Polaris Sportsman 570 Fuel Pump Replacement: Your Complete DIY Repair Guide

Replacing a faulty fuel pump on your Polaris Sportsman 570 ATV is a critical repair you can tackle yourself with the right tools, parts, and detailed guidance. Ignoring fuel pump failure means your ATV simply won't run – fuel cannot reach the engine. Symptoms like sputtering, loss of power, hard starting, or a no-start condition signal potential pump issues. Procrastination can strand you unexpectedly and potentially damage other engine components. This comprehensive guide provides every step you need to safely and effectively replace the Polaris Sportsman 570 fuel pump assembly in your own garage, saving significant time and money over dealer service costs. It covers essential diagnostics, required parts and tools, detailed disassembly instructions, installation steps, testing procedures, and vital safety precautions to ensure a successful repair. Accessing the pump requires removing the fuel tank, as the pump module sits inside it – a standard design for this model. Performing this repair requires mechanical aptitude and strict adherence to safety measures due to working with gasoline.

Understanding Fuel Pump Failure on the Polaris Sportsman 570

The fuel pump in your Sportsman 570 is a submerged electric pump housed within a module inside the fuel tank. Its job is to pull fuel from the tank and deliver it under consistent pressure to the engine's fuel injectors via the fuel line. Failure occurs gradually in most cases, with wear on internal components like brushes and bearings being common causes. Heat buildup and constant operation cycles contribute to degradation. Using contaminated or old gasoline significantly accelerates wear by introducing debris and gum deposits into the pump inlet and filter. Neglected fuel filters, often integrated into the pump module, becoming clogged also forces the pump to work harder, increasing failure risk. Symptoms manifest as insufficient fuel delivery: the engine stumbles under load, struggles to start, loses power randomly, or won't start at all despite having spark and air. In rare cases, the pump fails abruptly with no warning signs – often a wiring or relay issue, but sometimes catastrophic internal failure.

Essential Tools and Parts for the Replacement

Gathering everything beforehand prevents frustrating mid-repair interruptions. Required Tools: A basic metric socket set (typically sizes 8mm, 10mm, 12mm, 13mm are essential), ratchets and extensions, Phillips and flathead screwdrivers, needle-nose pliers, standard pliers, a fuel line disconnect tool set (specifically the correct size for the Polaris quick-connect fuel lines – usually 3/8" or 5/16"), a torque wrench suitable for small fasteners (inch-pounds range), shop towels, and a drain pan large enough to catch 4-5 gallons of fuel. Critical Safety Gear: Heavy-duty, chemical-resistant gloves designed for gasoline handling, impact-rated safety glasses, and a fire extinguisher rated for flammable liquids must be easily accessible at your workspace – never skip this. Replacement Part: The necessary component is a complete Polaris Sportsman 570 Fuel Pump Assembly. This includes the electric pump itself, often a pre-filter sock strainer, the pressure regulator, internal electrical connections, and the module housing with the fuel level sender. Purchase a quality OEM or reputable aftermarket assembly specifically engineered for the 570 model to ensure compatibility and reliability. Optional But Recommended: A low-pressure electric fuel pressure test gauge kit helps verify pump operation later. Plastic trim removal tools protect plastic parts when prying panels.

Crucial Safety Precautions Before Starting

Gasoline is dangerously flammable. Work in a well-ventilated area, ideally outdoors away from any structures or indoors with maximum cross-ventilation. Ensure there are absolutely no open flames, sparks, cigarettes, or any heat sources nearby, including water heaters, furnaces, or power tools not explicitly rated for flammable environments. Disconnect the negative (-) battery cable immediately before beginning any work near the fuel system to eliminate any risk of electrical sparks – tape the cable end away from the terminal to prevent accidental contact. Allow the engine to cool completely if it has been run recently to avoid handling a hot tank. Have your fire extinguisher directly beside you and confirm your gloves and eyewear are properly worn. Understand that gasoline vapors are heavier than air and can travel significant distances – maintain constant vigilance. Never use power tools during the tank removal or pump access phases. Keep skin contact with gasoline to an absolute minimum.

