2004 Bombardier Outlander 400 Fuel Pump Location: A Complete Guide for DIY Owners

The bottom line: The fuel pump on your 2004 Bombardier Outlander 400 is located inside the fuel tank, mounted on the top of the tank assembly. You need to remove the seat and the fuel tank to access it. The OEM part number for this fuel pump is 707200183, and it fits multiple Outlander 330 and 400 models from 2003 through 2008.

If your Outlander 400 is hard to start, stalls during riding, or you notice fuel leaking, the fuel pump is often the first thing to check. This guide walks you through exactly where to find it, how to get to it, and what to watch out for.

Where Is the Fuel Pump Located?

The 2004 Bombardier Outlander 400 uses a vacuum-operated pulse fuel pump. Unlike some modern ATVs that use an in-tank electric pump, this model has a fuel pump mounted externally on top of the fuel tank. The pump is a small, rectangular black unit with two fuel line connections and one vacuum line connection.

Key details about the location:

  1. Under the seat – You must remove the seat to access the fuel tank area.
  2. On top of the fuel tank – The pump sits on the left side of the tank near the front.
  3. Behind the air box – On some models, the air box partially covers the pump, so you may need to loosen the air box to get a clear view.

The 2004 Outlander 400 has a 4.2-gallon fuel tank, and the pump is secured to the tank with two screws or bolts.

Step-by-Step Access Guide

Step 1: Remove the Seat

The seat on the 2004 Outlander 400 is held in place by a latch at the front and a hinge at the rear. Pull the latch release, lift the seat slightly, and slide it backward to remove it. Set the seat aside in a clean area.

Step 2: Locate the Fuel Pump

With the seat removed, look at the top of the fuel tank. The fuel pump is a small black plastic or metal unit with two fuel lines and one vacuum line attached. It sits on the left side of the tank, close to the front. On some models, the pump is bolted directly to the tank bracket.

Step 3: Disconnect the Battery

Before working on any fuel system component, disconnect the negative battery terminal. This prevents accidental sparks or electrical shorts. The battery is located under the seat on the right side of the machine.

Step 4: Remove the Fuel Lines

The fuel pump has two fuel lines:

  • The inlet line – This brings fuel from the tank to the pump.
  • The outlet line – This sends pressurized fuel to the carburetor.

Use a pair of pliers to squeeze the spring clamps, then slide the lines off the pump barbs. Have a small rag ready to catch any fuel that drips out.

Step 5: Remove the Vacuum Line

The vacuum line connects to the pump and provides the pulsing vacuum that drives the pump diaphragm. Gently pull the vacuum line off the pump nipple. This line is usually smaller in diameter than the fuel lines.

Step 6: Unbolt the Pump

The fuel pump is held in place by two bolts or screws. Use a Phillips head screwdriver or a socket wrench to remove them. Once the bolts are out, lift the pump straight up and off the tank.

Understanding the Fuel Pump System

The 2004 Bombardier Outlander 400 uses a Rotax 400 engine with a single-cylinder, four-stroke design. It has a Mikuni carburetor and a mechanical pulse-type fuel pump. This pump works by using engine vacuum pulses to move fuel from the tank to the carburetor.

Key specifications:

  • Engine type: Single-cylinder, liquid-cooled, 400cc
  • Fuel system: Carbureted (Mikuni 33mm carburetor)
  • Fuel pump type: Vacuum-operated pulse pump
  • OEM part number: 707200183

The fuel pump is not electric, so you won't find any electrical connections to it. The only connections are the two fuel lines and one vacuum line.

Common Symptoms of a Failing Fuel Pump

If your Outlander 400 is having fuel delivery issues, watch for these signs:

  1. Engine cranks but won't start – This is the most common symptom. If the pump is not delivering fuel, the engine will crank but never fire.
  2. Engine stalls under load – When you accelerate or climb a hill, the engine may lose power and stall.
  3. Fuel leaking from the pump – If the diaphragm inside the pump is cracked, fuel can leak out through the vent hole or the vacuum line.
  4. Poor idle – The engine may idle rough or die at idle because the carburetor is not getting enough fuel.
  5. Fuel in the vacuum line – If you find fuel in the vacuum line, the pump diaphragm has failed and is allowing fuel to pass into the vacuum system.

One forum user reported that their 2004 Outlander 400 had fuel leaks from cracked fuel lines, and after replacing all the lines, they still had issues. The fuel pump diaphragm was the culprit.

How to Test the Fuel Pump

Before buying a new pump, test the old one. Here is a simple test you can do in your garage:

1. Check fuel flow – Disconnect the fuel line from the carburetor. Place the end of the line into a clean container. Crank the engine several times. You should see pulses of fuel coming out of the line. If no fuel comes out, the pump may be bad.

2. Check for vacuum – Disconnect the vacuum line from the pump. Place your finger over the end of the vacuum line. Have someone crank the engine. You should feel a pulsing vacuum. If you feel no vacuum, the engine may have a vacuum leak, or the pump is not getting enough vacuum signal.

3. Check for leaks – With the pump installed and the engine running, look for any fuel leaks around the pump body. A leaky pump needs to be replaced.

Important tip: When testing the fuel pump, make sure the carburetor is still mounted to the intake manifold, or place your hand over the intake opening. The pump needs engine vacuum to work. If you leave the intake open, the pump will not produce any fuel flow.

