A Practical Guide to Replacing the 2016 Sportsman Touring 570 Fuel Line

Shop parts for a 2016 Polaris Sportsman Touring 570 ATV.

Set yourself up properly and this is an afternoon job with a satisfying result. Rush it and you will be mopping gasoline off a garage floor. The 2016 Sportsman Touring 570 runs the ProStar single with electronic fuel injection, meaning the supply hose you are replacing belongs to a pressurized system fed by a pump mounted inside the tank. No petcock exists on this machine, so shutting off fuel takes a different approach than it would on an older carbureted quad.

Assembling Your Kit First

Lay all of this out before anything comes apart:

  • Nitrile or rubber gloves — gasoline pulls the natural oils straight out of your hands
  • A drain pan plus a sealed, fuel-rated container to store what you catch
  • Replacement hose in the original inside diameter, rated for injection pressure rather than gravity-feed carburetor use
  • New clamps sized to your fittings, or a clamp assortment so you are covered
  • Line-clamping pliers, which serve as your shutoff on a machine with no fuel valve
  • A razor knife, shop rags, a small flat screwdriver, and sockets for the seat and side panels

Pick your workspace with vapor in mind. Gasoline fumes are heavier than air, so they collect near the floor where an open window does nothing. Roll the machine outside or raise the overhead door completely, and clear the area of anything that sparks or holds a flame, including that shop heater in the corner.

The Reason Hoses Wear Out

Fuel hose depends on plasticizers to stay flexible, and those additives leach out steadily under heat cycling. What began as soft rubber becomes stiff and glassy, and at that point the constant vibration of a long two-up chassis is enough to start fine splits, usually at a bend or under a clamp that has been squeezing the same spot for years.

Ethanol-blended gasoline attacks from within. E10 draws in atmospheric moisture and works on the inner liner, so a Sportsman that spends a few idle months with fuel in the system can end up soft and flaking internally while still looking respectable outside. Owners in dry regions see the external hardening progress faster, because there is no humidity to slow the drying of the hose wall.

Warning Signs Worth Acting On

Watch for a fuel puddle or damp streak under the machine after it sits, a gasoline smell around the tank that will not clear, or visible cracking and a chalky surface on the hose itself. Pinch the line in several places; a section that feels rigid compared to the rest is already compromised. Dark rings of dirt at a fitting indicate fuel has been seeping and drying there.

Performance changes matter just as much. An engine that bogs when you load it, hesitates on hard throttle, or acts like it is running out of gas with plenty in the tank is telling you the supply is restricted or leaking. On this injected platform a pressure-side pinhole frequently mists and evaporates without ever dripping, so your nose can be more reliable than your eyes.

Taking the Old Line Off

Kill system pressure before loosening anything. Pull the fuel pump fuse, crank the starter until the engine stalls out, shut the key off, then disconnect the negative battery cable. Remove the seat and enough bodywork to see both the tank outlet and the run of hose feeding the throttle body.

Slide the pan into place and cover the joint you are opening with a rag, since even a depressurized line still holds fuel. Move worm-gear or spring clamps well back along the hose before disturbing the fitting. Quick-connect couplers release by pressing their tabs squarely and pulling straight off — prying sideways on an aged plastic collar is how they break. Loosen each barb with a gentle twist to break the varnish bond, or split the hose lengthwise with the razor if it has fused on.

Document the routing as it comes free. The Touring chassis is longer than a standard Sportsman and carries On-Demand AWD hardware, so the hose navigates additional clips and clearance gaps. Photographs beat memory here.

Fitting and Securing the New Hose

Cut the new piece to the exact length of the old one. Excess slack rubs frame tubes or drifts toward hot surfaces, while a short piece keeps tension on both fittings. Slide each end fully onto its barb until it seats against the shoulder, working dry throughout. Never apply grease, oil, or silicone to a fuel fitting — lubricant on the sealing face is precisely what lets pressurized fuel creep out past a clamp. A quick dip in hot water softens a stubborn end.

Set clamps just behind the raised bead on each fitting and snug them evenly without crushing the rubber. Where the machine uses a self-locking quick-connect, push until it clicks and verify with a firm pull; no clamp belongs on that style of fitting. Route the hose back through every original guide so it stays away from the front driveline and exhaust.

Proving It Before You Ride

Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without starting the engine. Each cycle primes the pump and brings the line up to pressure, which is the honest test of your connections. Dry both joints with a clean rag and look for any beading. Then start it, let it idle, and inspect again while the engine warms, swinging the handlebars fully in both directions to load the routing the way trail riding will.

Finally, remember where the filter lives on the 2016 Touring 570. It is built into the in-tank pump assembly rather than being an inline component you can swap on the visible hose. Fresh line solves a leak or a collapsed section, but a clogged internal filter needs its own attention if fuel delivery still feels soft afterward.

Related Shopping Categories

Shop Fuel Lines for a 2016 Polaris Sportsman Touring 570 ATV.

Shop Fuel Line Clamps for a 2016 Polaris Sportsman Touring 570 ATV.

Shop Petcocks for a 2016 Polaris Sportsman Touring 570 ATV.

Shop Fuel Filters for a 2016 Polaris Sportsman Touring 570 ATV.

Shop Fuel Stabilizer for a 2016 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.