Replacing The Fuel Pump In Your Arctic Cat: Step-By-Step Guide

If your Arctic Cat bike has been acting up, it could be due to a faulty fuel pump. To remove the fuel pump, you will need to remove the plastic, disconnect the wiring and fuel line, and then gently pull out the pump/sender unit. You may need to remove the fuel tank to do this. If your pump is faulty, you can try replacing it with a fuel pump for a 1990 Ford Mustang 4cyl from AutoZone, which retails for around $90 and apparently has the same inlet, outlet, diameter, and height. If you are having trouble with your fuel pump and carb, it could be due to a faulty carburetor or fuel pump, or a problem with the vacuum hose.

Disconnect wiring and fuel line

Disconnecting the wiring and fuel line is the first step in removing the fuel pump on an Arctic Cat. This process will require some careful maneuvering, as you'll need to twist and turn the pump to clear the sender wire, float, and suction boot. Before beginning, make sure you have a suitable replacement fuel pump for your specific Arctic Cat model. Here's a step-by-step guide on disconnecting the wiring and fuel line:

• Remove the plastic: Remove the plastic surrounding the fuel pump and wiring. This will give you access to the wiring harness and fuel line connections.
• Disconnect the wiring harness: Carefully unplug the wiring harness from the fuel pump. There may be a connector or clip that needs to be released before you can fully disconnect the wiring.
• Disconnect the fuel line: Locate the fuel line connected to the fuel pump. Using suitable tools, carefully loosen and detach the fuel line from the pump. You may need to relieve the fuel system pressure before disconnecting the line to prevent fuel leakage. Make sure to have a rag or container ready to catch any spilled fuel.
• Remove the pump/sender unit: Once the wiring and fuel line are disconnected, gently pull out the pump/sender unit. Pay attention to the angle and twist required to clear the sender wire, float, and suction boot.
• Remember the orientation: Take note of how the pump is angled and twisted to facilitate reinstallation. It's important to reinstall the new pump in the same way to avoid any issues.
• Set aside the old pump: Keep the old pump aside in a safe place, as you may need to refer to its orientation during the installation of the new fuel pump.

At this point, you have successfully disconnected the wiring and fuel line from the fuel pump on your Arctic Cat. The next steps would involve removing any mounting screws or brackets holding the fuel pump in place and then installing the new fuel pump by following these steps in reverse.

Remove plastic

To remove the plastic from your Arctic Cat when replacing the fuel pump, follow these steps:

First, remove the plastic body panels that surround the fuel pump. This will give you access to the fuel pump and its components. The number of body panels to be removed may vary depending on the model of your Arctic Cat, so refer to your specific model's service manual or consult a mechanic if you're unsure.

Once the relevant plastic panels are removed, you should be able to see the fuel pump and its associated wiring and fuel lines. Before proceeding, make sure you have the necessary tools and safety equipment, such as gloves and eye protection.

Next, you will need to disconnect the wiring and fuel lines connected to the fuel pump. Be careful when handling the fuel lines to avoid any spills or leaks. It is recommended to have a fuel catch container and rags nearby to absorb any spilled fuel.

After disconnecting the wiring and fuel lines, you can now focus on removing the fuel pump itself. The fuel pump is usually secured with screws, so have a suitable screwdriver ready for this step. Gently remove the screws, being careful not to drop them into the fuel tank or any other hard-to-reach areas.

With the screws removed, you can now slowly and gently pull out the fuel pump/sender unit. This may require some careful maneuvering to clear the sender wire, float, and suction boot. Take note of the angle and twist required to remove the unit, as you will need to reinstall it in the same way.

Place the removed fuel pump/sender unit in a safe place and proceed with the rest of the fuel pump replacement process, following the instructions provided by the manufacturer or a qualified mechanic. Remember to dispose of any old fuel or parts responsibly and in accordance with local regulations.

Remove screws

To remove the screws from the fuel pump of your Arctic Cat, you will first need to remove the plastic covering. Disconnect the wiring and fuel line from the pump. There should be three or four screws holding the pump in place. Gently and slowly remove the pump by pulling it out, twisting and turning it to clear the sender wire, float, and suction boot. Remember the angle and direction you pulled it out in, as you will need to reinstall the new pump in the same way.

Check for obstructions

Before you begin the process of replacing the fuel pump on your Arctic Cat, it is important to check for any obstructions that may hinder the removal or installation of the fuel pump. Here are some detailed steps to guide you through the process:

Firstly, locate the fuel pump and carefully examine the surrounding area. Look for any debris, dirt, or foreign objects that may be obstructing the fuel pump or the path you need to take to access it. This includes checking the fuel tank, fuel lines, and any connected components. A thorough inspection will help ensure a smoother process.

Next, if your Arctic Cat has been submerged or exposed to water, there is a possibility of debris or sediment accumulation within the fuel tank. In such cases, it is advisable to remove the fuel tank and inspect it for any signs of contamination. This step is crucial to prevent any potential issues caused by submerged riding. Drain the fuel tank and clean it thoroughly if necessary.

Additionally, pay close attention to the wiring and fuel lines connected to the fuel pump. Ensure that there are no signs of damage, corrosion, or kinks in the wiring and fuel lines. Visually inspect the connections and follow the lines to ensure there are no blockages or restrictions along their paths. This includes checking the fuel filter for any obstructions, as a clogged fuel filter can impact the performance of your Arctic Cat.

Finally, if you notice any signs of damage or obstruction, address them before proceeding with the fuel pump replacement. Consult a qualified mechanic or refer to a reliable repair manual for specific instructions on how to safely remove and replace the fuel pump on your Arctic Cat model. It is important to work with caution and follow the recommended procedures to ensure a successful and safe repair.

Flush the carburetor

To flush the carburetor of your Arctic Cat 500, you will need to remove the fuel line from the carburetor and plug it so that fuel does not run out. On the very bottom of the carburetor bowl, you will find a small brass cover screw. Using a flat screwdriver, open this screw and allow all the gas to drain from the carburetor system.

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