Can Am Outlander Renegade 500 650 800 Motor Assembly

Assembling a 800 can am Rotax engine
the 500, 650 and 800 all have the same internal parts just different sizes, the torque specs are the same
Rod Torque is 15 ft lbs at 90 degrees
Heads are 15, 30, 40 Ft lbs

[@victorcarr6449]

Thanks "shanesoutty" for one of the most step by step videos I have seen in yrs, it shows us non wrench people how to save big dollars PLUS, how our atv's work from the inside, I'm well awear of how hard you guys work, then to take your time and do videos for us, well appericated shanesoutty:)

[@diegonunez2927]

One piece of advice I recommend assembling the entire block and putting the chains until last, this will facilitate the movement of the crankshaft and pistons.

[@HossTexan]

The most badass youtube video on canals around. thanks so much for taking the time to help others out!

[@shanesoutty]

I'm glad it's appreciated Thank you for the comment

[@youfixitatvutv]

Wow no asembly lube on bearings???

[@shanesoutty]

I did this in multiple takes, this was the best video, thanks for watching so close though :)

[@air2bmc]

There was a small piece of gasket material that fell inside the motor right before you mated the two halves together. You can see it at 4:46.

[@shanesoutty]

although it does in some aspects in others I like them better, they are a perfect rod when not damaged, no machining necessary

[@renegade9758]

Hello i need the replaned the Heart cylindre or not ?and what torque specs small head bolt

[@air2bmc]

no problem man, nice job on the editing it looks like one video, keep up the good work and sweet videos!

[@shanesoutty]

yes oversize bearings are available But only for a machined crank, you can buy in +.25mm and +.50mm they are not machineable as the mating surface is unique to each rod, not gapped like most car or even other atv engine rods

[@shanesoutty]

both chains are brand new, it was dry and had not been oiled yet I replace chains 90% of the time when I do a motor, generally the ones I build have been sunk and even new chains will fail when contaminant has been introduced Thanks for the keen eye, but like I said they are new

[@jayson1134]

I notice you are not using assembly lube.... why not???? I am doing a 30 over on my 800 and your video answered all my questions ,,especially timing issues...are you using any light oil on rod bearings before assembly??? any info would be appreciated. .. thanks in advance

[@tysoncarroll2664]

Do a video on transmission

[@davidsquarepants1256]

I took apart my engine recently put a big bore 860 from mrrpm, my problem is I believe coolant is coming out of the wrong area. In the case for the primary clutch there are several plastic gears and the timing chain (I changed the chains) cooling is shooting out of the window screen looking thing on the right side, that's ainy right because the first time I removed the cover I remember just oil coming out from there and never is it okay if oil and coolant mix, so I'm confused what I did wrong hahah I need wisdom

[@javiergallegorodriguez8325]

Very good video, but I do not speak English and I would have liked the torque was written in the video, even so, congratulations

[@woodymiller3895]

Try cleaning all your parts prior to assembly.

[@shanesoutty]

Those chains are brand new

[@uncordobes]

I've had to split my engine due to the chains ripping up my guides and I found that one of the connecting rods had a very slight side to side movement where as the other had none. Is it necessary to replace it and do I replace one or both ? Your videos have made it possible for me to take on this project myself. Thanks for taking the time to do them.

[@shanesoutty]

side to side movement means either bearing failure or bearing failure to the point it has damaged the rod have a machine shop verify round on your rods

[@MrBerett315]

I'm swapping a 1000 xt into an XMR. Really wish you would make a video on that. I'm educated but nervous about that

[@shanesoutty]

I have shot the gen 2 motor addition but haven't edited it Few major differences Timing requires a tool unless you use gen 1 cams There is a hidden case bolt behind the oil gear And it has the oil cooler that has to be removed Any questions I'll help best I can until I get time to edit new video What year machine are you adding it to?

[@MrBerett315]

+shanesoutty thanks so much for the quick reply. I am switching a 2013 1000 XT motor into a 2014 XMR. I am sure that it is a piece of cake for someone who does this often but I don't know anyone with any experience. I got the 2014 for a steal and have always wanted one

[@shanesoutty]

That's an easy swap All same flywheel Same motor depending on a few options Are you rebuilding or just swapping?

[@MrBerett315]

+shanesoutty I'm swapping. Background- it was a repo. Owner stole the engine. I bought it off a dealer who didn't feel like messing with it for 2 grand. Only missing the engine, seat, side panels, and rear drive shaft. It's got an extended frame. Will my drive shaft fit (1000 xt)? I've basically just always wanted the extended frame in the first place for a passenger..

[@MrBerett315]

+shanesoutty but like I said. I know my way around mechanically but this is the most I've ever attempted coming up. Thanks for your help.

[@danielapodaca8719]

How do you make the engine run without install the starter assembly

[@luisbarrieta]

I have an 07 Outlander 800, the engine only turns about 180 degrees. Should I look into performing a full rebuild like you did in this video? Also where did you get the rebuild kit?

[@shanesoutty]

It was dry and had not been oiled in this portion of the video. Did you replace them in your assembly video?

[@josephskroch]

could you go into a little more detail to make sure the rods are not installed backwards,(4:50) and how to test that they are correct? you had mentioned that they are offset- where can you see that? thanks for the great videos saving me bukue bucks

[@shanesoutty]

Look at cylinder holes, the correct Rod offset will line rods up center of each cylinder hold

[@weflirtforfun]

nice video. but your killing me. you shoulda cleaned that engine before you reassembled it

[@MrThemodder22]

Could you do a video on rebiulding a brute force 750 motor I can't find how anywhere and I really need to know

[@krislpz90]

hey bud i have my torn apart right now and could you do one covering dissassembly of the trans and putting it back together

[@shanesoutty]

I have tried twice, its too complicated to do on video there is a specific order to assembly, its just too tough to video I need someone to come shoot the video while I do the work

[@Oliver9008]

Why are fractured rods not machinable? Are over sized bearings not available?

