Your Can Am Outlander tears through mud, climbs rocky trails, and conquers terrain that would break lesser machines. But every adventure leaves its mark—scratched fenders, cracked panels, and battle scars that tell stories but compromise protection. A plastics kit breathes new life into your ATV while delivering enhanced coverage against the elements that made those scars in the first place.
Understanding Can Am Outlander Plastics Kits
What’s Included in a Plastics Kit
A Can Am Outlander plastics kit typically encompasses the exterior body components that shield your ATV’s internals from mud, debris, and impact damage. These kits range from targeted fender flare extensions to comprehensive full-body panel replacements that transform your machine’s appearance and functionality.
Fender flare kits specifically include front and rear extensions designed to provide 6.5 to 7.5 cm of additional coverage on each side of your ATV. Complete body kits cover more ground—back wings, front wings, front panels, side panels, tank covers, and model-specific additional components. The Kimpex Overfender Set for Can Am Outlander models, priced around €172 (approximately $185 USD), comes with all four fender extensions plus mounting hardware.
OEM vs Aftermarket: The Material Difference
Original Equipment Manufacturer (OEM) parts come directly from Can-Am/BRP and match your factory specifications precisely. These injected plastic components deliver robust protection with guaranteed fit across Outlander 500, 570, 650, 800, 850, and 1000 models. OEM fender flares retail around $410 CAD for complete sets.
Aftermarket alternatives from manufacturers like Maier and Kimpex offer cost savings of 20-50% compared to OEM equivalents while maintaining compatibility across multiple model years. These third-party options use durable polyethylene construction that mimics factory durability at accessible price points. The trade-off? Some aftermarket parts require minor fitment adjustments, whereas OEM components drop in with zero modification.
Why Upgrade Your Outlander’s Plastics
Protection That Pays Dividends
Mud riders know the punishment—roosted debris, submerged logs, and relentless muck that finds every gap in your machine’s armor. Extended fender coverage acts like a shield wall, deflecting mud and flying rocks before they reach riders, engine components, or sensitive electronics. The XMR models come factory-equipped with mudguards and fender flare extensions precisely because that extra inch of protection prevents thousands in damage.
The rear mud flaps included in many kits serve double duty—they stop trail debris while protecting against rock strikes and stump impacts that crack standard bodywork. Think of them as insurance policies that cost hundreds instead of thousands.
Aesthetics Meet Function
Cracked plastics don’t just look rough—they compromise structural integrity and reduce resale value. A fresh plastics kit restores that showroom appearance while maintaining the OEM look that keeps your Outlander looking purposeful rather than pieced-together. Textured flat black finishes resist UV fading better than smooth plastics, extending the lifespan of your investment.
For riders who’ve upgraded to larger tires or spacers, fender flares provide necessary coverage that stock plastics can’t deliver. That extra clearance prevents tire rub while keeping mud spray controlled—functionality wrapped in form.
| Benefit | Impact | Models Affected |
|---|---|---|
| Enhanced mud protection | 6.5-7.5 cm additional coverage per side | All Outlander 500-1000 series |
| Reduced rider spray | Mud deflection protects rider and passenger | Standard and MAX configurations |
| Damage prevention | Shields engine and electronics from debris | All trail and mud models |
| Aesthetic restoration | Eliminates cracks and UV fading | 2012-2026 model years |
| Tire clearance | Accommodates larger tire upgrades | Modified Outlanders with 30″+ tires |
Installation: Simpler Than You Think
Tools and Preparation
Before diving in, gather your essentials: 13mm socket and wrench, 10mm socket, T30 Torx bit (or impact-rated equivalent), and an M5 drill bit for creating mounting points. The entire installation typically takes 45-90 minutes depending on whether you’re adding flares or replacing full body panels.
Step-by-Step Fender Flare Installation
1. Preparation Phase
Shift your Outlander into park, kill the ignition, and remove the key. If your model has an XU bumper, you’ll need that 13mm socket to remove it temporarily—standard bumpers stay in place.
2. Assembly
Many kits ship with split front and rear sections that require joining with included self-tapping screws before mounting. Pre-assemble these components on a clean workspace to avoid field adjustments.
