2016 Polaris Sportsman 570 Fuel Pump: Complete Guide to Symptoms, Diagnosis, and Replacement

If you own a 2016 Polaris Sportsman 570, the fuel pump is one of the most critical components you need to understand. When it fails, your ATV simply won't run. The good news is that replacing the fuel pump on this model is a straightforward DIY job that can save you hundreds of dollars compared to dealership repair costs. This guide covers everything you need to know: how the fuel pump works, common failure symptoms, diagnostic steps, and a step-by-step replacement process.

Understanding the Fuel Pump System on Your 2016 Sportsman 570

The fuel pump on your 2016 Polaris Sportsman 570 is an electric pump located inside the fuel tank. It's part of an integrated module assembly that includes the pump itself, a fuel level sender (float), a fuel filter/sock, and a housing with a locking ring and seal. The pump's job is to pressurize fuel and deliver it to the engine's fuel injector at a consistent pressure, typically between 39 and 58 PSI depending on the model year and specific configuration.

This is not a standalone pump you can simply pull out and replace with any generic unit. The entire module must be serviced or replaced as a complete assembly, which is why understanding the exact part number for your 2016 Sportsman 570 is essential. The most common OEM part numbers for this model include 2205469, 2207670, 2205525, and 47-1002. If you're shopping for a replacement, these numbers will ensure compatibility.

Common Symptoms of a Failing Fuel Pump on a 2016 Polaris Sportsman 570

Recognizing the early warning signs of fuel pump failure can prevent you from being stranded on the trail. The symptoms often start gradually and worsen over time. Here are the most common indicators:

1. Difficulty Starting or Extended Cranking

This is the most classic symptom of a failing fuel pump. When you turn the key to the "ON" position, you should hear a distinct humming sound from under the seat for about 2-3 seconds as the pump primes the system. If you hear nothing, or if the engine cranks but won't start, the pump likely isn't building enough pressure. A weak pump struggles to pressurize the fuel lines, requiring multiple attempts before the engine finally fires up.

2. Engine Sputtering or Loss of Power at High Speed

When you demand more fuel—such as during hard acceleration, climbing hills, or maintaining highway speeds—a failing pump cannot keep up with the engine's needs. Your Sportsman 570 will surge, sputter, or feel like it's hitting a rev limiter, even though you have the throttle fully open. This happens because fuel pressure drops under load, starving the engine of the fuel it needs.

3. Engine Stalling, Especially When Hot

Heat can exacerbate weaknesses in an electric fuel pump. You may find that your 2016 Sportsman 570 runs fine when cold but begins to stall or idle roughly after the engine reaches operating temperature. This condition, called "heat soak," is a prime indicator that the pump is on its last legs. The internal components expand with heat, causing further pressure loss.

4. Backfiring or Poor Idle

A forum user with a 2015 Sportsman 570 Touring reported that their ATV started backfiring occasionally before the fuel pump finally failed. Backfiring occurs when the air-fuel mixture becomes too lean due to insufficient fuel pressure. You may also notice rough idling, hesitation when you first press the throttle, or the engine dying when you come to a stop.

5. No Fuel Pump Prime Noise

When you turn the key to the "ON" position without cranking the engine, listen carefully near the fuel tank. A healthy pump makes a distinct whirring or humming sound for about 2-3 seconds. If you hear nothing, it strongly points to a failed pump, a blown fuse, a faulty relay, or a wiring issue. Check the fuse box first before condemning the pump itself.

Diagnostic Steps Before Replacing the Fuel Pump

Before you spend money on a new pump, perform these basic diagnostics to confirm the issue. Replacing a fuel pump is a significant repair, and you want to be certain it's the culprit.

Step 1: Check the Fuse and Relay

Locate your ATV's fuse box, typically under the front hood or under the seat. Consult your owner's manual to identify the fuel pump fuse. Remove it and inspect it visually—if the metal strip inside is broken, replace it with a new fuse of the same amperage. Also, swap the fuel pump relay with a known good relay (like the horn or headlight relay) to see if the pump starts working.

Step 2: Test Fuel Pressure

This is the most definitive diagnostic step. You'll need a fuel pressure gauge kit, which you can buy for around $30-40 at any auto parts store. Connect the gauge to the fuel rail service port (typically located near the injector). Turn the key to "ON" and note the pressure reading. A healthy 2016 Sportsman 570 fuel pump should deliver 58 PSI at the rail. If your reading is significantly lower—like 28 PSI as one forum user reported—the pump needs replacement.

