How to Replace a Fuel Line on the 2023 Sportsman Touring 570 EPS
Shop parts for a 2023 Polaris Sportsman Touring 570 EPS ATV.
A length of fuel hose costs almost nothing and takes an hour to change, yet a neglected one can end a weekend or start a fire. On a 2023 Sportsman Touring 570 EPS the job is entirely manageable at home once you know what system you are opening. The ProStar 570 here is electronically fuel injected, meaning an in-tank pump keeps the supply hose pressurized whenever the key is on, no petcock exists to close, and the fuel filter lives inside the tank rather than inline where you can reach it.
Why Hoses Harden and Split
Fuel line rubber depends on plasticizers for its flexibility, and heat cycling next to the engine drives those additives out season after season. What was once soft and conformable turns stiff and glassy, and at that point it can no longer move with the chassis. The long two-up Touring frame generates real flex over rough ground, and that flex is what turns a hardened hose into a cracked one, usually at a bend or under a clamp that has been squeezing the same band of material since new.
Fuel itself contributes. Ethanol-blended gasoline absorbs moisture from the air and gradually breaks down the hose's inner liner, so a machine that sits a few months with E10 in the system can end up soft and shedding internally while looking fine from outside. Owners in arid country see the external hardening progress faster because there is no humidity to slow it.
Symptoms of a Line on Its Way Out
A puddle or damp shine beneath the machine after it has been parked is the unmistakable one. Less obvious tells include a gasoline smell around the tank that will not clear after shutdown, visible crazing or a chalky texture on the hose, and a section that feels rigid compared to the rest when you pinch it. A dark ring of dirt at a fitting is dried fuel from slow weeping.
Watch the engine as well. Bogging under load, a stumble when you snap the throttle open, or lean-feeling surging at steady speed all say the engine is not getting the fuel volume it needs. Keep in mind that a pressurized leak frequently atomizes and evaporates rather than dripping, so a persistent smell over a clean floor still means there is something to find.
Supplies and Shop Air
- Nitrile or rubber gloves
- A drain pan and a sealed container approved for fuel storage
- Replacement hose in the original inside diameter, rated for fuel-injection pressure
- New clamps matched to your fittings, or a clamp assortment
- Line-clamping pliers, which take over the shutoff role a petcock would fill
- Razor knife, rags, a small flat screwdriver, and sockets for the seat and panels
Do the work outside or with the overhead door fully raised. Gasoline vapor is heavier than air and settles at floor level, exactly where cords, lights, and heaters usually sit, so ventilation down low matters far more than an open window overhead. Pull any pilot-flame appliance from the space, skip grinding and welding, and have an extinguisher within reach.
Taking the Old Hose Off
Relieve pressure first. Pull the fuel pump fuse, crank the starter until the engine dies, turn the key off, and disconnect the negative battery cable so nothing can run the pump while your hands are in the system. Remove the seat and enough bodywork to reach the tank outlet and follow the hose forward to the throttle body.
Slide the pan underneath and lay a rag over the fitting you are opening, because a bled line still holds 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 and pull straight off rather than levering, since aged plastic collars crack easily. Break each barb loose with a gentle twist instead of a hard pull, and if the hose has gummed itself on, split it lengthwise with the razor and peel it away.
Note the routing before the old piece is fully out. The Touring chassis carries a longer wheelbase and On-Demand AWD hardware up front, so the hose passes more brackets and clearance points than a short 2WD quad would present. Photograph each clip as you go.
Installation and Final Verification
Cut the new hose to the same length as the original. Too long and it chafes a frame tube or sags toward the exhaust; too short and both fittings stay tensioned. Seat each end fully onto its barb, dry, until it bottoms against the shoulder. No grease, no oil, no silicone spray — lubricant on a sealing surface is precisely how pressurized fuel finds a way past the clamp. Soften a stiff end in hot water for a few seconds if needed.
Place new clamps just behind the raised bead on each fitting and tighten evenly, firm without cutting into the rubber. A self-locking quick-connect pushes home until it clicks and needs no clamp; verify with a solid tug. Reseat the hose in every original clip so it stays clear of the driveline and hot surfaces.
Reinstall the fuse, Reconnect the battery, and cycle the key on and off several times without cranking so the pump pressurizes the circuit while the joints are dry. Wipe both connections with a clean rag and inspect for beading. Start the engine, idle it for several minutes, check again as heat builds, and turn the bars through their full sweep. If everything stays dry but fuel delivery still feels weak, the in-tank pump and filter assembly is your next target rather than more hose work.
Related Shopping Categories
Shop Fuel Lines for a 2023 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Line Clamps for a 2023 Polaris Sportsman Touring 570 EPS ATV.
Shop Petcocks for a 2023 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Filters for a 2023 Polaris Sportsman Touring 570 EPS ATV.
Shop Fuel Stabilizer for a 2023 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.