2018 Sportsman Touring 570 Fuel Line: Inspection and Replacement
Shop parts for a 2018 Polaris Sportsman Touring 570 ATV.
Fuel hose is one of the cheapest parts on a 2018 Sportsman Touring 570 and one of the few whose failure can leave you walking. It is also easy to overlook, buried under the seat and bodywork where nobody looks until something smells wrong. This machine runs the electronically injected ProStar 570, which means the line is under pressure any time the key is on, there is no petcock to close, and the pump and filter are combined in a module inside the tank.
How the Rubber Degrades
The flexibility in a fuel hose comes from plasticizers mixed into the rubber, and heat drives them out a little at a time. After enough seasons alongside a working single-cylinder engine, the wall stiffens and stops flexing with the chassis. From there the vibration of a long two-up frame does the rest, working hairline cracks into the outer surface at bends and clamp locations.
Ethanol adds a second front. E10 pump gas absorbs moisture and slowly attacks the hose's inner liner, so a Sportsman that sits idle between riding seasons can end up soft and shedding on the inside while the outside still passes a glance. Riders in dry climates get the harsh version of both problems, since low humidity accelerates the external hardening year round.
Spotting Trouble Early
Give the line a proper look whenever the seat is off:
- Pinch along the entire length. Healthy hose gives easily; a stiff or crunchy section is finished.
- Bend a short segment and watch for fine cracks opening in the outer skin.
- Inspect each fitting for a dark, dust-caked ring where fuel has seeped and dried.
- Note any gasoline smell that lingers around the tank after shutdown.
- Think about how it has been running. Bogging under load, a stumble on hard throttle, or lean-feeling surging all suggest compromised supply.
Do not let a clean floor reassure you. Fuel escaping a pressurized line frequently mists and evaporates before it can drip, so the smell often arrives well ahead of any visible puddle.
What You Need on the Bench
- Rubber or nitrile gloves
- A drain pan and a sealed container rated for fuel storage
- Replacement hose matched to the original inside diameter and rated for injection pressure
- Fresh clamps in the right size, or a small clamp kit
- Line-clamping pliers to pinch off flow, since this model has no fuel valve
- Razor knife, rags, a small flat screwdriver, and sockets for the seat and panels
Take ventilation seriously. Gasoline vapor is denser than air and settles at floor level, exactly where a stray spark tends to live. Work outdoors or with the overhead door fully open, and keep grinders, torches, cigarettes, and pilot-flame heaters out of the area entirely.
Pulling the Line Off the Fittings
Relieve pressure first. Pull the fuel pump fuse, crank the engine until it stalls, turn the key off, and disconnect the negative battery terminal. Remove the seat and whatever plastics stand between you and the tank outlet plus the hose run to the throttle body.
Set the pan underneath and keep a rag over the fitting you are opening, because residual fuel comes out even after the circuit is bled. Slide worm-gear or spring clamps back along the hose before touching the fitting. Quick-connect couplers come apart by pressing their tabs evenly and pulling straight back; sideways prying cracks aged plastic. Break each barb loose with a light twist rather than a hard pull, and split the hose with a razor if it has bonded itself on.
Note the path as the hose comes out. The Touring model's stretched frame and On-Demand AWD hardware mean more clips and tighter clearance than a short 2WD quad, and matching the original routing is what keeps the new hose away from the driveline and exhaust.
Fitting the Replacement
Measure the old hose and cut the new one to the same length. Slack invites chafing and heat contact; too short leaves both fittings under constant tension. Press each end fully onto its barb until it seats against the shoulder, working entirely dry. Grease, oil, and silicone have no place here — a lubricated sealing surface is a path for pressurized fuel to escape past the clamp. Warm a stubborn end in hot water rather than forcing it.
Install new clamps just behind the raised bead on each fitting, snug and even without cutting into the rubber. If your machine uses a self-locking quick-connect, push it home until you hear the click, then pull firmly to confirm the latch; that fitting seals on its own and wants no clamp. Return the hose to every original clip and guide.
Leak Testing and Final Checks
Reinstall the fuse and Reconnect the battery, then cycle the key on and off several times without cranking. The pump primes each cycle, bringing the line up to full pressure while the joints are still dry and easy to read. Wipe both connections and watch for beading. Start the engine, let it idle for a few minutes, and inspect again as things heat up. Turn the handlebars through their full range to be sure nothing tugs at a fitting.
Last thing to keep in mind on this platform: the 570's fuel filter is integrated into the in-tank pump assembly rather than being an inline piece you can change on the visible hose. New line handles leaks and cracking, but persistent fuel starvation after a clean install points at that internal filter instead.
Related Shopping Categories
Shop Fuel Lines for a 2018 Polaris Sportsman Touring 570 ATV.
Shop Fuel Line Clamps for a 2018 Polaris Sportsman Touring 570 ATV.
Shop Petcocks for a 2018 Polaris Sportsman Touring 570 ATV.
Shop Fuel Filters for a 2018 Polaris Sportsman Touring 570 ATV.
Shop Fuel Stabilizer for a 2018 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.