2016 Sportsman Touring 570 SP Fuel Line: How to Do the Job Right

Shop parts for a 2016 Polaris Sportsman Touring 570 SP ATV.

Aging fuel hose is one of those maintenance items that quietly moves from fine to failed. On a 2016 Sportsman Touring 570 SP it is worth checking on a schedule rather than waiting for a smell or a stall. This machine uses the electronically injected ProStar 570 single, which means the supply hose is pressurized by a pump mounted inside the tank, there is no petcock to close, and the fuel filter is part of that in-tank assembly rather than an inline component on the visible line.

Getting Set Up Properly

Everything on this list should be within arm's reach before the first fitting comes loose:

  • Nitrile or rubber gloves, because gasoline pulls the oils straight out of your skin
  • A drain pan and a sealed container approved for fuel
  • Replacement hose in the correct inside diameter, rated for injection pressure rather than gravity feed
  • New clamps matched to your fittings, or a small clamp assortment
  • Line-clamping pliers, which handle the shutoff duty a petcock would perform
  • Razor knife, shop rags, a small flat screwdriver, and sockets for the seat and side plastics

Choose the workspace with vapor in mind. Gasoline fumes are heavier than air and settle at floor level where cords, work lights, and heaters usually sit, so a cracked window high on a wall does nothing useful. Roll the quad outside or raise the overhead door completely, remove any pilot-flame appliance, hold off on grinding, and keep an extinguisher nearby.

Recognizing a Hose That Is Done

Squeeze the line along its full length and compare sections. Sound rubber compresses easily and rebounds; a stiff, crunchy, or glassy stretch has already lost its flexibility. Bend a curve and look for fine cracks opening in the outer skin. Inspect both fittings for a dark ring of dirt held in place by dried fuel, which is the signature of slow seepage.

Also weigh how the machine has been running. Bogging under load, a stumble when the throttle opens quickly, or lean-feeling surging at steady speed all point at a supply problem. Because this system is pressurized, fuel escaping a pinhole often mists and evaporates instead of dripping, so a lingering gasoline odor with nothing on the floor still means there is something to find.

What Ages the Rubber

Two mechanisms run in parallel. Heat cycling next to the engine drives the plasticizers out of the compound, leaving a wall too stiff to flex with the chassis, and the movement of a long two-up frame over rough ground turns that stiffness into cracks at bends and clamp locations. Dry climates accelerate the drying because there is no ambient humidity to slow it.

Meanwhile, ethanol-blended gasoline degrades the hose from within. E10 attracts moisture and slowly breaks down the inner liner, so a Sportsman parked for a few months with fuel in it can be soft and flaking internally while the exterior still looks reasonable. What that liner sheds travels toward the injector, which is why hose age deserves attention independent of appearance.

Removal Without Making a Mess

Relieve the pressure before touching a clamp. Pull the fuel pump fuse, crank the starter until the engine stalls, switch the key off, then disconnect the negative battery cable. Remove the seat and whatever bodywork blocks the tank outlet and the hose path to the throttle body.

Slide the pan into position and drape a rag over the joint you are opening, since a bled line still holds fuel. Move worm-gear or spring clamps well back along the hose before disturbing the fitting. On a locking quick-connect, press the release tabs squarely and pull straight off, never at an angle, because aged plastic collars crack. Break each barb loose with a gentle twist rather than a hard pull, and if the hose has bonded on, slit it lengthwise and peel it away.

Trace the routing before the old line is out. With its longer wheelbase and On-Demand AWD front driveline, this chassis routes the hose past additional clips and clearance points compared to a short 2WD quad. Photos of each retention point make reassembly quick.

Installing the New Hose and Checking for Leaks

Cut the replacement to the original length exactly. Extra slack chafes on frame tubes or sags toward the exhaust, while a short piece keeps both fittings under tension and eventually works loose. Push each end on dry until it bottoms out against the fitting shoulder. Grease, oil, and silicone stay off entirely, because lubricant on a sealing surface is precisely what gives pressurized fuel a route past the clamp. Dip a stiff end in hot water briefly if it will not seat.

Position new clamps just behind the raised bead on each fitting and tighten evenly, snug without cutting into the rubber. Where a self-locking quick-connect is used, push until it clicks and confirm with a firm tug; that design seals itself and takes no clamp. Reseat the hose in every original clip so it stays clear of the driveline and hot surfaces.

Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking so the pump pressurizes the line while the joints are still dry. Wipe both connections and inspect closely for beading. Start the engine, let it idle several minutes, check again as heat builds, and turn the handlebars fully both directions to load the routing before the panels go back on. Should delivery still feel weak with everything dry, the in-tank pump and filter module is the logical next step.

Related Shopping Categories

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

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

Shop Petcocks for a 2016 Polaris Sportsman Touring 570 SP ATV.

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

Shop Fuel Stabilizer for a 2016 Polaris Sportsman Touring 570 SP 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.