Step-by-Step Fuel Tank Removal for Pump Access

1. Depressurize the Fuel System: Start with a cold engine and the battery disconnected. Locate the fuel pressure test port near the throttle body or fuel rail (refer to your service manual). Place shop towels around it and carefully depress the center Schrader valve using the tip of a screwdriver or a dedicated valve tool. Expect a brief spray of fuel as pressure releases. Capture fuel with towels.
2. Relieve Remaining Fuel Tank Pressure: Carefully remove the fuel filler cap to equalize pressure inside the tank.
3. Locate and Drain the Fuel Tank: Position your large drain pan under the rear of the ATV below the tank bottom. Find the fuel tank drain plug (a hex-head bolt) typically positioned at the lowest point of the tank. Slowly loosen the drain plug, allowing fuel to flow smoothly into the pan. Be prepared – several gallons will drain out. Once drained, completely remove the plug and let all residual fuel drip out. Reinstall the drain plug finger-tight for now. Dispose of drained fuel responsibly at an approved hazardous waste facility; never pour it down drains or on the ground.
4. Disconnect Electrical Connections: Identify and disconnect the electrical connector attached to the fuel pump module. This is usually found on top of the fuel tank near where it feeds the wiring harness. Squeeze the locking tab to release and pull apart. Also, disconnect the connector for the fuel level sender on the pump module itself – note positions or take pictures.
5. Remove Fuel Lines: Locate the fuel supply and return lines near the tank outlet. These use quick-connect fittings. Insert the correct size fuel line disconnect tool into each fitting around the fuel line. Push the tool in firmly, then push the line itself towards the fitting. While holding pressure inward, pull the tool outward to release the retaining tabs inside the fitting. Once released, the line will pull straight out. Be prepared for minor fuel spillage.
6. Remove Vent/Vapor Lines: Detach any smaller vent and vapor recovery hoses connected to the tank top or neck. These usually pull off plastic nipples or may have small hose clamps. Note their locations. Release any wiring harness clips attached to the tank.
7. Support the Tank and Remove Mounting Bolts/Straps: Place a stable support like a transmission jack or sturdy box under the tank center. Locate the tank mounting points: typically two bolts at the rear (near the bed) securing brackets or tabs, and a strap system secured by bolts or nuts near the front. Carefully remove the rear mounting bolts and the front strap bolts/nuts.
8. Lower and Remove the Fuel Tank: Gently lower your support. Tilt and manipulate the tank carefully to clear the frame or any obstructions, ensuring no wires or hoses are still attached. Lift it clear of the ATV. Place it on a stable, clean surface where you have ample space to work.

Removing the Old Fuel Pump Module

1. Clean the Top Surface: Thoroughly wipe away all dirt and debris from the large circular locking ring and the surrounding area on the tank top where the pump module sits. Contamination falling into the tank is a major concern.
2. Unlock and Remove the Locking Ring: Positioned centrally, this ring holds the pump module sealed within the tank. It has multiple lugs. Using a suitable tool like a brass drift punch and a hammer, or a dedicated spanner wrench, strike the ring firmly counter-clockwise until it disengages and loosens. Continue tapping it loose until you can lift it off completely by hand. Store it safely.
3. Extract the Fuel Pump Module: Carefully grasp the plastic module assembly. There is a plastic tab specifically designed for this – use it. Lift the entire module straight up out of the tank opening. It carries the fuel level float arm, so lift vertically without tilting excessively to avoid bending the arm. Once partially out, angle it gently to clear the float arm through the opening.
4. Separate the Pump Assembly (Optional): With the module out, you often have the pump attached to a hanger with electrical connections. Disconnect these clips. Remove any screws securing the pump bracket to the module top plate. Separate the pump itself from the plastic hanger and strainer sock. Compare the old pump assembly physically with your new one to confirm compatibility before proceeding further.

Installing the New Polaris Sportsman 570 Fuel Pump Assembly

1. Transfer Necessary Components: Inspect the module housing and top plate. If serviceable, transfer the plastic hanger and strainer sock from the old module assembly to the new one. Check alignment and ensure the sock is firmly attached. If components are worn or damaged, use the new ones provided with the assembly. Reattach the fuel level sender float arm securely to the new assembly, copying the old configuration exactly. Ensure the gasket on the new pump module top plate is in perfect condition, clean, correctly positioned, and free of grease or damage. Do not reuse the old gasket – it will leak.
2. Lower the New Assembly into the Tank: Carefully lower the new pump module assembly straight down into the tank opening. Ensure the fuel level float arm enters first and remains unbent. Orient the module according to any notches or alignment marks on the tank opening – it should fit smoothly. Ensure the electrical connections exit the tank opening towards their future harness path and that the gasket is correctly seated within the tank opening's lip.
3. Secure with the Locking Ring: Place the locking ring back onto the tank top over the module flange. Ensure it engages correctly with the tank's threads. Using your drift punch and hammer, tap the ring firmly clockwise to lock it securely into place. Alternate striking points to apply even pressure until the ring is uniformly tight against the tank top around its entire circumference. Do not overtighten excessively as plastic components can break, but ensure it is secure and the gasket is fully compressed.
4. Final Check Inside: Visually verify the fuel pump strainer sock hangs freely at the bottom of the tank and the float arm moves smoothly without binding against the tank walls.

