Ever bolted a set of monster mud tires onto your Can-Am Outlander, hit the trail, and felt that snappy, low-end grunt just… vanish? You’re not alone. It’s that sinking feeling when your machine struggles to turn those big meats in thick mud or up a steep, rocky incline. You bought a beast of an ATV, but now it feels a bit sluggish right when you need the power most.
We promise, there is a definitive solution that brings back that lost power and then some. This comprehensive guide is your roadmap to understanding and implementing a can am outlander gear reduction. It’s one of the most transformative upgrades you can make.
In this article, you’ll discover the incredible benefits of this mod, how to choose the perfect ratio for your riding style, and what to expect during the installation. We’ll even cover common problems and best practices to ensure you get it right the first time. Let’s get that torque back.
What Exactly Is a Can Am Outlander Gear Reduction?
Think of a gear reduction like the granny gear on a mountain bike. You trade top-end speed for incredible climbing power and control. In your Outlander’s transmission, a gear reduction involves swapping out specific factory gears for new ones with a different tooth count.
This change alters the final drive ratio, effectively multiplying the engine’s torque before it reaches the wheels. The result? Your engine doesn’t have to work nearly as hard to turn the tires, especially oversized ones.
These kits are typically sold by their percentage of reduction, such as 15%, 25%, or even 40%. A higher percentage means more torque multiplication and a more significant drop in top speed. Understanding the core benefits of can am outlander gear reduction is the first step to deciding if it’s right for you.
The Top 5 Benefits of Gearing Down Your Outlander
Installing a gear reduction kit isn’t just about getting power back; it’s about making your entire machine more capable, reliable, and fun to ride. Here are the biggest advantages you’ll experience.
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Reclaim Power from Big Tires
This is the #1 reason most riders do it. Larger, heavier tires effectively raise your machine’s overall gear ratio, making it feel sluggish. A gear reduction counteracts this perfectly, making your ATV feel as peppy—or even peppier—than it was with stock tires. -
Unbelievable Low-Speed Control
For rock crawlers and technical trail riders, this is a game-changer. A gear reduction allows you to crawl over obstacles with incredible precision and minimal throttle input. No more jerky, lunging movements on tricky sections. -
Massively Reduced Drivetrain Strain
Your CVT belt is the unsung hero of your ATV. A gear reduction takes a huge load off it. With the mechanical advantage of the new gears, your belt is less likely to slip, glaze, or break. This reduced stress also extends to your clutches, axles, and differentials, which is a key part of any good can am outlander gear reduction care guide. -
Cooler Belt Temperatures
Less belt slippage means less friction, and less friction means less heat. Heat is the mortal enemy of a CVT belt. By keeping your belt and clutches cooler, you dramatically extend their service life and prevent catastrophic belt failures deep in the woods. -
Enhanced Towing and Hauling Power
If you use your Outlander for work, a gear reduction transforms it into a true workhorse. It provides the low-end grunt needed to pull heavy trailers, drag logs, or haul gear up steep grades without constantly smoking the belt.
Choosing the Right Gear Reduction Ratio for Your Ride
Picking the right gear ratio is the most critical step in this process. Your choice should be a balance between your tire size, typical terrain, and riding style. Overshooting or undershooting your needs can lead to a frustrating experience. This section of our can am outlander gear reduction guide will help you decide.
For the All-Around Trail Rider (Tires up to 30″)
If you primarily ride trails and have upgraded to 28-30″ tires, a mild reduction is your sweet spot. Look for something in the 12-15% range.
This will compensate for the larger tires, restore your low-end snap, and reduce belt strain without sacrificing too much top speed for those fast-paced fire roads.
For the Serious Mudder (Tires 31″ – 34″)
When you’re turning heavy, aggressive mud tires, you need serious torque to keep them spinning. A moderate reduction in the 25-35% range is ideal.
This provides the grunt needed to churn through the thickest peanut butter and takes a massive load off your drivetrain. You’ll notice a significant drop in top speed, but in deep mud, torque is king.
For the Extreme Rock Crawler & Swamp Donkey (Tires 35″+)
If your machine is a dedicated rock crawler or runs massive 35″+ tires, you need all the mechanical advantage you can get. An aggressive reduction of 40% or more is the way to go.
This setup is all about ultimate low-speed control and drivetrain preservation. Top speed will be severely limited, but you’ll be able to crawl over obstacles with surgical precision.
How to Can Am Outlander Gear Reduction: A Step-by-Step Overview
Disclaimer: This is a mechanically intensive job that requires specialized tools and a high degree of confidence. It involves completely removing and splitting the transmission case. If you’re not comfortable with major drivetrain work, we strongly recommend having a professional shop perform the installation. Always use a factory service manual for your specific model and year.
Essential Tools and Parts
Before you even think about starting, make sure you have everything you need. A mid-job run to the parts store is the last thing you want.
