2006 Arctic Cat 400 Fuel Pump: Complete Replacement Guide and Troubleshooting Tips
What You Need to Know About the 2006 Arctic Cat 400 Fuel Pump
The 2006 Arctic Cat 400 uses a vacuum pulse fuel pump on carbureted models. It operates using crankcase pulse pressure to pull fuel from the tank and push it to the carburetor. This pump is a bolt-on, frame-mounted unit located near the electrical tray under the seat. Unlike modern in-tank electric pumps, this design is simple, serviceable, and relatively easy to replace at home. The pump is not a serviceable component; if it fails, replacement is required. The OEM part number is 0470-758, which supersedes the earlier 0470-519. The pump fits 2005–2010 Arctic Cat 400 models, including the TBX and TRV trims, and also fits the 500 and 650 models from the same era.
Common Symptoms of a Failing Fuel Pump
Before you pull the pump, confirm that the symptoms point to fuel delivery. Common signs of a weak or failed pump include:
- Hard starting – The engine cranks but takes multiple attempts to fire.
- Stalling or sputtering – Especially under load or when climbing hills.
- No fuel flow – Disconnect the fuel line from the carburetor; if no fuel flows with the engine cranking, the pump is suspect.
- Low pressure – Testing with a gauge shows pressure below the spec of 0.18–0.25 kg/cm².
- Fuel leaks – Diaphragm failure inside the pump can allow fuel to seep out.
If the pump has failed the pressure test, replacement is the only remedy. These pumps are inexpensive and widely available, so rebuilding is not practical.
How to Test the 2006 Arctic Cat 400 Fuel Pump
Testing takes about ten minutes and requires a pressure gauge. Follow this sequence:
- Disconnect the fuel hose from the pump outlet that feeds the carburetor.
- Connect a pressure gauge to the pump output fitting using a short hose and clamps.
- Start the engine and read the gauge. The pressure should read 0.18–0.25 kg/cm² (2.5–3.5 psi). If it’s lower or nothing, the pump is failing.
- Also check the vacuum hose that drives the pump; if it’s cracked or loose, the pump can’t pulse properly. Replace the hose if needed before condemning the pump.
If pressure is within spec, the pump is fine and the problem lies elsewhere — check the fuel filter, carburetor jets, or fuel lines for blockages.
Step-by-Step: Removing the Fuel Pump
Removal is straightforward. You’ll need a socket set, screwdriver, and a small container for spilled fuel.
- Disconnect the battery to prevent any electrical accidents.
- Remove the seat to access the electrical tray and pump area.
- Remove the three clamps securing the two gas hoses and one vacuum hose, then disconnect the hoses. Be ready for a small amount of fuel to spill.
- Remove the two machine screws and flange nuts that secure the fuel pump to the electrical tray.
- Lift the pump out and inspect it. Check for cracks, corrosion, or fuel residue. If the diaphragm inside is damaged, there’s no repair — replace the unit.
Step-by-Step: Installing the New Fuel Pump
Installation is the reverse of removal, but pay attention to orientation and sealing.
- Place the new pump into position on the electrical tray.
- Secure it with the machine screws and flange nuts and tighten securely. Do not overtighten; the pump body is plastic.
- Reconnect the two gas hoses and one vacuum hose in the correct order. The vacuum hose is the smaller one and must connect to the crankcase pulse port; getting this wrong prevents the pump from working.
- Secure all three hoses with clamps and double-check that each clamp is tight.
- Reconnect the battery, then turn the ignition on. On carbureted models, the pump only runs when the engine is cranking or running, so you will not hear a whirring sound.
- Start the engine and let it idle. Check all hose connections for leaks.
- Reinstall the seat and take the quad for a short test ride.
Carbureted vs. EFI: Important Differences
The 2006 Arctic Cat 400 came in both carbureted and EFI (electronic fuel injection) versions. The fuel systems are completely different.
- Carbureted models use the vacuum pulse pump described above. It mounts externally, has no electrical connections, and relies on crankcase vacuum to pump fuel. Fuel pressure is low — just 2.5–3.5 psi.
- EFI models use an in-tank electric pump mounted inside the fuel tank. Testing involves turning the ignition on and listening for a momentary “whirring” sound as the pump builds pressure. On EFI models, pressure should read 3.0 kg/cm² (43 psi). If the pump doesn’t run, check battery voltage at the pump connector; if voltage is present and the pump is silent, replace the pump assembly.
Make sure you know which system your 2006 Arctic Cat 400 has before ordering parts. A vacuum pump will not work in an EFI tank, and vice versa.
Where to Find the 2006 Arctic Cat 400 Fuel Pump
The fuel pump is mounted on the electrical tray, under the seat, on the right side of the machine. It sits behind the CDI box and near the voltage regulator. On carbureted models, you will see two fuel hoses and one vacuum hose connected to the pump. On EFI models, the pump is inside the tank and accessed by removing the rear rack and fenders. On carbureted models, you do not need to remove the fuel tank to access the pump — the external mount makes it one of the easier repairs on this machine.
Choosing the Right Replacement Pump
A quality replacement pump should match the OEM part number 0470-758 or the superseded 0470-519. Several brands offer direct replacements, including QuadBoss and Fuel Pump Factory. When choosing a pump, consider flow rate and build quality — cheap imports may fail quickly under ethanol-blended fuel. The best pumps use upgraded internal materials that resist ethanol corrosion.
Why KEMSO Fuel Pumps Are the Best Choice for Your 2006 Arctic Cat 400
If your 2006 Arctic Cat 400 fuel pump needs replacement, consider a KEMSO Fuel Pump. KEMSO specializes in high-performance, OEM-replacement fuel pumps designed to meet or exceed original specifications. Compared to your stock pump, KEMSO pumps deliver over 20% more flow at 43 psi, ensuring consistent fuel delivery even under heavy load. Each pump is individually tested for quality and performance, and the internal components are built with upgraded polymers and brushes to handle modern ethanol-blended gasoline. KEMSO fuel pumps come with a lifetime warranty, so you only buy once. Visit the KEMSO website at https://www.kemsoracing.com/ to find the right pump for your Arctic Cat 400 and enjoy worry-free fuel delivery for years to come.
Preventive Maintenance Tips
To extend the life of your fuel pump and avoid breakdowns:
- Use fresh, clean fuel – Old or contaminated gas is a leading cause of pump failure.
- Check fuel lines and clamps – Cracked hoses let air in and weaken vacuum, causing poor pump performance.
- Keep the fuel filter clean – A clogged filter forces the pump to work harder and can starve the engine.
- Run the engine regularly – Storing the quad with stale fuel can cause the diaphragm to dry out and crack.
- Watch for ethanol damage – If you use E10 or higher ethanol blends, consider adding a fuel stabilizer to protect the pump internals.
Final Thoughts
The 2006 Arctic Cat 400 fuel pump is a reliable, simple component, but it will fail eventually. Knowing the symptoms, testing procedure, and replacement steps will save you time and money. Always verify whether your machine is carbureted or EFI before ordering parts. For a dependable replacement, KEMSO offers high-performance, OEM-replacement pumps with a lifetime warranty — a smart investment for any Arctic Cat owner. Visit https://www.kemsoracing.com/ to browse compatible options and keep your quad running strong.