The Can-Am Commander 800 is a legendary machine, a true workhorse on the farm and a beast on the trails. You love the power, the versatility, and the pure fun it delivers. But let’s be honest—when something goes wrong, that fun grinds to a halt, leaving you with a headache and a silent machine in the garage.
You’re not alone. We’ve seen it all in the shop and on the trail. That’s why we put together this definitive guide. We promise to walk you through the most common can am commander 800 problems, from annoying electrical gremlins to serious drivetrain issues, giving you the confidence to diagnose and fix them yourself.
In this article, you’ll get a no-nonsense breakdown of engine, electrical, clutch, and suspension issues. We’ll cover the symptoms to watch for, the tools you’ll need, and the step-by-step checks to get you back to riding. Let’s get those hands dirty.
The Heart of the Beast: Common Engine & Drivetrain Issues
The Rotax 800 engine is a powerhouse, but the components around it take a serious beating. When you hear a new noise or feel a change in performance, the engine and drivetrain are the first places to look. Ignoring these signs can lead to catastrophic (and expensive) failures.
Overheating and Cooling System Headaches
One of the fastest ways to end a ride is an overheating engine. The Commander’s cooling system works hard, and it’s a common trouble spot.
Symptoms: The most obvious sign is the temperature warning light on your dash. You might also see steam coming from the engine bay or smell the sweet, distinct scent of burning coolant.
Causes & Fixes:
- Low Coolant: It sounds simple, but it’s the first check. Make sure your overflow bottle is between the ‘min’ and ‘max’ lines when the engine is cold. Use a 50/50 mix of distilled water and a quality ethylene glycol coolant.
- Clogged Radiator: Your radiator is a magnet for mud and debris. A caked-on layer of dirt prevents air from passing through. Use a garden hose (never a high-pressure washer, which can bend the fins) to spray it clean from the back to the front.
- Faulty Radiator Fan: If you’re stopped on the trail and the temp gauge is climbing but you don’t hear the fan kick on, you have a problem. Check the fan’s fuse first. If the fuse is good, you can test the fan motor by carefully applying 12V power directly to its leads. If it doesn’t spin, the motor is likely shot.
The Infamous One-Way Starter Clutch Bearing
If you’ve spent any time on Can-Am forums, you’ve heard of the one-way bearing. This part is crucial for engaging the starter, and when it fails, it makes a truly awful noise.
Symptoms: A loud, metallic grinding or a high-pitched whirring sound the moment you hit the start button. The noise usually stops as soon as the engine is running.
Cause & Fix: This is primarily a wear-and-tear item. The bearing eventually fails from the stress of starting the big V-twin. Replacing it is a fairly involved job that requires removing the right-side engine cover (magneto cover). You’ll need a flywheel puller specific to the Rotax engine and a good set of sockets. This is a job where following the service manual is absolutely critical.
Taming Electrical Gremlins: Wiring and Sensor Faults
Modern UTVs are packed with electronics, which means more potential points of failure. Electrical issues can be frustrating, often causing intermittent problems that are hard to track down.
Check Engine Lights and “Limp Mode”
Nothing sours a ride like the dash lighting up and the machine suddenly losing power. This is “limp mode,” a safety feature that protects the engine when the ECU detects a serious fault.
Causes: This is often triggered by a faulty sensor. The most common culprits on the Commander 800 are the Throttle Position Sensor (TPS) and the Manifold Absolute Pressure (MAP) sensor. Chafed wires in the main harness, especially where they rub against the frame, are another major cause.
Diagnosis & Fixes: An OBD-II scanner with a Can-Am adapter is your best friend here. It will read the fault code and point you in the right direction. Carefully inspect the wiring harness for any signs of rubbing or damage. If a sensor is bad, replacement is usually straightforward, involving a couple of screws and an electrical connector.
Weak Starting & Charging System Problems
You hit the key and get a weak “click-click-click” or a very slow crank. Battery issues are common, but the problem often lies in the charging system.
Symptoms: A battery that won’t hold a charge, dimming headlights, or the machine dying mid-ride.
Causes & Fixes:
- The Battery: Start here. Get it load tested at an auto parts store. Even a battery that reads 12V can be bad under load.
- Grounds & Connections: Ensure your battery terminals are clean and tight. Follow the main ground cable from the battery to the frame and make sure that connection is clean and secure. A poor ground is one of the most overlooked common problems with can am commander 800 problems.
- Voltage Regulator/Rectifier: This component converts AC power from the stator to DC power to charge the battery. When it fails, it can either undercharge or overcharge the battery, killing it either way. With the engine running, use a multimeter to check the voltage at the battery terminals. You should see 13.5-14.5 volts. If it’s much lower or higher, the regulator is likely the problem.
- Stator: The stator generates the electrical power. Testing it involves checking the resistance between its output wires with a multimeter. This is a more advanced check, so consult your service manual for the correct specs.
The Achilles’ Heel: Clutch & Belt Woes
The CVT (Continuously Variable Transmission) system is brilliant, but it’s also a high-wear area. Proper care is non-negotiable if you want to avoid being stranded.
