Swapping the Fuel Line on a 2015 Sportsman Touring 570

Shop parts for a 2015 Polaris Sportsman Touring 570 ATV.

Most owners discover a bad fuel line the same way: a whiff of gas in the garage that does not fade, or a damp shine on the skid plate that was not there last week. On a 2015 Sportsman Touring 570 those clues deserve immediate attention, because this machine feeds its ProStar single through an electronically injected, pressurized circuit. There is no petcock to close, the pump sits inside the tank, and any breach is live the moment the key turns on.

Catching a Failing Line Before It Strands You

Work through this checklist any time the machine is on a stand:

  • Squeeze the hose along its whole length. Soft and springy is healthy; stiff, crunchy, or glassy is finished.
  • Flex a section gently and watch the outer surface for fine cracks opening up in the bend.
  • Check each fitting for a dark, dust-caked ring, which is the signature of slow seepage.
  • Note any fuel smell that lingers after shutdown, particularly around the tank outlet.
  • Pay attention to how the engine runs. Bogging under load, a stumble on hard acceleration, or lean surging at steady throttle all point at restricted or leaking supply.

Injected machines complicate the visual check. Pressurized fuel escaping a pinhole often mists and evaporates rather than dripping, so a line can be actively leaking with nothing on the floor to prove it.

Why Rubber Gives Up

Two separate processes attack the hose from opposite directions. From the outside, age and engine heat drive out the plasticizers that keep the rubber pliable, and the wall gradually hardens until vibration from the long Touring chassis starts splitting it. Dry climates speed this up noticeably, since low humidity pulls moisture from the hose wall year round.

From the inside, ethanol-blended fuel does the damage. Alcohol attracts water and slowly degrades the inner liner, and a Sportsman that sits between seasons with E10 in it can develop a soft, sloughing interior while the outside still looks presentable. That is exactly why hose age matters more than appearance on a machine now a decade into service.

Tools, Parts, and a Real Safety Setup

Collect the following before starting:

  • Rubber or nitrile gloves
  • A drain pan and a sealed fuel-rated container
  • Replacement hose in the correct inside diameter and rated for fuel-injection pressure
  • New clamps, or a small clamp assortment so you have the right size on hand
  • Line-clamping pliers to pinch off flow, since this model has no fuel valve
  • Hand tools for the seat and side plastics, plus plenty of rags

Ventilation is not a formality here. Gasoline vapor sinks and pools at floor level, so open the overhead door rather than a window, and get the machine into open air if you can. No smoking, no grinders, no space heaters, and nothing with a standing pilot flame anywhere nearby.

Removing the Old Hose

Start by killing pressure in the system. Pull the fuel pump fuse, crank briefly until the engine dies, turn the key off, then disconnect the battery negative terminal. Take off the seat and whatever bodywork blocks your view of the tank outlet and the hose run to the throttle body.

Position the pan and lay a rag over the first joint you open. Residual fuel will come out even after the circuit is depressurized. Slide worm-gear or spring clamps back along the hose before you disturb the fitting itself. For a quick-connect coupler, depress the tabs evenly and pull straight back; aged plastic collars crack readily if you pry at an angle. Twist the hose slightly to break the gum seal at the barb instead of yanking, and slit it with a razor if it has bonded on.

Take note of how the line is routed as it comes out. The Touring model's stretched frame and On-Demand AWD front end mean the hose passes more clips and clearance points than a compact two-wheel-drive quad, and reproducing that path exactly keeps the new hose away from heat and moving parts.

Installing the Replacement

Match the original length precisely. Too long and the hose rubs a frame tube or sags toward the exhaust; too short and it tugs at both ends every time the chassis flexes. Seat each end fully onto its barb, pushing until it bottoms out. Install it dry — grease, oil, and silicone all compromise the seal by giving pressurized fuel a slick escape route. Warm the hose end in hot water if it resists.

Place fresh clamps immediately behind the bead on each fitting, tightening enough to hold firmly without biting into the rubber. If your machine uses a self-locking quick-connect, push it home until you hear the click and confirm with a solid tug; that style seals on its own and takes no clamp. Reseat the hose in every original clip.

Leak Check and Wrap-Up

Refit the fuse and Reconnect the battery, then turn the key on and off four or five times without cranking. The pump primes on each cycle, pressurizing the line so you can inspect it under working conditions while everything is still dry. Wipe both fittings with a clean rag and study them closely. Fire the engine, let it idle a few minutes, and check again, turning the bars through their full sweep to load the routing.

Keep in mind that the 570's fuel filter is integrated with the in-tank pump module rather than sitting inline where you can reach it. If fuel delivery still feels weak once the new hose is proven leak-free, that internal filter is the logical next step rather than more hose work.

Related Shopping Categories

Shop Fuel Lines for a 2015 Polaris Sportsman Touring 570 ATV.

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

Shop Petcocks for a 2015 Polaris Sportsman Touring 570 ATV.

Shop Fuel Filters for a 2015 Polaris Sportsman Touring 570 ATV.

Shop Fuel Stabilizer for a 2015 Polaris Sportsman Touring 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.