Fuel Pump Can Am Outlander 800 – The Ultimate DIY Replacement

There’s nothing more frustrating than hitting the starter on your Can-Am Outlander 800, ready for a day on the trails, only to be met with a sputter, a stall, or worse—complete silence. That weak or dead engine is often pointing a finger directly at a failing fuel pump, a critical component that delivers the lifeblood to your machine’s powerful V-twin engine.

But don’t start dialing your local shop just yet. We promise this guide will walk you through everything you need to know, from diagnosis to replacement, with clear, expert steps. At FatBoysOffroad, we believe in empowering you to handle your own maintenance, saving you time and a stack of cash.

In this ultimate guide to the fuel pump can am outlander 800, we’ll cover the tell-tale signs of failure, the tools you’ll need for the job, a detailed step-by-step replacement process, and pro tips to keep your new pump running strong for years. Let’s get that beast back on the trail where it belongs.

Recognizing the Signs: Common Problems with Fuel Pump Can Am Outlander 800

Your Outlander’s fuel pump won’t usually fail without giving you a few warning signs. Learning to spot these symptoms early can save you from being stranded deep in the woods. These are the most common problems that point to a pump on its last legs.

Hard Starting or No-Start Condition

One of the most obvious signs is difficulty starting your ATV. You might find yourself cranking the engine longer than usual. This happens because the weakening pump can’t build up the necessary fuel pressure (typically around 51 psi) quickly enough for ignition.

When the pump fails completely, you’ll get a crank-no-start situation. The engine turns over, but it never fires up because it’s not receiving any fuel.

Sputtering and Stalling

Does your Outlander run fine for a few minutes and then start to sputter or stall, especially under load or when climbing a hill? This is a classic symptom of an intermittent or weak fuel pump. The pump can’t consistently supply the volume of fuel the engine demands, leading to fuel starvation.

Loss of Power and Poor Acceleration

If your once-snappy Outlander 800 now feels sluggish and lazy, the fuel pump could be the culprit. A failing pump struggles to deliver enough fuel when you hit the throttle, causing hesitation and a noticeable lack of power. You’ll feel it most when you’re trying to accelerate quickly or maintain speed on an incline.

A Loud Whining Noise from the Fuel Tank

Your fuel pump should make a faint, almost inaudible hum when you first turn the key. If that hum has turned into a loud, high-pitched whine, it’s a cry for help. This noise is often caused by a strained pump motor that is working too hard to move fuel, either due to a clog or internal wear.

Before You Start: Essential Tools and Safety First

Before you tear into your machine, let’s talk about safety and preparation. Working with gasoline is serious business. A single spark can lead to a disaster, so taking the right precautions is non-negotiable.

Gather your tools and set up your workspace before you disconnect a single wire. Here’s what you’ll need.

Required Tools & Supplies

Socket Set and Ratchet: A good metric set is essential for removing plastics and the fuel pump retaining ring.
Screwdriver Set: Both Phillips and flathead screwdrivers will be needed.
Pliers: Needle-nose and standard pliers for clips and hoses.
Fuel Pressure Gauge: The only way to definitively diagnose a bad pump. This is a must-have tool for any serious DIYer.
New Fuel Pump Assembly: We recommend buying a complete assembly, which includes the pump, filter, and sending unit. It saves a lot of hassle.
Clean Rags or Shop Towels: For cleaning surfaces and soaking up any spilled fuel.
Fire Extinguisher: Keep a Class B (flammable liquids) fire extinguisher within arm’s reach at all times. This is not optional.

Safety Best Practices

Work in a Well-Ventilated Area: Work outdoors or in a garage with the doors wide open. Fuel fumes are toxic and highly flammable.
Disconnect the Battery: Before you do anything else, disconnect the negative terminal on your battery to prevent any accidental sparks.
No Sparks, No Flames: This means no smoking, no welding, no grinding, and no open flames anywhere near your work area.
Wear Protective Gear: Safety glasses and nitrile gloves are a must to protect your eyes and skin from gasoline.

The Complete Fuel Pump Can Am Outlander 800 Guide: A Step-by-Step Replacement

With your tools gathered and your safety precautions in place, you’re ready to tackle the job. This how to fuel pump can am outlander 800 guide will walk you through the entire process. Take your time and follow each step carefully.

Step 1: Accessing the Fuel Tank

The fuel pump is located inside the fuel tank, so the first job is to get to it. On most Outlander 800 models, this involves removing the seat and some of the plastic body panels around the tank.

Remove the Seat: Unlatch and remove the rider’s seat.
Remove Body Plastics: Carefully remove the plastic panels covering the fuel tank. This usually involves a combination of plastic push-pins and a few bolts. Keep your hardware organized in a magnetic tray.
Clean the Area: Before you open the fuel system, thoroughly clean the top of the fuel tank and the area around the pump assembly. You do not want any dirt or debris falling into your tank.

Step 2: Removing the Old Fuel Pump Assembly

Now you can see the top of the fuel pump assembly with its electrical connector and fuel line. Pay close attention here.

