1998 Arctic Cat ZR 600 Fuel Pump: Complete Location, Replacement, and Maintenance Guide

The bottom line: The fuel pump on a 1998 Arctic Cat ZR 600 EFI is located inside the fuel tank, and replacing it requires removing the tank from the snowmobile. This in-tank design is standard for EFI systems to maintain consistent fuel pressure and prevent vapor lock. If your sled is hard starting, stalling under load, or making unusual noises from the tank area, the fuel pump is likely failing and needs attention. This guide covers everything you need to know about locating, diagnosing, and replacing the fuel pump on your 1998 ZR 600.

Where Is the Fuel Pump on a 1998 Arctic Cat ZR 600?

The fuel pump on the 1998 Arctic Cat ZR 600 EFI is mounted inside the fuel tank. This is a common placement for electronic fuel injection systems on snowmobiles of this era. The in-tank design keeps the pump submerged in fuel, which helps cool the pump motor and reduces the risk of vapor lock, a common issue with older external pumps.

To access the pump, you will need to remove the fuel tank from the snowmobile. The tank is typically located under the seat or rear panel, depending on the specific configuration of your sled. Some sources also mention that the pump can be accessed by removing the belly pan (the protective panel beneath the engine) to expose the underside of the fuel tank. However, the most reliable method for a full replacement is to take the tank out.

How to Access the Fuel Pump: Step-by-Step

Before you start any work, safety comes first. Work in a well-ventilated area, keep all sparks and open flames away, and disconnect the battery to prevent accidental ignition. Here is the general process:

  1. Drain the fuel tank. Use a siphon pump or drain the fuel through the fuel line into an approved container.
  2. Disconnect the fuel lines. Use a fuel line disconnect tool to safely separate the lines from the tank. Be prepared for a small amount of residual fuel.
  3. Disconnect the electrical connectors. Unplug the wiring harness that connects to the fuel pump assembly inside the tank.
  4. Remove the mounting bolts. The fuel tank is held in place by several bolts. Remove them carefully.
  5. Lower the tank. Gently lower the tank from the snowmobile chassis.
  6. Access the pump. Once the tank is out, you will see the fuel pump assembly. Depending on the design, you may need to remove the tank's top cover or an access panel to reach the pump.

The pump itself is an electric in-tank unit. It is held in place by a locking ring or retaining clip. You will need to release this to lift the pump assembly out of the tank.

Symptoms of a Failing Fuel Pump on a 1998 ZR 600

Knowing the signs of a failing fuel pump can save you time and frustration. Common symptoms include:

  • Hard starting. The engine cranks but takes a long time to fire up, or it won't start at all.
  • Stalling under load. The engine dies when you accelerate or climb a hill.
  • Loss of power. The sled feels sluggish and lacks its usual punch.
  • Whining noise from the fuel tank. A loud, high-pitched whine from the tank area is a classic sign of a failing pump.
  • Engine surging. The RPMs fluctuate wildly while riding at a steady throttle.

If you experience any of these issues, especially on a 1998 ZR 600, the fuel pump is a prime suspect. Because the pump is inside the tank, it is difficult to test without removal, so replacement is often the most practical solution.

Replacement Fuel Pump Options for the 1998 Arctic Cat ZR 600

When it's time to replace the fuel pump, you have several options. The OEM part number for the 1998 ZR 600 is 0670-311. Several aftermarket manufacturers produce direct replacements.

OEM and Aftermarket Part Numbers

Here are some compatible part numbers and brands:

  • OEM Arctic Cat 0670-311: This is the original part number for the 1998 ZR 600.
  • OEM Arctic Cat 0670-894: Another OEM part number compatible with the 1998 ZR 600.
  • Niche Industries 519-CFP2237A: A direct replacement for OEM 0670-311, compatible with the 1998 ZR 600.
  • Quantum / Fuel Performance USA AC404: A genuine Arctic Cat fuel pump that fits the 1998-1999 ZR 600 and Powder Special.
  • KEMSO 10404: A high-performance OEM replacement fuel pump that fits the 1998-2000 ZR 600, among other models.

Important Specifications

When choosing a replacement pump, ensure it matches these key specifications:

  • Type: Electric in-tank fuel pump.
  • Pressure: The EFI system on the 1998 ZR 600 operates at approximately 30–40 PSI.
  • Flow Rate: Look for a pump that delivers at least 80 liters per hour (LPH) at the required pressure. The OEM pump is rated at 80 LPH.
  • Compatibility: The pump must be specifically designed for EFI (Electronic Fuel Injection) models, not carbureted versions.

