Changing the Fuel Line on a 2023 Sportsman 570 EPS

Shop parts for a 2023 Polaris Sportsman 570 EPS ATV.

There is one step on this job that cannot be skipped, and it comes before any tool touches the machine: taking the pressure out of the fuel system. The 2023 Polaris Sportsman 570 EPS uses the ProStar 567cc single with electronic fuel injection, which means a pump inside the tank keeps the supply hose pressurized. Turning the key off does not bleed that pressure. Open a fitting cold and you get a spray of gasoline rather than a controlled trickle into a pan.

Relieving Pressure the Right Way

The sequence is short and worth following in order. Pull the fuel pump fuse or relay so the pump cannot run. Crank the engine for several seconds until it stalls or refuses to fire, which consumes the pressurized fuel remaining downstream. Switch the key off. Then disconnect the negative battery cable so nothing energizes while your hands are in the fuel plumbing. Because this Sportsman has no petcock — there is no valve to rotate and no gravity feed to interrupt — line-clamping pliers do that job for you when you need to isolate a section of hose. That is a genuine difference from an older carbureted quad, where closing a valve and draining a float bowl handles the same task.

Why the Line Needed Replacing in the First Place

Fuel hose fails through gradual chemistry. On the outside, engine heat cycles and years of weather steadily drive the plasticizers out of the rubber, leaving a wall that is stiff rather than supple. Dry climates hasten it because arid air pulls moisture out of the hose and hardens it from the surface inward. On the inside, ethanol-blended pump gas absorbs atmospheric water and works on the liner, leaving gum and softening the material, most aggressively when fuel sits still for weeks. A hardened hose can no longer absorb the vibration a big single sends through the frame, so cracks appear at the bends and right at the barbs.

The Symptoms That Send You Looking

  • Gasoline odor around the seat and tank, sharpest in the first minutes after shutdown
  • A damp spot or small puddle under the mid-chassis after the machine has sat overnight
  • Fine surface cracking, a chalky gray cast, or a stretch of hose that feels rigid to the pinch
  • Bogging under load, hesitation off idle, or an engine behaving as though it is out of fuel with a full tank
  • Dirt caked in a ring at a fitting, which is what repeated seeping and drying leaves behind

Because a pressurized leak often atomizes and evaporates before dripping, a strong recurring smell with no stain underneath still justifies replacing the hose.

Tools and a Straight Word on Gasoline

Stage everything first: nitrile gloves and eye protection, a drain pan, a sealed fuel-rated container, replacement hose in the correct inside diameter rated for injection pressure, fresh clamps in the existing style, a quick-disconnect release tool, line-clamping pliers, a socket set, a small flat blade, a razor knife, and clean rags.

Ventilation deserves real attention rather than a nod. Gasoline vapor is heavier than air, so it settles and creeps along the floor toward any ignition source sitting down at that level — a water heater pilot, a shop furnace, a hot work lamp on the concrete. Work outdoors or with the door open all the way, kill anything with a flame or a spark, and keep gloves on for the duration, since gasoline strips the oils right out of your skin.

Removing the Hose Without Breaking Anything

With pressure relieved and the battery disconnected, take off the seat and the side panels covering the tank and the hose run heading forward to the throttle body. Slide the drain pan underneath and drape a rag over the first joint you separate, because the hose remains full of fuel even after depressurizing.

Work any existing clamp well back along the hose before disturbing the fitting. If a self-locking quick-connect is used at the pump flange, press its tabs evenly and pull the coupler straight off the port. Prying sideways is how a weathered plastic collar breaks. Barbed connections normally need a gentle twist to break the varnish bond built up over years of service. When a hose will not release, slit it lengthwise with a razor and peel it away instead of forcing it and stressing the fitting.

Pay attention to routing. This is a 4x4 chassis, so the line runs past front differential hardware and threads through frame clearance points a two-wheel-drive machine does not have, held by clips that keep it clear of heat and moving parts. Photograph the path before the old hose is fully out.

Installation and Proving the Repair Dry

Cut the new hose to the length you removed and no more. Extra length lets the hose chafe against the frame or drift toward exhaust. Push each end fully onto its barb until it bottoms out against the shoulder, and install it dry. Grease, oil, and silicone spray must never go on a fuel fitting, since lubricant on the sealing face gives pressurized fuel a path past a clamp that seems perfectly tight. Soften a stubborn end in hot water for half a minute if needed.

Position new clamps just behind the raised bead on each fitting and tighten evenly rather than crushing one side. Self-locking quick-connects click when they seat; confirm with a firm tug and add no clamp. Return the hose to each original retainer so it holds position away from the front driveline and heat.

Reinstall the fuse or relay, Reconnect the battery, then cycle the ignition on and off five or six times without cranking. Each cycle runs the pump and pressurizes the circuit, which is the ideal moment to inspect both joints while the surrounding area is dry. Wipe each with a clean rag and look for the slightest transfer. Start the engine, let it idle for several minutes, and check once more with the system at full running pressure before the bodywork goes back on.

Keep one platform detail in mind: the fuel filter on this injected 570 sits inside the tank as part of the pump module rather than inline where you could swap it alongside the hose. Fresh line resolves a leaking line. Continued bogging or starvation after a dry, leak-free install points toward that in-tank assembly.

Related Shopping Categories

Shop Fuel Lines for a 2023 Polaris Sportsman 570 EPS ATV.

Shop Fuel Line Clamps for a 2023 Polaris Sportsman 570 EPS ATV.

Shop Petcocks for a 2023 Polaris Sportsman 570 EPS ATV.

Shop Fuel Filters for a 2023 Polaris Sportsman 570 EPS ATV.

Shop Fuel Stabilizer for a 2023 Polaris Sportsman 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.