Renewing the Fuel Line on a 2013 Sportsman Touring 500 H.O. 4X4

Shop parts for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 ATV.

Fuel hose is a consumable, and on a 2013 Sportsman Touring 500 H.O. the clock has been running for over a decade. This is a carbureted machine with a petcock controlling flow out of the tank, so the line runs at low pressure and the job is well within reach at home. Understanding what wore the old hose out is the best way to judge whether yours is due for replacement now.

The Way Fuel Hose Deteriorates

The wall of a fuel line stays flexible thanks to plasticizers blended into the rubber, and those compounds slowly migrate out over years of heat cycling. What remains behind is hard, glossy, and unable to absorb movement. Once a hose reaches that state, the ordinary vibration of trail riding concentrates stress at the two points where it bends, and cracks begin there rather than in the middle of a straight run.

Climate has a real effect. In dry, low-humidity country the surrounding air pulls moisture out of the rubber continuously, and hoses stiffen and craze noticeably sooner than the same part in a humid region. Ethanol-blended pump gas comes at the problem from the inside, drawing water into the fuel and slowly breaking down the inner liner, worst of all when the Sportsman sits for months with a partial tank. On a carbureted machine, the gum and shed material that results has a short trip to the float bowl and jets, so a marginal hose can cause running complaints before it ever leaks.

Petcock, Carburetor, and What That Means

Because this 500 H.O. is carbureted rather than injected, there is no fuel pump pressure to bleed off and no locking quick-connect coupler in the path. Turn the petcock to the off position and flow from the tank stops, which lets you open the hose downstream without emptying the whole supply. The carburetor float bowl carries its own drain, and opening it into a pan empties the bowl before you disturb the inlet fitting.

Both ends of the hose are plain barbs secured with clamps, so plan on new clamps as part of the parts order. A spring clip that has been on the machine since new has usually lost some tension. Keep line-clamping pliers on the bench as well, since a petcock with this many years on it may not seal perfectly and pinching the hose gives you a dependable backstop.

Signs the Line Needs Attention

  • A puddle or damp patch of fuel under the machine, often below the petcock or the carburetor
  • A gasoline odor hanging around the tank and carburetor area that does not fade
  • Fine cracks on the outside of a bend, a chalky texture, or a section that feels stiff when pinched
  • Bogging under acceleration, a lean stumble, or symptoms that mimic an almost empty tank
  • A grit-caked ring at a clamp where seeping fuel has dried and collected dust

Gravity-fed systems tend to leave visible evidence, so a wet spot after an overnight sit is strong reason to look closely at both connections rather than waiting for the problem to grow.

Access, Routing, and Preparation

The Touring model puts a passenger seat on a stretched frame, so pull the seat and side plastics for honest access instead of working through a gap. This is a 4X4 chassis as well, with front differential and driveshaft hardware occupying the area ahead of the engine, and the hose is routed around that structure through clips a two-wheel-drive quad would not have. Photograph the path and every clearance point before the old line is disturbed.

Gather gloves, eye protection, a drain pan, a sealed fuel-rated container, replacement hose in the original inside diameter, new clamps, a flat-blade screwdriver and pliers, line-clamping pliers, a razor knife, hand tools for the bodywork, and rags. Ventilation is the safety measure that matters most here, because gasoline vapor is heavier than air and pools along the floor where heaters, pilot lights, and cords sit. Work outside or with the door fully open so air moves low through the space, keep ignition sources out entirely, disconnect the battery negative cable, and seal the fuel you drain instead of leaving a pan open.

Pulling the Line Off the Spigots

Close the petcock, open the float bowl drain, and let the carburetor empty into the pan. Slide the pan under the hose run and lay a rag across the first joint you plan to open. Move each clamp well back along the hose before disturbing the fitting itself, then twist the hose gently to shear the varnish bond at the spigot rather than pulling hard on it.

If an end refuses to release, cut it lengthwise with a razor knife and peel it away. That protects both the petcock spigot and the carburetor inlet, and it costs nothing since the hose is being discarded. Keep the old line intact enough to use as a length reference for the replacement.

Installation and Verifying No Leaks

Cut the new hose to match the original exactly. Extra length loops into the frame and eventually chafes, and a line pulled tight puts constant tension on both barbs. Push each end fully onto its spigot working dry, with no grease, oil, or silicone anywhere near the fittings, since lubricant on a sealing surface is precisely what starts a slow weep. Soften a tight end in hot water if it resists. Set fresh clamps just behind the bead on each fitting, tighten them evenly without crushing the rubber, and reseat the hose in every original clip so it stays clear of the exhaust and the front driveline.

Open the petcock and watch both joints for a full minute before touching the starter, because gravity alone will reveal a poor seal. Wipe each connection with a clean rag and confirm it stays dry, then start the Sportsman Touring 500 H.O. and inspect again at idle and after a couple of throttle blips. Once several minutes pass with no seepage, reinstall the panels and seat, and glance underneath after your first short ride.

Related Shopping Categories

Shop Fuel Lines for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 ATV.

Shop Fuel Line Clamps for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 ATV.

Shop Petcocks for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 ATV.

Shop Fuel Filters for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 ATV.

Shop Fuel Stabilizer for a 2013 Polaris Sportsman Touring 500 H.O. 4X4 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.