Fuel Line Replacement on the 2013 Can-Am Renegade 800R X XC

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

The first two minutes of this job matter more than the rest of it, because that is when you either relieve the fuel pressure or learn the hard way that it was still there. The 2013 Renegade 800R X XC uses the injected Rotax V–twin, so the pump is inside the tank, the supply hose to the throttle body is pressurized whenever the key is on, and there is no petcock to close beforehand.

Relieving Pressure and Pulling the Old Line

Remove the fuel pump fuse or relay, then crank the starter for a few seconds until the engine dies from lack of supply. Switch the key off and disconnect the battery negative cable. With the circuit bled down, take off the seat and enough side plastic that you can see the tank outlet, the middle of the run, and the throttle body connection without fighting for room.

Slide a drain pan beneath the hose and lay a rag over the first fitting you plan to separate, because a depressurized hose still holds residual fuel. Push any spring clip or worm–gear clamp well back along the hose before you touch the joint itself. Quick–connect couplers need their locking tabs pressed squarely inward and the collar pulled straight off, with no prying to one side, since a collar that has been heat cycling for over a decade will split under side load. If varnish has bonded the hose to a barb, a small twist usually breaks it free; if not, slit the hose lengthwise with a razor and peel it away rather than stressing the fitting. This is a 4x4, so the line passes front differential hardware and extra frame crossmembers, and photographing every clip and clearance point before the old hose is out will save you guesswork later.

Why the Hose Needed Replacing

Fuel line ages out rather than wearing out. Plasticizers that keep the rubber flexible slowly migrate out of the compound, and the wall stiffens until ordinary vibration produces cracks instead of flex. Heat off the V–twin drives that along, and the clamped ends crack first because they are compressed and cannot move.

Two environmental influences change the schedule. Arid climates pull moisture from the hose wall, hardening it from the outside in and leaving a chalky, finely fissured surface early. Ethanol–blended pump gas attacks the inner liner instead, softening it chemically and leaving gum behind as it stales, which is worst when the XC sits between seasons with old fuel still in the system.

Symptoms That Point to the Line

  • Gasoline odor around the tank, strongest in the minute after shutdown while pressure remains
  • Fuel wetness or a small puddle on the skid plate after the quad has been parked
  • Fine cracking, a glassy hardened feel, or a permanent flat groove where a clamp sits
  • Bogging under load, a lean stumble at higher rpm, or hesitation like a nearly empty tank
  • Longer cranking than normal after an overnight sit, meaning pressure is bleeding down
  • A dirt–caked ring at a fitting, marking a seep that has been running for some time

Pressurized leaks often atomize before they can drip, so a persistent fuel smell with nothing visible below the machine is still worth chasing.

Tools and Genuine Fuel Safety

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 in place of the absent petcock, a quick–connect release tool if needed, a sharp hose cutter, rags, and sockets for the seat and panels all laid out before you begin.

Ventilation is worth stating plainly. Gasoline vapor is heavier than air, so it settles at floor level and travels along it, which means a window above the bench does nothing while a furnace pilot across the garage is a real ignition risk. Work outdoors when the weather allows, or with the shop door fully open and a fan moving air low. Shut off pilot lights, unplug chargers, keep grinders and torches out of the space, and wear gloves throughout, since gasoline strips the natural oils from skin fast.

Installing the New Hose

Cut the replacement to the same length as the piece you removed. Extra length is not insurance; it lets the hose chafe on a frame tube or interfere with steering travel. Seat each end fully onto its barb until it stops against the shoulder, working dry from start to finish. Keep grease, oil, and silicone entirely off the fittings, because a lubricated sealing surface is exactly the channel pressurized fuel will use to creep past a clamp. Thirty seconds with a stiff hose end in hot water makes it slide on without any help.

Place new clamps just behind the raised bead on each fitting and tighten them evenly instead of bearing down on one edge. Where the tank end uses a self–locking quick–connect, push until it clicks and then pull firmly to confirm the latch caught; that joint takes no clamp by design. Return the hose to every original clip and guide so it stays clear of exhaust heat and the front driveline.

Final Checks

Reinstall the fuse, Reconnect the battery, and cycle the key on and off four or five times without cranking. Each cycle runs the pump and pressurizes the hose while the surrounding area is still dry, which is the easiest possible condition for spotting a weep. Wipe both joints with a clean rag first, then inspect under strong light and run a fingertip around each fitting.

Start the engine and repeat the inspection at idle, letting it run for several minutes so the circuit sees sustained pressure and some heat soak. Only once both connections stay completely dry should the plastics and seat go back on. One closing platform note: the fuel filter on this injected XC is integrated with the in–tank pump module rather than sitting inline where you can service it, so if the engine still behaves fuel starved after a clean hose install, the module inside the tank is the next place to look.

Related Shopping Categories

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

Shop Fuel Line Clamps for a 2013 Can-Am Renegade 800R X XC ATV.

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

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

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