Premature Belt Wear and Slippage
The drive belt is the lifeblood of your CVT. If you smell burning rubber or feel the machine “slip” under acceleration, your belt needs immediate attention.
Causes: The number one cause is heat. Aggressive riding, towing heavy loads, or running oversized tires all generate massive amounts of heat. An improper belt break-in or using a cheap aftermarket belt can also lead to a quick failure.
Best Practices & Fixes:
- Break It In: When you install a new belt, follow a proper break-in procedure. This typically involves 20-30 miles of easy riding with varying RPMs and no full-throttle acceleration. This seats the belt to the clutch sheaves.
- Keep it Clean: When you change a belt, clean the primary and secondary clutch sheaves thoroughly. Use a red or green Scotch-Brite pad and some brake cleaner on a rag to remove old belt residue. This provides the best grip for the new belt.
- Use Low Gear: When riding slowly (under 15 mph), rock crawling, or towing, always use low gear. This keeps RPMs up and the clutches cool, drastically extending belt life.
A Comprehensive Can Am Commander 800 Problems Guide to Suspension & Steering
The “sport” part of a Sport-Utility UTV comes from its suspension. When these components wear out, the ride gets sloppy, noisy, and downright dangerous.
Worn Out Ball Joints and Tie Rod Ends
These are the pivot points for your steering and suspension. Over time, they develop play, leading to a loose and unpredictable feeling.
Symptoms: Vague or sloppy steering, a clunking noise when going over bumps or turning, and uneven tire wear.
Diagnosis & Fix: Safely jack up the front of the machine so the tire is off the ground. Grab the tire at the top and bottom (12 and 6 o’clock) and try to wiggle it. If you feel play, you likely have a bad ball joint. Grab it at the sides (9 and 3 o’clock) and wiggle it. Play here usually indicates a worn tie rod end. Replacement is a bolt-off, bolt-on affair, but getting an alignment afterward is highly recommended.
Leaking Shocks and Worn Bushings
Your shocks and bushings are responsible for a smooth ride. Worn A-arm bushings are a particularly common issue on these machines.
Symptoms: A bouncy, uncontrolled ride; visible oil leaking down the shock body; or loud squeaking and groaning from the suspension pivots.
Cause & Fix: Shocks can be rebuilt by a specialist or replaced entirely. The factory A-arm bushings are plastic and wear out quickly. A fantastic upgrade is to replace them with aftermarket bushings made from superior materials like Delrin or Oilite bronze. This is a great weekend project that dramatically tightens up the feel of your machine.
Best Practices for Prevention: Your Care Guide
The best way to deal with can am commander 800 problems is to prevent them from happening in the first place. A little proactive maintenance goes a long way.
The 5-Minute Pre-Ride Inspection
Before every ride, take five minutes to do a quick walk-around. This is one of the most important can am commander 800 problems best practices.
- Tires & Wheels: Check for proper air pressure and look for any damage. Grab a wheel and check for play.
- Fluids: Check the engine oil and coolant levels.
- Visual Check: Look under the machine for any new leaks or drips.
- Controls: Test your brakes, throttle, and steering before you hit full speed.
Sustainable Maintenance and Eco-Friendly Tips
Being a responsible owner means taking care of the machine and the environment. Following eco-friendly can am commander 800 problems practices is easier than you think.
When you change your oil, coolant, or differential fluids, always capture them in a drain pan. Take them to your local auto parts store or municipal recycling center for proper disposal. Never dump them on the ground or down a drain. Choosing to repair a component instead of immediately replacing it is also a form of sustainable can am commander 800 problems management, reducing waste and saving you money.
Frequently Asked Questions About Can Am Commander 800 Problems
What’s the most common issue on a Commander 800?
It’s a toss-up between CVT belt issues and electrical sensor failures. Because the belt is a wear item and subject to user habit, it’s often the first thing new owners experience. Electrical issues, like a bad TPS sensor causing limp mode, are also extremely common.
How can I tell if my one-way bearing is going bad?
The sound is unmistakable. It’s a very loud, sharp grinding or whirring noise that happens only during engine cranking. As soon as the engine fires up and is running on its own, the noise will disappear completely. If you hear a persistent grind while riding, your problem is elsewhere.
Is the Can-Am Commander 800 a reliable machine?
Absolutely. With a good maintenance schedule and a proactive owner, the Commander 800 is a very reliable platform. Like any high-performance off-road vehicle, it has known weak points that require attention, but its core engine and chassis are solid.
What are the benefits of knowing these can am commander 800 problems?
Understanding the common issues has huge benefits. It empowers you to perform your own repairs, saving a ton of money on shop labor. It reduces your downtime, meaning more time on the trail. Most importantly, it makes you a safer, more confident rider who understands the machine and can spot trouble before it becomes a major failure.
Owning a Can-Am Commander 800 is a rewarding experience, and being able to maintain and repair it yourself makes it even better. Don’t be intimidated by these common issues. See them as opportunities to learn more about your machine. Grab your tools, follow this can am commander 800 problems care guide, and ride with the confidence that you can handle whatever the trail throws at you. Stay safe out there!
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