Can-Am Outlander 24V - The Ultimate DIY Power Upgrade Guide

Let’s be honest. You love seeing your little one rip around on their Can-Am Outlander ride-on, but that stock 12-volt system is starting to feel a little… tame. It struggles in the grass, slows to a crawl on the slightest incline, and the battery life just isn’t what it used to be. You’ve seen the whispers online about a power boost, a way to unlock some real performance.

You’ve come to the right place. What if you could safely double the power, conquer the lawn, and turn that ride-on into the envy of the neighborhood? This guide promises to walk you through every step of the popular can am outlander 24v conversion. We’re not just talking about theory; we’re giving you the practical, hands-on advice you need to get this done right.

Get ready to dive in. We’ll cover the essential parts list, provide a step-by-step installation process, troubleshoot common issues, and share the critical safety tips that separate a successful project from a frustrating one. Let’s get wrenching.

What is a Can-Am Outlander 24V Conversion and Why Do It?

First things first, a “Can-Am Outlander 24V” isn’t something you buy off the showroom floor. It’s a popular and rewarding DIY modification performed on the kid’s ride-on toy version of the iconic ATV. The goal is simple: replace the stock 12-volt electrical system with a more powerful 24-volt setup.

This project is a favorite among DIY parents and grandparents because it breathes new life into a toy that a child might be outgrowing. It’s a fantastic introduction to basic DC electronics and mechanical work.

The Key Benefits of a 24V Upgrade

Why go through the trouble? The payoff is huge, especially in the smile department. This is a core part of understanding the benefits of can am outlander 24v modifications.

More Speed: This is the big one. In most cases, doubling the voltage will roughly double the top speed of the ride-on. It turns a slow crawl into an exciting cruise.
Serious Torque: Forget getting stuck in thick grass or on small hills. A 24V system delivers the grunt needed to power through tougher terrain, making backyard adventures much more fun.
Longer Ride Times: When you wire two 12V batteries together, you can often use batteries with a higher Amp-hour (Ah) rating than the stock one, potentially increasing runtime.

A Word of Caution: Understanding the Risks

Before you start ordering parts, let’s talk reality. More power means more stress on the vehicle’s components. This isn’t to scare you off, but to prepare you. Being a good mechanic means knowing the limits.

The stock motors and plastic gearboxes are designed for 12 volts. Hitting them with 24 volts will shorten their lifespan. The most common failure point is a stripped gearbox or a burned-out motor. Think of these as consumables in a high-performance setup. Thankfully, replacement motor/gearbox assemblies are widely available and often a planned “Phase 2” upgrade for enthusiasts.

Your Essential Can-Am Outlander 24V Guide: Parts & Tools

A successful project starts with the right gear. Don’t skimp here, especially on safety components. Investing in quality parts from the start will save you headaches and ensure a more reliable ride for your little one.

The Core Components List

Two 12V Batteries: You’ll need two identical 12V Sealed Lead Acid (SLA) or Absorbent Glass Mat (AGM) batteries. Match the Amp-hour (Ah) rating on both for balanced performance and charging.
24V Speed Controller: This is not optional. Do not simply wire the batteries to the stock switch. A dedicated 24V controller provides a soft start (preventing stripped gears), variable speed on the pedal, and often includes a low-voltage cutoff to protect your batteries.
In-line Fuse Holder and Fuse: Your most important safety device. A 30A or 40A fuse placed right after the battery is crucial to prevent fire in case of a short circuit.
Heavy Gauge Wire: Use 12-gauge or, preferably, 10-gauge stranded copper wire for all high-current connections (battery to controller, controller to motors).
Connectors: A good assortment of spade, ring, and butt connectors will make for clean and secure wiring.
(Optional) 24V-to-12V Voltage Reducer: If your Outlander has lights or a sound system, they will likely burn out on 24V. A voltage reducer (or “buck converter”) taps into your 24V system and provides a safe 12V output for these accessories.

The Right Tools for the Job

You don’t need a professional shop, but a few key tools will make this job much easier and safer.

Wire Strippers & Crimpers
Multimeter (for verifying voltage and troubleshooting)
Screwdriver Set (Phillips and flathead)
Socket Set or Wrenches
Soldering Iron & Solder (for the most reliable connections)
Heat Shrink Tubing & Heat Gun (to protect your soldered joints)

How to Can-Am Outlander 24V: A Step-by-Step Conversion

Alright, it’s time to get our hands dirty. This section details how to can am outlander 24v works in practice. Work slowly, double-check your connections, and always prioritize safety. Remember, we are dealing with enough current to create heat and sparks.

SAFETY FIRST: Before you do anything else, disconnect and remove the original 12V battery from the vehicle.

