular, diligent maintenance, you can ensure it provides thrilling and reliable performance for many more years. It’s a classic for a reason.
So get out in the garage, get your hands dirty, and give your Outlander the care it deserves. The trail is waiting. Stay safe, ride smart, and enjoy every moment of it!
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