How to Change Out the Fuel Line on a 2020 Sportsman Touring 570
Shop parts for a 2020 Polaris Sportsman Touring 570 ATV.
Gasoline demands respect, and that is the honest starting point for this job. Before you touch the fuel plumbing on a 2020 Sportsman Touring 570, get the machine into open air or throw the overhead door wide. Fuel vapor is heavier than air and settles at floor level, which is where extension cords, work lights, and heaters usually live. Kill anything with a flame or a spark, keep a fire extinguisher within reach, and wear gloves — gasoline pulls the oil straight out of your skin.
Knowing What System You Are Working On
The ProStar 570 in this machine is electronically fuel injected. That means the supply hose is part of a pressurized circuit fed by a pump mounted inside the tank, and there is no petcock anywhere to close. You cannot simply shut a valve and start pulling clamps the way you would on an older carbureted quad. Pressure has to be relieved on purpose, and line-clamping pliers take over the job the petcock would have done. The fuel filter is bundled into that in-tank pump module rather than sitting inline where you could reach it.
Why the Old Hose Gave Out
Fuel hose relies on plasticizers to stay pliable, and those additives migrate out under years of engine heat. As the rubber hardens it loses the ability to move with the chassis, and the ordinary vibration of a long two-up frame starts opening hairline splits, typically at a bend or right where a clamp has compressed the same ring of material for a decade.
Fuel chemistry finishes the job from inside. Ethanol-blended gasoline draws moisture from the air and gradually breaks down the hose's inner liner, so a Sportsman that sits for a stretch with E10 in the system can be soft and shedding internally while the exterior still looks acceptable. Dry-climate machines suffer more on the outside, since low humidity accelerates the drying of the hose wall.
Symptoms Worth Chasing Down
- Fuel puddled or smeared beneath the machine after it has been parked
- A gasoline smell that lingers near the tank, strongest just after shutdown
- Surface cracking, a chalky feel, or a hardened length you notice while pinching the hose
- Dark, dust-caked rings at a fitting, which are dried fuel from slow weeping
- The engine bogging under load, stumbling on hard throttle, or running lean at cruise
On an injected machine, a small breach on the pressure side often atomizes and evaporates rather than dripping. A strong smell with a clean floor still means you have a leak to find.
Removing the Line
Start by pulling the fuel pump fuse and cranking the starter until the engine quits. That dumps the stored pressure. Switch the key off and disconnect the negative battery terminal so nothing can run the pump while you work. Remove the seat and the side plastics blocking the tank outlet and the hose run to the throttle body.
Slide a drain pan underneath and keep a rag over whichever fitting you are opening; a depressurized line is not an empty one. Move worm-gear or spring clamps well back along the hose before you disturb the fitting itself. If your Touring 570 uses a locking quick-connect, press the release tabs squarely and pull straight off, never at an angle, because those plastic collars grow brittle with age. Break each barb loose with a gentle twist instead of a hard pull, and slit the hose lengthwise with a razor if it has gummed itself in place. The fitting matters more than a hose you are discarding.
Trace the routing before the old piece is entirely out. This chassis carries a longer wheelbase and On-Demand AWD hardware up front, so the hose passes more clips, brackets, and clearance gaps than a short two-wheel-drive quad. Photograph each retention point.
Installing and Sealing the New Line
Cut the replacement to match the original length precisely. Extra length rubs on frame tubes or drifts toward the exhaust, and a short piece stays tensioned and eventually walks off a barb. Push both ends on dry, seating each until it bottoms against the fitting shoulder. Do not lubricate the fittings with grease, oil, or silicone; a slick sealing surface is exactly the path pressurized fuel needs to escape past a clamp. Dip a stiff hose end in hot water for a few seconds if it will not go on.
Position new clamps immediately behind the raised bead on each fitting and tighten them evenly, firm without crushing the rubber. A self-locking quick-connect simply pushes home until it clicks; tug it firmly to confirm and leave the clamp off, because that design seals itself. Reseat the hose in every original clip so it stays clear of moving driveline parts and hot exhaust.
Testing the Repair
Reinstall the fuse, Reconnect the battery, and cycle the key on and off five or six times without cranking. The pump primes on each cycle, pressurizing the line while the connections are still dry and easy to read. Wipe both fittings with a clean rag and look closely for beading or dampness. Then start the engine, hold it at idle for several minutes, and inspect again as heat builds, turning the handlebars through their full sweep to load the routing.
If everything stays dry but the machine still feels starved for fuel, shift your attention to the in-tank pump and filter assembly. Fresh hose cures leaks and cracking, not a restricted filter buried inside the tank.
Related Shopping Categories
Shop Fuel Lines for a 2020 Polaris Sportsman Touring 570 ATV.
Shop Fuel Line Clamps for a 2020 Polaris Sportsman Touring 570 ATV.
Shop Petcocks for a 2020 Polaris Sportsman Touring 570 ATV.
Shop Fuel Filters for a 2020 Polaris Sportsman Touring 570 ATV.
Shop Fuel Stabilizer for a 2020 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.