Access and Gut the Electronics: Open up the seat or battery compartment. Carefully unplug and remove the stock 12V battery, the stock wiring harness, and the control board. Take pictures with your phone as you go if you’re worried about remembering how things fit.
Position Your New Batteries: Find a secure location for your two new 12V batteries. They need to be snug and unable to slide around. You may need to remove some plastic housing to make them fit.
Wire the Batteries in Series: This is the key to creating 24 volts. Take a short piece of your heavy-gauge wire. Connect the POSITIVE (+) terminal of Battery #1 to the NEGATIVE (-) terminal of Battery #2. That’s it. The remaining open terminals—the negative on Battery #1 and the positive on Battery #2—are now the 24V output for your system.
Install the Fuse and Controller: Mount your 24V speed controller in a safe place. Run a wire from the main POSITIVE (+) battery terminal (on Battery #2) to your in-line fuse holder. Then, run a wire from the other side of the fuse holder to the main power input on your controller. Connect the main NEGATIVE (-) battery terminal (on Battery #1) to the main ground input on the controller.
Wire the Controller Outputs: Your controller will have outputs for the foot pedal throttle and the motors. Connect the wires from the foot pedal to the corresponding inputs on the controller. Then, run new heavy-gauge wires from the controller’s motor outputs directly to the terminals on the two drive motors.
(Optional) Install the Voltage Reducer: If you’re keeping the lights and sounds, wire the input of your 24V-to-12V reducer to your main 24V power source (after the fuse). Then, connect the original 12V accessory wiring to the 12V output of the reducer.
Secure and Tidy Up: Use zip ties to secure all loose wiring. Make sure no wires can be pinched by the seat or rubbed by the wheels. Ensure your batteries are firmly in place. Double-check that all your connections are tight and insulated.
The First Test: Before putting your little one in, carefully reconnect the main battery terminals. Prop the back wheels of the ATV off the ground. Gently press the pedal. The wheels should spin smoothly. Test forward and reverse. If everything checks out, you’re ready for a supervised test drive!

Common Problems with Can-Am Outlander 24V Conversions

Even the best mechanics hit a snag. Here are some common problems with can am outlander 24v mods and how to diagnose them. This is where your multimeter becomes your best friend.

Problem: The ATV is completely dead.

First, don’t panic. Start with the simplest solution. Check that your new 30A/40A fuse hasn’t blown. If it has, you have a short circuit somewhere that you must find before installing a new fuse. If the fuse is good, use your multimeter to confirm you have ~24-26 volts across your main power leads.

Problem: It runs for a second, then cuts out.

This is often a sign of a self-resetting breaker or a safety feature in the controller. It can happen if the motors are under too much load (like starting on a steep hill) or if you have a poor connection that’s causing a voltage drop. Check that all your crimps and connections are rock solid.

Problem: I smell burning plastic or see smoke.

STOP IMMEDIATELY. Disconnect the battery. This is the most serious issue. A burning smell almost always means you’ve either melted a wire’s insulation due to using too thin of a gauge, or you’ve officially burned out one of the stock motors. This is the risk we discussed earlier. Let everything cool down, inspect the motors and wiring, and prepare to replace any damaged components.

Can-Am Outlander 24V Best Practices for Safety and Longevity

Your project is complete, but the job isn’t over. Proper care ensures your hard work pays off with a fun, reliable machine. This can am outlander 24v care guide is all about protecting your investment and your rider.

The Golden Rules of Charging

You CANNOT use your old 12V charger. You need a dedicated 24V smart charger designed for SLA/AGM batteries. You can either charge the batteries together in the vehicle through a new charging port or remove them and charge them separately with a 12V charger. Never attempt to charge two batteries wired in series with a 12V charger.

A Sustainable Can-Am Outlander 24V Approach

Thinking about a sustainable can am outlander 24v setup means making it last. Instead of this toy ending up in a landfill, your upgrades give it a second, more exciting life. Part of this is responsible maintenance.

Perform a quick check-up every few rides. Look for loose wires and listen for any new grinding sounds from the gearboxes. Being proactive prevents small issues from becoming big ones. This is the most eco-friendly can am outlander 24v practice—reducing waste by extending the toy’s useful life and ensuring you properly recycle old batteries at an auto parts store or recycling center.

Safety First, Speed Second

This machine is now significantly faster. Non-negotiable safety rules must be established.

Always Supervise: A responsible adult should always be watching when the vehicle is in use.
Helmet On: Treat it like a bicycle or a real ATV. A helmet is a must.
Know the Terrain: Stick to safe, open areas away from traffic, pools, or steep drop-offs.

Frequently Asked Questions About the Can-Am Outlander 24V Mod

Can I just connect two 12V batteries to the stock system?

Absolutely not. This is the fastest way to instantly destroy the stock controller, wiring, switches, and possibly the motors. The stock components are not rated for 24 volts and will fail immediately. You must use a 24V-rated controller and wiring.

Will the 24V conversion definitely burn out the motors?

It’s a strong possibility, but not a guarantee. The lifespan depends on the rider’s weight, the terrain, and driving habits. Aggressive driving with lots of starting and stopping on hills will wear them out much faster. Many people get months or even years of fun before needing to replace them. Consider them a wear item.

How much faster will it really be?

A good rule of thumb is that speed will increase proportionally to the voltage. So, going from 12V to 24V will roughly double your speed. If the stock speed was 3 MPH, you can expect to be in the 6 MPH range, which is a very exciting pace for a young child.

What are some good “next-level” upgrades after the 24V conversion?

Once you’ve mastered the 24V system, the next logical steps are upgrading the motors and gearboxes to more robust metal versions. You can also add rubber tires for better traction, install a variable throttle pedal for finer control, or even add a remote kill switch for parental peace of mind.

You’ve got the knowledge and the plan. This can am outlander 24v conversion is an incredibly rewarding project that teaches basic electrical skills and delivers a huge amount of fun. Take your time, double-check your work, and always put safety first. Now get out there and build something awesome!

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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.