Is your 2016 Polaris Sportsman 570 sputtering on inclines, struggling to start, or losing power when you hit the throttle? There’s nothing more frustrating than a reliable machine turning into a trailside headache. That weak or failing fuel pump is often the culprit, robbing your ATV of the performance you count on.
You’ve come to the right place. At FatBoysOffroad, we believe in empowering owners to tackle their own repairs. We promise this guide will demystify the 2016 polaris sportsman 570 fuel pump replacement, turning a daunting task into a manageable weekend project that saves you money and gets you back on the trail fast.
In this article, we’ll cover everything from diagnosing the problem with certainty and gathering the right tools to a detailed, step-by-step installation guide. We’ll even throw in some pro tips to make the job smoother and ensure your Sportsman runs strong for years to come.
Why Your Sportsman’s Fuel Pump Fails (And How to Know for Sure)
Before you start turning wrenches, it’s crucial to confirm the fuel pump is actually the problem. A fuel pump is a small electric motor that lives inside your gas tank, responsible for sending fuel at a precise pressure to the engine. Over time, wear, tear, and fuel contaminants can cause it to fail.
Telltale Signs of a Dying Fuel Pump
A failing fuel pump rarely dies without warning. Keep an ear out and a feel for these common symptoms:
- Hard Starting: The engine cranks and cranks but struggles to fire up. This happens because the pump isn’t building enough initial pressure.
- Sputtering or Stalling: Especially under load, like climbing a hill or accelerating hard. The engine is demanding more fuel than the weak pump can deliver.
- Loss of Power: Your Sportsman just feels sluggish and doesn’t have its usual “get up and go.”
- A Whining Noise from the Fuel Tank: A loud, unusual hum or whine from the tank area when you turn the key on is a classic sign of a struggling pump motor.
- Engine Surging: The ATV’s RPMs might randomly increase and decrease as the pump delivers inconsistent fuel pressure.
Confirming the Diagnosis: Fuel Pressure Testing
While the symptoms above are strong indicators, the only way to be 100% sure is with a fuel pressure test. This is one of the most important best practices for any fuel system diagnosis.
You’ll need a fuel pressure gauge. The 2016 Sportsman 570 has a Schrader valve on the fuel rail, making this test relatively simple. Connect the gauge, turn the key to the “on” position (without starting the engine), and check the reading. Your service manual will have the exact spec, but for this model, you should see around 58 psi (+/- 2 psi).
If the pressure is low, inconsistent, or drops off quickly, you’ve found your problem. It’s time for a 2016 polaris sportsman 570 fuel pump replacement.
Gearing Up: Tools and Parts for the Job
Having everything you need on hand before you start makes the process infinitely smoother. Nothing’s worse than having to stop mid-job for a run to the auto parts store.
Essential Tools List
You don’t need a professional shop, but a solid set of basic tools is a must. Here’s what we recommend:
- Socket Set (Metric)
- Wrenches
- Screwdriver Set (Phillips and Flathead)
- Pliers (Needle-nose and standard)
- Torx Bit Set
- A clean drain pan for fuel
- An approved fuel container for siphoning
- Clean, lint-free rags
- Safety Glasses and Nitrile Gloves
- Fire Extinguisher (non-negotiable safety item)
*Siphon pump (optional but highly recommended)
Choosing the Right Replacement Fuel Pump
You have two main options: an OEM (Original Equipment Manufacturer) pump from Polaris or a quality aftermarket pump. OEM guarantees a perfect fit but comes at a premium price. High-quality aftermarket brands like Quantum Fuel Systems or All Balls Racing offer excellent performance and value.
We recommend buying a complete module assembly. This includes the pump, filter, pressure regulator, and sending unit all in one housing. It’s a direct drop-in replacement and eliminates the hassle of rebuilding the old, gunked-up assembly.
The Complete 2016 Polaris Sportsman 570 Fuel Pump Replacement Guide
Alright, you’ve confirmed the diagnosis and gathered your gear. It’s time to get to work. This comprehensive 2016 polaris sportsman 570 fuel pump replacement guide will walk you through every step. Take your time, stay organized, and prioritize safety.
Step 1: Safety First – Prep Your Workspace
You are working with gasoline. Safety is paramount.
- Work in a well-ventilated area, like an open garage or outdoors. Fumes are flammable and hazardous.
- Disconnect the negative terminal of your battery to prevent any accidental sparks.
- Have your fire extinguisher within arm’s reach. No smoking, no open flames, no sparks!
- Give your machine a good wash, especially around the fuel tank and seat area, to prevent dirt from falling into the tank later.
Step 2: Accessing the Fuel Tank
On the Sportsman 570, the fuel pump is accessed from the top of the tank, which sits under the seat and some plastic body panels.
First, remove the seat. Next, you’ll need to remove the plastic body panels surrounding the front of the seat and the fuel tank. These are typically held on by a series of plastic push-rivets and a few bolts. Be gentle with the plastic tabs to avoid breaking them.
Once the plastics are off, you’ll have a clear view of the top of the fuel tank and the fuel pump assembly’s mounting plate.
Step 3: Removing the Old Fuel Pump Assembly
This is where things get hands-on. Before you do anything else, thoroughly clean the top of the tank and around the pump assembly. Use a brush and compressed air if you have it. You do not want any debris falling into your fuel tank.
- Siphon the Fuel: The less fuel in the tank, the easier and safer this job is. Use a siphon pump to transfer as much gasoline as possible into an approved container.
