Sylvie Willis
The Can-Am Outlander 800 is an all-terrain vehicle (ATV) manufactured by BRP. While the Outlander 800 is a popular ATV, some models, particularly those from 2007 to 2009, have experienced fuel pump problems. This has led to issues with the fuel gauge and, in some cases, the need to replace the fuel pump. In this article, we will explore the process of removing the fuel tank on the Can-Am Outlander 800, including the steps involved, common challenges, and potential solutions to ensure a successful and safe fuel tank removal.
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What You'll Learn
Fuel tank cleaning
Step 1: Prepare the Workspace
Park your Can-Am Outlander 800 on a level surface and engage the parking brake. Place a suitable container underneath the fuel tank to catch any spilled fuel.
Step 2: Drain the Fuel Tank
Before cleaning the fuel tank of your Can-Am Outlander 800, you must first drain it. Siphoning is a commonly suggested method for draining the fuel tank. You can use a small hose to siphon the fuel out of the tank. Be cautious and avoid inserting any objects into the tank if the pump assembly is still in place, as it is delicate.
Step 3: Remove the Fuel Tank
Once the fuel tank is drained, you can proceed to remove it from your Can-Am Outlander 800. Refer to your owner's manual or seek guidance from an authorised mechanic to ensure you are safely removing the fuel tank, as the process may vary slightly between models.
Step 4: Clean the Fuel Tank
With the fuel tank removed, you can now focus on cleaning it. Inspect the tank for any dirt, debris, or contaminants. Use a suitable cleaning solution and a soft cloth to wipe down the interior and exterior of the fuel tank. Ensure that the cleaning solution is compatible with the materials of your fuel tank to avoid damage.
Step 5: Dry the Fuel Tank
After cleaning, make sure the fuel tank is completely dry before reinstalling it. Use a clean, dry cloth to wipe down the tank, absorbing any remaining moisture. Leave the tank open and in a well-ventilated area to ensure thorough drying.
Step 6: Reinstall the Fuel Tank
Once the fuel tank is clean and dry, you can carefully reinstall it into your Can-Am Outlander 800, following the reverse of the removal process. Ensure that all connections are secure and properly sealed.
Step 7: Refill and Test
Finally, refill the fuel tank with fresh fuel and start your Can-Am Outlander 800 to ensure that it is running smoothly. Check for any leaks or unusual noises.
Remember to consult a professional mechanic or the Can-Am authorised service centre if you have any doubts or concerns during the fuel tank cleaning process.
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Removing the fuel pump
To remove the fuel pump from a Can-Am Outlander 800, you will first need to remove the fuel tank. It is a one-piece unit in the tank, so the tank will have to be taken out to access the pump.
Before starting, ensure you are wearing the correct safety gear, including gloves and eye protection. Work in a well-ventilated area to avoid inhaling fumes.
Once the tank is out, locate the fasteners holding the fuel pump unit in place. Carefully undo these fasteners, being mindful not to drop them into the tank. With the fasteners removed, you can now lift the fuel pump assembly out of the tank. Take care not to damage the surrounding components or contaminate the fuel tank with dirt or debris.
After removing the pump, it is important to clean the inside of the fuel tank, especially if it is dirty. This can be done by wiping it down with a clean cloth. Additionally, it is recommended to replace the fuel filter with a new one before installing a new pump to avoid premature damage.
Finally, install the new fuel pump assembly by securing it with the fasteners and ensuring all connections are secure.
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Replacing the fuel pump
To replace the fuel pump on a Can-Am Outlander 800, you will first need to remove the fuel tank. This process can be challenging, so it is recommended to have a professional do it or proceed with caution if you are doing it yourself.
- Remove the fuel tank: This step involves detaching the fuel lines and carefully taking out the tank. Make sure to place a container underneath to catch any remaining fuel.
- Clean the fuel tank: Before installing the new fuel pump, it is essential to clean the tank thoroughly. Use a suitable cleaning solution and ensure that all dirt and debris are removed.
- Purchase a compatible fuel pump: Ensure that you acquire a fuel pump that is specifically designed for the Can-Am Outlander 800. You can find these at authorised dealers or online retailers.