[@doughermansen3543]

Thanks for the reply. How come you don't do the outside as well since it's already broken down?

[@shanesoutty]

Depends what motor is for

[@juansalazar1153]

Does your timing mess up when you remove and install the fly wheel???

[@shanesoutty]

Generally not, unless you remove the rear gear. Behind the flywheel. If you took that off yes 100% it’s likely off

[@BigSnakeATV]

I have an 07 outlander 650 getting coolant in the oil. I replaced the water pump seal and new head and base gaskets. Any other ideas? Thanks!!

[@jaymoore3318]

Could you tell me how to remove the two piece main crank bearings? The ones that are in the crankcase.

[@rossmcdowell8086]

You should use a Plain Bearing Remover/Installer (P/N 529 035 917) and they're pressed in. There's also a support sleeve listed (P/N 529 036 031) but you could get away with something that was close

[@doughermansen3543]

You don't show it but did you go back and torque the flywheel bolt or do you just go impact tight?

[@shanesoutty]

I torque it But it's done after motor is installed with clutch If lock tite is used and you trust your impact it's not necessary I've never seen one loose before

[@doughermansen3543]

Shane, How did you get the inside of the casing so clean?

[@shanesoutty]

Mag wheel cleaner if it's stained but usually brake cleaner works good enough Or parts washer that's aluminum safe

[@RikterZilla]

Also, No ring compressor needed? you just finesse them in with a blade screwdriver. It looks like no room for a ring compressor anyways.

[@shanesoutty]

There isn't room I've tried a few styles Since making this video I started using a home to slightly bevel the bottom of the cylinder They slide right in

[@benjamin.25junkie57]

hey man got a 2009 can am outlander 800r efi and the seals are leaking is there a tool used to pull the front diff oil seal and front pto oil seal the ones where the shaft comes out the front to the diff and the seal in the front of the diff where the shaft goes in the front diff this is for any that reads and knows

[@RikterZilla]

To install new bearings (Crank & con rods) can I just press in new ones? Assuming no serious wear on the journals.

[@shanesoutty]

Yes if they are in tolerance

[@mikepalmer3308]

Really, blue surgical gloves but no torque wrench?

[@victorcarr6449]

Then we guess if you seen it you will not make the same mistake, even though it was planned to make sure small things like that don't happen to you.

[@doughermansen3543]

I realize your experience tells you the tension on the timing chain but are there specs or a way to measure the tension?

[@diegonunez2927]

the factory spec is 0.1nm but you can adjust it so it's a bit taut that's fine

[@MrThemodder22]

Or where I could find how

[@shanesoutty]

Use torque wrench on rods and heads, only two things that need it, torque specs are posted in part two

[@jgb998]

Do you replace the timing gears also or just the chains?

[@shanesoutty]

Just chains Tensioner if it's worn

[@shanesoutty]

Just chains Tensioner if it's worn

[@gabrielross7235]

why no pressure washing the fucking casing prior to this ..it bugs me a lot to see him do this

[@bmwtechduran]

I need to replace crank bearings.Are they pressed in?

[@shanesoutty]

If you mean the bearings on the rods the answer is no But if you mean the bearings in the cases yes and if takes a special press tool

[@bmwtechduran]

shanesoutty any way possible to send me a picture of tool? Txt me 407-867-0233

[@donataskk354]

do you know is it possible to remove drive shaft without taking out the engine?

[@shanesoutty]

Depends on how it broke Due to the usual bearing damage that comes from breaking a through shaft I recommend just removing engine and splitting it from trans I have done hundreds and if I had one break I would just take engine out The aggregation of retrieving the broken piece will make you wish you had anyway

[@donataskk354]

shanesoutty thanks for quick reply.my through shaft not broken but very slightly bended.I take out the front bearing of through shaft but can not remove through shaft.it seems like stucked. I nedd to spend some weekend and take out the engine and replace through shaft

[@shanesoutty]

If the shaft is bent You defiantly need to replace bearings on transmission side and verify seal That can only be done with motor removed Hope this helps

[@shanesoutty]

Not sure what your talking about mike

[@foxcrosss6669]

Scuse shanesoutty what a compression its good my renegade 800 he have a 200 psi

[@RaymondBelec]

How did you clean your engine case halves?

[@shanesoutty]

Brake cleaner inside case, when I remove stains on outer I use a bead blaster but it's a mess to get out of all of the holes You can also use aluminum wheel cleaner and wash off with water I did not scrub cases on this one just internals and enough to keep it out of bottom end

[@AmmDuMan]

Did you reuse the head old head gasket?

[@shanesoutty]

Sorry didn't reply sooner, no I do not generally re use them If I do I Cooper coat them

[@AmmDuMan]

Thanks.

[@THOMAS01ify]

Not one ounce of assembly lube WTF.

[@charlesnribeiro]

Hallo shanesoutty i want talk with about this motor i have renegade 500 and need change to 800 i boutht crank shaft with rods and cilinder piston too can you send your email?

[@matthewfeener1418]

So much false information is given. If you're going to follow a video, use LetDirtFly's rebuild vid. No assembly oil, the rods amd crank CAN have side play. Check the manual for axial allowances.

[@Oliver9008]

Hum that kind of sucks.

[@quadtech115]

at the time of 11:15 you can see the timing chain kinked...not good should have put a new timing chain in.