Diagnosing and Replacing the Fuel Line on a 2015 Sportsman 570

Shop parts for a 2015 Polaris Sportsman 570 ATV.

Almost nobody replaces a fuel line for fun. The job usually begins with a symptom — a smell, a stain, a stumble — and knowing how to read those symptoms on a 2015 Sportsman 570 keeps you from chasing the wrong part. This machine runs the ProStar 567 single with electronic fuel injection, which means there is no petcock to shut off and the supply hose carries pressurized fuel from a pump inside the tank. Injected systems present their symptoms a little differently than carbureted quads do, so it pays to know the tells.

The Evidence a Failing Hose Leaves Behind

  • A gasoline smell that lingers around the tank area, sharpest in the first couple of minutes after shutdown while the circuit still holds pressure
  • Dried fuel residue forming a caked dust ring at a fitting, which is the signature of slow, repeated seepage
  • Surface cracking, a chalky texture, or a length of hose that feels stiff and glassy when you pinch it
  • A wet patch or actual puddle beneath the machine after it has been parked, which on an injected quad indicates the leak has become substantial
  • Bogging under throttle, a lean surge at steady cruise, or hesitation climbing a grade as the pressure side loses volume

The key difference from a carbureted machine is that you cannot close a petcock and watch whether a drip stops. A pressure side pinhole also tends to atomize fuel into vapor that evaporates before it reaches the floor. That makes your nose and a fingertip run along the hose more reliable than looking for drips.

What Actually Wears Hose Out

Two mechanisms operate at once. Externally, heat cycling from the single cylinder engine and steady vibration through the chassis drive out the plasticizers that make the compound flexible. The hose hardens, and a hardened hose develops fine cracks anywhere the frame flexes it. Arid climates accelerate the process by pulling moisture out of the hose wall.

Internally, ethanol-blended pump fuel is corrosive to the liner over time. E10 draws in atmospheric water, and fuel left standing through a long layup degrades the inner surface while depositing gum at the barbs. Because these two processes are unrelated, a hose can present a perfectly good exterior while its liner is already flaking material downstream toward the injector. On a 570 that has been in service a decade, elapsed years alone are a defensible reason to replace it.

Assembling What You Need

  • Hose rated for fuel-injection pressure and matched to the original inside diameter
  • New clamps of the correct style, plus a quick-disconnect release tool if a self-locking coupler is present
  • Line-clamping pliers for any low pressure or vent hose, since the platform has no shutoff valve
  • An approved sealed container and a shallow drain pan
  • Nitrile gloves, rags, a razor knife, a flashlight, and sockets for the seat and side plastics

Ventilation is a genuine safety matter rather than a formality. Gasoline vapor is heavier than air, so it sinks and travels along the floor toward pilot lights and power tools instead of dispersing upward. Work outdoors, or open the shop door fully and move air at floor level with a fan. Keep an extinguisher within reach and keep the gloves on, because fuel strips skin oils instantly.

Depressurizing and Pulling the Old Line

Remove the fuel pump fuse or relay and crank the engine until it dies. That vents the pressure. Key off, then disconnect the battery negative cable. Take the seat off and remove whatever side panels stand between you and the tank flange and the hose run heading to the throttle body. Position the pan and lay a rag over the first joint before opening it, since standing fuel remains regardless of pressure state.

Slide clamps back along the hose before you disturb the fitting. On a quick-connect, press both release tabs squarely and pull straight off; angled prying splits aged plastic collars. Where varnish has bonded hose to barb, a gentle twist usually breaks it loose, and if it does not, slit the hose lengthwise and peel it away instead of levering on the fitting. Photograph the path before the hose is fully out. This is a 4x4 machine, so front differential and driveline hardware dictate a longer routing with additional clearance points and clips compared with a two wheel drive chassis.

Fitting and Clamping the New Hose

Cut the replacement to the exact length of the old piece. Extra hose finds a frame edge to rub or drops toward something rotating. Seat each end completely on its barb, and do it dry — grease, oil, and silicone spray on a sealing surface give pressurized fuel a path out under the clamp. Soften a tight end in hot water for a few seconds instead of lubricating it.

Position new clamps just behind the raised bead on each fitting so they cannot migrate, and tighten uniformly without crushing the hose wall. A self-locking quick-connect takes no clamp; push it on until the collar clicks and then pull firmly to confirm engagement. Reinstall the hose in every original clip so it keeps its designed clearance from exhaust heat and the front driveline.

Confirming a Dry Repair

Refit the fuse, Reconnect the battery, and cycle the key on and off five times without cranking. Each cycle runs the pump and pressurizes the line while the area is clean and dry, the ideal condition for spotting a weep. Look closely at both joints, wipe them, and check again. Then start the engine and hold a clean rag near each fitting at idle for a minute or two before the plastics and seat go back on.

Worth noting before you finish: on the fuel-injected Sportsman 570 the filter is integrated into the in-tank pump assembly rather than existing as a serviceable inline element on the visible hose. New line does nothing for a restricted filter, so if the delivery symptoms that started this project survive a clean installation, that module inside the tank is the next stop.

Related Shopping Categories

Shop Fuel Lines for a 2015 Polaris Sportsman 570 ATV.

Shop Fuel Line Clamps for a 2015 Polaris Sportsman 570 ATV.

Shop Petcocks for a 2015 Polaris Sportsman 570 ATV.

Shop Fuel Filters for a 2015 Polaris Sportsman 570 ATV.

Shop Fuel Stabilizer for a 2015 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.