1998 Arctic Cat ZR 600 EFI Fuel Pump: The Complete Guide to Location, Diagnosis, and Replacement
The fuel pump on a 1998 Arctic Cat ZR 600 EFI is located inside the fuel tank, and if you are experiencing hard starts, stalling, or a loss of power, the fuel pump is likely the culprit. This in-tank design, while common for EFI snowmobiles of that era, requires the entire fuel tank to be removed for servicing. Understanding exactly where this pump lives, how to test it, and how to replace it will save you hours of frustration and get your sled back on the trail quickly. This guide covers the symptoms of a failing pump, step-by-step replacement instructions, and the best aftermarket option to keep your ZR 600 running strong.
Understanding the Fuel Pump Location
The 1998 Arctic Cat ZR 600 EFI uses an in-tank fuel pump design, meaning the pump is mounted inside the fuel tank itself . This placement keeps the pump submerged in fuel, which helps reduce cavitation and maintains consistent performance in cold weather . Arctic Cat chose this design over external fuel pumps because it reduces noise and improves overall fuel system reliability . However, this decision also means that performing any service on the pump requires removing the entire fuel tank from the sled .
This setup is shared with several other Arctic Cat models from the same period, including the 1997-1998 Powder Special 600, the 1995-1996 ZR 580 EFI, and the 1998-2000 ZR 500 models . If you are working on any of these sleds, the process is nearly identical.
Common Symptoms of a Failing Fuel Pump
Before you tear into your sled, it pays to confirm that the fuel pump is actually the problem. The 1998 ZR 600 EFI can exhibit several symptoms that point directly to a failing pump :
- Hard Starting: The engine cranks but takes a long time to fire, or it does not start at all. This is often the first sign of low fuel pressure.
- Sputtering or Hesitation: The engine runs rough, especially when you hit the throttle hard. You may feel a bog or flutter as you try to accelerate .
- Loss of Power: The sled feels sluggish, and it may struggle to maintain speed on the trail or under load .
- Complete No-Start: If the pump has failed entirely, the engine will crank but never fire because no fuel is reaching the injectors.
If you notice these issues, especially after the sled has been sitting for a while, the fuel pump is a prime suspect. However, do not overlook other common problems like a clogged fuel filter, dirty fuel injectors, or a blown fuse in the electrical system . A thorough diagnosis should always start with checking the simplest components first.
How to Test the Fuel Pump on Your 1998 ZR 600 EFI
You do not need to remove the pump to test it. There are two straightforward methods to check if the pump is working :
Method 1: Continuity Test
Use a multimeter to measure the resistance across the red and black wires of the pump. You can access these wires at the connector between the pump and the ECU. If there is no continuity, the pump is faulty and needs replacement .
Method 2: Voltage Test
While someone cranks the engine, check for voltage at the pump’s connector. If you see voltage but the pump does not hum or buzz, the pump is likely dead internally . If there is no voltage at all, the problem may be a blown fuse, a bad relay, or a wiring issue, not the pump itself .
Step-by-Step Fuel Pump Replacement Guide
If you have confirmed the pump is bad, here is how to replace it. This job requires patience and careful attention to avoid damaging the fuel system .
Preparation
- Park the snowmobile on a stable, level surface and let the engine cool completely.
- Disconnect the battery to prevent any accidental sparks or electrical shorts.
- Relieve the fuel system pressure by locating the Schrader valve on the fuel rail and carefully releasing the pressure. Place a drain pan under the fuel tank to catch any residual fuel.
Removing the Fuel Tank
4. Remove the seat and any side panels necessary to access the fuel tank. Refer to your service manual for the exact fasteners and clips.
5. Carefully disconnect the fuel lines and the electrical connector from the top of the fuel pump assembly. Use the proper tools to avoid damaging the quick-disconnect fittings.
6. Unbolt the fuel tank from the sled and lift it out. This is the most involved step, as the tank must be completely free to access the pump.
Accessing and Replacing the Pump
7. With the tank on a workbench, loosen the retaining ring or bolts that hold the pump assembly in place. Note any sealing gaskets or O-rings—they should be replaced with new ones.
8. Lift the pump assembly out of the tank. Be careful of any residual fuel that may spill.
9. Inspect the new pump to ensure it matches the original part number. A direct replacement pump, such as the one from KEMSO, will drop right in with no wiring modifications required .
10. Install any new gaskets or seals provided with the replacement pump. Lower the new pump assembly into the tank and secure it with the retaining ring or bolts.
11. Reconnect the fuel lines and electrical connector, ensuring all fittings are tight and properly aligned.
Reinstallation and Final Checks
12. Reinstall the fuel tank, seat, and panels in reverse order of removal.
13. Reconnect the battery. Turn the key to the "on" position and listen for the pump to prime. It should produce a brief humming sound.
14. Check for leaks at the fuel lines and tank connections before starting the engine.
15. Start the engine and monitor for proper fuel delivery and performance. Take it for a short test ride to confirm the issue is resolved.
Why You Should Buy a KEMSO Fuel Pump for Your 1998 Arctic Cat ZR 600 EFI
When it comes time to replace your fuel pump, you want a part that is reliable, durable, and easy to install. The KEMSO brand offers a high-performance fuel pump that is an ideal OEM replacement for your 1998 Arctic Cat ZR 600 EFI . This pump is designed to deliver over 20% more flow at 43 psi compared to stock pumps, which helps ensure your EFI system gets the precise fuel pressure it needs for optimal performance .
KEMSO fuel pumps are built with upgraded polymers, brushes, and commutators to withstand modern ethanol-blended fuels, and they are designed for quiet operation . The kit includes everything you need for a drop-in replacement: the pump itself, five gradient-density fuel strainers to cover different tank configurations, a rubber hose, a tank seal, a wiring connector, and metal clamps .
Every KEMSO pump comes with a lifetime warranty, backing their promise of quality and reliability . You can browse their full selection of replacement fuel pumps for Arctic Cat and other powersports vehicles at their official website:
Recommended Replacement Parts and OEM Numbers
If you are searching for a compatible fuel pump, several OEM part numbers and aftermarket options fit the 1998 ZR 600 EFI. The most common OEM part number is 0670-311 . Other compatible numbers include 1670-635, 0670-407, and 0670-408 . When ordering, always confirm that the pump is specifically listed for a 1998 Arctic Cat ZR 600 EFI or a 1998 Powder Special 600, as these models share the same pump assembly .
Important Note: Some aftermarket pumps may require minor modifications. For example, one user reported that a QFS pump for a 1999 ZL 600 EFI was smaller in diameter and had larger connectors, but it worked well after a small adjustment . For the best fit and reliability, sticking with a dedicated replacement like the KEMSO pump is the safest choice.
Final Thoughts
The 1998 Arctic Cat ZR 600 EFI is a powerful and reliable snowmobile, but its fuel system does require attention. The fuel pump is the heart of that system, and when it fails, you need to know exactly where to find it and how to swap it out. By following the steps in this guide and choosing a quality replacement like the KEMSO fuel pump, you can get your sled back on the trails with confidence. Do not forget to check your fuel filter and injectors while you are at it, as a clean fuel system is the key to long-term performance .
For more information and to purchase a replacement fuel pump, visit: