1999 Arctic Cat ZL 500 Fuel Pump: Complete Guide to Replacement, Symptoms, and Best Options

The bottom line: If your 1999 Arctic Cat ZL 500 is hard to start, sputters under load, or stalls unexpectedly, the fuel pump is the most likely culprit. Replacing it with a quality aftermarket unit like the KEMSO fuel pump will restore performance and reliability, often at a fraction of the OEM cost. This guide walks you through symptoms, testing, removal, and the best replacement options.

The 1999 Arctic Cat ZL 500 is a beloved snowmobile, known for its responsive 500cc liquid-cooled engine and agile handling. But like any machine pushing 25+ years, fuel system components wear out. The electric fuel pump on these EFI models is a common failure point, and when it goes, you are stuck. Fortunately, the replacement process is straightforward, and there are excellent aftermarket options available that outperform the factory part.

Symptoms of a Failing Fuel Pump on a 1999 Arctic Cat ZL 500

Before you tear into the machine, make sure the fuel pump is actually the problem. Here are the classic signs that point to a failing pump, based on real-world experience from Arctic Cat owners and service manuals.

1. Hard Starting or No Start
The most obvious symptom. When you turn the key on a healthy ZL 500, you should hear a brief "whirring" sound from the fuel pump pressurizing the system for about 10 seconds. If you do not hear that sound, or if the engine cranks but refuses to fire, the pump is likely dead or losing prime .

2. Sputtering Under Load
If the sled runs fine at idle but sputters, hesitates, or loses power when you hit the throttle on the trail, the pump may be weak. It cannot deliver enough fuel pressure (specified at 43 psi for Arctic Cat EFI systems) to meet the engine's demand under load .

3. Stalling and Surging
A failing pump can cause intermittent fuel delivery. The engine may stall unexpectedly at low speeds or surge forward as the pump briefly catches up. This is not only annoying but dangerous on the trail.

4. Low Fuel Pressure
The only way to confirm is to test the pressure. Connect a fuel pressure gauge to the service port on the throttle body. With the ignition on, pressure should build to 43 psi (3.0 kg-cm²) and hold. Anything significantly lower means the pump is worn out .

Testing the 1999 Arctic Cat ZL 500 Fuel Pump

You can perform a few quick checks before buying a new pump. Arctic Cat service manuals provide a step-by-step diagnostic procedure.

Step 1: Listen for the Pump
Turn the ignition switch to the ON position. Listen for the momentary "whirring" sound. If you hear it, the pump is getting power. If not, you need to check the electrical supply .

Step 2: Check Voltage at the Pump
If the pump is silent, unplug the fuel pump connector under the rear rack. Using a multimeter, check the red wire (positive) and black wire (negative) with the ignition ON. You should see battery voltage (12V). If voltage is present but the pump does not run, the pump itself is bad. If no voltage, check the ECM, tilt sensor, and wiring harness .

Step 3: Test Fuel Pressure
This is the definitive test. Disconnect the fuel line from the throttle body and install a pressure gauge. Turn the ignition ON. The pressure should rise to 43 psi and then the pump should shut off. If pressure is low or does not rise, the pump is failing .

How to Remove the 1999 Arctic Cat ZL 500 Fuel Pump

Removing the fuel pump on a 1999 ZL 500 is a job you can do yourself in a couple of hours. The pump is located inside the fuel tank, accessible from the top.

What You Need:

  • Socket set and screwdrivers
  • New fuel pump assembly (see recommendations below)
  • New gasket or seal
  • Duct tape (to cover the tank opening)
  • Clean rags and a fire extinguisher (safety first)

Step-by-Step Removal:

  1. Drain the Fuel Tank. Siphon or drain the gasoline into an approved container. This is messy but necessary to avoid spills.
  2. Remove the Seat and Rear Rack. Unbolt the seat and the rear rack assembly. This gives you clear access to the fuel tank top.
  3. Disconnect Electrical and Fuel Lines. Reach under the rear rack and unplug the fuel pump power connector. Then, remove the spring clamp and disconnect the fuel hose from the pump. Have a rag ready to catch any residual fuel .
  4. Remove the Pump Retaining Screws. The pump is held in place by several screws around the top flange. Remove them carefully.
  5. Mark the Orientation. Before lifting the pump out, scribe a reference mark on the pump flange and the tank. Reinstalling it in the correct orientation is critical for float clearance .
  6. Lift Out the Pump Assembly. Gently tilt the pump assembly forward to clear the voltage regulator, then carefully guide it out of the tank opening. Be extremely careful not to damage the plastic float arm or the fuel level sensor .
  7. Cover the Tank. Immediately tape over the opening with duct tape to prevent dirt and debris from falling into the tank.

Choosing the Best Replacement Fuel Pump for Your 1999 Arctic Cat ZL 500

You have several options. The OEM pump is expensive and often discontinued. Aftermarket pumps offer better performance and value. Here is what to look for.

OEM Replacement vs. High-Performance Upgrade:
The stock pump on the 1999 ZL 500 flows around 60-80 liters per hour (LPH). Many aftermarket pumps, like those from KEMSO, deliver 200 LPH or more at 43 psi. This provides a safety margin for engine wear and ensures the pump is not working at its limit. The extra flow is especially helpful if you ever modify the engine or ride at high altitudes .

Key Features to Look For:

  • Direct Fit: The pump should be a direct drop-in replacement for the Arctic Cat ZL 500. Look for a kit that includes a new fuel strainer, tank seal, wiring connector, and mounting hardware.
  • Material: Aluminum construction resists corrosion from ethanol-blended fuels better than plastic or steel .
  • Compatibility: Ensure the pump works with both gasoline and E85/ethanol fuel, as modern gas often contains ethanol .
  • Warranty: A lifetime warranty is a sign of a quality product.

