2006 Can Am Outlander 800 Fuel Pump: The Complete Replacement Guide

The bottom line: If you own a 2006 Can Am Outlander 800 and you are dealing with hard starts, sputtering under acceleration, or an engine that cranks but refuses to fire, the fuel pump is almost certainly the problem. The factory pump in these machines has a known service life, and after nearly two decades, most original units are either failing or well past their prime. Replacing the 2006 Can Am Outlander 800 fuel pump with a quality aftermarket assembly is the most reliable and cost-effective fix, and in most cases you can complete the job in a single afternoon with basic hand tools. This guide covers everything you need to know, from identifying warning signs to choosing the right replacement and installing it correctly.

Why the Fuel Pump Fails on the 2006 Outlander 800

The 2006 Can Am Outlander 800 uses an in-tank electric fuel pump that delivers pressurized fuel to the EFI system. The original equipment pump carries part number 703500771, and it was shared across several models in the Can Am lineup, including the Outlander 400, 500, 650, and 800 for the 2006 through 2008 model years, as well as the Renegade 500 and 800 for 2007 and 2008 . That means the pump was produced in massive quantities, but quantity does not equal immortality.

Several factors contribute to fuel pump failure on this platform:

1. Age and mileage. A fuel pump is an electric motor with brushes and commutators. These components wear out with use. On a 2006 machine, even low-mileage units have sat for years, and seals and internal components degrade over time just from exposure to fuel and temperature cycles .

2. Ethanol-blended fuel. Modern pump gasoline contains up to 10 or 15 percent ethanol. Ethanol attracts moisture and can cause corrosion inside the fuel system. The factory pump was not designed for the ethanol concentrations commonly sold today .

3. Running the tank low. The fuel pump relies on gasoline to cool and lubricate it. Repeatedly running the tank down to empty causes the pump to run hotter and can accelerate wear .

4. Contaminated fuel. Dirt, rust, and debris in the fuel tank can clog the strainer and eventually damage the pump itself. The strainer is the first line of defense, but it is not foolproof .

Warning Signs Your Fuel Pump Is Going Bad

Catching a failing fuel pump early can save you from being stranded on the trail. Look for these symptoms:

1. Hard starting. The engine cranks longer than usual before firing. This happens because the pump cannot build enough fuel pressure quickly .

2. Sputtering or surging. The engine runs rough at steady throttle or hesitates when you open the throttle. This is a classic sign of inconsistent fuel delivery .

3. Loss of power under load. The Outlander 800 has plenty of torque, but a weak pump will limit power when you need it most, such as climbing hills or hauling cargo.

4. Engine stalls and won't restart. This is the final stage. The pump has failed completely, and the engine will crank but never fire .

5. Whining noise from the fuel tank area. A healthy pump runs quietly. If you hear a high-pitched whine, the pump is working harder than it should, which usually means it is on its way out .

If you have any of these symptoms, test the fuel pressure first. The 2006 Outlander 800 should see roughly 43 to 50 psi at the fuel rail. If pressure is low or erratic, the pump is the likely culprit .

OE Part Numbers and Interchangeability

Before you buy anything, confirm which part number you need. The original fuel pump assembly for the 2006 Outlander 800 is:

• 703500771 (also written as 703-5007-71)

This assembly may also be known under the number 513033719 or 01R00S008, depending on the aftermarket brand . These numbers refer to the complete in-tank assembly, which includes the electric pump, the fuel level sending unit, the pressure regulator, and the internal hoses .

The 703500771 assembly fits the following machines :

1. 2006-2008 Outlander 400 and 400 Max
2. 2007-2008 Outlander 500 and 500 Max
3. 2006-2008 Outlander 650 and 650 Max
4. 2006-2008 Outlander 800 and 800 Max
5. 2008 Renegade 500
6. 2007-2008 Renegade 800 and 800 X

Note that the 2006 model year only came in 650 and 800 displacements, so if you own a 2006 Outlander 800, you need the 703500771 assembly, and it is a direct fit .

