Fuel Line Replacement Guide for the 2019 Sportsman 570 EPS

Shop parts for a 2019 Polaris Sportsman 570 EPS ATV.

Knowing where the hose goes before you pull it is half the battle. On the 2019 Polaris Sportsman 570 EPS, the fuel line leaves the pump flange on the tank, runs forward under the seat and bodywork, and terminates at the throttle body on the ProStar 567cc single. It does not take the shortest possible path. It follows retaining clips that hold it away from hot surfaces and moving parts, and on this 4x4 chassis it also has to clear front differential hardware and frame crossmembers a two-wheel-drive machine would not carry. Get that routing recorded before anything comes off and reassembly stops being guesswork.

The Fuel System You Are Working With

This Sportsman is electronically fuel injected, and that changes the job in specific ways. There is no petcock beneath the tank to shut off, no valve to rotate to off, and no gravity feed to stop. A pump inside the tank pressurizes the hose, and the pressure stays there after shutdown. So the sequence starts with deliberately bleeding that pressure, and line-clamping pliers become a necessary tool because the machine offers no shutoff valve. Expect a conventional clamp at the throttle body and possibly a self-locking quick-connect coupler at the pump flange, which needs no clamp of any kind.

Why Rubber Fuel Lines Wear Out

Two forms of degradation run in parallel. Heat cycles off the engine and ordinary weather exposure slowly drive the plasticizers out of the hose, so the wall stiffens and eventually cracks instead of flexing. Dry, low-humidity regions push this along faster because arid air pulls moisture out of the rubber and hardens it from the surface inward. Meanwhile ethanol-blended pump gas absorbs atmospheric water and degrades the inner liner, leaving gum behind and softening the hose from inside, particularly when the machine sits with fuel standing in the line. Vibration from a single-cylinder engine finishes the work, concentrating the failures right where the hose bends or meets a barb.

Catching It Before You Are Stranded

  • A fuel puddle or damp patch beneath the mid-chassis after the machine sits overnight
  • A gasoline smell hanging around the seat area, sharpest immediately after you shut down
  • Visible fine cracking, a chalky surface, or a hose section that feels rigid to the pinch
  • Engine bogging under load, stumbling off idle, or acting like it is running out of fuel with a full tank
  • A ring of caked dirt at a fitting where fuel has seeped and dried repeatedly

Do not require a puddle before you believe a leak. On the pressure side of an injected system, fuel escaping a pinhole often atomizes and evaporates before it hits the ground, leaving only the smell.

Setting Up: Tools and Ventilation

Have gloves, eye protection, a drain pan, a sealed fuel-rated container, injection-rated replacement hose in the correct inside diameter, new clamps, a quick-disconnect release tool, line-clamping pliers, hand tools for the panels and clips, a razor knife, and clean rags laid out and ready.

Then handle ventilation honestly. Gasoline vapor is denser than air, so it settles and travels along the floor toward whatever ignition source happens to be down there. Work outside or with the door open all the way, shut down heaters and hot work lights, and keep clear of any appliance with a standing pilot. Wear the gloves start to finish, because gasoline strips skin oils quickly and the additives in modern fuel are worth keeping off your hands.

Removal Without Damage

Kill system pressure first. Pull the fuel pump fuse or relay, crank the engine a few seconds until it stalls or will not fire, switch the key off, then disconnect the negative battery cable. Remove the seat and the covers over the tank and the hose run.

Slide the pan into position and cover the joint with a rag before opening it, since a depressurized hose is still a full one. Move the existing clamp well back along the hose. Quick-connect couplers release when their tabs are pressed evenly and the fitting is pulled straight off the port; side loading is what cracks brittle plastic collars. Barbed connections geneRally need a gentle twist to break years of varnish bonding hose to metal. If the hose will not come free, slit it lengthwise and peel it off instead of forcing it and risking the spigot.

Installing and Verifying the New Line

Cut the replacement to the length you removed. Longer is not safer; excess hose chafes on the frame or wanders toward exhaust heat. Push each end fully onto its barb until it bottoms out against the shoulder, and install it dry. Never put grease, oil, or silicone on a fuel fitting — a lubricated sealing surface is precisely how pressurized fuel escapes past a clamp that feels perfectly tight. Hot water is the only acceptable help for a tight hose end.

Position new clamps just behind the raised bead and tighten them evenly. A self-locking quick-connect clicks when it seats, and a firm pull confirms the latch; that style takes no clamp. Reinstall the hose into every original clip so it stays away from the front driveline and heat.

Replace the fuse or relay, Reconnect the battery, and cycle the ignition on and off five or six times without starting. Each cycle runs the pump and pressurizes the line, giving you a clean, dry field to inspect both joints. Wipe each with a fresh rag and look for any transfer. Start the engine, idle it for several minutes, and check once more at full running pressure before the bodywork returns.

Worth noting on this platform: the fuel filter lives inside the tank as part of the pump assembly rather than sitting inline where you could change it with the hose. New line solves a cracked or leaking line. If the 570 EPS still bogs or starves after a leak-free install, that in-tank module is the next thing to examine.

Related Shopping Categories

Shop Fuel Lines for a 2019 Polaris Sportsman 570 EPS ATV.

Shop Fuel Line Clamps for a 2019 Polaris Sportsman 570 EPS ATV.

Shop Petcocks for a 2019 Polaris Sportsman 570 EPS ATV.

Shop Fuel Filters for a 2019 Polaris Sportsman 570 EPS ATV.

Shop Fuel Stabilizer for a 2019 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.