How to Replace a Fuel Line on a 2020 Can-Am Outlander MAX 570
Shop parts for a 2020 Can-Am Outlander MAX 570 ATV.
A fuel line is cheap insurance against a long walk. On the 2020 Outlander MAX 570, the Rotax 570 V-twin is fuel injected and draws from a pump housed inside the tank, so the hose running forward to the throttle body carries pressure. There is no petcock anywhere on the machine, and that shapes the whole procedure from the first step to the last leak check.
Tools and Supplies to Stage First
- Nitrile or rubber gloves and eye protection
- Replacement hose rated for fuel-injection pressure, matched to the original inside diameter rather than approximated
- New clamps in the style your machine uses, or a quick-disconnect release tool if a locking coupler is fitted at the tank
- Line-clamping pliers, which do the job the absent petcock would have done
- A shallow catch pan plus a sealed, fuel-rated container for collected fuel
- A razor blade, a small flat-blade screwdriver, sockets for the seat and side panels, and a stack of clean rags
A Real Word About Working With Gasoline
This is not a formality. Gasoline vapor is heavier than air, so it flows down off the machine and settles into a layer across the shop floor, precisely where you will be kneeling for the next hour, and your nose adapts to it fast enough that you will stop noticing. Roll the quad outdoors when the weather cooperates, or open the shop wide so air moves at ground level rather than relying on a high window.
Shut down water heaters and furnaces with standing pilot flames before you start, keep grinders, welders, and torches out of the building entirely, skip the drop light with a hot bulb near an open fitting, and stage a fire extinguisher beside the machine rather than on a wall across the room. Get drained fuel into a sealed container and out of the work area before you begin testing.
Why Fuel Hose Reaches the End of Its Life
Two things wear the hose out. From outside, engine heat drives the plasticizers out of the rubber over years of riding, and the wall stiffens from supple to firm to brittle. Brittle rubber cannot absorb the flex a utility chassis puts through it on rough ground, so cracks form and eventually go through. Dry, low-humidity regions accelerate this, drawing moisture out of the hose wall from the outside in.
From inside, ethanol-blended pump gas is the problem. Alcohol pulls water out of the air, and fuel left sitting in the line during an inactive stretch of the season degrades the inner liner, softening it and releasing debris toward the injectors. Because that damage is invisible externally, a hose can pass a look-over and still be well past its useful service life.
Symptoms Worth Chasing Down
- Fuel puddled or smeared on the skid plate or floor after the machine has been parked
- A gasoline odor near the tank that does not clear, sharpest in the minutes after shutdown
- Surface cracking, chalkiness, or a hardened section you can feel by pinching the hose
- Dirt caked in a ring at a fitting where fuel has repeatedly seeped and dried
- The V-twin bogging under load, running lean, or acting fuel-starved with a full tank
On a pressurized system a pinhole often mists rather than drips, so absence of a puddle proves nothing. Believe a persistent fuel smell.
Pulling the Old Line Off
Start by relieving pressure. Pull the fuel pump fuse, run the engine until it starves and quits, turn the key off, then disconnect the negative battery cable so the pump stays dead. Take off the seat and enough plastic that both ends of the hose are easy to reach.
With the catch pan positioned, drape a rag over the first joint before you open it, since the hose is still full of fuel. Slide clamps well back along the hose before disturbing the fitting. On a self-locking quick-connect, press the tabs squarely and pull the coupler straight off – levering it sideways cracks the collar. Where dried varnish has cemented the hose to a barb, break the bond with a light twist, and if it will not release, slit the hose lengthwise and peel it away rather than risking damage to the fitting.
Note the path as the hose comes out. This is a selectable 4x4 chassis, and the front differential and its associated hardware route the supply line past extra clips and clearance points that a two-wheel-drive quad simply does not have. A couple of photos beforehand pay for themselves during reassembly.
Installation and Verification
Cut the new hose to match the removed piece. Extra length is not helpful; it is a section waiting to chafe on a frame tube or contact something that moves. Push each end fully onto its barb until it seats past the raised bead, working entirely dry. Keep grease, oil, and silicone away from every sealing surface, because lubricant is what allows pressurized fuel to creep out from beneath a correctly tightened clamp. Softening the hose end in hot water is the safe alternative when the fit is tight.
Set new clamps just behind the bead and snug them evenly rather than crushing them. A self-locking quick-connect takes no clamp; push until the collar clicks and pull firmly to confirm the latch caught. Seat the hose in every original clip so it stays clear of the exhaust and the front driveline.
Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking so the pump pressurizes the circuit. Inspect both joints while the area is dry, wiping each with a clean light rag and watching for staining. Then start the engine and check again at idle, since vibration exposes seals that hold under static pressure. Once several minutes of dry running have passed, reinstall the bodywork and recheck after a short ride. If delivery still feels weak, remember the filter on this injected 570 lives inside the tank with the pump and is the next thing to address.
Related Shopping Categories
Shop Fuel Lines for a 2020 Can-Am Outlander MAX 570 ATV.
Shop Fuel Line Clamps for a 2020 Can-Am Outlander MAX 570 ATV.
Shop Petcocks for a 2020 Can-Am Outlander MAX 570 ATV.
Shop Fuel Filters for a 2020 Can-Am Outlander MAX 570 ATV.
Shop Fuel Stabilizer for a 2020 Can-Am Outlander MAX 570 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.