If you’ve got a can am commander 800 xt parked in your garage, you already know you’re sitting on a legendary piece of off-road machinery. It’s a machine that’s just as comfortable hauling firewood on the property as it is tearing up a mountain trail on a Saturday morning. You agree it’s a versatile and powerful side-by-side, right?
But with great power comes the need for great maintenance. We promise this isn’t just another boring owner’s manual. This is the FatBoysOffroad guide, built from years in the shop and on the trail, to help you keep your rig running strong, diagnose common issues before they become disasters, and make smart upgrades that actually work.
In this ultimate can am commander 800 xt guide, we’ll cover the essential pre-ride checks, dive deep into the most common problems (and their fixes), explore performance mods that give you the best bang for your buck, and even share some tips for responsible riding. Let’s get those hands dirty.
What Makes the Can-Am Commander 800 XT a Trail Legend?
Before we start turning wrenches, let’s appreciate what we’re working with. The Commander 800 wasn’t just another UTV; it set a standard for blending utility and sport performance. Understanding its core components helps you appreciate its strengths and weaknesses.
The primary reason for its long-standing popularity is the incredible balance it strikes. It’s a true “do-it-all” machine, which is one of the main benefits of can am commander 800 xt ownership.
The Heart of the Beast: The Rotax 800 V-Twin
The soul of this machine is its 71-horsepower Rotax 800cc V-twin engine. This powerplant is known for its robust torque and a signature V-twin rumble. It delivers smooth, predictable power that’s perfect for technical rock crawling and has enough guts to open up on a fire road.
It’s a reliable engine, but it demands clean oil and a clean air filter to live a long, happy life. Neglect these, and you’ll find its limits sooner than you’d like.
Understanding the “XT” Package Advantage
The “XT” badge isn’t just a sticker. It signifies a factory-upgraded package designed for tougher work and more aggressive trails. Most XT models came standard with crucial add-ons that you’d otherwise be buying from the aftermarket.
- Upgraded Wheels and Tires: Usually equipped with tougher ITP Terracross tires on cast-aluminum wheels for better puncture resistance and traction.
- Factory Winch: A 4,000-lb WARN winch is a lifesaver, whether you’re pulling yourself out of a mud hole or moving a downed tree off the trail.
- Heavy-Duty Bumpers: The front and rear bumpers on the XT provide serious protection against rocks, trees, and other trail hazards.
- Visco-Lok QE: A quicker-engaging front differential that locks up faster to give you 4WD traction right when you need it.
The Essential Can Am Commander 800 XT Care Guide: Pre-Ride & Routine Service
Here’s where the rubber meets the road—or the dirt. Consistent maintenance is the number one thing that separates a reliable rig from a trail-side breakdown. This is the core of our can am commander 800 xt care guide.
Think of these checks not as a chore, but as a conversation with your machine. It’ll tell you what it needs if you know how to listen.
Your Pre-Ride T-CLOCS Checklist
Before every single ride, take five minutes to do a walk-around. We use a modified version of the motorcycle T-CLOCS checklist (Tires, Controls, Lights, Oil, Chassis, Stands).
- Tires & Wheels: Check for proper air pressure. Look for any cuts or punctures. Grab the wheel and check for any play or looseness in the wheel bearings.
- Controls & Cables: Test your throttle—does it snap back cleanly? Check your brake pedal feel—is it firm, not spongy? Ensure the steering is smooth lock-to-lock.
- Lights & Electrics: Turn the key on. Check your headlights (high and low beams), taillights, and brake lights. A flickering light could signal a loose connection.
- Oil & Fluids: This is non-negotiable. Pull the dipstick and check the engine oil level. Take a quick peek at the coolant overflow bottle and the brake fluid reservoir.
- Chassis & Suspension: Glance over your A-arm bushings, CV boots (look for rips or grease spray), and shocks. Check for any new dents, cracks, or loose bolts on the frame and skid plates.
The 50-Hour Service: Your DIY Game Plan
Your owner’s manual has a detailed schedule, but the 50-hour (or annual) service is a great interval for the DIY mechanic to hit the key points. Here’s how to can am commander 800 xt basic service.
- Engine Oil & Filter Change: The lifeblood of your Rotax. Use a quality oil like BRP XPS Synthetic Blend and a new oil filter. Pro Tip: Warm the engine for a few minutes to help the old oil drain completely.
- Air Filter Service: Pull the air filter. If it’s a paper filter, tap it out and replace if it’s filthy. If it’s a reusable foam filter, clean and re-oil it according to the manufacturer’s instructions. A dirty air filter robs power and can destroy an engine.
- CVT Inspection: Pop the CVT cover off. Blow out the dust with compressed air (wear a mask!). Inspect the CVT belt for glazing, cracks, or missing cogs. Check for excessive wear on the clutch sheaves.
Common Problems with Can Am Commander 800 XT and How to Fix Them
No machine is perfect. After seeing hundreds of these in the shop, we’ve identified a few recurring issues. Knowing the common problems with can am commander 800 xt models can save you a massive headache and a ton of money.