- Install the new fuel pump: Carefully place the new fuel pump into the fuel tank, following the manufacturer's instructions. Ensure that all connections are secure and that the pump is properly seated.
- Reattach the fuel tank: Once the new fuel pump is installed, carefully reattach the fuel tank, ensuring that all connections are secure.
- Test the fuel pump: After the installation, test the fuel pump to ensure it is functioning correctly. Start the engine and check for any leaks or unusual noises.
It is important to note that working with fuel can be dangerous, so ensure a safe environment and take appropriate precautions. Additionally, always refer to the owner's manual or seek professional assistance if you are unsure about any steps in the process.
Some common issues with the Can-Am Outlander 800 fuel pump include poor engine acceleration, easy stalling, and loud fuel tank noises. These issues may indicate the need for a fuel pump replacement.
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Draining the fuel
To drain the fuel from a Can-Am Outlander 800, you have a few options. One user on an online forum suggested siphoning out the fuel, disconnecting the injectors, and turning the key on and off until the bike starts to sputter, before reconnecting the injectors and letting the bike idle until it dies.
Another user on the same forum thread suggested that the only way to get the tank truly empty and dry is to take the pump out and physically wipe it dry. They also suggested siphoning out the fuel, but acknowledged that a small amount of fuel will always remain in the tank.
A third user, this time on a different forum, suggested taking the fuel line off at the "Y" before it hits the injectors and turning the key on, so the pump pushes most of the fuel out. They recommended shutting the key off when the tank starts spitting.
It is also possible to drain the fuel tank by removing it entirely. However, this is a more complex process and may require dealing directly with Can-Am to obtain the necessary parts. Other forum users have also discussed issues with the fuel gauge and pump, which may be relevant to the process of draining the fuel tank.
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Fuel gauge issues
Troubleshooting Fuel Gauge Issues
Intermittent fuel gauge readings on the Can-Am Outlander 800 are a known issue, often stemming from problems with the fuel pump or sending unit. The fuel pump is a critical component that transfers fuel from the tank to the engine. If it malfunctions, the vehicle may experience issues like poor engine acceleration, stalling, and loud fuel tank noises.
Diagnosing the Problem
To diagnose fuel gauge issues, start by considering common causes. One possibility is a faulty float in the fuel tank, which may be malfunctioning, causing the gauge to sink and inaccurately indicate an empty tank. Another potential cause is a blown fuse in the sending unit, which can be resolved by resoldering. Additionally, the sending unit itself may be defective, leading to inaccurate fuel level readings.
Taking Corrective Action
If you suspect a faulty fuel pump, it's recommended to replace it. The fuel pump on the Can-Am Outlander 800 is a one-piece unit located inside the fuel tank, making its replacement a labour-intensive process. Before installing a new fuel pump, it's crucial to clean the fuel tank thoroughly and ensure no contaminants are present, as these can damage the new pump.
In some cases, the issue may lie with the sending unit. Unfortunately, BRP does not sell the sending unit separately, so replacement is often necessary. However, addressing issues with the sending unit can help improve fuel gauge accuracy and prevent future problems.
Preventative Measures
To avoid future fuel gauge issues, it's essential to maintain your Can-Am Outlander 800 properly. Regularly inspect the fuel system for any signs of wear or damage, and consider replacing critical components like the fuel pump and sending unit proactively to prevent unexpected failures.
Additionally, when storing your vehicle for extended periods, ensure the fuel tank is empty and properly aired out. You can achieve this by siphoning out the fuel, disconnecting the injectors, and turning the key on and off until the vehicle sputters.
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Frequently asked questions
To remove the fuel tank of your Can-Am Outlander 800, first install a new fuel pump. Then, clean the fuel tank and injectors, and install new plugs.
To clean the fuel tank, you can siphon out the fuel using a small hose. You can also disconnect the injectors, turn the key on and off until the bike starts to sputter, reconnect the injectors, and let the bike idle until it dies.
Take the fuel line off at the "Y" before it hits the injectors and turn the key on. The pump will push most of the fuel out, and you can shut off the key when it starts spitting.
The fuel tank may need to be removed to replace the fuel pump. This is because the fuel pump is a one-piece unit inside the tank.
