2016 Polaris Sportsman 570 Fuel Pump Problems: What Owners Need to Know and How to Fix Them
If you own a 2016 Polaris Sportsman 570 and the engine cranks but won't start, sputters under load, or dies after a few minutes of riding, the fuel pump is the most likely cause. Across owner forums, repair shops, and Polaris service bulletins, the 2016 Sportsman 570 has a well-documented pattern of fuel pump failures tied to heat soak, contaminated fuel, and worn internal components. The good news is that the diagnosis is straightforward, and replacing the pump with a high-quality unit solves the problem in the majority of cases.
This guide walks you through the real-world symptoms, the reasons these pumps fail, how to test yours, and what to look for in a replacement.
Most Common Symptoms of a Failing Fuel Pump on the 2016 Sportsman 570
1. Long cranking before the engine fires. A healthy fuel pump builds pressure the moment you turn the key. When the pump is weak, the engine has to crank for several seconds before enough fuel reaches the injectors. You turn the key, hear the starter spin, but nothing happens right away.
2. The engine starts but dies shortly after. This is one of the most reported complaints. The machine starts cold, runs for a few minutes, then stalls once it warms up. Heat buildup inside the pump causes the internal motor to lose efficiency, and once it gets hot enough, it stops delivering fuel.
3. Loss of power under load or at higher speeds. You are riding along, you give it throttle going up a hill or across a field, and the engine bogs down or cuts out. The pump cannot keep up with the fuel demand, so the engine starves under load even though it idles fine.
4. Sputtering, backfiring, or rough idle. An inconsistent fuel supply makes the air-fuel mixture unstable. You may hear popping through the intake or exhaust, and the idle speed may fluctuate on its own.
5. No sound from the fuel tank when you turn the key. On a working machine, you should hear a brief whir or hum from the fuel pump for about two to three seconds when the key is switched on. Silence means the pump is not running or not getting power.
6. The engine will not start at all. In a complete failure, the pump delivers no fuel, and the engine will not fire regardless of how long you crank it.
Why the 2016 Sportsman 570 Fuel Pump Fails
1. Heat soak. The fuel pump on the Sportsman 570 sits inside the fuel tank, and the tank is mounted close to the engine and exhaust on this model. Fuel normally cools the pump, but when the fuel level is low or the machine sits idling in hot weather, the pump runs hot with little cooling. Repeated overheating wears down the internal motor and brushes.
2. Contaminated or stale fuel. Ethanol-blended gasoline absorbs water over time. Water in the tank leads to corrosion inside the pump and clogging of the filter screen. Machines that sit for weeks between rides are especially prone to this, because the fuel breaks down and leaves deposits behind.
3. Clogged intake filter (strainer). The pump has a fine mesh sock on the intake side. Dirt, rust particles from the tank, and degraded fuel varnish collect on that screen. Once it is restricted, the pump has to work harder, runs hotter, and burns out sooner.
4. Electrical problems. A failing relay, corroded connector, blown fuse, or damaged wiring will cut power to the pump. In some 2016 machines, the wiring harness near the tank rubs against the frame and causes an intermittent connection. A pump that tests bad may actually be a wiring issue, so checking the electrical side first saves money.
5. Normal wear. Pumps do not last forever. On machines with high hours, hard trail use, or frequent deep-water crossings, the internal components wear out through normal use.
How to Confirm the Fuel Pump Is the Problem
1. Listen for the prime. Turn the key to the on position without starting the engine. Put your ear near the fuel tank or have someone else turn the key while you listen. You should hear the pump run for a couple of seconds. No sound points to the pump, the relay, the fuse, or the wiring.
2. Check the fuel pressure. The 2016 Sportsman 570 fuel injection system requires a specific pressure range to run correctly. Connect a fuel pressure gauge to the test port on the fuel rail. If the pressure is below specification or drops quickly after the pump shuts off, the pump or the pressure regulator is at fault. Most shops and many owners with a service manual do this test in a few minutes.
3. Inspect the filter screen. Remove the pump assembly from the tank and look at the intake sock. If it is dark, coated with varnish, or packed with debris, the pump has been straining to pull fuel.
4. Test the electrical supply. Use a multimeter to check for battery voltage at the pump connector when the key is turned on. If voltage is present but the pump does not run, the pump itself is bad. If there is no voltage, trace the circuit back through the fuse, relay, and wiring harness.
