Fuel Line Service for the 2019 Polaris Sportsman Touring 570

Shop parts for a 2019 Polaris Sportsman Touring 570 ATV.

Understanding how fuel gets from the tank to the engine on a 2019 Sportsman Touring 570 makes this whole job straightforward. The ProStar 570 single is electronically fuel injected, so an electric pump sitting inside the tank pushes fuel through the supply hose to the throttle body under constant pressure. That architecture has two consequences for anyone with a wrench in hand: there is no petcock to shut off flow, and the circuit must be depressurized deliberately before you open it.

Parts and Preparation

Set these out before you start:

  • Nitrile or rubber gloves, because gasoline strips skin oils immediately
  • A drain pan plus a sealed, fuel-rated container
  • Replacement hose in the correct inside diameter, rated for fuel-injection pressure rather than low-pressure carburetor duty
  • New clamps matched to your fittings
  • Line-clamping pliers to serve as a shutoff on a machine with no fuel valve
  • Razor knife, shop rags, a small flat screwdriver, and sockets for the seat and side panels

Choose your workspace deliberately. Gasoline vapor is heavier than air and collects near the floor, so an open window high on a wall accomplishes nothing. Roll the quad outside or open the overhead door completely, and get every ignition source out of the space, including any heater with a standing flame.

The Reason Lines Go Bad

Fuel hose stays soft because of plasticizers blended into the rubber, and heat cycling next to the engine drives them out over the years. As the wall hardens it stops absorbing vibration, and the flexing of a long Touring chassis begins opening cracks — most often at a bend or under a clamp that has been squeezing the same spot since day one.

Ethanol-blended fuel works the other side of the wall. E10 attracts moisture and gradually degrades the inner liner, so a Sportsman left sitting with fuel in it for a few months can develop a soft, flaking interior while looking perfectly sound outside. Arid climates compound the external drying, which is why a machine that lives in dust and heat often needs hose sooner than one from a humid region.

Reading the Symptoms

A puddle or damp shine under the machine after it sits is the obvious tell, but plenty of failures announce themselves more subtly. A gasoline odor that hangs around the tank, visible crazing or chalkiness on the hose, and a section that feels rigid when you pinch it are all clear evidence. So is a dark ring of dirt at a fitting, which is dried fuel from a slow weep.

Watch the way it runs, too. An engine that bogs under load, hesitates when you crack the throttle open, or behaves as if the tank is nearly dry is not getting the volume it needs. Remember that on this injected platform a small pressure-side leak can atomize and vanish before it drips, so a persistent smell with a dry floor still deserves investigation.

Removal

Bleed pressure before anything else. Pull the fuel pump fuse, crank the starter until the engine dies, shut the key off, and disconnect the negative battery cable. Take off the seat and enough bodywork to reach the tank outlet and follow the hose to the throttle body.

Slide the pan into position and drape a rag over the joint you are opening, since even a bled line retains fuel. Move worm-gear or spring clamps well back along the hose before disturbing the fitting. For a locking quick-connect, press the tabs squarely and pull straight off — never lever a weathered plastic collar sideways. Twist gently at each barb to break the varnish bond, or slit the hose lengthwise with the razor if it refuses to release.

Study the routing as the old piece comes free. This is a two-up chassis with a longer wheelbase and On-Demand AWD hardware forward, so the hose threads past more brackets and clearance points than a compact 2WD quad. Photos beat guesswork on reassembly.

Installation and Verification

Cut the new hose to the original length exactly. Excess slack chafes on frame tubes or sags toward hot surfaces, while a short piece keeps both fittings loaded. Push each end on dry until it bottoms out against the shoulder. Do not use grease, oil, or silicone anywhere near a fuel fitting — lubricant on the sealing face is exactly how pressurized fuel finds its way out past a clamp. Soften a stiff end in hot water instead.

Set new clamps just behind the raised bead on each fitting, tightened evenly and firmly without biting into the rubber. Where a self-locking quick-connect is fitted, push until it clicks, then tug to confirm engagement; that style needs no clamp at all. Reseat the hose in every original clip so it stays clear of the front driveline and exhaust.

Refit the fuse, Reconnect the battery, and cycle the key on and off several times without cranking so the pump pressurizes the line while the joints are still dry. Wipe both connections and look for beading. Start the engine, idle it for several minutes, check again as heat builds, and swing the bars fully both directions to load the routing. Finally, note that the filter on this injected 570 lives inside the tank as part of the pump module rather than inline on the visible hose — if delivery still feels weak after a leak-free install, that assembly is your next stop.

Related Shopping Categories

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

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

Shop Petcocks for a 2019 Polaris Sportsman Touring 570 ATV.

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

Shop Fuel Stabilizer for a 2019 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.