Taking On the Fuel Line Job on a 2013 Can-Am Renegade 800R

Shop parts for a 2013 Can-Am Renegade 800R ATV.

Getting the old hose off cleanly is what most of this job actually consists of, and rushing it is what turns a simple repair into a fuel spill. On a 2013 Renegade 800R you are working on an injected Rotax V–twin, meaning the fuel pump lives inside the tank, the supply hose is pressurized any time the key is on, and there is no petcock to close before you start.

Bleeding Down Pressure and Freeing the Hose

Pull the fuel pump fuse or relay, then crank the starter for a few seconds until the engine stalls from lack of supply. Turn the key off and disconnect the battery negative cable. That order matters, because attempting to separate a fitting with pressure still in the circuit is how people end up with fuel on their forearms and across the floor.

Take off the seat and enough side plastic to see the tank outlet and trace the run to the throttle body. Slide a drain pan beneath the work area and lay a rag over the first joint you open, since a depressurized hose still holds fuel. Move any spring clip or worm–gear clamp well back along the hose before you touch the fitting itself. Quick–connect couplers require the locking tabs to be pressed squarely inward and the collar pulled straight off; prying to one side splits plastic that has been heat cycling for over a decade.

Expect varnish to have bonded the hose to its barbs. A small twist usually breaks that loose. If it does not, slit the hose lengthwise with a razor and peel it away rather than pulling hard enough to stress the fitting. Because this Renegade is a 4x4, the line passes front differential hardware and extra frame crossmembers, so photograph every clip and clearance point before the old hose is out of the chassis.

The Slow Death of a Fuel Hose

Rubber fuel line degrades whether the machine is ridden hard or parked in a shed. Plasticizers that keep the compound pliable migrate out over the years, leaving a wall that is stiff instead of flexible and unable to absorb the vibration it once shrugged off. Cracks then appear, typically right where a clamp squeezes the hose and heat from the V–twin has been concentrated.

Regional conditions change the pace. Arid air pulls moisture from the hose wall and hardens it from the outside in, which is why desert machines show that chalky surface early. Working in the other direction, ethanol–blended pump gas softens the inner liner chemically and leaves gum and varnish, particularly when a Renegade sits between seasons with stale fuel in the line. The two together explain how a hose can be brittle outside and mushy inside simultaneously.

What a Failing Line Looks and Sounds Like

  • A gasoline smell around the tank that is strongest right after shutdown while pressure remains
  • Fuel wetness or a small puddle collecting on the skid plate after the quad has been sitting
  • Fine cracking, a glassy hardened texture, or a permanent flattened groove at a clamp
  • Bogging under load or a lean stumble at higher rpm, as though the tank were nearly empty
  • Extended cranking after an overnight sit, pointing to pressure bleeding down through a weep
  • Dust caked into a damp ring at a fitting, marking a seep that has run for some time

Remember that pressurized leaks frequently atomize instead of dripping, so a strong fuel odor with no visible puddle is still worth chasing down.

Tools and a Genuinely Safe Work Area

Have gloves and eye protection, a sealed fuel–rated container, a shallow drain pan, injection–rated hose in the correct inside diameter, new clamps matched to the fittings, line–clamping pliers to substitute for the missing petcock, a quick–connect release tool if needed, a sharp hose cutter, rags, and sockets for the seat and panels all within arm's reach before you begin.

The ventilation point is worth stating plainly. Gasoline vapor is heavier than air, so it settles at floor level and travels along it, which means an open window above the bench does nothing while a furnace pilot on the far wall is a real risk. Work outdoors or with the door wide open and a fan moving air low. Shut off pilot lights, unplug chargers, and keep grinders and open flames out of the space. Gloves stay on for the duration, since gasoline strips skin oils quickly.

Installing the Replacement

Cut the new hose to match the length you removed. Extra length does not buy you anything except a hose that chafes a frame tube or interferes with steering travel. Push each end fully onto its barb until it seats against the shoulder, and do this dry. Grease, oil, and silicone have no business on a fuel fitting, because a lubricated sealing surface is exactly the channel pressurized fuel will use to escape past a clamp. A stiff hose end becomes cooperative after thirty seconds in hot water.

Set new clamps just behind the raised bead on each fitting and tighten them evenly rather than bearing down on one edge. A self–locking quick–connect gets pushed home until it clicks, then pulled firmly to confirm engagement, and takes no clamp. Return the hose to its original clips and guides so it stays away from exhaust heat and the front driveline.

Verifying the Repair

Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. Every cycle runs the pump and pressurizes the line while the area is still dry, which is the best opportunity you will have to catch a weep. Wipe both joints clean and inspect them under good light, then start the engine and watch again at idle for several minutes before refitting the bodywork.

One platform detail closes this out: the fuel filter on the injected 800R is part of the in–tank pump assembly rather than an inline element you can reach on the visible hose. Replacing the line fixes the line only, so if the engine still behaves starved afterward, the module inside the tank is where the investigation continues.

Related Shopping Categories

Shop Fuel Lines for a 2013 Can-Am Renegade 800R ATV.

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Shop Petcocks for a 2013 Can-Am Renegade 800R ATV.

Shop Fuel Filters for a 2013 Can-Am Renegade 800R ATV.

Shop Fuel Stabilizer for a 2013 Can-Am Renegade 800R ATV.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.