Reinstalling the Fuel Tank

1. Position the Tank: Carefully lift the tank and maneuver it back into place over the frame. Align the mounting points. Ensure all fuel lines, vent hoses, and wiring harnesses inside the engine bay are ready to connect and won't be pinched.
2. Secure Tank Mounts: Place the support back under the tank slightly to hold its weight. Reinstall the front strap bolts/nuts, tightening them securely. Reinstall the rear mounting bolts and tighten to factory specifications if available, or until firmly snug. Remove the support.
3. Reconnect Electrical: Reattach the primary electrical connector for the pump module near the tank top. Reconnect the fuel level sender connector onto its terminals on the module. Secure the wiring harness to any clips.
4. Reconnect Fuel Lines: Push the fuel supply and return lines firmly onto their respective quick-connect fittings until a distinct "click" is heard and felt, confirming they are fully locked. Pull gently on each line to verify security. This is critical – improper connection causes leaks or pressure loss.
5. Reconnect Vent/Vapor Lines: Slide all vent and vapor recovery hoses back onto their nipples or secure them with clamps.
6. Reinstall Fuel Filler Cap: Replace the fuel filler cap securely.

Refilling and System Testing

1. Reconnect the Negative Battery Cable: Secure the cable back onto the negative (-) battery terminal and tighten.
2. Add Fresh Fuel: Pour clean, fresh gasoline into the tank – 2-3 gallons minimum to cover the pump inlet.
3. Prime the Fuel System: Turn the ignition key to the "ON" position (do not start the engine). Listen carefully near the fuel tank. You should hear the new fuel pump run loudly for approximately 2-5 seconds as it pressurizes the system, then shut off. Turn the key to "OFF". Repeat this "key-on" cycle 2-3 times to ensure the pump primes the fuel lines fully. If you hear no priming noise, double-check all electrical connections and the battery connection immediately.
4. Check for Fuel Leaks: Before attempting to start, perform a meticulous leak check: Inspect all fuel line connections, the module locking ring perimeter, the tank drain plug, and around the fuel filler neck. Look for any signs of wetness or dripping fuel. Never skip this step. If any leaks are found, DO NOT start the engine. Shut off the key, disconnect the battery again, and repair the leak source. Have towels ready.
5. Initial Startup Attempt: Assuming no leaks, attempt to start the engine. It may crank for slightly longer than normal as fuel fills the lines completely. Allow it to start and idle.
6. Monitor Engine Operation: Once running, observe the ATV carefully. Listen for smooth, steady idle without hesitation or misfire. Note the instrument panel – the fuel gauge should register the fuel level accurately. Be alert for any smell of gasoline. Let it run for several minutes while continuing to watch for leaks.
7. Performance Test: After warm-up, engage drive and gently ride the ATV at low speed nearby. Test gentle acceleration and higher RPM operation. Ensure smooth power delivery without stumbling or hesitation, especially under load. Return to the work area.
8. Final Verification: Re-inspect all fuel connections once more thoroughly while the engine is still running and warm, confirming absolutely no leaks exist. Listen for any unusual noises from the pump – a consistent, steady low hum is normal. A loud whine, grinding, or clicking indicates a potential issue.

Post-Installation Tips and Troubleshooting

Perform short, local rides initially after the repair instead of long excursions, allowing close monitoring. Pay attention to any recurring symptoms – they demand immediate investigation. Avoid "bad gas": Consistently use fresh, top-tier fuel and consider adding a fuel stabilizer suitable for ethanol blends if the ATV sits unused frequently, as old gas damages the pump. Replace the fuel filter as recommended by the manufacturer; a clogged filter strains the pump. Key troubleshooting points: If priming noise is absent, immediately disconnect power and inspect the main fuel pump fuse and relay. Ensure all connectors clicked securely into place. If the ATV runs poorly or dies, recheck fuel line connections and electrical continuity at the pump connector (use a multimeter for +12V ignition power and ground continuity). Suspect air trapped in the fuel system – prime the pump several more times with key cycles before restarting. If leaks occur at the module, the locking ring likely isn't tight enough or the gasket is damaged/missing – depressurize the system and reinspect immediately. Difficult starting alone after replacement sometimes indicates a related fuel injector issue or a problem with the fuel pressure regulator on the new module.

Conclusion

Successfully replacing the fuel pump in your Polaris Sportsman 570 ATV restores vital engine functionality. While requiring caution due to the inherent risks of gasoline and system pressure, following the detailed steps outlined – meticulous tank removal, careful old pump extraction, proper new pump installation, secure tank reinstallation, leak-free connections, and thorough testing – empowers you to achieve professional results safely at home. The process grants invaluable understanding of your ATV's fuel delivery system and substantial cost savings. Prioritize safety preparations and leak detection checks above all else. Once confirmed leak-free and running correctly, your Sportsman is ready for dependable operation. Proper fuel maintenance practices prevent premature pump failure, safeguarding your investment. Enjoy the satisfaction and capability restored to your trusted off-road companion.