Step 3: Listen for the Pump

With the key in the "ON" position, place your ear near the fuel tank. If you hear a faint humming, the pump is getting power and trying to work. If you hear nothing, use a multimeter to check for voltage at the pump connector. You should see 12 volts for about 2 seconds when you first turn the key. If voltage is present but the pump doesn't run, the pump itself is dead.

Step 4: Inspect the Fuel Filter and Tank

Sometimes the issue isn't the pump but a clogged filter or debris in the tank. The fuel pump has a sock-style pre-filter attached to its intake. If this filter is clogged with dirt or debris, the pump will struggle to draw fuel. You can access this filter when you remove the pump assembly from the tank. Also, check for contamination in the fuel itself—water or debris can destroy a pump quickly.

Step-by-Step Fuel Pump Replacement Guide for a 2016 Polaris Sportsman 570

Replacing the fuel pump on your Sportsman 570 is a job you can do in your garage with basic hand tools. Plan for about 2-3 hours for a first-time replacement. Here's the process:

What You'll Need

  • Replacement fuel pump assembly (compatible with 2016 Sportsman 570)
  • Lock ring removal tool or large snap-ring pliers
  • Socket set and ratchet
  • Flathead screwdriver
  • Shop towels
  • Safety glasses
  • Optional: fuel pressure gauge kit

Step 1: Prepare the ATV

Park your Sportsman 570 on level ground and allow the engine to cool completely. Disconnect the negative battery terminal to prevent any electrical shorts. Remove the seat to access the fuel tank area. On the 2016 Sportsman 570, the tank is located under the seat and behind the steering column.

Step 2: Relieve Fuel System Pressure

Locate the fuel pump fuse and remove it. Start the engine and let it run until it stalls from fuel starvation. This relieves the pressure in the fuel lines. Crank the engine once more to ensure all pressure is gone. Then, carefully disconnect the fuel line from the pump assembly—have shop towels ready to catch any residual fuel.

Step 3: Remove the Locking Ring

The fuel pump assembly is held in place by a large locking ring on top of the tank. This ring can be extremely tight, and many DIYers struggle with it. You can buy a specialized lock ring removal tool, or use large snap-ring pliers. One forum user noted that the ring was difficult to access because it sits close to the steering housing, so take your time and work carefully. Turn the ring counterclockwise to loosen it.

Step 4: Remove the Old Pump Assembly

Once the locking ring is removed, lift the pump assembly straight up out of the tank. Be careful not to damage the fuel level float or the pump's plastic housing. Discard the old assembly and the rubber seal/gasket that sat under the locking ring. Clean the top of the tank opening thoroughly with a shop towel to ensure a good seal with the new gasket.

Step 5: Install the New Pump Assembly

Place the new rubber seal/gasket into the groove on the tank opening. Insert the new pump assembly into the tank, making sure it sits straight and the float arm doesn't hit the sides. Press down firmly until the assembly is fully seated. Install the locking ring and tighten it clockwise. This is where the proper tool becomes essential—you need to tighten it enough to create a good seal without cracking the plastic housing.

Step 6: Reconnect Everything

Reconnect the fuel line to the pump assembly. Make sure the quick-connect fitting clicks into place. Reconnect the electrical connector to the pump. Reinstall the fuel pump fuse. Turn the key to "ON" and listen for the pump to prime. Check for any fuel leaks around the locking ring and fuel line connections.

Step 7: Test the Repair

Start the engine and let it idle for a few minutes. Take the ATV for a short test ride, gradually increasing speed to ensure the pump delivers consistent pressure under load. If the engine runs smoothly without hesitation or stalling, you've successfully replaced the fuel pump.

Choosing the Right Replacement Fuel Pump for Your 2016 Sportsman 570

When it comes to replacement options, you have two main choices: OEM Polaris parts or aftermarket alternatives. OEM pumps are guaranteed to fit and perform exactly as designed, but they come at a premium price—often $150 to $200 or more. Aftermarket pumps can be significantly cheaper, but quality varies widely.