Which Fuel Pump Fits the 2004 Outlander 400?

The OEM part number for the fuel pump on the 2004 Bombardier Outlander 400 is 707200183. This pump also fits the following models:

  • 2003-2005 Bombardier Outlander 330 2x4 HO
  • 2003-2005 Bombardier Outlander 330 4x4 HO
  • 2003-2006 Bombardier Outlander 400 4x4 HO
  • 2003-2006 Bombardier Outlander 400 4x4 XT HO
  • 2003-2004 Bombardier Outlander 400 2x4 HO
  • 2004-2006 Bombardier Outlander Max 400 4x4 HO
  • 2004-2006 Bombardier Outlander Max 400 4x4 XT HO
  • 2007-2008 Can-Am Outlander 400 4x4 HO
  • 2008 Can-Am Outlander 400 4x4 HO EFI

The same pump also fits some Arctic Cat and Kawasaki models, including the Arctic Cat 400 (2005-2010), Arctic Cat 500 (2005-2009), and Kawasaki Brute Force 650 (2006-2013).

Important: When buying a replacement pump, pay attention to the direction of the inlet and outlet ports. Some pumps have different port orientations, and you need to match the original pump.

Replacement Tips and Common Mistakes

1. Replace all fuel lines – When you replace the fuel pump, it is smart to replace all the fuel lines at the same time. The original rubber lines on the 2004 Outlander 400 are now over 20 years old and are likely cracked or brittle.

2. Move the fuel lines away from heat – Some owners recommend rerouting the fuel lines to the left side of the machine, away from the engine heat. Run the lines over the top of the air box. This keeps the fuel cooler and extends the life of the lines.

3. Replace the fuel filter – The Outlander 400 has a fuel filter in the line between the tank and the pump. Replace this filter when you do the pump. A clogged filter can cause the same symptoms as a bad pump.

4. Check the carburetor – If the pump tests good but the engine still has issues, the problem may be in the carburetor. Common carburetor problems include a stuck float needle, a clogged pilot jet, or a dirty screen under the needle and seat.

5. Use the right fuel line – Use fuel line rated for today's ethanol-blended gasoline. Regular rubber fuel line can degrade quickly with ethanol fuel.

What Other Owners Have Learned

Real-world experience from Outlander 400 owners can save you a lot of trouble. Here are some lessons shared by owners on forums:

One owner had a 2004 Outlander 400 that leaked gas and would not stay running. They replaced all the fuel lines, but the problem came back the next year. They found fuel streaming from the overflow tube on the carburetor and suspected the fuel pump diaphragm was leaking. After checking the fuel flow at the carburetor, they discovered the pump was fine, but the needle valve in the carburetor was stuck. They freed the needle valve, and the machine ran well for a short test ride. Then it died again, and they found an adjustment screw and spring had fallen out of the carburetor.

Another owner pointed out that the fuel pump on the 2003-2007 Outlander 400 uses the same part number (707200183) and that some riding lawnmowers use a similar pump. While you can sometimes use a lawnmower pump in a pinch, it is not recommended for off-road use because the pump may not be sealed against water and mud.

Why You Should Consider KEMSO Fuel Pump for Your Outlander 400

When it comes time to replace the fuel pump on your 2004 Bombardier Outlander 400, you want a product that is reliable, durable, and performs like the original equipment. That is where KEMSO comes in.

KEMSO fuel pumps are designed as high-performance OEM replacement units. They are built with premium materials and undergo strict quality control testing to ensure they meet or exceed factory specifications. Each pump is tested before it leaves the factory, so you can be confident that it will work right out of the box.

What sets KEMSO apart is their commitment to quality and customer satisfaction. Every KEMSO fuel pump comes with a lifetime warranty. If you ever have a problem with the pump, KEMSO will take care of it. That kind of warranty gives you peace of mind, especially when you are working on a 20-year-old ATV that you depend on for work or recreation.

KEMSO has a wide range of fuel pumps for various vehicles, including ATVs, motorcycles, and personal watercraft. Their products are trusted by thousands of customers worldwide. Whether you are a weekend rider or a full-time mechanic, KEMSO offers a reliable solution at a fair price.

Visit KEMSO today to find the right fuel pump for your 2004 Bombardier Outlander 400:
https://www.kemsoracing.com/

Summary

The fuel pump on your 2004 Bombardier Outlander 400 is located on top of the fuel tank, under the seat. It is a vacuum-operated pulse pump that uses engine vacuum to draw fuel from the tank and send it to the carburetor. The OEM part number is 707200183, and the pump fits many Outlander 330 and 400 models from 2003 to 2008.

To access the pump, remove the seat, disconnect the fuel lines and vacuum line, and unbolt the pump from the tank. Common symptoms of a failing pump include hard starting, stalling, and fuel leaks. Before replacing the pump, test it by checking fuel flow and vacuum at the pump.

When you need a replacement, choose a quality pump that will last. KEMSO offers OEM replacement fuel pumps with a lifetime warranty, giving you the reliability you need for years of trouble-free riding.

For more information and to browse their selection of fuel pumps, visit KEMSO Racing at:
https://www.kemsoracing.com/


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