Getting a Fresh Fuel Line onto a 2014 Polaris Sportsman 570

Shop parts for a 2014 Polaris Sportsman 570 ATV.

The 2014 Sportsman 570 introduced the ProStar 567 single to the utility lineup, and like every machine in that family it arrived with electronic fuel injection rather than a carburetor. That detail governs the entire replacement procedure. There is no petcock lever anywhere on this quad, fuel does not feed by gravity, and the hose you are opening is part of a pressurized circuit supplied by a pump submerged in the tank. Order the steps correctly and this is a calm hour of work on a 4x4 chassis you know well.

Start by Taking the Pressure Out

Nothing gets disconnected until the circuit is dead. Pull the fuel pump fuse or its relay, then crank the engine for a few seconds until it stumbles and quits on its own residual supply. Switch the key off and disconnect the battery negative cable so the pump cannot be energized by accident. Only then does the seat come off and the side plastics come away to expose the tank flange and the hose run climbing toward the throttle body.

Even with pressure relieved, the hose still holds standing fuel. Slide a shallow pan underneath and lay a rag across the first joint before you open it, and keep an approved sealed container nearby for whatever you capture.

Working the Old Hose Free

Move any clamp well back along the hose before disturbing the connection itself. Worm gear and spring clamps both slide readily once loosened. If instead you find a self-locking quick-connect coupler, squeeze the release tabs evenly and draw it straight off the nipple — lateral prying is what cracks collars that have grown brittle over a decade of heat cycles.

Varnish frequently cements aged hose to a metal barb. Break that bond with a gentle quarter turn twist rather than pulling hard. If the hose still refuses to release, slit it lengthwise with a razor knife and peel it off in two halves; sacrificing a hose you are throwing away is far better than deforming a fitting you are not. Photograph the routing before the old piece is completely out. This 570 is a 4x4 machine, so the front differential and driveline hardware push the hose along a longer path with more clearance points and retaining clips than a two wheel drive layout would need.

Ventilation and Gasoline Sense

Gasoline vapor is heavier than air. It settles onto the floor and flows outward at that level, which puts it in company with water heater pilots, shop heaters, and power tool sparks. Work outside when you can, or open the overhead door fully and put a fan low to the ground pushing air out. Keep a fire extinguisher within arm's reach rather than across the shop, and wear nitrile gloves start to finish, because pump fuel pulls the oils out of skin on contact and carries its additives straight through.

Understanding Why the Hose Aged Out

Fuel line degrades on two fronts simultaneously. On the outside, the plasticizers that keep the compound soft migrate out under repeated engine heat and constant vibration. The hose turns stiff, and once stiff it can no longer absorb chassis flex, so hairline cracks open and creep inward. Dry climates hasten this because low humidity draws residual moisture out of the hose wall.

On the inside, ethanol-blended pump gas is the aggressor. E10 absorbs atmospheric water and, when it sits motionless through an off season, attacks the liner while leaving gum and varnish at the barb joints. The two processes are independent, which is why a hose can look and feel acceptable while its liner is already shedding particulate toward the injector. On a machine of this vintage, years in service justify replacement on their own.

Recognizing a Hose That Is Ready to Quit

  • Gasoline odor hanging around the tank, most noticeable in the first minutes after shutdown while pressure remains trapped
  • A stain, damp patch, or genuine puddle under the machine after it has sat overnight
  • Fine surface checking, a chalky gray cast, or a stretch that feels hard when pinched between your fingers
  • A crusted ring of dust at either fitting, the residue of seepage that has dried repeatedly
  • Bogging under load, a lean stumble on acceleration, or behavior that mimics an almost empty tank

Remember that pressurized fuel escaping a pinhole often atomizes and evaporates before anything drips, so a clean floor is not a clean bill of health on an injected 570.

Installing the Replacement the Right Way

Buy hose rated for fuel-injection pressure in the original inside diameter, not general purpose carburetor line, which will balloon and weep at the barbs on this system. Cut it to the same length as the piece you removed; surplus hose sags into moving parts or chafes on a frame edge until it wears through.

Push each end fully onto its barb, dry. Grease, oil, and silicone spray have no business on a fuel fitting, because a lubricated sealing surface gives pressurized fuel a route to migrate out from under the clamp. When a hose end resists, dip it in hot water for ten or fifteen seconds and it will slide on without help. Set fresh clamps just inboard of the raised bead so they cannot walk off, and tighten evenly instead of hard. Quick-connect couplers take no clamp at all: push until the collar clicks, then tug firmly to confirm the latch caught. Return the hose to every original clip before you call it done.

Leak Check, Then Reassembly

Reinstall the pump fuse, Reconnect the battery, and cycle the key on and off four or five times without cranking. Each cycle spins the pump and pressurizes the circuit while everything around it is still dry, which is precisely when a weep is easiest to catch. Study both joints, wipe them clean, and look once more. Start the engine and hold a fresh rag near each fitting for a minute or two at idle before the plastics and seat go back on.

One last point worth carrying forward: on the injected Sportsman 570 the fuel filter is built into the pump assembly inside the tank rather than sitting inline where you can see and replace it. A new hose does nothing for a restricted filter, so if the machine still acts starved after a clean installation, that in-tank module is where the next round of diagnosis belongs.

Related Shopping Categories

Shop Fuel Lines for a 2014 Polaris Sportsman 570 ATV.

Shop Fuel Line Clamps for a 2014 Polaris Sportsman 570 ATV.

Shop Petcocks for a 2014 Polaris Sportsman 570 ATV.

Shop Fuel Filters for a 2014 Polaris Sportsman 570 ATV.

Shop Fuel Stabilizer for a 2014 Polaris Sportsman 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.