Replacing a Cracked Fuel Line on Your 2019 Polaris Sportsman Touring 570 SP
Shop parts for a 2019 Polaris Sportsman Touring 570 SP ATV.
Rubber does not last forever, and the fuel hose on a 2019 Sportsman Touring 570 SP lives in about the worst environment you could design for it: sandwiched between hot engine components and cold outside air, flexed constantly by a chassis built to carry two riders over rough ground, and filled with a fuel blend that is chemically hostile to it. Understanding how that hose deteriorates tells you exactly when to replace it.
The Slow Chemistry of a Failing Hose
Fuel line is a rubber compound loaded with plasticizers that keep it soft and flexible. Every heat cycle the ProStar 567 puts through the engine bay drives some of that out, and the process only runs one direction. Over several seasons, hose that once compressed easily between your fingers turns firm, then glassy. A rigid hose cannot absorb chassis movement, so the flex points and the spots just behind each clamp begin to craze with fine cracks. In dry, arid country the timeline compresses noticeably, because low ambient humidity pulls moisture from the hose wall and hardens it from the surface inward.
Ethanol-blended pump gas comes at the same hose from the inside. The alcohol content draws in atmospheric moisture and slowly degrades the inner liner, and a Touring 570 SP parked for a few months with fuel sitting in the line gives it an uninterrupted opportunity. The result is a hose that can pass a casual glance while quietly softening internally and shedding debris downstream.
Confirming the Fuel Delivery Setup
Do this before you touch a tool. The 2019 Touring 570 SP is fuel injected, which rules out the petcock-and-float-bowl approach that works on carbureted quads. There is no fuel valve to close. Instead, an electric pump inside the tank feeds a pressurized line up to the throttle body, and that line holds pressure long after shutdown. You have to bleed it down electrically before opening a joint. The fuel filter is also part of the in-tank pump module rather than an inline canister on the hose, so replacing the hose does nothing for filtration.
Reading the Warning Signs
A hose rarely fails without notice. Look and smell for:
- Gasoline odor hanging around the seat area, strongest in the first moments after you shut the key off
- A wet patch or thin puddle on the skid plate or floor beneath the front half of the machine
- Fine surface cracking or a hard, discolored section revealed when you pinch the hose along its length
- A dust-caked ring at a fitting, left behind by fuel that has repeatedly seeped and evaporated
- Bogging when the throttle opens under a passenger load, or a lean stumble that comes and goes
Because pressurized fuel can atomize and disappear before it drips, an injected machine will sometimes smell strongly with nothing visible on the ground. Treat the odor as evidence in its own right.
Tools, Parts, and a Serious Word on Fumes
Assemble your kit up front: nitrile or rubber gloves, a sealed approved container for captured fuel and a shallow pan for drips, replacement hose rated for injection pressure in the original inside diameter, new clamps of the correct type, a quick-disconnect release tool if the tank coupler uses a locking collar, line-clamping pliers to substitute for the petcock this machine lacks, plus sockets, a trim tool, rags, and a razor blade.
Take the fumes seriously. Gasoline vapor is heavier than air and pools at floor level, exactly where your face ends up when you are working under the front of a quad. Roll the machine outside if you can, or open the door completely and leave it open the whole time. Kill any pilot light, heater, charger, or spark-producing tool in the space before the first fitting comes apart.
Working the Old Line Free
Start by pulling the fuel pump fuse or relay and cranking the engine until it stalls, then switch off the key and disconnect the battery negative cable. Strip both seats and the adjacent side plastics so you can follow the whole run from the tank flange to the throttle body. The two-up Touring frame is longer than a standard single-seat Sportsman, so expect a longer hose and more retaining clips along the way, and note where the run passes front driveline components on this On-Demand AWD chassis. Photograph the routing while it is still intact.
Slide the pan into place and lay a rag over each fitting before you open it, since a depressurized line still contains fuel. Push clamps well back along the hose first. Quick-connects come apart when the tabs are squeezed evenly and the coupler is pulled straight off, never levered sideways. If varnish has welded a hose end to its barb, slit the hose lengthwise and peel it off rather than forcing a twist.
Installation and the Final Leak Check
Match the new hose to the original length, no longer. Excess hose chafes on frame edges or wanders into hot exhaust shielding. Press each end onto its barb until it bottoms, and install it dry — no grease, oil, or silicone on any fuel fitting, because lubricant on a sealing surface is exactly how pressurized fuel escapes. Warm water on a stiff hose end makes it slide on without help. Seat new clamps just behind the bead on each fitting and tighten evenly. A self-locking quick-connect at the tank should click and then resist a firm pull; that joint takes no clamp. Route the hose back through every original clip.
To verify, reinstall the pump fuse, Reconnect the battery, and cycle the key on and off repeatedly without cranking. Each cycle pressurizes the line, letting you inspect both joints with the engine cold and still. Wipe them and watch for fuel beading up. Then start the 570 SP and inspect again while it idles and vibrates. Give it several minutes clean before you reinstall the bodywork. Should a fuel delivery complaint persist after the hose is new and dry, the in-tank pump and filter assembly is your next step.
Related Shopping Categories
Shop Fuel Lines for a 2019 Polaris Sportsman Touring 570 SP ATV.
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Shop Petcocks for a 2019 Polaris Sportsman Touring 570 SP ATV.
Shop Fuel Filters for a 2019 Polaris Sportsman Touring 570 SP ATV.
Shop Fuel Stabilizer for a 2019 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.