Replacing the Fuel Line on a 2021 Sportsman Touring 570 EPS
Shop parts for a 2021 Polaris Sportsman Touring 570 EPS ATV.
Identify the fuel system before you plan anything else. The 2021 Sportsman Touring 570 EPS runs the ProStar 570 single with electronic fuel injection, which means an electric pump inside the tank pressurizes the supply hose feeding the throttle body. No petcock exists on this machine, there is no float bowl to drain, and the circuit stays pressurized until you deliberately relieve it. Every step below is shaped by those facts, and skipping the first one is how garages end up smelling like gasoline for a week.
Relieving Pressure and Gaining Access
Pull the fuel pump fuse and crank the starter until the engine coughs and dies. That burns off the stored pressure in the line. Turn the key off, then disconnect the negative battery terminal so the pump cannot be energized while your hands are inside the fuel system. Remove the seat and the side panels standing between you and the tank outlet plus the hose run forward.
Put a drain pan underneath and keep a rag over whichever fitting you plan to open first. Depressurizing does not empty the hose, and residual fuel escapes faster than expected. This is where line-clamping pliers earn their place, taking over the shutoff duty that a carbureted quad's petcock would have handled.
What Made the Old Hose Fail
Fuel hose relies on plasticizers to remain flexible, and years of heat cycling next to the engine drive those additives out. The wall hardens, stops flexing with the frame, and eventually cracks. On a stretched two-up chassis that works over rough terrain, those cracks show up first at bends and under clamps where the material has been compressed and stressed the longest. Dry climates speed the process because low humidity continually pulls moisture out of the rubber.
Ethanol-blended fuel handles the inside. E10 attracts water and gradually degrades the hose's inner liner, so a machine that sits a few months with fuel in the system can be soft and shedding internally while the outer surface looks presentable. That shed material heads toward the injector, which is why hose age deserves as much weight as appearance.
Symptoms Worth Investigating
- A puddle or damp streak beneath the machine after it has been parked overnight
- Gasoline odor lingering around the tank, sharpest just after shutdown
- Fine cracking, chalky texture, or a hardened section found by pinching along the hose
- A dark, grime-packed ring at a fitting, left behind by fuel that seeped and dried
- Bogging under load, a stumble on hard throttle, or lean surging at steady speed
Do not treat a dry floor as a clean bill of health. Pressurized fuel escaping a pinhole often mists off before it can drip, which is why the smell frequently arrives long before any visible evidence.
Tools and a Real Safety Setup
- Nitrile or rubber gloves
- A drain pan and a sealed, fuel-rated container
- Replacement hose in the original inside diameter, rated for injection pressure
- Fresh clamps matched to the fitting style you find, or a clamp assortment
- Line-clamping pliers to pinch off flow on a machine with no fuel valve
- Razor knife, rags, a small flat screwdriver, and sockets for seat and bodywork
Gasoline vapor is heavier than air and settles at floor level, so ventilation low in the space is what counts. Work outside or with the overhead door fully open, pull any flame-burning heater out of the area, and keep an extinguisher close. Gloves are not optional if you would rather not spend the evening with cracked, stinging hands.
Fitting the New Line and Proving the Repair
Working the old hose off comes down to patience. Slide clamps well back before moving the hose on the barb, press quick-connect tabs squarely and pull straight off rather than levering, and twist gently to break the gum bond at each fitting. If a hose has bonded on, slit it lengthwise and peel it away. Note the routing as it comes out — with a longer wheelbase and On-Demand AWD hardware forward, this chassis threads the hose past more brackets and clearance points than a compact 2WD quad, and photographs of each clip make reassembly simple.
Cut the new hose to match the original exactly. Slack chafes or drifts toward heat; short hose keeps both fittings loaded. Push each end on dry until it bottoms against the shoulder, and use no grease, oil, or silicone anywhere near the sealing surface, since lubricant is precisely what allows pressurized fuel to creep past a clamp. Hot water will soften a stiff end. Set clamps just behind the raised bead on each fitting, tightened evenly without cutting the rubber, and leave a self-locking quick-connect clamp-free after confirming the click with a firm tug. Reseat the hose in every original clip.
Reinstall 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 dry. Wipe both connections and inspect closely for beading, then start the engine, idle it a few minutes, and check again as heat builds while turning the bars lock to lock. Keep in mind that the filter on this injected 570 sits inside the tank as part of the pump assembly rather than inline, so lingering fuel starvation after a leak-free install points there rather than at the hose.
Related Shopping Categories
Shop Fuel Lines for a 2021 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Line Clamps for a 2021 Polaris Sportsman Touring 570 EPS ATV.
Shop Petcocks for a 2021 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Filters for a 2021 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Stabilizer for a 2021 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.