Inspecting and Replacing the Fuel Line on a 2024 Sportsman 570 EPS

Shop parts for a 2024 Polaris Sportsman 570 EPS ATV.

Before you order parts, spend ten minutes with a flashlight. A proper inspection of the 2024 Polaris Sportsman 570 EPS tells you whether the hose is genuinely failing or whether the fuel smell you noticed is coming from somewhere else entirely. Pull the seat, get light on the run of hose between the tank and the throttle body, and work through the machine methodically.

A Hands-On Inspection Routine

  • Squeeze the hose along its full length. Healthy line compresses and springs back; a failing one feels rigid, almost like hard plastic
  • Flex each bend gently and look for fine crazing or a chalky gray bloom opening up on the outer surface
  • Inspect both fittings for a caked ring of dust, which forms where fuel seeps and dries again and again
  • Check the retaining clips. A hose that has slipped a clip may have been rubbing the frame or sitting closer to heat than intended
  • With the seat off, cycle the key on and sniff around the tank flange and the throttle body connection while the pump primes

That last step matters because this machine is electronically fuel injected. On the pressure side, escaping fuel frequently atomizes into a mist that evaporates before it drips, so a leak can be real and obvious to your nose while leaving nothing on the concrete.

Understanding the Fuel Delivery on This Machine

The 2024 Sportsman 570 EPS uses the ProStar 567cc single with electronic fuel injection and on-demand all-wheel drive. There is no petcock beneath the tank, no valve to close, and no gravity feed to shut off. A pump inside the tank pressurizes the supply hose, and pressure lingers after the key comes off. That drives two additions to the procedure: you must relieve pressure deliberately before separating any fitting, and you need line-clamping pliers to stand in for the shutoff valve the machine does not carry. Hardware differs too, with a conventional clamp usually at the throttle body and possibly a self-locking quick-connect coupler at the pump flange that takes no clamp at all.

What Causes the Hose to Degrade

Two mechanisms work in opposite directions on the same rubber. Externally, heat cycling from the engine and ordinary exposure gradually drive out the plasticizers that keep the wall flexible, hardening it until it can no longer move with a vibrating single-cylinder engine or a chassis that flexes over rough ground. Low-humidity climates push this along faster by pulling moisture out of the hose from the surface inward. Internally, ethanol-blended pump gasoline absorbs atmospheric water and slowly attacks the liner, leaving gum deposits and soft spots, particularly during periods when the machine sits with fuel standing in the line. The failures then concentrate exactly where the hose is loaded hardest: at the bends and at the barbs.

Getting Set Up and Working Safely

Have gloves and eye protection, a drain pan, a sealed fuel-rated container, injection-rated replacement hose in the correct inside diameter, fresh clamps, a quick-disconnect release tool, line-clamping pliers, hand tools for the panels and clips, a razor knife, and clean rags on the bench before you begin.

Ventilation is worth taking seriously. Gasoline vapor is denser than air, so it sinks and travels along the floor toward whatever ignition source happens to be at that level rather than venting out an open window overhead. Work outside or with the shop door fully open, shut down space heaters and hot work lights, and keep clear of appliances with standing pilot flames. Wear the gloves the whole time, since gasoline strips skin oils quickly.

Removal and Routing Notes

Relieve pressure first: pull the fuel pump fuse or relay, crank the engine for several seconds until it stalls or refuses to catch, turn the key off, and disconnect the negative battery cable. Remove the seat and the covers over the tank and hose run.

Slide the drain pan into place and lay a rag over the first joint you open, because a depressurized hose still holds fuel. Move any existing clamp well back along the hose before disturbing the connection. A locking quick-connect releases when its tabs are pressed squarely and the coupler is pulled straight off the port; side loading cracks brittle plastic collars. Barbed fittings geneRally need a gentle twist to break years of varnish bonding. If a hose refuses to release, slit it lengthwise and peel it away to protect the barb.

As a 4x4, this Sportsman routes its line past front differential hardware and through frame clearance points a two-wheel-drive machine lacks, so the hose sits in more clips than you might expect. Photograph the layout before the old line is fully clear.

Installation, Leak Test, and Wrap-Up

Cut the replacement to the exact length you removed. Slack invites chafing on the frame or drift toward hot exhaust. Push each end fully onto its barb until it bottoms against the shoulder, and install it dry. Grease, oil, and silicone spray belong nowhere near a fuel fitting, because lubricant on the sealing surface is how pressurized fuel escapes past an otherwise tight clamp. Hot water for thirty seconds is the only correct assist for a stubborn hose end.

Set new clamps just behind the raised bead on each fitting and tighten them evenly. A self-locking quick-connect clicks when it seats, and a firm pull confirms the latch; leave that style clamp-free. Reinstall the hose into every original retainer so it stays away from the driveline and heat.

Restore the fuse or relay, Reconnect the battery, and cycle the key on and off five or six times without cranking. Each cycle primes the pump and pressurizes the hose, giving you a clean, dry field in which to inspect both joints. Wipe each with a fresh rag and look for transfer. Then start the engine, idle it for several minutes, and check once more at full running pressure before the panels and seat return.

One last platform note: the filter on this injected 570 lives inside the tank as part of the pump assembly rather than inline on the visible hose. New line cures a cracked or leaking line, but persistent bogging afterward points to that in-tank module instead.

Related Shopping Categories

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Shop Fuel Stabilizer for a 2024 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.