- A high-quality gear reduction kit (e.g., from SuperATV, High Lifter, Turner Cycles)
- New transmission gaskets and seals
- A heavy-duty gear puller
- Impact wrench and a comprehensive socket set
- A calibrated torque wrench
- Seal driver set or appropriately sized sockets
- Assembly lube and high-quality gear oil
- Your ATV’s factory service manual (non-negotiable)
The Installation Process (Simplified)
This overview covers the major phases. Remember, the devil is in the details, which your service manual will provide.
- Preparation and Safety: Start by thoroughly cleaning your machine, especially around the transmission. Disconnect the battery. Safely support the ATV on jack stands and drain the transmission fluid.
- Major Disassembly: This is the long part. You’ll need to remove rear plastics, exhaust, driveshafts, clutch cover, and both the primary and secondary clutches. This gives you access to the transmission.
- Remove and Split the Transmission: Carefully unbolt the transmission from the frame and move it to a clean workbench. Meticulously remove the bolts holding the case halves together and gently split the case open. Keep every part organized!
- Swap The Gears: This is the heart of the operation. Following the kit’s instructions, use your gear puller to remove the stock gears from their shafts. Carefully press the new, lower-ratio gears on, ensuring they are fully seated. This is one of the most important can am outlander gear reduction best practices.
- Clean and Reassemble: Scrupulously clean the mating surfaces of the transmission case, removing all old gasket material. Install new seals. Apply the recommended sealant, lay down your new gasket, and carefully join the case halves. Torque all bolts to the factory specification in the correct sequence.
- Reinstallation and Final Checks: Reinstall the transmission into the frame. Reconnect everything you removed (clutches, driveshafts, etc.). Fill the transmission with the correct type and amount of gear oil. Double-check everything before starting the engine.
Common Problems with Can Am Outlander Gear Reduction (And How to Avoid Them)
Even with careful work, issues can arise. Knowing about these common problems with can am outlander gear reduction ahead of time can help you prevent them.
Gear Whine or Noise
A loud whine after installation often points to poorly manufactured gears or incorrect installation. Avoid this by purchasing a kit from a reputable brand. During installation, ensure all bearings are in perfect condition and properly seated.
Transmission Leaks
Leaks are almost always caused by improper sealing. To prevent this, ensure the case mating surfaces are surgically clean. Use a new, high-quality gasket and apply sealant exactly as the service manual directs. Torque the case bolts to spec in the proper pattern.
Shifting Difficulties
If your ATV has trouble shifting or won’t go into gear, a shift fork was likely misaligned during reassembly. Take photos during disassembly to reference how the shift forks and linkage are oriented. Work slowly and confirm smooth operation before sealing the case.
The Sustainable Side: An Eco-Friendly Upgrade?
When we talk about a sustainable can am outlander gear reduction, we’re not talking about emissions. We’re talking about the longevity of your machine and minimizing your impact on the trail.
By reducing the strain on your entire drivetrain, a gear reduction helps components like belts and clutches last significantly longer. This means fewer used parts ending up in a landfill. This is a practical approach to an eco-friendly can am outlander gear reduction.
Furthermore, the enhanced low-speed throttle control you gain helps prevent excessive wheel spin. This minimizes damage to sensitive trails, helping to preserve the natural environments we all love to ride in.
Frequently Asked Questions About Can Am Outlander Gear Reduction
Will a gear reduction make my Outlander really slow?
Yes, you will lose top-end speed. The loss is roughly proportional to the reduction percentage. A 25% gear reduction will likely reduce your top speed by about 25%. It’s a trade-off: top speed for low-end torque.
Do I need to install a new clutch kit at the same time?
It’s not strictly required, but it is highly recommended. A gear reduction changes how the engine’s power needs to be delivered. A clutch kit tuned for your new gearing, tire size, and riding style will ensure you get every ounce of performance from your upgrade.
How much does a Can-Am Outlander gear reduction cost?
The gear sets themselves typically range from $300 to $700, depending on the brand and reduction percentage. You’ll also need to budget for new gaskets, seals, and fluids. If you have a shop do the labor, expect to pay for 6-10 hours of work, which can be a significant additional cost.
Is this a realistic DIY job for a weekend mechanic?
This is an advanced-level project. If you have experience rebuilding engines or transmissions and own the necessary tools (especially a gear puller and torque wrench), you can likely handle it. If you’re hesitant about opening a transmission case, it’s best to entrust this job to a qualified technician.
A can am outlander gear reduction is one of the most rewarding modifications you can make, especially after adding larger tires. It restores lost performance, enhances control on technical terrain, and improves the overall durability of your machine’s drivetrain.
By choosing the right ratio and following proper installation procedures, you can transform your Outlander into the exact machine you’ve always wanted it to be. Gear up, ride smart, and enjoy that incredible new crawling power. We’ll see you on the trails!
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