Fuel Line Work on the 2020 Sportsman Touring 570 EPS

Shop parts for a 2020 Polaris Sportsman Touring 570 EPS ATV.

Fuel plumbing is the kind of maintenance that gets ignored until it demands attention, and by then you are usually stranded or standing in a puddle. Replacing the supply hose on a 2020 Sportsman Touring 570 EPS is well within reach for anyone comfortable with hand tools, provided you respect what you are working with. The ProStar 570 in this machine is electronically fuel injected, so the hose carries pressurized gasoline from a tank-mounted pump and there is no petcock in the system to close before you start.

Laying Out Parts and Preparing the Space

Have everything staged before a fitting comes loose:

  • Nitrile or rubber gloves, since gasoline defats skin quickly
  • A drain pan plus a sealed container approved for fuel
  • Replacement hose in the original inside diameter, rated for injection pressure
  • New clamps sized to your fittings
  • Line-clamping pliers, which substitute for the petcock this model does not have
  • Razor knife, rags, a small flat screwdriver, and sockets for the seat and plastics

Ventilation matters more than most people credit. Gasoline vapor is denser than air and pools at floor level, which is where cords, lights, and heaters usually sit. Roll the machine into the open or raise the overhead door fully, remove anything with a pilot flame from the space, postpone grinding and welding, and keep an extinguisher nearby.

Why the Rubber Stops Doing Its Job

Fuel hose stays pliable because of plasticizers mixed into the rubber, and heat cycling next to a working engine drives those compounds out over the seasons. As the wall stiffens it loses the ability to move with the chassis, and the vibration of a long two-up frame turns that rigidity into fine cracks, typically at a bend or under a clamp that has squeezed the same ring of material since the machine was new.

The inside of the hose faces a different threat. Ethanol-blended pump gas absorbs moisture and slowly breaks down the inner liner, so a Sportsman that sits a few months with E10 in it can be soft and flaking internally while the exterior still looks acceptable. Machines in dry regions harden faster on the outside as well, since low humidity keeps drawing moisture out of the rubber.

Signs You Should Not Ignore

A wet spot or puddle under the machine after it has been parked is the clearest signal, but the subtler ones matter just as much. A gasoline odor that hangs around the tank after shutdown, visible crazing on the hose surface, or a section that feels rigid when you pinch it all indicate the line is finished. Dirt caked into a dark ring at a fitting is dried fuel from a weep that has been going on quietly.

Pay attention to performance too. Bogging under load, hesitation when you crack the throttle open, or a lean surge at cruising speed suggest the engine is being starved. On this injected platform a small pressure-side breach frequently atomizes and evaporates rather than dripping, so a clean floor does not clear the line if the smell says otherwise.

Extracting the Worn Hose

Kill the pressure before anything else. Pull the fuel pump fuse, crank the engine until it stalls, turn the key off, then disconnect the negative battery cable. Take off the seat and enough bodywork to reach the tank outlet and follow the hose forward to the throttle body.

Slide the pan underneath and keep a rag over the joint you are opening, because a bled line is not an empty line. Move worm-gear or spring clamps well back along the hose before disturbing the fitting. On a locking quick-connect, press the release tabs squarely and pull straight off — prying sideways on aged plastic is how those collars break. Break the varnish bond at each barb with a gentle twist rather than a hard pull, and split a bonded hose lengthwise with the razor instead of risking the fitting.

Study the routing before the old piece is entirely free. This chassis has a longer wheelbase than a standard Sportsman and carries On-Demand AWD hardware forward, so the hose passes additional clips and clearance points. Photograph each one before it comes apart.

Fitting the New Line and Confirming It Holds

Cut the replacement to the same length as the original. Extra slack chafes on frame tubes or drifts toward the exhaust; a short piece keeps both ends under tension. Seat each end fully onto its barb, dry, until it bottoms against the shoulder. Grease, oil, and silicone all stay off the fittings, because a lubricated sealing surface is exactly what lets pressurized fuel creep past a clamp. Warm a stubborn end in hot water for a few seconds instead of forcing it.

Set new clamps just behind the raised bead on each fitting, tightened evenly and firmly without cutting into the rubber. A self-locking quick-connect pushes home until it clicks and requires no clamp at all; verify the latch with a solid tug. Reseat the hose in every original clip so it stays away from the driveline and hot surfaces.

Refit the fuse, Reconnect the battery, and cycle the key on and off several times without cranking. The pump primes each cycle and pressurizes the line while the joints are still dry, which is the most honest test you can run. Wipe both connections and look for beading, then start the engine, idle it several minutes, and check again as heat builds. Turn the handlebars through their full sweep to make sure nothing pulls. Worth noting at the end: the filter on this injected 570 is part of the in-tank pump module rather than an inline component, so if delivery still feels weak after a leak-free install, that assembly is next.

Related Shopping Categories

Shop Fuel Lines for a 2020 Polaris Sportsman Touring 570 EPS ATV.

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

Shop Petcocks for a 2020 Polaris Sportsman Touring 570 EPS ATV.

Shop Fuel Filters for a 2020 Polaris Sportsman Touring 570 EPS ATV.

Shop Fuel Stabilizer for a 2020 Polaris Sportsman Touring 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.