Fuel Line Replacement on a 2015 Can-Am Renegade 800R

Shop parts for a 2015 Can-Am Renegade 800R ATV.

Half the difficulty in this job is simply reaching everything. On a 2015 Renegade 800R the supply hose runs from the tank outlet, along a guided path on the frame, and forward to the throttle body, and how easily you get at it determines whether this takes thirty minutes or two hours. Confirm the system before you start: this is an injected Rotax V–twin, the pump is inside the tank, the hose holds pressure with the key on, and there is no petcock to close.

Opening Up Access to the Run

Take the seat off and remove enough side plastic that you can see the tank outlet, the middle of the run, and the throttle body connection without contorting. Trying to work through a single small gap is where hoses get damaged and clamps get dropped into the frame. Being a 4x4, this Renegade routes the line past front differential hardware and a couple of frame crossmembers a two–wheel–drive quad does not have, so at least one clip will sit in awkward quarters and there is geneRally a clearance point where the hose has to pass on a specific side of a bracket to stay away from exhaust heat.

Photograph every clip, guide, and pass–through before anything comes apart. Reproducing the factory path is not about neatness; a hose that takes a shortcut will chafe on a frame tube or rest against something hot, and you will be doing this job again far sooner than planned.

How Fuel Hose Reaches the End of Its Life

Aging does most of the damage. The plasticizers that keep fuel hose flexible slowly migrate out of the rubber, and the wall progresses from soft to stiff to brittle until it can no longer flex without cracking. Heat cycling off the V–twin accelerates that, and the vibration a Renegade absorbs over rough terrain focuses the stress at the clamped ends.

Environment sets the pace. In arid climates the hose wall loses moisture and hardens from the outside in, producing a chalky, finely cracked surface years early. Ethanol–blended fuel attacks the inner liner instead, softening it and leaving gum behind, which is most pronounced when the machine sits between seasons with old gasoline in the system. Because neither process is visible from a distance, hose age alone is a legitimate reason to replace.

The Signs to Watch For

  • 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 after an overnight sit, indicating pressure is bleeding down through a weep
  • Caked dirt forming a ring at a fitting where fuel has been seeping and evaporating

On a pressurized circuit, small leaks often atomize before they can drip, so a fuel smell with no wet spot underneath is not a false alarm.

Tools, Supplies, and Ventilation

Collect 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 serve in place of the absent petcock, a quick–connect release tool if the tank outlet uses a locking coupler, a sharp hose cutter, rags, and the sockets needed for the seat and panels.

Take the fuel handling seriously. Gasoline vapor is heavier than air, settling at floor level and drifting outward, which is why it can reach a furnace pilot or an arcing battery charger on the far side of a garage. Work outside if the weather cooperates, or with the door fully open and a fan sweeping air low across the floor. Shut off pilot lights, unplug chargers, put away grinders and torches, and keep gloves on the entire time, because gasoline strips skin oils rapidly.

Removal and Installation

Depressurize the circuit first: pull the fuel pump fuse or relay, crank the starter until the engine stalls, switch the key off, and disconnect the battery negative cable. Slide the drain pan into position and lay a rag over the joint you separate first, because a depressurized hose still holds fuel that has to go somewhere.

Walk worm or spring clamps well back along the hose before touching a fitting. For a quick–connect coupler, press the locking tabs squarely and pull the collar straight off with no sideways leverage. If varnish has bonded the hose to a barb, twist gently to break it loose, or slit the hose lengthwise with a razor and peel it away instead of pulling hard enough to damage the fitting.

Cut the replacement to the same length as the original, then push each end fully onto its barb until it bottoms out, working dry throughout. Keep grease, oil, and silicone off the fittings entirely, since a lubricated sealing surface is exactly how pressurized fuel escapes past a clamp. Warm a stiff hose end in hot water for thirty seconds if it resists. Position new clamps just behind the raised bead on each fitting and tighten them evenly, and where a self–locking quick–connect is used, push until it clicks and tug to confirm engagement, leaving that joint unclamped as designed. Reseat the hose in every original clip using the photos you took.

Testing the Repair

Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. Each cycle pressurizes the line while the area is still dry, giving you the clearest possible look at both joints. Wipe them with a clean rag and inspect under good light, then start the engine and check again at idle for several minutes before the bodywork goes back on.

Finally, keep in mind that the fuel filter on this injected 800R is part of the in–tank pump module rather than an inline element on the visible hose. A new line addresses the hose alone, so if the engine still acts fuel starved after a clean install, the next place to look is inside the tank.

Related Shopping Categories

Shop Fuel Lines for a 2015 Can-Am Renegade 800R ATV.

Shop Fuel Line Clamps for a 2015 Can-Am Renegade 800R ATV.

Shop Petcocks for a 2015 Can-Am Renegade 800R ATV.

Shop Fuel Filters for a 2015 Can-Am Renegade 800R ATV.

Shop Fuel Stabilizer for a 2015 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.