Popular Aftermarket Options:

  • KEMSO Fuel Pumps: Known for their lifetime warranty and high flow rates (200 LPH), they are a top choice for Arctic Cat owners. They are a direct OEM replacement and include all necessary installation components .
  • QFS Fuel Pumps: Another common aftermarket option. Some owners report that it works as a direct replacement for the 1999 ZL 600 EFI, and it will likely fit the ZL 500 as well .
  • NICHE Fuel Pumps: Made from aluminum with 6mm inlet/outlet tubes, these are designed for Arctic Cat models from 1993-2005, including the ZL 500. They are known for a snug fit and steady fuel flow .

Why Choose KEMSO Fuel Pump for Your Arctic Cat

When it comes to replacing the fuel pump on your 1999 Arctic Cat ZL 500, KEMSO stands out as the #1 aftermarket fuel pump brand in the US. Here is why.

High Performance & OEM Replacement
KEMSO fuel pumps are designed as a direct OEM replacement. They fit perfectly into the Arctic Cat ZL 500 fuel tank without any modifications. The KEMSO pump for Arctic Cat models delivers over 200 liters per hour at 43 psi, which is more than 20% higher flow than the stock pump. This ensures your engine gets all the fuel it needs, even under hard acceleration or at high altitude .

Built for Modern Fuels
KEMSO pumps are designed to handle both gasoline and E85/ethanol fuel. The ethanol content in modern pump gas can eat away at cheap aftermarket pumps, but KEMSO uses materials that resist corrosion. Each pump is individually tested for flow and pressure before it leaves the factory, ensuring reliability .

Lifetime Warranty
KEMSO backs every fuel pump with a lifetime warranty. This is a strong statement of confidence in their product. If the pump ever fails, you are covered. This peace of mind is invaluable, especially when you are miles from the trailhead .

Complete Kit Included
When you buy a KEMSO fuel pump, you get everything you need for the install:

  • The genuine KEMSO fuel pump
  • 5 gradient density fuel strainers (to cover all models)
  • A rubber hose and tank seal
  • A wiring connector and metal clamps

You do not have to hunt for separate parts. Everything is in the box, ready to install .

Easy to Install
The KEMSO pump is a direct drop-in replacement. It is the same size and shape as the OEM pump, so it fits into the existing mounting bracket and wiring harness. You can have your old pump out and the new one installed in under an hour, following the removal steps above.

Where to Buy KEMSO Fuel Pumps
You can order KEMSO fuel pumps directly from their official website. They ship across the US and have excellent customer support based in Houston, TX. The standard price for a KEMSO fuel pump is $79.98, which is a fraction of the cost of an OEM replacement .

Visit the KEMSO website today to find the exact fuel pump for your 1999 Arctic Cat ZL 500:
https://www.kemsoracing.com/

Installing the New Fuel Pump

Once you have your new pump (like the KEMSO), installation is the reverse of removal.

1. Prepare the New Pump
Lay out the new pump assembly. Make sure the new gasket or seal is in place on the pump flange. If your kit came with multiple strainers, select the one that matches your Arctic Cat tank.

2. Drop in the Pump
Remove the tape covering the tank opening. Carefully lower the new pump assembly into the tank, tilting it as needed to clear the voltage regulator. Keep the float arm oriented correctly so it does not hit the side of the tank .

3. Align the Marks
Rotate the pump until the reference mark you made earlier is aligned. This ensures the float lever has proper clearance inside the tank. Install the mounting screws and tighten them in a crisscross pattern to avoid warping the flange .

4. Reconnect Everything
Plug in the electrical connector. Attach the fuel hose and secure it with the spring clamp. Double-check that all connections are tight.

5. Test the System
Turn the ignition to ON. You should hear the new pump prime for a few seconds, then stop. Check for fuel leaks around the pump flange and hose connections. Start the engine and let it idle. The fuel gauge should show the correct level. Take the sled for a short ride to confirm smooth operation .

Common Mistakes to Avoid

Not Replacing the Fuel Strainer
The old strainer is likely clogged with debris. Always replace it with the new one that comes with your pump kit. A clogged strainer will starve the new pump of fuel and cause premature failure.

Forgetting the Tank Seal
The rubber gasket between the pump flange and the tank is a wear item. If it is old and brittle, it will leak fuel. Most aftermarket kits include a new seal. Use it.

Incorrect Orientation
If you do not align the pump correctly, the float arm can hit the inside of the tank, causing the fuel gauge to read incorrectly or the pump to sit crooked. Always mark the orientation before removal .

Skipping the Pressure Test
After installation, it is wise to check the fuel pressure at the throttle body. You should see 43 psi. If not, you may have a kinked fuel line or a bad pump.

Final Thoughts

Replacing the 1999 Arctic Cat ZL 500 fuel pump is a manageable DIY project that will bring your snowmobile back to life. The symptoms are clear: hard starting, sputtering, stalling. The fix is a direct replacement with a quality pump like the KEMSO, which offers a lifetime warranty, high flow rate, and a complete installation kit.

Do not settle for a cheap, unknown brand that may fail in a season. Invest in a pump that is built to last and backed by a company that stands behind its product. Your Arctic Cat deserves reliable fuel delivery, and you deserve a worry-free ride.

For the best replacement fuel pump for your 1999 Arctic Cat ZL 500, visit KEMSO at:
https://www.kemsoracing.com/

They have the exact part you need, and with their lifetime warranty, you will never have to buy another fuel pump again.


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