Fuel Pump Can Am Outlander 650 - Your Complete DIY Replacement Guide

There’s nothing quite like the feeling of your Can-Am Outlander 650 suddenly sputtering, bogging down, or refusing to start when you’re miles from the trailhead. You hit the throttle, but the power just isn’t there. We’ve all been there, and that sinking feeling often points to one critical component: a failing fuel pump.

Don’t let a bad pump ruin your ride. We promise this guide will walk you through everything you need to know about your fuel pump can am outlander 650, from diagnosing the symptoms to replacing it yourself with confidence. You’ll save money, learn more about your machine, and get back on the trail faster.

In this comprehensive guide, we’ll cover the tell-tale signs of a failing pump, the tools you’ll need for the job, a detailed step-by-step replacement process, and pro tips to make the job go smoothly. Let’s get those wrenches turning.

Signs Your Outlander 650 Fuel Pump is Failing

Before you start tearing things apart, it’s crucial to correctly diagnose the issue. A faulty fuel pump often mimics other problems, but there are a few classic symptoms to watch for. Understanding these common problems with fuel pump can am outlander 650 will save you time and headaches.

Difficulty Starting or No-Start Condition

One of the most obvious signs is trouble getting your ATV started. You might hear the engine crank over and over, but it just won’t fire up. This happens because the pump isn’t delivering enough fuel pressure to the engine for combustion.

A good first check is to turn the key to the “on” position without starting it. You should hear a faint, 2-3 second whirring or humming sound from the fuel tank area. If you hear nothing, your pump is likely dead.

Sputtering, Stalling, and Power Loss

Is your Outlander running rough, especially under acceleration? A weak fuel pump can’t keep up with the engine’s demand for fuel. This leads to hesitation, sputtering, or a “bogging down” feeling when you hit the gas.

You might also experience stalling, either at idle or while riding. The engine is essentially being starved of fuel intermittently, causing it to cut out. This is not only frustrating but can be a safety hazard on steep or technical terrain.

Whining Noise from the Fuel Tank

While a quiet hum is normal, a loud, high-pitched whining or groaning sound from the fuel tank area is a bad sign. This noise often indicates the pump motor is strained and working overtime to build pressure, a clear signal that it’s on its last legs.

Your Essential Toolkit and Parts List

Having the right tools and parts ready before you start is one of the most important fuel pump can am outlander 650 tips we can offer. It turns a frustrating afternoon into a smooth, successful project. Here’s what you’ll need.

Required Tools

Ratchet and Socket Set: You’ll need various sizes, typically 8mm, 10mm, and a Torx bit set (T25/T30 are common on Can-Ams).
Screwdrivers: A set of both flathead and Phillips head screwdrivers.
Pliers: Needle-nose and standard pliers for clips and hoses.
Fuel Line Disconnect Tool: While not always mandatory, this makes releasing quick-connect fuel lines much easier and safer.
Clean Rags or Shop Towels: For cleaning surfaces and soaking up any spilled fuel.
Fire Extinguisher: Safety first! Always have a Class B (flammable liquids) fire extinguisher within arm’s reach when working with fuel.
Safety Glasses and Nitrile Gloves: Protect your eyes from splashes and your hands from gasoline.

Replacement Parts

The main part is, of course, a new fuel pump assembly. You have a few options:

OEM Can-Am Pump: The most expensive option, but a guaranteed fit and quality.
Quality Aftermarket Pump: Brands like Quantum Fuel Systems, All Balls Racing, or Kemso offer reliable, direct-fit replacements at a fraction of the OEM cost. Be sure to buy from a reputable seller.
New Fuel Filter/Strainer: Your new pump assembly should come with one, but if it doesn’t, do not reuse the old one. A clogged strainer is a primary cause of pump failure.

How to Fuel Pump Can Am Outlander 650: A Step-by-Step Guide

Alright, let’s get down to business. This fuel pump can am outlander 650 guide will walk you through the replacement process. Work in a well-ventilated area, away from any open flames or sparks. Remember, you’re dealing with gasoline.

Step 1: Preparation and Disassembly

First, relieve the fuel system pressure. You can do this by running the ATV until it stalls or by locating and pulling the fuel pump fuse/relay and then cranking the engine for a few seconds.

Next, disconnect the negative terminal on your battery. This prevents any accidental sparks. Now, you need to access the fuel tank. This usually involves removing the seat and the surrounding plastic body panels (the rear rack and fenders). Take your time and keep track of all the bolts and clips.

