Choosing and Installing New Fuel Line on a 2024 Sportsman 570
Shop parts for a 2024 Polaris Sportsman 570 ATV.
Hose is not generic. That is the single most expensive lesson available on this job, and it is worth learning before you order anything for a 2024 Sportsman 570. This machine runs the ProStar 567 single with electronic fuel injection, so the supply line carries fuel under genuine pump pressure rather than the low pressure gravity flow a carbureted quad relies on. There is no petcock anywhere on it. Fit the wrong hose and it will swell, weep at the barbs, and eventually let go.
Specifying the Right Hose and Hardware
- Hose rated for fuel-injection service, in the same inside diameter as the piece you remove. General purpose carburetor line is not a substitute on a pressurized circuit.
- New clamps sized to the hose outside diameter, in whichever style your machine actually uses. Fresh hose deserves fresh clamps; reusing tired ones invites a slow seep.
- A quick-disconnect release tool if you find a self-locking coupler at the pump flange or throttle body
- Line-clamping pliers for pinching off low pressure or vent hose, since this platform gives you nothing to shut
- An approved sealed container, a wide shallow catch pan, and plenty of clean rags
- Nitrile gloves, a razor knife, a flashlight, and sockets for the seat and side plastics
Handling Gasoline Without Drama
Gasoline vapor is denser than air. It settles to the floor and travels outward at that level, where it can find a water heater pilot, a shop heater, a battery charger, or a spark from a power tool. Move the 570 outdoors if the weather cooperates, or open the overhead door fully and place a fan low to the ground pushing air out of the space. Keep an extinguisher within arm's reach rather than on a far wall, and leave the gloves on for the duration, because fuel strips skin oils on contact and its additives pass through skin.
What Was Wrong With the Old Hose
Fuel line degrades on two fronts. Externally, heat cycling from the engine and constant chassis vibration drive out the plasticizers that keep the compound flexible. The hose hardens, and a hardened hose develops fine cracks wherever the frame flexes it, those cracks progressing inward season after season. Riders in arid country see it happen sooner, because low ambient humidity draws moisture out of the hose wall.
Internally, ethanol-blended fuel does its own work. E10 absorbs water from the atmosphere, and fuel that sits motionless in the line through a long layup slowly attacks the liner while leaving gum and varnish at the barb joints. The two processes are independent, which is why a hose can look and feel serviceable while its liner has already begun flaking material downstream toward the injector.
Signs You Should Not Ignore
- Raw fuel smell around the tank, most noticeable right after shutdown while the circuit still holds pressure
- Dried residue forming a caked dust ring at either fitting
- Visible checking, a chalky gray finish, or a stiff glassy stretch you can feel by pinching the hose
- A damp patch, stain, or puddle under the machine after it sits overnight
- Bogging under throttle, stumbling on acceleration, or a lean condition that mimics a low tank
On a pressurized system, escaping fuel often atomizes and evaporates before it reaches the ground, so an absent puddle does not exonerate the hose.
Killing the Pressure, Then Unhooking the Hose
Pull the fuel pump fuse or relay, then crank the engine for a few seconds until it runs out of supply and stops. That relieves the pressure. Switch the key off and disconnect the battery negative cable. Remove the seat and whatever side plastics stand between you and the tank flange and the hose run heading toward the throttle body. Position the pan and drape a rag over the first joint before opening it, because a depressurized hose still holds standing fuel.
Push clamps well back along the hose before you disturb a fitting. On a quick-connect, press both tabs squarely and pull straight off the nipple; angled prying splits collars that have grown brittle. If varnish has glued hose to barb, a gentle twist normally frees it, and if it does not, slit the hose lengthwise and peel it away rather than deforming the fitting. Photograph the path before the old hose is fully clear. This is a 4x4 machine, so front differential and driveline hardware dictate a longer routing with additional clearance points and retaining clips compared with a two wheel drive layout.
Fitting the New Line Correctly
Cut the replacement to the exact length of the original. Surplus hose sags into moving parts or wears through against a frame edge over time. Seat each end fully on its barb and install it completely dry. Grease, oil, and silicone spray stay off fuel fittings without exception, since a lubricated sealing surface gives pressurized fuel a path to creep out beneath the clamp. Soften a stubborn end in hot water for ten seconds and it will slide on unaided.
Place fresh clamps just inboard of the raised bead so they cannot migrate, and tighten uniformly rather than crushing the hose wall. A self-locking quick-connect needs no clamp at all: push until the collar clicks, then tug firmly to confirm the latch engaged. Feed the hose back through each original clip so it keeps clearance from exhaust heat and the front driveline.
Leak Check and Final Assembly
Reinstall the fuse, Reconnect the battery, and cycle the key on and off five times without cranking. Each cycle pressurizes the line while the surrounding area is still dry, the ideal condition for spotting a weep. Inspect both joints carefully, wipe them clean, and look again. Then start the engine and hold a fresh rag near each fitting for a minute or two at idle before the plastics and seat go back on.
Keep one detail in mind afterward: the injected 570 carries its fuel filter inside the tank as part of the pump assembly rather than as an inline element on the visible hose. New line will not resolve a restricted filter, so if starvation symptoms outlive a clean installation, that in-tank module is the next component to address.
Related Shopping Categories
Shop Fuel Lines for a 2024 Polaris Sportsman 570 ATV.
Shop Fuel Line Clamps for a 2024 Polaris Sportsman 570 ATV.
Shop Petcocks for a 2024 Polaris Sportsman 570 ATV.
Shop Fuel Filters for a 2024 Polaris Sportsman 570 ATV.
Shop Fuel Stabilizer for a 2024 Polaris Sportsman 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.