Swapping the Fuel Line on a 2018 Polaris Sportsman Touring 570 SP

Shop parts for a 2018 Polaris Sportsman Touring 570 SP ATV.

Fuel line replacement is one of the few repairs where preparation matters more than wrenching skill. The actual hose swap on a 2018 Sportsman Touring 570 SP takes well under an hour; the trouble comes from starting the job without the right hose, the right clamps, or a safe place to spill a little gasoline. Get the setup right and the rest is straightforward.

Lay Out Your Tools and Parts First

Collect all of this before a single fastener moves:

  • Rubber or nitrile gloves — gasoline defats skin quickly and soaks through fabric
  • A sealed metal or approved plastic fuel container, plus a shallow catch pan for drips
  • Fuel-injection rated hose in the same inside diameter as the original, cut a little long so you can trim to fit
  • New clamps in the correct style, since reusing a fatigued spring clamp is a false economy
  • A quick-disconnect release tool sized for the tank-side coupler if yours uses a locking collar
  • Line-clamping pliers, which take the place of the petcock this machine does not have
  • Sockets, a trim removal tool, shop rags, and a razor blade for stubborn hose ends

Ventilation deserves real attention rather than a passing mention. Gasoline vapor is denser than air and collects at floor level where you are kneeling. Work outdoors when you can, or with the garage door fully raised, and shut off any water heater, space heater, battery charger, or power tool that could throw a spark near the ground.

This One Is Injected, Not Carbureted

The 2018 Touring 570 SP runs electronic fuel injection on the ProStar 567 single, and that changes the job in one important way: there is no petcock. On a carbureted quad you would rotate the fuel valve closed, drain the float bowl, pop a couple of pinch clamps, and swap the hose with barely a drop spilled. Here, an electric pump lives inside the tank and keeps the feed line to the throttle body pressurized even after the engine has been off for hours. You bleed that pressure electrically. The fuel filter is built into the in-tank pump module too, so nothing on the visible hose is a serviceable filter.

Why the Hose Ages Out

Fuel hose fails from chemistry, not mileage. The compound gradually gives up the plasticizers that keep it pliable, and each heat cycle from the engine bay accelerates that loss. What began as a soft, squeezable hose eventually feels like hard plastic, and once it reaches that state, normal frame flex on rough two-track opens micro cracks at bends and just behind the clamps. Dry inland climates speed this along, since low humidity draws moisture out of the hose wall and hardens it from the outside in.

Ethanol-blended fuel attacks the inner liner at the same time, especially on a Touring 570 SP that sits idle for months with a partial tank. The alcohol content absorbs water and slowly breaks down the liner, so a hose can look acceptable outside while shedding material into the fuel it carries.

Catching a Failing Line Early

Symptoms usually arrive in a predictable order. A faint fuel smell around the seats comes first, often noticeable right after shutdown. Next comes a small stain or wet spot on the skid plate, or a dusty crust at one of the fittings where fuel has seeped and dried repeatedly. Squeeze the hose and you may find a stiff, glazed section that no longer springs back. Performance symptoms show up last: hesitation as you roll on the throttle with a passenger aboard, a lean surge at steady speed, or the engine acting starved at higher rpm. Because a pressure-side leak on an injected machine can atomize before it drips, do not wait for a puddle to confirm what your nose already told you.

Taking the Old Hose Off

Relieve system pressure by pulling the fuel pump fuse or relay, cranking until the engine quits, turning the key off, and disconnecting the battery negative terminal. Remove both seats and the surrounding side panels so you can trace the hose from the tank flange forward. The two-up Touring chassis is longer than a standard Sportsman, which means a longer hose run held by more clips, and this being an On-Demand AWD machine, the routing threads past front differential hardware and extra frame structure that a two-wheel-drive layout would not have. Photograph each retainer before anything comes loose.

Slide the pan under the first joint and cover it with a rag, since a depressurized line still holds fuel. Work clamps back along the hose before disturbing the fitting. Quick-connect couplers release when the tabs are pressed squarely and the fitting is pulled straight off; prying at an angle cracks aged plastic. When varnish has bonded the hose to a barb, slice it lengthwise and peel it away instead of twisting hard on the fitting.

Installing the New Line and Verifying It

Trim the replacement to match the original length exactly. A hose that is too long rubs on the frame or drifts toward heat shielding, and either one eventually wears through. Seat each end fully onto its barb, dry. Grease and lubricant have no place on a fuel fitting; they contaminate the sealing surface and let pressurized fuel work its way out. If a hose end is tight, dip it briefly in hot water to soften it and push it home. Position new clamps just past the raised bead on each fitting and snug them evenly. If your tank side uses a self-locking quick-connect, push until you hear the click and pull firmly to confirm it has latched — no clamp needed there. Reinstall every clip so the hose sits exactly where it did.

Now check your work. Put the pump fuse back, Reconnect the battery, and cycle the key on and off several times without starting. That pressurizes the line so you can inspect both joints dry. Wipe each with a clean rag and look for any fuel forming. Fire the engine, let it idle, and check again with everything running and vibrating. Give it several minutes of leak-free operation before the bodywork returns. If the 570 SP still feels short on fuel afterward, the in-tank pump and filter assembly is where to look next.

Related Shopping Categories

Shop Fuel Lines for a 2018 Polaris Sportsman Touring 570 SP ATV.

Shop Fuel Line Clamps for a 2018 Polaris Sportsman Touring 570 SP ATV.

Shop Petcocks for a 2018 Polaris Sportsman Touring 570 SP ATV.

Shop Fuel Filters for a 2018 Polaris Sportsman Touring 570 SP ATV.

Shop Fuel Stabilizer for a 2018 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.