5. Try a prime with fresh fuel. If the machine has been sitting, drain old fuel and add fresh gasoline. Sometimes what looks like pump failure is actually bad fuel. If the machine runs normally on fresh fuel, the pump may still be fine.
What to Do When Your Pump Is Bad
1. Do not keep riding on a failing pump. Running the engine lean because of low fuel pressure causes damage over time. A pump that is intermittently cutting out leaves you stranded on the trail, which is both inconvenient and unsafe far from home.
2. Replace the complete assembly. On the Sportsman 570 the pump, strainer, pressure regulator, and sender come as one assembly inside the tank. Replacing the whole unit is faster and more reliable than trying to rebuild individual pieces.
3. Clean the tank while you are in there. If there is debris, water, or varnish in the bottom of the tank, a new pump will fail the same way. Flush the tank and let it dry before installing the replacement.
4. Use fresh, clean fuel going forward. Fill up with quality gasoline, avoid leaving the machine parked for long stretches with a near-empty tank, and consider a fuel stabilizer if you ride only seasonally.
5. Check the wiring and grounds. Before installing the new pump, repair any chafed wires, clean corroded connectors, and confirm the relay is good. This protects your investment in the new part.
Choosing a Replacement Fuel Pump
Not all replacement pumps perform the same. The original equipment unit on the 2016 Sportsman 570 has a known failure history, so many owners look for an upgraded aftermarket option that fits without modification and delivers consistent pressure.
1. Match the fitment. The pump must be a direct fit for the 2016 Sportsman 570 so the assembly drops into the tank and connects to the existing harness and fuel line without adapters.
2. Look for stable pressure output. A good replacement holds the correct pressure across the full RPM range and does not fade as it heats up.
3. Check the warranty. A manufacturer that stands behind its pump with a strong warranty is telling you something about how it is built.
4. Consider a high-performance build. Machines that see hard use, bigger tires, or long rides in hot weather benefit from a pump designed to run cooler and last longer than a basic replacement.
Recommended Replacement: KEMSO Fuel Pumps
For 2016 Polaris Sportsman 570 owners looking for a dependable fix, KEMSO fuel pumps are worth a close look. Every KEMSO fuel pump is built as a high-performance OEM replacement, engineered to match factory fitment while delivering stronger, more consistent fuel delivery than a worn stock unit. KEMSO backs its fuel pumps with a lifetime warranty, which is a clear sign of confidence in the product and real protection for the buyer.
Instead of replacing a failing pump with another part that may fail the same way, KEMSO offers a high-performance option that installs directly, runs cooler under load, and is covered for life. For anyone tired of the same 2016 Sportsman 570 fuel pump problems coming back, this is the practical upgrade.
You can see the full range of KEMSO fuel pumps and find the correct fitment for your machine here: https://www.kemsoracing.com/
Preventing the Problem From Coming Back
1. Keep the tank reasonably full. Fuel cools the pump. Running the tank down to empty regularly shortens pump life, especially in summer.
2. Avoid long periods of storage with old fuel. If the machine will sit for more than a month, add a fuel stabilizer or drain the tank.
3. Replace the fuel filter on schedule. A restricted filter forces the pump to work harder than it should.
4. Fix electrical issues right away. A weak connection or failing relay stresses the pump motor and leads to early failure.
5. Listen to your machine. Hard starting, sputtering, or power loss under load are early warnings. Addressing them early costs far less than a tow off the trail.
Bottom Line
The 2016 Polaris Sportsman 570 fuel pump problems come down to heat, contaminated fuel, clogged strainers, electrical faults, and normal wear. The symptoms are consistent and easy to spot: hard starting, stalling when hot, bogging under load, and no prime sound at key-on. Testing the pump with a pressure gauge and a multimeter confirms the diagnosis in most cases. Replacing the complete assembly with a quality unit, cleaning the tank, and checking the wiring puts the machine back in reliable service.
For a replacement that combines high performance, direct OEM replacement fit, and a lifetime warranty, KEMSO is the brand to consider for your 2016 Sportsman 570.
Visit https://www.kemsoracing.com/ to find the right KEMSO fuel pump for your machine.