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New owner, 2005 outlander 400 beat to hell. Lives to ride another day

1485 Views 31 Replies 6 Participants Last post by  CanAmRancher1
So new guy here.. never owned a can am or bombardier. I came from having a 2006 arctic cat 400 trv and my sons 2017 alterra 90.. btw Great little bike for kids Super reliable. Anyways, so I love fixing up stuff and word gets out so I had a friend recommended me to repair some mowers and a atv for a lady. So she brings the stuff by and says let her know what can be fixed if not scrap it.

So I end up fixing a mower and the other one is junk and not worth fixing. So I take a look and the atv is in rough shape, been sitting for years and was beat to hell. No key, tires are flat looks bad and honestly I didn't have any hope for it. I look a little at it and looks like rats got to part of the harness and I was like this thing is junk, so It sits for about 6 Months at my house and didn't touch it.

So i was bored one day I decided what the hell let me see what's up with this thing. I pull it into the garage and start going over it. At this point I don't have a key and I need to be able to power it up to do anything. So I decide to cut the ignition cylinder in half so I can be able to turn it with a screw driver instead of hot wiring it. So I get that done hook up a jumper box and boom now we have power and it turns over and sounds like it has compression. So I know I need to check a few things before I try and fire it up. Oil is good, so I check for spark.. got spark so I decided to remove the air box and spray some starter fluid in it to see if it goes boom..

Got it to fire off and sputter so I knew it was worthy of a carb clean. So I bust out the ultra sonic cleaner and give the carb a good cleaning. So slap the carb back on and hook up an auxiliary fuel source and try and start it up. We'll I'll be damned it started up and ran good.

So I decided to keep going and see what all it needs. Get a parts list together and its huge. So I let the lady know and its just too much for her to pay me to fix it so I end up getting the bike for free. 2 months into fixing it up and it's running good and already had it out riding a few times with friends.. never skipped a beat and runs perfect. Super surprised to be honest from how bad of shape it was in. So I will ride it for a bit then ended up giving it to my older son. Gonna get me a 2023 outlander XMR1000 or a side by side. Haven't decided yet, but this bike got me into the whole can am thing. It's a though machine and it surprised me. Here's a pics of the rebuild.. first to last. Enjoy
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2005 Outlander 330 HO Upgraded To A 400
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I feel your pain. I recently acquired a 2005 Outlander that had a horribly bent frame and a ton of neglect. What started out as a simple frame swap became a late evening and weekend gobbling up monster. Being a mechanic with OCD about perfection didn't help either.
But as you say, they are tough and can be easily brought back to a dependable machine.

Good job and enjoy!
 

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Discussion Starter · #22 ·
How did cam chain tensioner look? How many threads out?

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You know I totally forgot to look at that when I had the valve cover off. But I dont think it was much, I did look at the guide and it didn't look worn much from what I could see. I have seen real worn ones on here. But Mine didn't look bad at all. I'm gonna check again because I have adjust the valves anyways. I should have done that when I had the cover off but I was messing with alot of other things. I really don't think this bike has that many hours/miles. I think it sat alot and when they did ride it they beat it and just parked it when they were done.
 

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Discussion Starter · #24 ·
I feel your pain. I recently acquired a 2005 Outlander that had a horribly bent frame and a ton of neglect. What started out as a simple frame swap became a late evening and weekend gobbling up monster. Being a mechanic with OCD about perfection didn't help either.
But as you say, they are tough and can be easily brought back to a dependable machine.

Good job and enjoy!
Thanks, yeah man I'm bad like that too. It has to be right or it bothers me. How that bike turn out ? Working good now ? I like doing this stuff I learn alot.
 

· Regular Joe
2014 Maverick 1000r
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8,222 Posts
I have no words...... really really good stuff

really really

I almost caught a feeling of deja vu, but I didn't have to deal with half the stuff you have. Thanks for sharing! (y)


Justincase ya wanna scroll through mine ^
 
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Discussion Starter · #27 ·
I have no words...... really really good stuff

really really

I almost caught a feeling of deja vu, but I didn't have to deal with half the stuff you have. Thanks for sharing! (y)


Justincase ya wanna scroll through mine ^
Hey thanks I appreciate that. I like sharing things. It might help someone out in some way. Alot of these threads helped me along the process. Learned alot surfing the forums for information. Gonna definitely check out your post. I'm always on YouTube watching will it start vids or rebuilds. I love this stuff
 

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Discussion Starter · #28 ·
I have no words...... really really good stuff

really really

I almost caught a feeling of deja vu, but I didn't have to deal with half the stuff you have. Thanks for sharing! (y)


Justincase ya wanna scroll through mine ^
Hey checked out your build and love it man. Funny how rats got into mine aswell lol chewed up part of the harness and lived in the belt box. I just repaired the harness, works fine. But those wheels you got, can you use them without spacers ? I would like to upgrade mine aswell. Not trying to go big tires though cause then I gotta to clutch work.
 

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· Regular Joe
2014 Maverick 1000r
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8,222 Posts
But those wheels you got, can you use them without spacers ?
The rears wouldn't have been any problem, there's plenty of room back there, the fronts probably not as well, depending on what size tire you went with. If you're just looking to stick to around the stock size, the tie rod end would come into play for width sake up front, that'd be the limiting factor for front width.
 
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Discussion Starter · #30 ·
The rears wouldn't have been any problem, there's plenty of room back there, the fronts probably not as well, depending on what size tire you went with. If you're just looking to stick to around the stock size, the tie rod end would come into play for width sake up front, that'd be the limiting factor for front width.
Ok cool man thanks.
 

· Super Moderator
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I checked those threads. 9 threads .. time for a timing chain and guides !
Yep unfortunately those original chains and guides were junk.

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