Fuel Line Renewal on the 2022 Polaris Sportsman Touring 570

Shop parts for a 2022 Polaris Sportsman Touring 570 ATV.

The first question to answer on a 2022 Sportsman Touring 570 is which fuel system you are dealing with, because the answer dictates every step that follows. This machine runs the ProStar 570 single with electronic fuel injection. An electric pump inside the tank pressurizes the supply hose running to the throttle body, and no petcock exists anywhere in the circuit. Where a carbureted quad would let you close a valve, drain a float bowl, and pull clamps at leisure, this one holds pressure until you deliberately bleed it off.

Deciding Whether the Hose Needs Replacing

Take the seat off and evaluate honestly. Squeeze the hose in several places and compare; sound rubber compresses and rebounds, while a stiff or glassy section has already given up. Bend a curve and look for fine cracks in the outer surface. Check both fittings for a dark ring of grime, which is dirt trapped by fuel that seeped and dried. Trust your nose as well — a gasoline odor around the tank that persists after shutdown is meaningful even with nothing on the floor, since pressurized fuel escaping a pinhole often mists off before it can drip.

Running behavior tells the same story. Bogging under load, hesitation when you open the throttle quickly, or a lean surge at steady cruise all suggest the supply is compromised somewhere between the tank and the injector.

Why Hoses Fail With Age

Fuel line rubber stays supple thanks to plasticizers, and heat cycling next to the engine drives those additives out over the years. Once the wall stiffens it stops flexing with the frame, and a long two-up chassis working over rough ground provides plenty of vibration to open hairline splits at bends and clamp positions. Machines living in arid regions harden faster, since dry air keeps drawing moisture out of the rubber.

Ethanol works from the inside. E10 gasoline pulls in atmospheric moisture and slowly degrades the hose's inner liner, so a Sportsman that sits idle for a few months with fuel in the system can be soft and shedding internally while the exterior still looks presentable. That is why the calendar deserves as much weight as a visual inspection.

Setting Up the Job Safely

Gather these before you begin:

  • Nitrile or rubber gloves
  • A drain pan and a sealed, fuel-rated storage container
  • Replacement hose in the correct inside diameter, rated for injection pressure rather than gravity feed
  • New clamps to match your fittings
  • Line-clamping pliers, which do the petcock's job on this model
  • Razor knife, rags, a small flat screwdriver, and sockets for the seat and bodywork

Work outdoors or with the overhead door fully raised. Gasoline vapor is heavier than air and settles low, which is exactly where power tools and heaters tend to sit, so ventilation at floor level matters far more than an open window overhead. Clear the space of flames and sparks and keep an extinguisher within arm's reach.

Taking the Line Apart

Bleed the pressure before loosening anything. Pull the fuel pump fuse, crank the starter until the engine stalls, shut the key off, then disconnect the negative battery cable. Remove the seat and whatever plastics block your access to the tank outlet and the hose run forward to the throttle body.

Slide the pan into position and lay a rag across the first joint you open, because a depressurized line still contains fuel. Push worm-gear or spring clamps well back along the hose before disturbing the fitting. On a locking quick-connect, press the release tabs squarely with even pressure and pull straight off; aged plastic collars snap when levered sideways. Break each barb loose with a gentle twist rather than a hard yank, and if the hose has gummed itself on, slit it lengthwise and peel it away rather than risking the fitting.

Map the routing before the old piece is out. The Touring chassis is longer than a standard Sportsman and carries On-Demand AWD hardware forward, so the hose threads past additional brackets and clearance points. Photograph every clip.

Installing the New Hose and Proving It

Cut the replacement to match the original exactly. Too long and it chafes a frame tube or drapes toward the exhaust; too short and both fittings stay under tension. Push each end fully onto its barb until it bottoms out against the shoulder, and do it dry. Grease, oil, and silicone all belong nowhere near a fuel fitting — a lubricated sealing surface is precisely the escape path pressurized fuel needs. Hot water for a few seconds will soften a stiff end enough to seat.

Set new clamps just behind the raised bead on each fitting, tightening evenly and firmly without cutting into the rubber. Where a self-locking quick-connect is used, push until it clicks and confirm with a solid tug; that fitting seals itself and takes no clamp. Reseat the hose in every original clip so it stays clear of the front driveline and hot surfaces.

Refit the fuse, Reconnect the battery, and cycle the key on and off several times without cranking so the pump brings the line to pressure while the joints are still dry. Wipe both connections and look hard for beading. Start the engine, idle it several minutes, and inspect once more as heat builds, swinging the handlebars fully both ways to load the routing. If everything stays dry but the machine still feels short on fuel, remember the filter is integrated with the in-tank pump assembly rather than being an inline part, and that module becomes your next stop.

Related Shopping Categories

Shop Fuel Lines for a 2022 Polaris Sportsman Touring 570 ATV.

Shop Fuel Line Clamps for a 2022 Polaris Sportsman Touring 570 ATV.

Shop Petcocks for a 2022 Polaris Sportsman Touring 570 ATV.

Shop Fuel Filters for a 2022 Polaris Sportsman Touring 570 ATV.

Shop Fuel Stabilizer for a 2022 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.