HOW-TO REPLACE CAN-AM BODYWORK

— Oops, we scuffed up our Maverick Trail —

Accidents happen, and any machine can be scarred when driven in challenging terrain. Here’s how to replace the colored body parts that are most in harm’s way on Can-Am’s Maverick Trail and Maverick Sport.

A tip-over left our Maverick Trail 1000 DPS with a scuffed and cracked hood piece, door skin, air-filter cover and some scuffed black plastic. We freshened the machine’s looks with new painted parts and cleaned the still usable larger black pieces. Bodywork on Can-Am Trail and Sport UTVs comes without decals, so be sure to order the decals you need for the body pieces you want to replace.
Minor cosmetic damage may be repairable, but replacing parts with cracks and finish damage is more cost-effective unless you have the skills and equipment to the finish work. The painted hood piece is $335. The painted door skin is $130. The painted air filter cover panel is $125. The Maverick Trail and 1000 decals were $13 each. Body pieces on base models with colored, unpainted plastic are far less expensive and can be a cost-saving way to refresh an entire machine. The unpainted hood piece is $50. The unpainted door skin is $85. The unpainted air filter cover panel is $13.
The Maverick Trail’s toolkit comes with a T30 Torx wrench that fits most of the screws that hold the hood piece on, but you’ll also need a 1/4-inch-drive ratchet handle and a T30 Torx bit for the hard-to-reach screw under the corner of the hood near the headlight housing and a T20 bit for the screws on the door skins and air filter cover. Harbor Freight is a great source for affordable, quality tools.
To remove the painted hood piece, first remove the black snap-on center hood. Then remove the three screws on the painted hood piece and the screws on the black front fascia. You don’t need to remove the front fascia completely. Removing its screws lets you lift and flex the hood piece to get at the hard-to-reach T30 screw under the hood by the headlight housing. Note the type and position of the washers on the screws for the painted hood piece and the spring clip that retains the black center hood piece. We reused the spring clip from our damaged hood piece. The screw closest to the front of the vehicle has no washer, the middle screw has a round steel washer and the screw closest to the windshield has a square plastic washer.
To remove the painted panel on the air filter cover, first remove the air filter cover from the machine by undoing the two quarter-turn fasteners that hold it on. No tools are needed. The painted panel on the air filter cover is held on from the inside with a T20 screw and three tabs. Remove the screw and separate the pieces to remove the painted panel. Installation is the reverse order of disassembly.
Here’s a look at the inside of the painted hood piece showing the tab with the screw clip in place. We were able to reuse the screw clip from our damaged hood piece.
The door skin is held from the inside by three T20 screws and three tabs that engage with the slots at the top of the door. The door is shown here with the door skin removed to show the location of the slots. To remove the door skin, first remove the screws, grip the door skin and pull it towards the front of the vehicle to disengage the tabs. Install the door skin by engaging the tabs on the door skin with the slots on the door, pulling the door skin towards the rear of the vehicle and reinstalling the screws.
Here’s our Maverick Trail wearing its new painted bodywork. Cleaning with soap and water and some Maxima SC1 spray got the scuffed black plastic looking good again. Refer to photos of your machine in UTV Action or on www.utvactionmag.com to place the decals correctly. To position them just right, it’s usually best to place the decals after you’ve put the body parts on the machine.

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