There’s a reason the Can Am Outlander 800 XT holds a legendary status among off-road enthusiasts. That big Rotax V-twin engine has a sound and a fury that’s hard to beat, delivering a thrilling ride whether you’re tackling muddy trails or hauling gear around the property. You know the power, you know the capability, and you know it’s a machine built for serious fun.
But like any high-performance machine, it demands respect and the right know-how to keep it running strong. You’re in the right place. We promise this is the most comprehensive, no-fluff guide you’ll find online, written by mechanics who have turned wrenches on these exact models.
In this ultimate can am outlander 800 xt guide, we’re going to break down the common problems you might face and how to fix them, provide a rock-solid maintenance checklist, and share some pro tips to get the absolute most out of your quad. Let’s get those hands dirty.
The Enduring Legacy: Why the Can-Am Outlander 800 XT Still Rips
Before we dive into the nuts and bolts, it’s worth appreciating what makes this machine so special. Understanding its core strengths helps you appreciate why proper maintenance is so crucial. The benefits of a Can Am Outlander 800 XT go far beyond raw power.
The Heart of the Beast: The Rotax V-Twin Engine
The star of the show is the 800cc Rotax V-twin engine. It’s known for its incredible torque and responsive throttle, which makes climbing hills and powering out of mud bogs an absolute blast. This isn’t just an engine; it’s a statement.
Unlike many single-cylinder competitors, the V-twin design provides a smoother power delivery and a distinctive, throaty exhaust note that’s pure music to any rider’s ears.
Unmatched Comfort and Handling
Can-Am didn’t just drop a monster engine into a basic frame. The Outlander platform, with its Torsional Trailing arm Independent (TTI) rear suspension, offers a remarkably plush ride. It soaks up rocks and ruts, keeping the tires planted for better traction and reducing rider fatigue on long days.
This focus on rider comfort is a key reason why many trail veterans swear by these machines.
XT Package: More Than Just a Sticker
The “XT” designation is where this quad really shines for the serious off-roader. From the factory, the XT package typically includes crucial upgrades that you’d otherwise have to buy yourself.
- Heavy-Duty Winch: A factory-installed WARN winch is a lifesaver for getting yourself or your buddies out of sticky situations.
- Upgraded Bumpers: The stout front and rear bumpers offer serious protection against trail hazards.
- Cast-Aluminum Wheels: These are stronger and lighter than the steel wheels found on base models.
- Carlisle ACT Radial Tires: A great all-around tire that provides solid traction in a variety of conditions.
Common Problems with Can Am Outlander 800 XT and How to Fix Them
No machine is perfect. After years on the trail, we’ve seen a few recurring issues with the Outlander 800. The good news is that most are well-documented and fixable for a confident DIYer. Here’s a look at the most common problems with can am outlander 800 xt.
Overheating Issues: Keeping Your Cool on the Trail
The Symptom: The temperature light flashes, you see steam, or the machine goes into limp mode, especially during slow, muddy rides.
The Cause: The radiator on these machines is a magnet for mud and debris. When it gets caked, air can’t pass through to cool the engine coolant. A failing radiator fan or low coolant can also be the culprit.
The Fix:
- Clean the Radiator: After every muddy ride, thoroughly wash the radiator from the backside forward. Use a garden hose, not a high-pressure washer that can bend the delicate fins. A radiator fin comb is a great tool for gently straightening any bent fins.
- Check the Fan: With the key on (engine off), let the machine get up to temperature. The fan should kick on. If it doesn’t, check the fan’s fuse and wiring connections first. The fan motor itself can fail over time.
- Verify Coolant Level: Always check the coolant overflow bottle when the engine is cold. If it’s low, top it off with a 50/50 mix of distilled water and an ethylene glycol-based coolant recommended for aluminum engines.
Electrical Gremlins: Stator and Rectifier Failures
The Symptom: The battery won’t stay charged, the ATV is hard to start, or the headlights dim at idle. You might also get “CHECK ENGINE” or “LOW VOLTAGE” warnings on the display.
The Cause: The stator (inside the engine case) generates AC power, and the voltage regulator/rectifier converts it to DC power to charge the battery. One or both of these components can fail, especially on earlier models.
The Fix: This requires some diagnostic skill.
- Test the Battery: First, ensure you have a good, fully charged battery. A weak battery can mimic charging system problems.
- Check Voltage: With a multimeter set to DC volts, check the battery voltage with the engine off (should be ~12.5V). Then start the engine and rev it to around 3,000 RPM. The voltage should climb to 13.5V – 14.5V. If it doesn’t, you have a charging problem.
- Stator Test: This is more advanced. You’ll need to locate the stator wires, disconnect them, and test the resistance (ohms) and AC voltage output according to the service manual’s specifications. If the tests fail, the stator needs replacement. If the stator tests good but the battery isn’t charging, the regulator/rectifier is the likely suspect.
Drivetrain Woes: Clicking CV Joints
The Symptom: A loud, rhythmic clicking or popping sound when turning, which gets worse under acceleration.
The Cause: The CV (Constant Velocity) joints are protected by rubber boots. A tear or rip in a boot allows dirt and water in, which destroys the grease and the joint itself.
The Fix:
- Inspect Boots Regularly: Make checking your four CV boots part of your pre-ride routine. Look for any cracks, tears, or grease flung around the A-arms.
- Replace Torn Boots Immediately: If you catch a torn boot early before the joint starts clicking, you can often just clean, re-grease, and install a new boot kit.
