Inspecting and Renewing the Fuel Line on a 2020 Sportsman 570

Shop parts for a 2020 Polaris Sportsman 570 ATV.

A five minute inspection with a flashlight is the cheapest maintenance you can perform on a 2020 Sportsman 570, and the fuel line deserves to be on that list. The 570 runs the ProStar 567 single with electronic fuel injection, so the hose you are checking is a pressurized supply line fed by an in-tank pump rather than a gravity feed running to a carburetor. That distinction affects both how the hose fails and how you go about replacing it, since there is no petcock on the machine to shut off flow.

Running a Proper Inspection

Pull the seat and get light onto the hose from the tank flange forward to the throttle body. Work along its length with a gloved finger and look for the following:

  • A hard, glassy feel in any section, or a chalky gray cast where the surface used to be black and supple
  • Fine surface checking, especially at bends and anywhere a clip holds the hose against a frame tube
  • Caked dust rings at either fitting, which form when fuel seeps slowly and dries over and over
  • Swelling or softness immediately behind a clamp, a sign the liner is breaking down
  • A gasoline smell that lingers around the tank area well after the engine has been shut off

Symptoms you feel while riding count too. Bogging under load, hesitation on hard acceleration, or a lean surge that mimics an almost empty tank can all trace back to a supply line losing volume. A puddle under the machine after it sits overnight means the leak is already well advanced. Keep in mind that pressurized fuel escaping a pinhole frequently atomizes and evaporates before it drips, so on this injected 570 a dry floor does not clear the hose.

What Drives the Deterioration

Fuel hose wears out from two directions at once. Externally, the plasticizers that keep the compound flexible migrate out under repeated heat cycles from the engine and the constant vibration of a working utility quad. The hose stiffens, and once stiff it cannot absorb chassis flex, so cracks open on the outer wall and progress inward. Owners in arid country see this accelerate, because low humidity draws moisture out of the hose wall and speeds the hardening.

Internally, ethanol-blended pump gas attacks the liner. E10 absorbs water from the atmosphere, and fuel left motionless in the hose through an off season slowly degrades the inner surface while leaving gum and varnish at the barbs. The two processes are unconnected, which is why a hose can look presentable while its liner is already flaking material toward the injector.

Preparation and Safe Fuel Handling

Gather everything before a fitting comes loose: hose rated for fuel-injection pressure in the original inside diameter, new clamps in the correct style, a quick-disconnect release tool if the machine uses locking couplers, line-clamping pliers for low pressure or vent hose, an approved sealed container, a shallow catch pan, nitrile gloves, rags, a razor knife, and sockets for the seat and side plastics.

Ventilation is not a throwaway line. Gasoline vapor is heavier than air, so it settles onto the floor and flows outward at that level, toward water heater pilots, shop heaters, and power tools. Work outdoors, or open the overhead door completely and run a fan low to the ground pushing air out. Keep an extinguisher within arm's reach, and wear gloves throughout, since fuel strips skin oils on contact and carries its additives through.

Getting Pressure Out and the Hose Off

Pull the fuel pump fuse or relay and crank the engine for a few seconds until it starves and stalls. That relieves the pressure. Turn the key off and disconnect the battery negative cable so the pump cannot energize by accident. Remove the side plastics needed to expose the tank flange and the run heading toward the throttle body, slide the pan underneath, and drape a rag over the first joint before opening it, because standing fuel remains in the hose regardless.

Push clamps well back along the hose before disturbing a fitting. On a self-locking quick-connect, compress both release tabs squarely and draw it straight off the nipple; sideways prying splits collars that have grown brittle with age. Where varnish has cemented hose to barb, a gentle quarter turn twist usually frees it, and if it does not, slit the hose lengthwise and peel it away rather than deforming the fitting. Photograph the routing before the old piece is entirely clear. As a 4x4 chassis, this Sportsman runs its line past front differential and driveline hardware, giving it a longer path with more clearance points and retaining clips than a two wheel drive machine has.

Putting the New Line In

Cut the replacement to match the original length exactly. Surplus hose sags into moving parts or wears through against a frame edge. Push each end fully onto its barb and install it dry — grease, oil, and silicone spray must stay off fuel fittings, because a lubricated sealing surface gives pressurized fuel a route to migrate out from under the clamp. When an end resists, dip it in hot water for ten or fifteen seconds and it will slide on unassisted.

Place fresh clamps just inboard of the raised bead on each fitting so they cannot walk off, and tighten them evenly rather than crushing the hose wall. A quick-connect coupler needs no clamp: push until the collar clicks and then pull firmly to confirm the latch engaged. Return the hose to every original clip so it keeps clearance from exhaust heat and the front driveline.

Confirming the Repair Holds

Reinstall the fuse, Reconnect the battery, and cycle the key on and off four or five times without cranking. Each cycle runs the pump and pressurizes the circuit while everything is still clean and dry, the easiest condition in which to catch a weep. Study both joints, wipe them down, and inspect again. Then start the engine and hold a clean white rag near each fitting for a minute or two at idle before the plastics and seat go back on.

One platform note to carry forward: on the injected Sportsman 570 the fuel filter is part of the pump assembly inside the tank rather than an inline element on the visible hose. New line does nothing for a restricted filter, so if delivery symptoms survive a clean installation, that in-tank module is where the diagnosis continues.

Related Shopping Categories

Shop Fuel Lines for a 2020 Polaris Sportsman 570 ATV.

Shop Fuel Line Clamps for a 2020 Polaris Sportsman 570 ATV.

Shop Petcocks for a 2020 Polaris Sportsman 570 ATV.

Shop Fuel Filters for a 2020 Polaris Sportsman 570 ATV.

Shop Fuel Stabilizer for a 2020 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.