3. Test Fitting and Drilling
Position each fender flare against the vehicle body, verifying alignment before committing to holes. Use the M5 drill bit to create mounting points that correspond to the pre-drilled holes in the flares. Pro tip from the field: drill and fasten just two holes initially to confirm alignment before completing the remaining mounting points.
4. Securing Components
Work from inside the fender cavity, driving screws from the interior into the pre-drilled body holes. This interior mounting approach keeps hardware hidden while providing solid retention that won’t shake loose on rough trails.
5. Rear Mudguard Attachment
Align rear mudguards with the installed flares, temporarily securing with self-tapping screws before final drilling and reinforcement with screws and nuts for permanent installation.
What Installation Teaches You About Your Machine
Removing body panels reveals the engineering beneath—coolant reservoirs, electrical routing, and frame structure that most riders never see. This familiarity pays off during maintenance, turning you from owner to informed operator who spots potential issues before they become trailside emergencies.
Choosing the Right Kit for Your Riding Style
Trail Riders vs Mud Enthusiasts
Recreational trail riders on 500-700 series Outlanders benefit most from basic four-piece fender flare sets that provide coverage without excessive weight. These riders encounter occasional mud but prioritize maneuverability over maximum protection.
Mud-dedicated machines like the XMR variants demand comprehensive coverage—think complete fender kits with integrated mudguards that handle 30-inch XPS Swamp King tires throwing rooster tails. These setups include relocated bumpers and mud-specific rear racks that work in concert with extended plastics.
Brand Considerations
Maier Manufacturing produces aftermarket fender kits ranging from $435-$436 for premium applications, emphasizing fitment precision and durability. Their textured black finish resists scratching better than smooth alternatives while maintaining professional appearance.
Kimpex positions itself in the value segment with Canadian-made polyethylene kits backed by 1-year limited warranties against breakage. This warranty coverage matters when trail obstacles exceed expectations.
OEM Can-Am/BRP parts guarantee perfect fitment across all model years but command premium pricing. These factory components shine when resale value matters or when insurance claims require original equipment specifications.
Cost Analysis: Investment vs Return
Upfront Pricing Breakdown
Fender flare kits occupy the $170-$410 range depending on manufacturer and model compatibility. The Maier fender flare set for Outlander 500/650/800R/1000 models retails at $410 CAD through authorized dealers, while Kimpex alternatives land around €142.15 (approximately $153 USD) before taxes.
Complete OEM body panel replacements vary wildly based on components needed—individual fenders start around $64 for console supports, while full-side panels exceed $200 per side. Budgeting $600-$1,200 for comprehensive factory replacement proves realistic for models with significant damage.
Long-Term Value Proposition
OEM components demonstrate 1.5-2x longer service life than budget aftermarket alternatives in controlled testing. This longevity translates to fewer replacements, reduced installation labor, and consistent performance throughout ownership. The higher initial cost often proves more economical over the full ownership period when factoring replacement frequency and fitment complications.
Aftermarket premium brands like Maier split the difference—offering 80-90% of OEM durability at 60-70% of factory pricing. For riders who replace machines every 3-5 years, these options deliver adequate protection without premium outlay.
Common Pitfalls and How to Avoid Them
Fitment Frustrations
Universal fit components designed for multiple brands often require modification for proper installation. Verify that advertised kits specify your exact year and model—a kit for 2012-2018 Outlanders won’t necessarily fit 2023+ models without adjustments.
Material Quality Misconceptions
Not all plastics perform equally. Budget aftermarket panels use thinner material with fewer structural ribs than OEM equivalents, making them more susceptible to impact damage. When comparing options, examine wall thickness and reinforcement structure rather than just surface appearance.
Installation Shortcuts That Create Problems
Skipping the test-fit stage before drilling leads to misaligned holes that stress mounting points. Those stressed connections crack under trail vibration, turning a permanent fix into temporary patchwork. Always dry-fit, mark carefully, and drill conservatively—you can enlarge holes but can’t un-drill them.
Maintenance: Keeping Your Investment Fresh
Cleaning and Protection
XPS Multi-Surface Cleaner cuts through trail grime on plastics without degrading polyethylene or painted surfaces. Regular cleaning prevents abrasive dirt from grinding micro-scratches that dull finish and weaken material over time.