- Replace the Axle: If the joint is already clicking, the damage is done. The easiest and most reliable fix is to replace the entire axle shaft assembly. It’s often cheaper than paying for labor to rebuild the joint.
Your Essential Can Am Outlander 800 XT Care Guide
An ounce of prevention is worth a pound of cure, especially with a high-performance ATV. Following a simple but consistent maintenance schedule is the key to reliability. This is your go-to can am outlander 800 xt care guide.
Pre-Ride Checklist: The 5-Minute Safety Check
Before every single ride, take five minutes to walk around your machine. It could save you from a breakdown or an accident.
- Tires & Wheels: Check for proper air pressure and look for any cuts or damage. Grab the wheels and check for any play in the bearings.
- Controls & Cables: Check your throttle and brake lever for smooth operation.
- Lights & Electrics: Turn the key on and check your headlights (high and low beam), taillights, and brake lights.
- Oil & Fluids: Check your engine oil level and take a quick look at the coolant overflow bottle. Look underneath for any fresh drips.
- Chassis & Suspension: Quickly glance over your suspension components, looking for any loose bolts or damage.
The Holy Trinity of Fluids
Fluids are the lifeblood of your Outlander. Using the right fluids and changing them on schedule is non-negotiable.
Engine Oil: The Rotax V-twin is a hard-working engine. Use a high-quality synthetic 4-stroke oil like XPS 5W-40 Synthetic Blend. Change the oil and filter every 50 hours or 6 months, whichever comes first—sooner if you ride in very dusty or wet conditions.
Differential & Gearbox Fluids: Your front and rear differentials and gearbox also need fresh fluid. Check your owner’s manual for the specific intervals, but a good rule of thumb is to change them at least once a season. This is one of the most overlooked can am outlander 800 xt tips.
Air Filter Maintenance: The Lungs of Your ATV
A dirty air filter will choke your engine, robbing it of power and efficiency. In dusty off-road environments, it’s your engine’s number one defense.
Remove the foam air filter after every few rides (or after every single ride in heavy dust). Wash it with filter cleaner and warm water, let it dry completely, and then re-apply a quality foam filter oil, squeezing out any excess. A clean, properly oiled filter is critical.
How to Can Am Outlander 800 XT: Best Practices for Performance
Knowing your machine is about more than just maintenance; it’s about how you use it. Following these can am outlander 800 xt best practices will improve your experience and extend the life of your quad.
Mastering the Visco-Lok 4WD System
The Visco-Lok system is an automatic locking front differential. It sends power to the wheel with the most traction when it detects slippage. Understand that it needs a moment of wheel spin to engage. When approaching a tough obstacle, give it a little steady throttle before you hit it to allow the system to lock in.
Smart Upgrades: Where to Spend Your Money First
It’s easy to go crazy with mods, but focus on protection and traction first.
- Skid Plates: Full-body aluminum or UHMW plastic skid plates will protect your frame, engine, and drivetrain components from rocks and stumps.
- Better Tires: The stock tires are decent, but a quality 6-ply or 8-ply tire like a Maxxis Bighorn 2.0 or ITP TerraCross R/T will drastically improve traction and puncture resistance.
- Clutch Kit: If you add larger tires, a clutch kit (like one from EPI or Dalton) will recalibrate your CVT to regain lost low-end power and reduce belt strain.
The Sustainable Rider: Eco-Friendly Can Am Outlander 800 XT Tips
Being a true enthusiast means respecting the trails we ride on. Adopting a few eco-friendly can am outlander 800 xt habits ensures our riding areas stay open and beautiful for years to come.
Treading Lightly: Minimizing Trail Impact
The power of the Outlander 800 can easily tear up the terrain. Always practice “Tread Lightly!” principles. Stay on designated trails, avoid sensitive areas like meadows and wetlands, and cross streams only at designated crossings. Use your winch instead of spinning your tires to get unstuck.
Eco-Conscious Maintenance
When performing maintenance, be mindful of your environmental footprint. Use a drain pan to catch all used fluids and take them to an auto parts store or local recycling center for proper disposal. Never dump oil or coolant on the ground. Consider using biodegradable cleaners and degreasers when washing your machine.
Frequently Asked Questions About the Can-Am Outlander 800 XT
What year is the most reliable for the Outlander 800?
Generally, later models from 2012 onwards are considered more reliable. Can-Am made several improvements to the frame, suspension, and electrical systems over the years. However, a well-maintained earlier model can still be a fantastic machine.
How much horsepower does a Can-Am Outlander 800 XT have?
The Can-Am Outlander 800 Rotax V-twin engine produces around 71 horsepower. This was class-leading power for its time and is still very competitive today, providing excellent acceleration and trail performance.
What is the top speed of a Can-Am Outlander 800 XT?
Under ideal conditions, a stock Can-Am Outlander 800 XT can reach a top speed of around 70-75 mph. However, these machines are designed for trail torque and acceleration, not sustained high-speed runs.
Is the Can-Am Outlander 800 XT a good machine for a beginner?
Due to its significant power and weight, the Outlander 800 XT is generally not recommended for a true beginner with no riding experience. Its responsive throttle can be intimidating. It’s better suited for intermediate to experienced riders.
The Can-Am Outlander 800 XT is a truly rewarding machine to own and ride. It’s a powerhouse that, with the right knowledge and a little bit of wrenching, will deliver incredible adventures for years to come.
By staying on top of maintenance, understanding its common quirks, and riding with respect for the trail, you’re not just an owner—you’re a true steward of a legendary off-road icon. Now get out there, stay safe, and have a blast!
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