Fuel Hose Service on a 2021 Can-Am Outlander MAX 570

Shop parts for a 2021 Can-Am Outlander MAX 570 ATV.

Ethanol is the reason this maintenance item exists at all. The 2021 Outlander MAX 570 runs a fuel-injected Rotax 570 V-twin with the pump and filter both mounted inside the tank, which means the supply hose sees pressurized, ethanol-blended fuel every time the machine is used and sees that same fuel sitting still every time it is not. Both conditions take a toll on rubber.

What Modern Pump Gas Does to Rubber

Alcohol in blended gasoline is hygroscopic, meaning it pulls moisture out of the surrounding air and holds it in suspension. When fuel sits in the line for weeks between rides, that water-laden mixture works on the inner liner of the hose, softening it and gradually releasing fine material into the fuel stream heading toward the injectors. None of that is visible from outside the hose, which is what makes it dangerous to judge a fuel line by appearance alone.

The outer wall degrades along a separate path. Heat cycling from the V-twin drives out the plasticizers that keep rubber pliable, so the hose goes from soft to firm to genuinely brittle over the years. Once brittle, ordinary chassis flex across rocks and ruts opens fine cracks in the surface. Owners in dry, arid regions watch this arrive earlier, because low ambient humidity draws moisture from the hose wall and speeds the hardening.

Reading the Warning Signs

  • A wet film or small puddle beneath the tank area after the machine has been parked
  • A gasoline smell that lingers around the quad, strongest right after shutdown while the line still holds pressure
  • Fine cracking that opens when you flex the hose, a chalky grey cast, or a section that pinches hard
  • Dirt caked into a ring at either fitting, the residue of fuel seeping and drying repeatedly
  • The V-twin bogging under load, stumbling lean, or acting starved for fuel with a full tank

Since this is a pressurized system, a pinhole frequently atomizes fuel into vapor that evaporates before it can drip. A persistent smell over a clean floor is still a leak.

Setting Up and Staying Safe

Gather gloves and eye protection, injection-rated hose in the original inside diameter, new clamps of the correct style or a quick-connect release tool, line-clamping pliers to substitute for the petcock this machine does not have, a catch pan, a sealed fuel-rated container, a razor blade, hand tools for the seat and side panels, and rags.

Then handle the space. Gasoline vapor is heavier than air and settles into a layer across the floor rather than rising away, and your nose stops registering it after a few minutes of exposure. Work outside if the weather permits, or open the shop enough that air moves at ground level instead of relying on a high window. Shut off water heaters and furnaces with standing pilots, keep grinders and torches out of the building, and put a fire extinguisher next to the machine rather than across the shop.

Depressurizing and Removing the Line

With no fuel valve on this Outlander, shutting off flow is electrical. Pull the fuel pump fuse, run the engine until it stalls from starvation, turn the key off, and disconnect the battery negative cable so the pump cannot cycle while you work. Remove the seat and side plastics so both hose ends are genuinely accessible.

Slide the catch pan under the area and lay a rag over the first fitting you open, because the hose remains full of liquid fuel after pressure is gone. Push clamps well back along the hose before disturbing a joint. On a self-locking quick-connect, compress the tabs evenly and draw the coupler straight off; angled prying cracks a collar that has hardened in sun and mud. Where varnish has bonded hose to barb, break it with a gentle twist, then slit the hose lengthwise and peel it off if it still holds.

Record the routing before the line is fully out. The MAX 570 is a selectable 4x4, and the front differential and its hardware route the supply hose past additional clips and clearance points that a two-wheel-drive quad does not need.

Fitting the New Hose

Cut the replacement to the same length as the original. Excess hose does not buy you anything but a section that chafes on the frame or interferes with steering. Push each end fully onto its barb until it seats past the raised bead, and assemble everything dry. Grease, oil, and silicone spray on a sealing surface are exactly what allows pressurized fuel to creep out from under a clamp, so keep lubricant away from the fittings entirely. Twenty seconds in hot water will soften a stubborn hose end.

Position new clamps just behind the bead and tighten them evenly, snug enough to seal without cutting into the rubber. A self-locking quick-connect requires no clamp; push it until the collar clicks and pull firmly to confirm the latch engaged. Route the finished hose through every original guide so it stays away from exhaust heat and clear of the front driveline.

The Final Leak Check

Reinstall the pump 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 line, giving you a clean look at both joints while everything is still dry. Wipe each fitting with a light-colored rag and inspect for staining, which appears well before an actual drip forms.

Start the V-twin and check again at idle, because vibration reveals seals that pass a static pressure test and weep under running conditions. Allow several minutes of clean idle before the bodywork goes back on, then look once more after a short ride with the machine warm.

Keep one platform detail in mind afterward. On this injected 570 the fuel filter is integrated into the in-tank pump module rather than sitting inline where you can reach it, so a fresh hose cures leaks and cracked rubber but does nothing for a restriction upstream. If delivery still feels soft under load, that assembly inside the tank is where the next step leads.

Related Shopping Categories

Shop Fuel Lines for a 2021 Can-Am Outlander MAX 570 ATV.

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Shop Petcocks for a 2021 Can-Am Outlander MAX 570 ATV.

Shop Fuel Filters for a 2021 Can-Am Outlander MAX 570 ATV.

Shop Fuel Stabilizer for a 2021 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.