How to Change the Fuel Line on a 2017 Sportsman 570 EPS
Shop parts for a 2017 Polaris Sportsman 570 EPS ATV.
The 2017 Polaris Sportsman 570 EPS carries the ProStar 567cc single with electronic fuel injection and on-demand all-wheel drive. That combination sets the terms for this job. Because the machine is injected, there is no petcock under the tank to shut off flow, and the hose you plan to remove carries pressurized fuel supplied by a pump mounted inside the tank. Everything below assumes that reality rather than the simpler gravity-feed setup found on older carbureted quads.
Breaking the Old Line Loose
The removal is where most owners make their mistakes, so it is worth walking through first. Begin by killing pressure in the system deliberately. Pull the fuel pump fuse or relay, crank the starter for a few seconds until the engine stalls or will not catch, then turn the key off and disconnect the negative battery cable. Take off the seat and the side panels that expose the tank and the hose run heading forward to the throttle body.
Set a drain pan beneath the work area and lay a rag over the first joint you open. A depressurized hose is still a full hose, and it will empty itself the moment the connection breaks. Slide the existing clamp well back before disturbing anything. If the pump flange uses a self-locking quick-connect coupler, press its tabs evenly and pull the fitting straight off the port — levering it sideways is what cracks a collar that has been aging in the weather. On a barbed connection, twist the hose gently to break the varnish bond that forms over years of service. Any hose that refuses to release should be slit lengthwise with a razor and peeled off, which protects the barb underneath.
This is a 4x4 chassis, so the line routes past front differential hardware and through frame clearance points a two-wheel-drive machine does not have. Photograph the retaining clips and the exact path before the old hose is fully out.
What Kills a Fuel Hose
Nothing dramatic. The rubber slowly loses the plasticizers that keep it flexible, and over several seasons a soft, compliant tube turns stiff and glassy. Once that happens it can no longer absorb the vibration a big single feeds into the frame, and cracks open at the bends and at the fittings. Dry climates accelerate the process because low humidity draws moisture out of the hose wall, hardening it from the outside in. At the same time, ethanol-blended pump gas pulls in atmospheric water and works on the inner liner, leaving gum and softening the hose from within. A line can be brittle outside and degraded inside simultaneously, which is why age matters as much as appearance on a machine this far into its service life.
Signs the Line Is Going
- A fuel stain or puddle beneath the mid-chassis after the Sportsman has sat overnight
- Gasoline odor around the seat and tank, sharpest in the first minutes after shutdown while residual pressure bleeds off
- Surface cracking, chalkiness, or noticeable hardness when you pinch the hose
- Bogging under load, hesitation off idle, or the engine behaving as though the tank is nearly dry when it is not
- A ring of caked dirt at a fitting, left behind by fuel that seeped and evaporated repeatedly
Keep in mind that a pinhole on the pressure side of an injected system can atomize fuel into a mist that never reaches the ground. A persistent smell with no visible puddle still tells you something.
Tools and a Real Word About Gasoline
- Nitrile or rubber gloves and eye protection
- Drain pan plus a sealed, fuel-rated container
- Replacement hose in the correct inside diameter, rated for injection pressure rather than low-pressure carburetor use
- New clamps matching the existing style, and a quick-disconnect release tool if a locking coupler is present
- Line-clamping pliers, since this model has no fuel valve to shut
- Socket set, small flat blade, razor knife, and clean rags
Work outdoors or with the shop door open all the way. Gasoline vapor is heavier than air, so it drifts down and pools along the floor rather than rising out an open window. Shut off space heaters, move hot work lamps, and stay well clear of any appliance with a standing pilot flame. Wear the gloves the entire time; gasoline strips skin oils fast and carries additives worth keeping off your hands.
Fitting the New Hose
Cut the replacement to match the old line exactly. Extra length is not a safety margin — it gives the hose room to chafe against the frame or drift toward the exhaust. Push each end fully onto its barb until it bottoms against the shoulder, and install it dry. Do not use grease, oil, or silicone spray on any fuel fitting. Lubricant on a sealing surface is the most common reason a properly tightened clamp still weeps under pressure. If a hose end fights you, soften it in hot water for half a minute and try again.
Place new clamps just behind the raised bead on each fitting and tighten them evenly rather than crushing one side. Where the machine uses a self-locking quick-connect, push until you feel the collar click, then pull firmly to confirm it has latched. No clamp goes on that style of fitting. Reinstall the hose into every original clip and guide so it holds position away from the front driveline and heat sources.
Pressure Test and Final Checks
Put the fuse or relay back, Reconnect the battery, then cycle the key on and off five or six times without cranking. Each cycle runs the pump and pressurizes the hose, letting you examine both joints while the surrounding area is clean and dry. Wipe each connection with a fresh white rag and look for the slightest transfer. Then start the engine and let it idle for several minutes, checking once more with the system at full running pressure. Only after that should the panels and seat go back on.
One detail specific to the injected 570: the fuel filter is integrated into the in-tank pump module rather than sitting inline where you can reach it. A new hose fixes a leaking or cracked hose. If the 570 EPS continues to bog or starve after a clean, leak-free install, the pump and filter assembly inside the tank is the logical next step.
Related Shopping Categories
Shop Fuel Lines for a 2017 Polaris Sportsman 570 EPS ATV.
Shop Fuel Line Clamps for a 2017 Polaris Sportsman 570 EPS ATV.
Shop Petcocks for a 2017 Polaris Sportsman 570 EPS ATV.
Shop Fuel Filters for a 2017 Polaris Sportsman 570 EPS ATV.
Shop Fuel Stabilizer for a 2017 Polaris Sportsman 570 EPS 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.