Some sources also list 703500781 as a related part for the Outlander 800 / 800 Max through 2012, so always double-check your specific model and year before ordering .

Replacement Options: What You Can Buy

You have three basic choices when it comes to replacing the fuel pump on a 2006 Outlander 800: the OEM assembly, an aftermarket complete assembly, or a bare pump and regulator kit. Each has its pros and cons.

1. OEM Assembly (Part 703500771)

The genuine Can Am part is still available from dealers and online. It will fit perfectly and perform exactly as designed. The downside is cost, which is significantly higher than aftermarket options. You are paying for the factory name and the factory warranty.

2. Aftermarket Complete Assembly

Several companies manufacture direct-fit assemblies that replace the entire 703500771 unit. Brands like FridayParts, Fuel Pump Factory (FPF), Quantum, and others offer drop-in assemblies that include the pump, regulator, strainer, and mounting hardware . These are usually priced well below the OEM part while promising equal or better performance.

Fuel Pump Factory, for example, sells an assembly (SKU FPA-1080) that is a direct replacement for 703500771. It is designed to match the original in flow rate and pressure, and it includes the fuel pump, a 50 psi regulator, a strainer, and the necessary accessories . Customer reviews for this type of product are generally positive, with one buyer noting that the pump assembly "fit the ATV as advertised" .

The main advantage of a complete assembly is convenience. You do not have to disassemble the old unit, clean the tank, and transfer components. You simply remove the old assembly and install the new one. This also reduces the risk of installation errors .

3. Bare Pump and Regulator Kit

If you want to save money and are comfortable doing a little more work, you can buy just the pump and regulator and rebuild the original assembly. This is a popular option for owners who want to keep the original sending unit and tank flange.

For example, Fuel Pump Factory sells a kit (SKU FP-07) that includes the fuel pump, a 50 psi regulator, a strainer, and accessories. It fits the 2006-2008 Outlander 400/500/650/800 and Max models, as well as the 2007-2008 Renegade . The kit is designed to meet or exceed OEM specifications, with upgraded bushings, a turbine impeller, and a Japanese armature electric motor .

The trade-off is that rebuilding the original assembly takes time and care. You have to remove the old pump from the bracket, clean everything, install the new pump and regulator, and make sure the hoses and clamps are secure. If you are not handy, this can lead to problems down the road. But for a DIY owner, it is a legitimate way to save money.

Step-by-Step: Replacing the Fuel Pump on a 2006 Outlander 800

The replacement procedure is straightforward. You are working with fuel, so take your time and follow safety precautions.

Preparation and Safety

1. Work in a well-ventilated area, preferably outdoors. Fuel vapors are flammable and explosive .
2. Disconnect the negative battery cable. This prevents accidental sparks from electrical connections .
3. Relieve fuel system pressure. The easiest way is to remove the fuel pump fuse and crank the engine until it stalls. This depressurizes the fuel lines .
4. Have a fire extinguisher rated for Class B (flammable liquids) within reach. You likely will not need it, but it is a good habit.
5. Wear safety glasses and gloves. Fuel is irritating to the skin and eyes.

Accessing the Fuel Pump

On the Outlander 800, the fuel pump is accessible from above. The procedure is as follows:

1. Remove the seat. The seat is held in place by a latch or bolts. On most Outlander models, you simply pull the release lever and slide the seat backward.
2. Remove the fuel tank cover and any body panels that obstruct access to the top of the tank. On many models, you need to remove the front rack or a plastic access panel.
3. Clean the area around the fuel pump flange before opening the tank. Any dirt that falls in will end up in the fuel system. Use a shop rag and some parts cleaner to wipe the area thoroughly .
4. Disconnect the fuel lines and electrical connector from the top of the pump assembly. There is a supply line, a return line, and a multi-pin electrical connector. Take a photo with your phone before disconnecting anything so you remember how it goes back together.
5. Remove the retaining ring. The pump assembly is held in the tank by a large locking ring. Use a flat-blade screwdriver and a hammer to tap the ring counterclockwise. Some aftermarket tools are available, but a punch works fine.