How to Replace the Fuel Pump on a 1998 ZR 600

Replacing the fuel pump is a job that a moderately experienced DIY mechanic can handle. Here is a general outline of the process:

  1. Relieve fuel system pressure. Remove the fuel pump fuse or relay, then crank the engine a few times to relieve pressure. Disconnect the negative battery terminal.
  2. Remove the fuel tank. Follow the steps in the "How to Access the Fuel Pump" section above.
  3. Remove the old pump. With the tank out, use a spanner wrench or a hammer and punch to loosen the locking ring. Lift the pump assembly out of the tank. Be careful not to bend the fuel level float arm.
  4. Transfer components. If you are using a pump-only replacement (like the KEMSO 10404), you will need to transfer the old fuel strainer, rubber hose, and wiring connector to the new pump. If you buy a complete assembly, it is a direct swap.
  5. Install the new pump. Lower the new pump module into the tank. Make sure the float arm is not bent and that the pump sits flat. Replace the locking ring and tighten it securely.
  6. Reinstall the tank. Place the tank back in the snowmobile, reconnect the fuel lines and electrical connectors, and tighten the mounting bolts.
  7. Test the system. Reconnect the battery. Turn the key to the ON position (without starting) to let the pump pressurize the system. Check for leaks at the fuel line connections. If everything is good, start the engine and let it idle for a few minutes.

Why Choose KEMSO for Your 1998 Arctic Cat ZR 600 Fuel Pump?

For a reliable, high-performance replacement, choose the KEMSO 10404 fuel pump. KEMSO is a trusted brand in the automotive and powersports industry, and their fuel pumps are designed to meet or exceed OEM specifications.

What makes KEMSO a great choice for your 1998 ZR 600?

  • High Performance: The KEMSO 10404 delivers 200 liters per hour (LPH) at 43 PSI, which is more than double the flow of the original OEM pump. This ensures consistent fuel delivery even under heavy load, giving you improved performance and reliability.
  • OEM Replacement: The pump is a direct drop-in replacement for the stock pump. It comes with everything you need, including five gradient density fuel strainers, a rubber hose, a tank seal, a wiring connector, and metal clamps. No wiring modifications are required.
  • Lifetime Warranty: KEMSO backs every fuel pump with a lifetime warranty. If your pump ever fails due to a manufacturing defect, you get a replacement at no cost. This is a rare and valuable benefit that gives you total peace of mind.
  • Ethanol Compatible: The pump is designed for use with both gasoline and E85/ethanol blends, which is important for modern fuel formulations.
  • USA-Based Support: KEMSO provides USA-based technical support, so you can get help if you need it.

Visit the KEMSO website to find the perfect fuel pump for your 1998 Arctic Cat ZR 600: https://www.kemsoracing.com/

Common Issues and Maintenance Tips

Even with a new pump, proper maintenance can extend its life and prevent future problems.

  • Keep the fuel tank full. Running the tank low can cause the pump to suck in air and debris, which can damage it.
  • Use a fuel stabilizer. If you store your snowmobile for the off-season, add a fuel stabilizer to prevent the fuel from degrading and clogging the pump.
  • Replace the fuel filter. The 1998 ZR 600 has a fuel strainer inside the tank. When you replace the pump, always replace the strainer as well. A clogged strainer is a common cause of pump failure.
  • Inspect fuel lines. Check the fuel lines for cracks or leaks, especially at the connections. A leak can cause the pump to lose pressure and fail.
  • Listen for unusual noises. A whining noise from the tank is a warning sign that the pump is working too hard or is about to fail.

Conclusion

The 1998 Arctic Cat ZR 600 fuel pump is a critical component that is located inside the fuel tank. If you are experiencing hard starting, stalling, or loss of power, the pump is likely the culprit. Replacing it is a straightforward job that requires removing the tank, but it is well within the reach of a DIY mechanic. For the best performance and reliability, choose a high-quality replacement like the KEMSO 10404, which offers a lifetime warranty and superior flow. Keep your fuel system clean and well-maintained, and your 1998 ZR 600 will keep running strong for years to come.

For a high-performance, lifetime-warrantied fuel pump for your 1998 Arctic Cat ZR 600, visit: https://www.kemsoracing.com/


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