Step 2: Disconnecting the Fuel Tank

With the plastics removed, you’ll see the top of the fuel tank. Carefully disconnect the electrical connector going to the pump assembly. Next, disconnect the fuel line. Use your disconnect tool or carefully press the tabs on the quick-connect fitting to release it. Have a rag ready to catch a small amount of residual fuel.

Unbolt the fuel tank from the frame. It’s usually held in by a few bolts. Once it’s free, carefully lift the tank out of the ATV and place it on a clean, stable workbench.

Step 3: Removing the Old Fuel Pump Assembly

The fuel pump assembly is held in the tank by a large locking ring. You may need a specialized tool, but you can often tap it loose counter-clockwise using a brass drift or a blunt screwdriver and a mallet. Never use steel on steel, as it can create a spark.

Once the ring is off, you can carefully lift the entire pump assembly out of the tank. Be mindful of the float arm so you don’t bend or damage it on the way out. Drain any remaining fuel from the tank into an approved container and wipe the inside clean of any debris.

Step 4: Installing the New Pump

Prepare your new pump assembly. Ensure the new sealing gasket or O-ring is properly seated. Carefully lower the new assembly into the tank, again being gentle with the float arm. Align it correctly—there’s usually a tab or mark to line up.

Install the locking ring and tighten it down securely. Hand-tight plus a quarter turn with your tapping tool is usually sufficient. Overtightening can damage the ring or the tank.

Step 5: Reassembly and Final Checks

Now, simply reverse the process. Place the fuel tank back into the frame and bolt it down. Reconnect the fuel line (it should click into place) and the electrical connector. Reinstall all the plastic body panels and the seat.

Reconnect the negative battery terminal. Before you try to start it, turn the key to the “on” position a few times for 2-3 seconds each. This allows the new pump to prime the system with fuel. Now, fire it up! Let it idle for a few minutes and check thoroughly for any leaks around the fuel line connection.

Benefits of a New Fuel Pump Can Am Outlander 650

Replacing a worn-out pump isn’t just about fixing a problem; it’s about restoring your machine’s performance and reliability. The benefits of fuel pump can am outlander 650 replacement are immediate.

Restored Power and Throttle Response: Your Outlander will feel crisp and responsive again, with no hesitation.
Improved Starting and Reliability: Say goodbye to frustrating no-start situations on the trail.
Better Fuel Efficiency: A pump providing correct, consistent pressure allows the engine to run more efficiently.
Peace of Mind: Knowing a critical component is fresh and reliable lets you ride with more confidence, no matter how far you go.

Fuel Pump Care and Best Practices

Want to make your new pump last as long as possible? Follow this simple fuel pump can am outlander 650 care guide.

The single best practice is to avoid running your tank low on fuel. Gasoline acts as a coolant for the fuel pump motor. Consistently running on fumes causes the pump to overheat, drastically shortening its lifespan.

Using high-quality fuel and occasionally running a fuel system cleaner can also help keep the internal components, including the filter and strainer, clean and free of debris. When considering a sustainable fuel pump can am outlander 650 solution, longevity is key. A pump that lasts longer means less waste and fewer resources used for replacements.

Frequently Asked Questions About the Can-Am Outlander 650 Fuel Pump

How much does a Can-Am Outlander 650 fuel pump cost?

An OEM pump from Can-Am can cost several hundred dollars. High-quality aftermarket pump assemblies are much more affordable, typically ranging from $50 to $150, offering a great balance of performance and value.

How long does a fuel pump last on a Can-Am Outlander?

With proper care, a stock or quality replacement fuel pump can last for many years and thousands of miles. The biggest factors in its lifespan are fuel quality and avoiding running the tank dry, which causes overheating.

Can I just replace the motor instead of the whole assembly?

Yes, you can often buy just the pump motor, which is cheaper. However, this is a more involved repair that requires disassembling the pump housing. For most DIYers, replacing the entire assembly is faster, easier, and ensures all components like the filter and pressure regulator are new.

Tackling your own fuel pump can am outlander 650 replacement is a totally achievable project that will give you a huge sense of accomplishment. By following this guide, taking your time, and prioritizing safety, you’ll have your Outlander running like new. Now get out there, stay safe, and enjoy the ride!

Author
Recent Posts

Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.