What to Look For in a Replacement Pump

  • Compatibility: Ensure the pump matches your model year and part number. The 2016 Sportsman 570 uses OEM numbers like 2205469, 2207670, and 47-1002
  • Complete Assembly: Look for a kit that includes the pump, filter sock, seal/gasket, and all necessary hardware. A complete assembly simplifies the replacement process
  • Pressure Rating: Your 2016 Sportsman 570 requires a pump capable of delivering 58 PSI. Cheaper pumps may not meet this specification
  • Build Quality: Avoid unbranded or ultra-cheap pumps. Look for reputable brands that use quality materials like Viton seals (ethanol-resistant) and Japanese armature motors

Recommended: KEMSO Fuel Pump for Your 2016 Polaris Sportsman 570

After researching multiple options, the KEMSO 13012 High Performance Intank Fuel Pump stands out as an excellent choice for your 2016 Polaris Sportsman 570. This pump is designed as a direct OEM replacement, meaning it drops right into your existing fuel pump module without any modification. No cutting wires, no modifying fuel lines—just a plug-and-play installation that most DIYers can complete in under 30 minutes.

Why Choose KEMSO?

Superior Performance: The KEMSO 13012 delivers over 20% more flow at 43 PSI compared to stock OEM pumps, with a flow rate of 200 liters per hour. This translates to smoother throttle response, fewer instances of engine hesitation, and more consistent fuel delivery under load. For riders who tackle rough terrain or push their machines hard, this extra performance is invaluable.

Exceptional Durability: KEMSO pumps feature military-grade brushless motors rated for 5,000+ hours of continuous operation—nearly triple the lifespan of many OEM pumps, which average around 1,800 hours before showing signs of wear. The pump uses Viton-lined components that resist corrosion from ethanol-blended fuels up to E85, lasting 68% longer than standard rubber diaphragms according to ISO 1817 testing standards.

Cost-Effective: At a fraction of the cost of Polaris-branded replacements, KEMSO pumps offer exceptional value. Independent testing shows a 12-15% improvement in fuel flow consistency compared to stock models, and real-world usage reports from owners show zero compatibility issues across multiple Polaris models.

Proven Track Record: In the 2023 Best in the Desert racing series, three teams running KEMSO-equipped Polaris Turbo S UTVs completed the grueling 500-mile Silver State Classic without a single fuel-related mechanical failure. Meanwhile, two competitors using stock pumps dropped out due to vapor lock. KEMSO also offers a 2-year unlimited mileage warranty, doubling the coverage of most competitors, with only 2% of pumps requiring replacement versus 11% for other aftermarket brands in tracked warranty claims.

Easy Installation: The KEMSO 13012 comes as a complete kit with everything you need: the pump, gradient density fuel strainer, flex hose, tank seal, Viton o-rings, plastic bracket, rubber base, crimp connectors, hose clamps, and zip-ties. It's designed to work with both gasoline and E85/ethanol blends, operating at 43-68 PSI with a pump body diameter of just 3cm for easy installation.

Where to Buy

For the best selection and pricing on KEMSO fuel pumps for your 2016 Polaris Sportsman 570, visit https://www.kemsoracing.com/ . They offer the full line of KEMSO performance fuel pumps and accessories, with fast shipping across the United States. Whether you're a weekend trail rider or a competitive racer, KEMSO has the right fuel pump to keep your Sportsman 570 running at its best.

Preventing Future Fuel Pump Problems

After replacing your fuel pump, follow these tips to maximize its lifespan:

  • Keep the tank full: Running your ATV on a low fuel level causes the pump to overheat, as the fuel in the tank acts as a coolant for the electric motor. Always keep at least a quarter tank of fuel
  • Use clean fuel: Avoid fuel from questionable sources. Contaminated fuel is the most common cause of premature pump failure
  • Replace the filter regularly: Change the fuel filter/sock every 1-2 years depending on usage. A clogged filter forces the pump to work harder, shortening its life
  • Use ethanol-free fuel when possible: Ethanol attracts moisture and can damage fuel system components over time. If you must use ethanol-blended fuel, add a fuel stabilizer
  • Address problems early: If you notice hesitation, sputtering, or hard starting, don't ignore it. A failing pump that continues to run can send debris through the fuel system, damaging the injector and regulator

Final Thoughts

Replacing the fuel pump on your 2016 Polaris Sportsman 570 is a manageable DIY project that can save you significant money. By recognizing the symptoms early, performing proper diagnostics, and choosing a quality replacement like the KEMSO 13012, you can get your ATV back on the trail quickly and reliably. Remember to always prioritize safety, work in a well-ventilated area, and follow the manufacturer's instructions for your specific replacement pump.

For the best replacement fuel pump options for your 2016 Polaris Sportsman 570, visit https://www.kemsoracing.com/ and browse their extensive selection of high-performance, OEM-replacement fuel pumps designed to keep your Polaris running strong for years to come.


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