Relieve Fuel Pressure: If you can, start the ATV and pull the fuel pump fuse or relay. Let it run until it stalls. This will relieve most of the pressure in the fuel line, minimizing spray when you disconnect it.
Disconnect the Electrical Connector: Press the tab and carefully pull the wiring harness off the pump assembly.
Disconnect the Fuel Line: There is a quick-disconnect fitting on the fuel line. You may need a special tool, but often you can release it by pressing the tabs on the side. Have a rag ready to catch a small amount of residual fuel.
Remove the Retaining Ring: The pump is held in by a large plastic or metal retaining ring. You may need a brass punch and a mallet to gently tap it counter-clockwise to loosen it. Never use a steel punch, as it can create a spark.
Lift Out the Old Pump: Carefully and slowly lift the entire fuel pump assembly out of the tank. Be mindful of the float arm; you may need to angle it to get it out without bending or breaking it.

Step 3: Installing the New Fuel Pump

You’re halfway there! Installing the new pump is essentially the reverse of removal, but with a few key details to get right.

Inspect and Clean the Tank: With the pump out, shine a flashlight into the tank. Look for any debris, water, or sediment. If you see any, now is the perfect time to drain and clean the tank thoroughly. This is a crucial step in our fuel pump can am outlander 800 care guide.
Prepare the New Pump: Unbox your new pump assembly. Make sure it comes with a new O-ring/gasket for the tank opening. Lightly lubricate the new gasket with some clean motor oil or grease to ensure a good seal.
Install the New Assembly: Carefully lower the new pump assembly into the tank, again being gentle with the float arm. Ensure it is seated correctly and the gasket is properly positioned.
Secure the Retaining Ring: Thread the retaining ring on by hand until it’s snug. Then, use your brass punch and mallet to gently tap it clockwise until it’s tight. Check your service manual for torque specs if available, but “snug” is generally sufficient.

Step 4: Reassembly and Testing

The final stretch! Let’s get everything hooked back up and make sure it works.

Reconnect Lines and Wires: Snap the fuel line back onto the new pump until it clicks securely. Reconnect the electrical connector.
Prime the System: Reconnect your battery. Turn the key to the “on” position (but don’t start it) and wait 3-5 seconds. You should hear the new pump hum to life as it primes the system. Cycle the key 2-3 times to build full pressure.
Check for Leaks: Before going any further, carefully inspect the retaining ring and fuel line connection for any signs of leaking fuel. If you see or smell gas, STOP and fix the leak.
Start the Engine: Once you’re certain there are no leaks, fire up the engine. It should start quickly and run smoothly.
Reinstall Plastics: Once you’ve confirmed a successful start, shut it down and reinstall all the body panels and the seat.

Pro Tips for Success: Fuel Pump Can Am Outlander 800 Best Practices

Doing the job is one thing; doing it like a pro is another. Following these fuel pump can am outlander 800 tips will ensure a long life for your new part and prevent future headaches.

Always Use High-Quality Fuel: Poor quality fuel with ethanol and debris is the number one killer of fuel pumps. Stick to top-tier, ethanol-free gasoline whenever possible.
Keep the Tank Above 1/4 Full: The fuel in the tank helps cool the pump motor. Consistently running on empty can cause the pump to overheat and fail prematurely.
Replace the Fuel Filter: If your new pump assembly doesn’t include a new in-line fuel filter (some models have them), replace it separately. A clogged filter makes the new pump work harder.
Double-Check Your Seal: The large O-ring that seals the pump to the tank is critical. Make sure it’s not pinched, twisted, or damaged during installation to prevent dangerous fuel leaks and evaporative emissions.

Beyond Replacement: Benefits of a New Fuel Pump Can Am Outlander 800

Replacing a failing 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 800 replacement are immediately noticeable.

You’ll experience quicker starts, crisp throttle response, and the return of that signature Rotax V-twin power. A properly functioning pump also ensures the correct air-fuel ratio, which can improve fuel economy. A more efficient engine is a more eco-friendly fuel pump can am outlander 800 solution, as it burns cleaner and uses less gas.

Most importantly, you gain peace of mind. Knowing you have a reliable fuel system means you can tackle remote trails with confidence, free from the worry of being stranded by a preventable failure.

Frequently Asked Questions About the Fuel Pump Can Am Outlander 800

How do I test my Can-Am Outlander 800 fuel pump?

The most accurate way is with a fuel pressure gauge. Connect the gauge to the service port on the fuel rail. With the key on, the pressure should jump to approximately 51 PSI (+/- 2 PSI). If the pressure is low, fails to hold, or drops under load, the pump is likely bad.

Can I just replace the motor or do I need the whole assembly?

While you can sometimes buy just the internal pump motor, we strongly recommend replacing the entire assembly. The assembly includes a new fuel strainer, pressure regulator, and float/sending unit, all of which can also wear out. It’s more reliable and often easier in the long run.

What causes a fuel pump to fail on an Outlander?

The most common causes are contamination from dirt or water in the fuel, degradation from ethanol-blended fuels, and overheating from consistently running the tank near empty. Simple preventative maintenance, like using good fuel, is the core of any sustainable fuel pump can am outlander 800 care strategy.

You’ve done it! By following this guide, you’ve not only saved yourself a significant amount of money but also gained invaluable experience working on your own machine. Take pride in the work you’ve done, and get ready to enjoy the restored power and reliability of your Outlander 800.

Now, gear up, get out there, and hit the trails with confidence. Stay safe and happy riding!

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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.