UV protectants specifically formulated for ATV plastics combat sun damage that fades black components to chalky gray. Apply these treatments after every 3-4 rides or monthly during storage to maintain that factory-fresh appearance.
Inspection Points
Check mounting hardware quarterly—trail vibration loosens fasteners that seemed tight during installation. Plastic threads strip easier than metal, so verify that bolts remain snug without over-torquing. Examine crack-prone areas like fender edges and panel seams after particularly aggressive rides, catching small damage before it propagates.
Key Takeaways
- Can Am Outlander plastics kits range from targeted fender flare extensions ($170-$410) to comprehensive body panel replacements, providing enhanced mud protection and aesthetic restoration
- OEM parts guarantee perfect fitment and typically last 1.5-2x longer than budget alternatives, while premium aftermarket brands like Maier and Kimpex offer 20-50% cost savings with comparable durability
- Installation requires basic tools (13mm socket, T30 Torx bit, M5 drill bit) and takes 45-90 minutes, with proper test-fitting critical to avoiding alignment issues
- Fender flares provide 6.5-7.5 cm additional coverage per side, crucial for riders running larger tires or tackling mud-heavy terrain where debris protection prevents costly component damage
- Material quality matters more than price—examine wall thickness and reinforcement structure rather than surface appearance when choosing between manufacturers
Frequently Asked Questions (FAQ)
What size tires require fender flare upgrades on Can Am Outlanders?
Stock fenders accommodate factory tire sizes up to approximately 27 inches without clearance issues. When upgrading to 28-30 inch tires or adding wheel spacers, fender flare kits become necessary to prevent tire rub and contain mud spray effectively. The additional 6.5-7.5 cm coverage provided by quality flare kits ensures adequate clearance for aggressive tread patterns.
Can I install plastics kits without removing the front bumper?
Installation depends on your bumper configuration—standard factory bumpers typically remain in place during fender flare installation. However, upgraded XU bumpers require temporary removal using a 13mm socket to access mounting points on the front fenders. The entire bumper removal and reinstallation process adds roughly 15-20 minutes to total installation time.
How do Maier fender flares compare to OEM Can-Am parts?
Maier fender flares retail at approximately $410 CAD, matching OEM pricing while offering aftermarket availability advantages. These textured black polyethylene components include mounting hardware and maintain the factory appearance that many riders prefer over universal-fit alternatives. Customer feedback indicates comparable durability to OEM with occasional minor fitment adjustments required.
What’s the warranty coverage on aftermarket plastics kits?
Kimpex plastics kits include an industry-leading 1-year limited warranty against breakage, covering manufacturing defects and material failures. This warranty excludes normal wear, UV fading, and impact damage from trail obstacles—standard limitations across the aftermarket parts industry. OEM Can-Am parts typically carry the standard 1-year BRP Limited Warranty that covers the entire vehicle.
Will fender flares affect my Outlander’s resale value?
Quality OEM or premium aftermarket flares installed correctly typically enhance resale value by demonstrating proactive maintenance and damage prevention. Buyers perceive well-maintained plastics as indicators of overall care, while cracked or faded body panels suggest neglect that may extend to mechanical components. Retain original parts if possible—offering buyers the option between extended coverage and stock configuration maximizes appeal.
Do plastics kits fit both standard and MAX Outlander models?
Many manufacturers produce model-specific kits designated for standard Outlanders versus MAX extended-wheelbase variants. The Kimpex Overfender Set, for example, offers separate part numbers for Outlander and Outlander MAX configurations across the 500-1000 series. Always verify that product listings explicitly mention your specific model configuration before purchasing to avoid costly fitment issues.
Can I use 2012-2018 plastics on newer 2023+ Outlander models?
Body panel compatibility typically spans generation-specific model years rather than the entire Outlander lineup. The 2012-2018 G2 Outlander generation shares component compatibility, while 2023+ models may feature revised mounting points that prevent direct fitment of older parts. Consult manufacturer fitment guides or dealer parts diagrams to confirm compatibility before ordering components for model year transitions.
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