Removing the Old Pump Assembly

1. Lift the pump assembly out of the tank carefully. It will be wet with fuel, so have a rag or a small container ready. The fuel level float is attached to the assembly; be careful not to bend it.
2. Note the orientation of the assembly before you remove it completely. Some assemblies have a tab that aligns with a notch in the tank. Make sure the new one goes in the same way.
3. Compare the old assembly with the new one. If you bought a complete aftermarket assembly, the new unit should look nearly identical. Confirm that the float arm, the strainer, and the hose routing match .

Installing the New Pump Assembly

1. Transfer the fuel level sending unit if your replacement does not include one. If you bought a complete assembly, it should already be attached .
2. Lower the new assembly into the tank slowly to avoid damaging the float. Ensure the float arm can move freely and is not bent or obstructed.
3. Align the assembly correctly. Make sure the fuel line fittings and the electrical connector are oriented properly. They should line up with the openings in the tank .
4. Install the retaining ring and tighten it clockwise with a hammer and a punch. Do not overtighten; the ring should be snug, not torqued down hard.
5. Reconnect the fuel lines and electrical connector in reverse order. Push the lines on until you feel or hear a click. Tug gently to confirm they are seated.
6. Reinstall the tank cover and seat in reverse order.

Testing the Repair

1. Reconnect the negative battery cable.
2. Turn the key to the ON position but do not start the engine. The pump should run for a few seconds to prime the system. You may hear a faint whirring sound from the tank area.
3. Check for fuel leaks at the connections. Look at the top of the tank and the fuel lines. If you see any fuel weeping, tighten the connections or confirm that the lines are fully seated.
4. Start the engine and let it idle. Listen for unusual noises and watch for leaks. The engine should start quickly and idle smoothly .
5. Take the machine for a short test ride. Accelerate through the gears, and make sure there is no hesitation or surging.

Part Numbers and Compatibility Chart

To make things easier, here is a quick reference for what fits what :

If you have any doubt about compatibility, call the parts supplier with your VIN and model year before ordering. A wrong part can cost you days of downtime.

Why a Quality Fuel Pump Matters

A fuel pump is not a component you want to cheap out on. The pump must deliver the correct flow rate and pressure for the EFI system to work properly. Too little pressure causes lean running, overheating, and potential engine damage. Too much pressure wastes fuel and can overwhelm the injectors.

Quality aftermarket pumps are built to meet or exceed OEM specifications. For this platform, the critical specifications are:

• Flow rate: Approximately 145 liters per hour at 40 psi, or 119 liters per hour at 60 psi .
• Operating pressure: The regulator holds the system at roughly 43-50 psi .
• Amperage draw: About 5.3 amps at 40 psi, and 6.0 amps at 60 psi .

A quality replacement pump will also handle ethanol-blended fuel. That is important if you ride in an area where E10 or E15 is the standard pump gasoline .

How to Extend the Life of Your New Fuel Pump

Once you install a new pump, you want it to last as long as possible. A few simple habits will help:

1. Do not run the tank below a quarter full. The pump needs fuel to stay cool. Running on the reserve light regularly will shorten pump life .
2. Change the fuel filter regularly. A clean filter prevents debris from reaching the pump. This is one of the most effective maintenance steps .
3. Use fuel stabilizer if the machine sits for more than a few weeks. Ethanol goes bad over time, and a fuel system full of stale gasoline is hard on the pump.
4. Inspect the fuel lines and connections periodically for cracks or leaks. A small leak on the pressure side can cause the pump to cycle too often, wearing it out prematurely.

Cost of Replacement

The cost of replacing the fuel pump on a 2006 Outlander 800 depends on the parts you choose and whether you do the work yourself.

