2023 Sportsman Touring 570: Replacing a Worn Fuel Line

Shop parts for a 2023 Polaris Sportsman Touring 570 ATV.

A fuel line does not usually fail spectacularly. It hardens quietly for years, develops a weep nobody notices, and then splits on a trail miles from the truck. Staying ahead of that on a 2023 Sportsman Touring 570 takes nothing more than a periodic look and an hour of work when the hose is due. This machine's ProStar 570 is electronically fuel injected, so the supply hose carries pressurized fuel from a tank-mounted pump and there is no petcock in the system to shut off flow.

Removal Starts With Killing Pressure

Because there is no fuel valve, the first move is depressurizing the circuit. Pull the fuel pump fuse, crank the starter until the engine coughs and dies, turn the key off, then disconnect the negative battery cable so nothing can energize the pump while your hands are in the fuel system. Only then does bodywork come off — the seat and whatever side panels stand between you and the tank outlet plus the hose run to the throttle body.

Slide a drain pan underneath and drape a rag over the fitting you plan to open. Bleeding the pressure does not empty the hose, and the residual fuel comes out quicker than most people expect. Line-clamping pliers are worth having here to pinch off any section you want to isolate, since the petcock a carbureted quad would offer simply does not exist on this platform.

Working the Fittings Loose

Slide worm-gear or spring clamps well back along the hose before you attempt to move the hose on the barb. If your Touring 570 uses a locking quick-connect, depress the release tabs with even, square pressure and pull straight off. Do not lever those collars sideways; the plastic grows brittle with heat and age and will crack. At each barb, twist the hose gently to break the varnish bond instead of pulling with force. When a hose has effectively glued itself in place, slit it lengthwise with a razor and peel it off — protecting the fitting is worth far more than saving a hose you are discarding.

Note the routing carefully as the old line comes out. The Touring's longer wheelbase and On-Demand AWD front driveline give the hose more brackets, clips, and clearance points to pass through than a compact two-wheel-drive quad. Photographs of each retention point save real time on reassembly.

Why the Rubber Wore Out

Fuel hose depends on plasticizers for flexibility, and heat cycling beside a working single-cylinder engine drives those compounds out season after season. As the wall stiffens it no longer moves with the chassis, and the vibration of a long two-up frame opens hairline cracks at bends and under clamps. Dry climates accelerate this, since low humidity continually pulls moisture out of the rubber.

Ethanol-blended gasoline attacks from the other side. E10 draws in moisture and degrades the hose's inner liner over time, so a Sportsman that sits a few months with fuel in the system can be soft and flaking internally while the exterior still looks acceptable. Material shed from that liner travels toward the injector, which is why the age of the hose matters as much as how it looks.

Symptoms That Precede a Failure

  • A puddle or damp patch beneath the machine after it has sat overnight
  • A gasoline smell hanging around the tank, sharpest right after shutdown
  • Fine cracking, chalky texture, or a rigid section you find by pinching along the hose
  • A dark, dirt-caked ring at a fitting, left by fuel that has been weeping and drying
  • Bogging under load, a stumble on hard throttle, or lean-feeling surging at cruise

On this injected platform, fuel escaping a pinhole under pressure frequently atomizes and evaporates rather than dripping. A clean floor is not proof of a healthy line when the smell says otherwise.

Putting the New Hose In Place

Cut the new hose to match the original length. Extra slack chafes on frame tubes or sags toward the exhaust, while a short piece keeps constant tension on both fittings and eventually works itself loose. Push each end fully onto its barb until it seats against the shoulder, and install it completely dry. Grease, oil, and silicone all compromise the joint by giving pressurized fuel a slick path past the clamp. If the hose is too stiff to seat, dip the end in hot water for a few seconds.

Position new clamps just behind the raised bead on each fitting, snugged evenly and firmly without cutting into the rubber. A self-locking quick-connect simply pushes home until it clicks; tug it to confirm the latch and leave the clamp off, since that design seals on its own. Return the hose to every original clip so it stays away from the driveline and hot exhaust.

Leak Check Before the Panels Go On

Reinstall the fuse, Reconnect the battery, and cycle the key on and off five or six times without cranking. The pump primes each cycle and brings the hose up to full pressure while the joints are still dry and easy to read. Wipe both connections with a clean rag and inspect for beading or dampness. Start the engine, hold it at idle several minutes, and look again as heat builds, turning the bars through their full sweep. Bodywork goes back on only after several minutes of leak-free running.

Worth remembering afterward: the filter on this injected 570 is part of the in-tank pump assembly, not a serviceable inline component. If fuel delivery still feels soft once the new hose is proven tight, that module is the logical next thing to address.

Related Shopping Categories

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

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

Shop Petcocks for a 2023 Polaris Sportsman Touring 570 ATV.

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

Shop Fuel Stabilizer for a 2023 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.