What It Takes to Replace the Fuel Line on a 2019 Sportsman 570
Shop parts for a 2019 Polaris Sportsman 570 ATV.
Buy the wrong hose and this job fails twice: once when it weeps at a barb, and again when you take it all apart to redo it. That is why the parts and tools discussion comes first for a 2019 Sportsman 570. This is a fuel-injected machine running the ProStar 567 single, so the supply hose sees pump pressure rather than gravity feed, there is no petcock to close, and the specification of the hose you install genuinely matters.
The Right Parts on the Bench First
- Hose rated for fuel-injection service, matched to the inside diameter of the original. General purpose carburetor line will balloon under pressure and seep at the fittings on this system.
- New clamps in whichever style your 570 uses, worm gear or spring type, sized to the hose outside diameter. Reusing tired clamps on fresh hose is a false economy.
- A quick-disconnect release tool if you find a self-locking coupler at the pump flange or throttle body
- Line-clamping pliers for pinching off any low pressure or vent hose, since this platform gives you nothing to shut off
- An approved sealed fuel container plus a wide, shallow catch pan
- Nitrile gloves, clean rags, a sharp razor knife, a flashlight, and sockets for the seat and side plastics
Gasoline, Ventilation, and Common Sense
Gasoline vapor is heavier than air. It sinks to the floor and spreads outward at that level, which is exactly where a water heater pilot, a shop heater, a charger, or a power tool lives. Push the 570 outside if the weather cooperates. If not, open the overhead door completely and set a fan at floor height moving air out of the space. Keep a fire extinguisher within arm's reach rather than across the shop, and wear the gloves from start to finish, because pump fuel strips the oils out of skin immediately and carries additives through it.
Why the Original Hose Wore Out
The rubber fails from both directions. Externally, plasticizers that keep the compound flexible migrate out under repeated engine heat and steady chassis vibration. The hose hardens, and a hardened hose cracks wherever the frame flexes it, those cracks working inward year after year. Low humidity accelerates the process by pulling moisture out of the hose wall, so machines in dry country tend to need hose sooner than their hour meters imply.
Internally, ethanol-blended fuel does its own work. E10 absorbs atmospheric water and, left standing in the hose through a long idle stretch, degrades the liner while depositing gum at the barb joints. These two mechanisms are unrelated, which is why a hose can look fine outside while shedding particulate downstream toward the injector. On a 570 of this age, elapsed service years alone justify replacement.
The Symptoms Worth Watching For
- Gasoline odor lingering near the tank, sharpest right after shutdown while the circuit still holds pressure
- A crusted dust ring at either fitting where seepage has dried repeatedly
- Fine surface cracks, a chalky texture, or a stretch that feels stiff and glassy when pinched
- A stain, damp spot, or puddle beneath the machine after it has been parked overnight
- Bogging under throttle, hesitation on a climb, or a lean surge that feels like running out of fuel
Keep in mind that pressurized fuel escaping a pinhole often atomizes and evaporates before anything reaches the ground, so no puddle does not mean no leak.
Depressurizing and Taking the Old Line Off
Remove the fuel pump fuse or relay and crank the engine for a few seconds until it stalls, which bleeds the pressure. Key off, then disconnect the battery negative cable. Take the seat off and pull whatever side plastics block your reach to the tank flange and the hose run heading toward the throttle body. Position the pan and lay a rag over the joint before you open it, because standing fuel stays in the hose after depressurizing.
Slide clamps back along the hose before disturbing the fitting. For a self-locking quick-connect, press both release tabs squarely and pull straight off the nipple; angled prying cracks collars that have grown brittle. If varnish has glued hose to barb, break it with a gentle twist, or slit the hose lengthwise and peel it away rather than levering on the fitting. Photograph the routing before the old hose is fully out. Being a 4x4 chassis, this 570 routes its line past front differential and driveline components, so it travels farther and passes through more clips than a two wheel drive machine would.
Fitting the New Hose Without Errors
Cut the replacement to the exact length of the piece you removed. Extra hose finds a frame edge to chafe on or drifts toward something rotating. Push each end fully onto its barb until it bottoms, and install it dry. Grease, oil, and silicone spray have no place on a fuel fitting, since a lubricated sealing surface gives pressurized fuel a path to creep out from beneath the clamp. Dip a tight end in hot water for ten seconds instead.
Set new clamps just inboard of the raised bead so they cannot walk off, and tighten them evenly rather than aggressively. A quick-connect coupler requires no clamp: push until the collar clicks audibly, then pull firmly to confirm engagement. Feed the hose back through every original clip so it retains clearance from exhaust heat and the front drive hardware.
Checking the Work and Closing Up
Reinstall the fuse, Reconnect the battery, and cycle the key on and off five times without cranking. Each cycle runs the pump and pressurizes the line while the surrounding area is clean and dry, the ideal state for catching a weep. Look carefully at both joints, wipe them, and inspect again. Then start the engine and hold a clean rag near each fitting for a minute or two at idle before reassembling the plastics and seat.
One final detail specific to this platform: the fuel filter on the injected Sportsman 570 is integrated into the in-tank pump assembly rather than existing as an inline element you can reach on the visible hose. New line will not resolve a restricted filter, so if fuel starvation symptoms outlast a clean installation, that module is the next place to look.
Related Shopping Categories
Shop Fuel Lines for a 2019 Polaris Sportsman 570 ATV.
Shop Fuel Line Clamps for a 2019 Polaris Sportsman 570 ATV.
Shop Petcocks for a 2019 Polaris Sportsman 570 ATV.
Shop Fuel Filters for a 2019 Polaris Sportsman 570 ATV.
Shop Fuel Stabilizer for a 2019 Polaris Sportsman 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.