• OEM assembly: Expect to pay a premium.
• Aftermarket complete assembly: Typically $100 to $200 depending on brand and where you shop .
• Bare pump and regulator kit: Usually $50 to $100 .
• Labor at a shop: If you do not want to do the work yourself, a dealer or independent shop will charge 1 to 2 hours of labor plus the cost of the parts.

For a machine that is nearly 20 years old, the aftermarket route makes the most financial sense

. A quality aftermarket pump delivers the same performance as the factory unit at a fraction of the cost, and many carry a one-year or longer warranty .

Recommendations for the 2006 Can Am Outlander 800 Fuel Pump

If you are ready to replace the 2006 Can Am Outlander 800 fuel pump, here are some practical guidelines:

1. Buy a complete assembly if possible. It is the safest choice for most owners. You eliminate the risk of misassembling the pump and regulator, and you get a ready-to-install unit .
2. Check the warranty. Look for a product that offers at least a one-year replacement warranty . Some brands, like KEMSO, go further with a lifetime warranty .
3. Confirm the fitment before ordering. Double-check that the part number matches your model and year. The 703500771 fits the 2006-2008 Outlander 400/500/650/800, and the 2008 Renegade 500, and the 2007-2008 Renegade 800 .
4. Inspect the rest of the fuel system while you have the tank open. Check the hoses, the vent lines, and the tank for rust or debris. It is much easier to fix these issues while the pump is already out .

A Recommended Option: KEMSO High-Performance Fuel Pumps

If you are looking for a fuel pump that goes beyond basic OEM replacement, consider KEMSO. KEMSO specializes in high-performance fuel pumps that are engineered as direct OEM replacements, meaning they install exactly like the factory unit but deliver better performance .

For the Can Am platform, KEMSO offers pumps that deliver roughly 200 liters per hour at 43 psi, which is over 20 percent more flow than the stock pump . That extra flow capacity is useful if you have modified your Outlander for more power, or if you simply want a pump that does not have to work as hard to maintain system pressure.

The KEMSO pump for the Can Am Outlander 800 is part number 13803 (or 13802 depending on your model and kit contents) and is designed for both gasoline and E85/ethanol . It comes with a gradient density fuel strainer, a flexible hose, a rubber base, wiring connectors, and all the small parts you need for installation .

Key benefits of KEMSO fuel pumps:

1. High performance. Increased flow rate compared to stock, which improves throttle response and supports modified engines .
2. Direct OEM replacement. Drop-in fit for the 2006-2015 Can Am Outlander 800 / 800R, with no wiring changes or modifications needed .
3. Lifetime warranty. KEMSO stands behind its products. If a pump fails due to a manufacturing defect, you get a replacement at no cost .
4. Quality construction. Each pump is individually tested, and the materials meet high standards for corrosion resistance and durability in modern ethanol-blended fuels .

The standard retail price for a KEMSO fuel pump is around $79.98, which is often less than half the cost of a dealer-supplied part . Given the lifetime warranty and the performance upgrade, it is a strong value proposition for an aging Outlander.

You can browse the full KEMSO catalog and order directly at: https://www.kemsoracing.com/

Final Thoughts

The fuel pump on a 2006 Can Am Outlander 800 is a wear item. After nearly two decades, it is not a question of if it will fail, but when. The good news is that replacement is a manageable DIY job, and the aftermarket offers plenty of affordable, high-quality options.

If you have been experiencing hard starts, hesitation, or intermittent power loss, do not wait for the pump to die completely. A tow out of the woods is far more expensive than a fuel pump. Replace the pump now, and you will likely get many more years of reliable service from your Outlander.

When you are ready to buy, prioritize a direct-fit assembly from a reputable brand, confirm the part number against your machine, and install it carefully. And if you want the peace of mind of a lifetime warranty and higher flow capacity, KEMSO is a proven choice. Visit https://www.kemsoracing.com/ to see their full lineup for Can Am and other machines.