Fuel Line Replacement Guide for the 2016 Outlander MAX L570

Shop parts for a 2016 Can-Am Outlander MAX L570 ATV.

The L-series Outlander was built as an approachable, work-ready machine, and the 2016 Outlander MAX L570 backs that up with a 570cc Rotax V-twin and a two-up chassis sized for real jobs. What it does not have is a carburetor. This Outlander runs electronic fuel injection, which means an electric pump sits in the tank and the supply hose is pressurized whenever the key is on. There is no petcock to reach under and close, so the job starts with cutting power to the pump instead of turning a valve.

Getting Your Parts and Tools Together

Stage all of it before touching a fastener:

  • Nitrile or rubber gloves — gasoline absorbs through skin and strips its oils quickly
  • A drain pan plus a sealed, fuel-rated container for whatever comes out
  • Replacement hose rated for injection pressure in the original inside diameter, not soft carburetor line
  • New clamps in the correct style, and a quick-connect release tool if the pump flange uses a locking coupler
  • Line-clamping pliers, standing in for the shutoff valve this L570 does not have
  • Sockets and drivers for the seat and side panels, a razor blade, a flashlight, and clean rags

Set up the space with the same care. Gasoline vapor is heavier than air and collects on the floor, so open the overhead door fully or move the quad outdoors rather than depending on a window. Turn off heaters with standing pilots, get chargers and ground-level lights out of the area, and keep an extinguisher beside you.

Why an Older L570 Line Deserves Suspicion

Fuel hose does not wear out from mileage; it ages chemically. Heat cycling from the V-twin drives plasticizers out of the rubber wall year after year, and the hose stiffens until ordinary frame flex begins opening surface cracks. In dry regions the process runs faster because low humidity draws the remaining moisture out of the material and hardens it from the outside inward.

Ethanol in modern pump fuel attacks the other side. Alcohol pulls water vapor out of the air and degrades the liner, softening the bore while the exterior grows brittle. Fuel sitting unused across a long layup leaves gum and varnish behind as well. On a machine from 2016, that combination has had plenty of time to work, and a hose that still looks presentable may be shedding material toward the injectors.

Recognizing a Line About to Give Up

  • Gasoline pooling on the skid plate or spotting the floor beneath the tank area
  • A strong fuel smell, most obvious in the minute after shutdown while pressure lingers
  • Visible checking, a chalky cast, or a hard section that will not flex under a pinch
  • The engine bogging under load, running lean, or acting like the tank is nearly dry
  • Dust caked into a ring at a fitting, which happens where fuel seeps and dries repeatedly

On an injected machine a small pressure-side leak may evaporate before it drips, so a clean floor is not a clean bill of health. If you smell fuel, keep investigating.

Relieving Pressure and Removing the Old Hose

Take out the fuel pump fuse or relay, then crank the engine until it dies on residual fuel. That drops most of the pressure in the circuit. Switch the key off and disconnect the battery negative cable. Pull the seat and enough side bodywork to see the tank outlet and follow the hose toward the throttle body. Slide the pan underneath and drape a rag over each joint as you open it, because a bled line still carries fuel that will run down the frame.

Slide worm-gear or spring clamps well back before you disturb anything. Release a quick-connect by pressing both tabs squarely and pulling straight off along the fitting axis, never at an angle, since an aged plastic collar cracks under side load. If varnish has glued the hose to a barb, twist gently to break the bond, or split it lengthwise with a razor and peel it away instead of forcing the fitting.

Routing on a Two-Up 4x4 Frame

Study the path while the hose is still clipped in place. The MAX chassis stretches the wheelbase and lengthens the run compared with a single-seat L570, and the selectable four-wheel-drive system fills the forward frame area with differential and driveshaft hardware plus additional crossmembers that a two-wheel-drive quad simply does not carry. Extra guides and tighter pass-throughs come with that layout. Photograph each clip before the old hose comes free so you can duplicate the routing precisely and keep the new line away from driveline movement and hot exhaust.

Fitting the New Line and Checking It

Cut the replacement to the original length exactly. Too long and it chafes a frame tube or interferes with steering; too short and it loads both barbs constantly. Slide it fully onto each fitting until it bottoms out, and assemble it dry. Grease, oil, and silicone have no place here, because lubricant on a sealing surface gives pressurized fuel a channel to creep out through. Dipping the hose end in hot water for a few seconds is all the help it should need.

Locate new clamps just behind the raised bead on each barb and tighten them evenly so the hose keeps its round shape. Where a self-locking quick-connect is used, push until you hear the click, then pull firmly to confirm the latch has captured — no clamp belongs on that joint. Reseat the hose in every original retainer.

Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. Each cycle primes the pump and pressurizes the line while the area is still dry, which is exactly when a marginal connection reveals itself. Inspect both ends with a light and a white rag, then start the V-twin and check again at idle with vibration in play. Give it a few minutes before reinstalling plastics. Worth noting on this Outlander: the fuel filter lives inside the tank as part of the pump module rather than inline, so a lingering delivery problem after a clean install points there next.

Related Shopping Categories

Shop Fuel Lines for a 2016 Can-Am Outlander MAX L570 ATV.

Shop Fuel Line Clamps for a 2016 Can-Am Outlander MAX L570 ATV.

Shop Petcocks for a 2016 Can-Am Outlander MAX L570 ATV.

Shop Fuel Filters for a 2016 Can-Am Outlander MAX L570 ATV.

Shop Fuel Stabilizer for a 2016 Can-Am Outlander MAX L570 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.