- Disconnect Lines: Carefully disconnect the electrical connector and the fuel line from the top of the pump assembly. The fuel line will have a quick-disconnect fitting; you may need to press a tab or use a special tool. Have a rag ready to catch any residual fuel.
- Unbolt the Assembly: The pump is held in place by a metal retaining ring secured by several bolts (usually 8mm). Loosen these bolts in a star pattern to keep the pressure even.
- Lift Out the Old Pump: Once all bolts are removed, carefully and slowly lift the entire fuel pump assembly straight out of the tank. You may need to angle it slightly to clear the float arm. Be prepared for it to drip fuel—place it directly into a drain pan.
Step 4: Installing the New Fuel Pump
With the old pump out, take a moment to inspect the inside of your fuel tank with a flashlight. Look for any sediment or debris. This is the perfect time to clean it out if needed.
Compare your new pump assembly with the old one to ensure they match. Most importantly, check the new O-ring or gasket that seals the pump to the tank. Never reuse the old gasket.
Carefully lower the new assembly into the tank, making sure not to bend the float arm. Align it correctly with the bolt holes. Re-install the retaining ring and start all the bolts by hand. Tighten them down gradually in a star pattern to ensure the gasket seals evenly. Check your service manual for torque specs, but if you don’t have one, snug and even is the goal—don’t overtighten!
Step 5: Reassembly and Final Checks
You’re on the home stretch! Reconnect the fuel line and the electrical connector. You should hear a solid “click” when they are properly seated.
Before putting all the plastics back on, it’s time for a function check. Reconnect your battery’s negative terminal. Add a gallon or two of fresh gasoline to the tank. Turn the key to the “on” position (don’t start it yet). You should hear the new pump prime for a few seconds. Cycle the key on and off 2-3 times to build full pressure.
Carefully inspect the top of the tank for any leaks. If all looks good, fire up the engine! It may take a few extra seconds of cranking to start. Let it run for a minute and check for leaks again. If everything is dry and the engine is running smoothly, you can shut it off and reinstall all the plastic body panels and the seat.
Benefits of a Timely Fuel Pump Replacement
Putting off this job can lead to more than just a frustrating day on the trail. Here are some of the key benefits of a 2016 polaris sportsman 570 fuel pump replacement:
- Restored Performance: Get back that crisp throttle response and full power you’ve been missing.
- Improved Reliability: No more worrying about getting stranded miles from the trailhead. A new pump is peace of mind.
- Better Fuel Efficiency: An engine receiving the correct fuel pressure operates more efficiently.
- Prevents Further Damage: Running lean due to a weak pump can cause engine damage over time.
Common Problems and Pro Tips for Your Replacement
Even a straightforward job can have hiccups. Here are some common problems with 2016 polaris sportsman 570 fuel pump replacement and tips from our experience:
Pro Tip 1: The Clogged Sock. The pre-filter on the bottom of the pump, often called a “sock,” can get clogged with debris. This is why replacing the entire assembly is often better than just the motor. It ensures your new pump is breathing through a clean filter.
Pro Tip 2: Be Gentle with Fittings. The plastic quick-disconnect fittings can become brittle over time. Apply steady pressure and wiggle them gently rather than forcing them off.
Pro Tip 3: Check the Tank Vent. While you have everything apart, it’s a great time to check that your fuel tank’s vent line isn’t clogged or pinched. A blocked vent can create a vacuum in the tank and cause symptoms similar to a bad fuel pump.
Sustainable and Eco-Friendly Best Practices
Being a responsible DIYer means taking care of our environment. A sustainable 2016 polaris sportsman 570 fuel pump replacement is easy to achieve.
The most important step is proper fluid disposal. Never pour old gasoline down a drain or onto the ground. Your local auto parts store or municipal waste facility will have a recycling program for old fuel and other automotive fluids.
Choosing a high-quality replacement part is also an eco-friendly 2016 polaris sportsman 570 fuel pump replacement practice. A durable, well-made pump will last longer, reducing waste and the need for another replacement down the road.
Frequently Asked Questions About Your 2016 Polaris Sportsman 570 Fuel Pump Replacement
How long does a Polaris Sportsman 570 fuel pump last?
There’s no set mileage or hour mark. Longevity depends on factors like fuel quality, how often the machine is run with low fuel (which can cause the pump to overheat), and simple manufacturing variance. They can last anywhere from a few thousand to over 10,000 miles.
Can I just replace the motor instead of the whole assembly?
Yes, you can often buy just the pump motor. However, we generally advise against it. The job requires disassembling the plastic housing, which can be brittle. You also risk not getting a perfect seal, and you’ll still have the old filter and regulator. For the small price difference, a full assembly is a more reliable and simpler repair.
What is the proper fuel pressure for a 2016 Sportsman 570?
The target fuel pressure is 58 PSI, plus or minus 2 PSI. Any reading significantly below 55 PSI indicates a problem with the pump or pressure regulator.
Is this a difficult job for a beginner?
On a scale of 1 to 10, this is about a 4. It doesn’t require highly specialized tools, but it demands patience, organization, and a strong commitment to safety due to working with fuel. If you can follow instructions and are comfortable with basic tools, you can do this.
Congratulations! You’ve successfully completed the 2016 polaris sportsman 570 fuel pump replacement. By taking on this job yourself, you’ve not only saved a significant amount of money but also gained valuable experience and a deeper understanding of your machine. Now, it’s time to reap the rewards.
Go fill up the tank with some fresh, high-quality fuel, and hit the trails with the confidence that your Sportsman is ready to perform. Ride safe, and have fun out there!
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