The Infamous Hot Start Issue
The Symptom: The machine starts perfectly when cold, but after a long ride, you shut it off, and it just cranks and cranks without firing up when you try to restart it. Sound familiar?
The Cause: This is often due to heat soak causing vapor lock in the fuel lines, especially on earlier models. The fuel pump’s pressure might also be on the weak side when hot.
The Fix: A simple fix is to cycle the key a few times to let the fuel pump prime the system. For a more permanent solution, you can insulate the fuel lines near the engine with heat-reflective tape. If the problem persists, test your fuel pressure when the machine is hot—you may need a new fuel pump.
Drivetrain Noises: Decoding Whines and Clunks
The Symptom: You hear a new whine, clunk, or vibration that changes with speed.
The Cause & Fix:
- Whining from the CVT: Often a sign of a worn belt or glazed clutch sheaves. Start with a belt inspection and replacement.
- Clunking on take-off: Check your U-joints and carrier bearing. Grab the driveshafts and try to move them—any slop is bad news.
- Grinding from the differentials: This is a bad sign. First, check your diff fluid level and condition. If it’s low or looks like metallic paint, you may have internal damage. Stop riding and get it inspected.
Electrical Gremlins: Fuses, Grounds, and the Stator
The Symptom: A dead battery, intermittent power loss, or accessories that don’t work.
The Cause: The charging systems can be a weak point. The stator is known to fail, and bad ground connections are common.
The Fix: Always start simple. Check your battery terminals for tightness and corrosion. Inspect the main ground wire where it connects to the frame. Use a multimeter to test your battery voltage with the machine off (should be ~12.5V) and running at 3000 RPM (should be ~13.5-14.5V). If it’s not charging, you’re likely looking at a bad stator or voltage regulator.
Unlocking Performance: Smart Mods and Upgrades
Once you have the maintenance dialed in, it’s time for the fun stuff. The Commander is a fantastic platform for modifications. Here are a few can am commander 800 xt tips for upgrades that provide the best results.
Tires & Wheels: The Single Best Upgrade
Nothing changes the look and capability of your machine more than a new set of tires. Ditching the stock tires for a more aggressive, durable 8-ply radial tire will dramatically improve traction, reduce flats, and give you more confidence in rough terrain.
Clutch Kits: Getting Your Power to the Ground
If you’ve added bigger tires or plan on riding in heavy mud or sand, a clutch kit is a must. A good kit will recalibrate your CVT to better handle the increased load, preventing belt slippage, improving acceleration, and keeping your machine in its optimal powerband. It’s one of the most effective performance mods you can make.
Skid Plates and Armor: Protecting Your Investment
The factory “skid plates” offer minimal protection. A full set of aluminum or UHMW (Ultra-High-Molecular-Weight polyethylene) skid plates will protect your engine, transmission, and differentials from trail-destroying rocks and stumps. This is cheap insurance against a very expensive repair.
Sustainable Can Am Commander 800 XT Best Practices
Being a true off-roader means being a steward of the trails we love. Adopting a few sustainable can am commander 800 xt habits ensures these areas stay open and beautiful for generations to come. It’s about more than just performance; it’s about responsibility.
Tread Lightly: Minimizing Your Trail Impact
This is the golden rule of off-roading. Stay on designated trails, avoid creating new bypasses around obstacles, and cross water at designated points. Avoid spinning your tires excessively, as it accelerates trail erosion. These simple eco-friendly can am commander 800 xt practices make a huge difference.
Eco-Friendly Maintenance
Responsible ownership extends to your garage. Always capture used fluids like oil and coolant in a sealed container and take them to an auto parts store or local recycling center for proper disposal. Never dump fluids on the ground or down a drain. When cleaning your rig, use a biodegradable, phosphate-free soap to protect local waterways.
Frequently Asked Questions About the Can Am Commander 800 XT
What kind of oil does a Can-Am Commander 800 take?
The manufacturer recommends a 5W-40 synthetic blend oil specifically designed for Rotax engines, like the BRP XPS brand. In a pinch, any high-quality 5W-40 synthetic oil for powersports applications will work, but sticking to the OEM recommendation is always a safe bet.
How fast is a Can-Am Commander 800 XT?
A stock Can-Am Commander 800 XT has a top speed of around 65-70 mph. However, factors like tire size, clutch condition, and added weight can affect the actual top speed you experience on the trail.
Is the Can-Am Commander 800 a reliable machine?
Yes, when properly maintained, the Commander 800 is a very reliable machine. The Rotax engine is proven, and the drivetrain is robust. Most major issues stem from neglect of basic maintenance like oil changes, air filter cleaning, and CVT belt inspection.
What should I look for when buying a used Commander 800 XT?
Check for play in the wheel bearings, A-arm bushings, and ball joints. Look for torn CV boots. Ask for service records. Check the diff and engine oil for any milky or metallic appearance. Listen for strange noises on a test drive and ensure the 4WD system engages properly.
Your Can-Am Commander 800 XT is more than just a machine; it’s a ticket to adventure. By understanding how it works, staying on top of maintenance, and treating it with respect, you’ll ensure it’s ready to roll whenever the trail calls. Now, get out there, stay safe, and have some fun!
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