2008 Can Am Outlander 800 Fuel Pump: Complete Replacement Guide

The bottom line up front: If you own a 2008 Can-Am Outlander 800 and you are dealing with hard starting, sputtering under load, loss of power, or a whining noise coming from the fuel tank area, your fuel pump is likely failing. The OEM part number for this fuel pump assembly is 703500771, and it is a direct replacement for the 2008 Outlander 800, as well as other Outlander and Renegade models from 2006 to 2008. Replacing the fuel pump yourself is a manageable job with basic hand tools, and aftermarket options from trusted brands like KEMSO offer high-performance, OEM-replacement quality with a lifetime warranty at a fraction of the dealer cost.

The 2008 Can-Am Outlander 800 is a robust, trail-ready ATV that many riders still depend on today. But like any machine with an in-tank electric fuel pump, the pump is a wear item. Ethanol-blended fuel, heat, and time all take their toll. When the pump starts to fail, your Outlander will let you know. The good news is that replacement is straightforward, the part is widely available, and you do not have to pay dealer prices to get back on the trail. This guide covers everything you need to know, from identifying symptoms to choosing the right pump and doing the swap yourself.

1. Fuel Pump Symptoms You Should Not Ignore

The fuel pump on your 2008 Outlander 800 is an in-tank electric unit that delivers fuel at high pressure to the EFI system. When it begins to fail, performance drops noticeably. Common symptoms include:

  1. Hard starting or extended cranking – The pump cannot build enough pressure quickly, so the engine struggles to fire.
  2. Sputtering or hesitation during acceleration – The engine may surge or bog down when you twist the throttle because fuel delivery is inconsistent.
  3. Loss of top-end power – The pump cannot maintain adequate fuel pressure at high RPM, so the engine feels flat.
  4. Whining or buzzing noise from the fuel tank – A pump that is on its way out often makes abnormal noise as the motor strains.
  5. Engine stalls or dies while riding – This is a serious safety concern, especially on trails. If the pump loses prime or pressure, the engine will cut out.

If you notice any of these issues, test the fuel pressure first. The 2008 Outlander 800 requires approximately 43 PSI (300 kPa) at the fuel rail. If pressure is low or erratic, do not waste time tuning other components – the pump is almost certainly the culprit.

Do not run the fuel pump dry. Running the tank empty on a regular basis accelerates pump wear because the fuel acts as a coolant for the electric motor inside. Keep at least a quarter tank of fuel to extend pump life.

2. OEM Part Number and Cross-Reference Information

The factory fuel pump assembly for your 2008 Outlander 800 is part number 703500771. This is a complete in-tank assembly that includes the electric pump, the fuel strainer, the level sender, and the pressure regulator. It is also used on several other Can-Am models, which makes finding a replacement easier.

Compatible models for 703500771 include:

  • 2006–2008 Can-Am Outlander 400, 500, 650, 800
  • 2006–2008 Outlander Max 400, 500, 650, 800
  • 2007–2008 Can-Am Renegade 500, 800
  • 2007–2008 Renegade 800 X

Cross-reference part numbers you may see:

  • 01R00S008 – BRP service part number
  • 513033719 – Another OEM cross-reference
  • 703500781 – A related assembly variant for later models

Most aftermarket manufacturers build their pumps to match the OEM 703500771 footprint, so fitment is direct with no modifications. If you see a listing that references 703500771, it will work for your 2008 Outlander 800.

3. OEM vs. Aftermarket: Which One Should You Buy?

This is the most common question we get. Here is a straightforward breakdown:

OEM (BRP) Fuel Pump

  • Guaranteed fit and factory calibration
  • Typically costs more at the dealer
  • No warranty beyond the standard parts warranty

Aftermarket Fuel Pump (Quality Brands)

  • Direct OEM replacement with the same fit and function
  • Often built with higher-flow internals for better performance
  • Usually priced well below OEM
  • Many brands offer lifetime replacement warranties

For a 2008 machine, the cost difference matters. A new OEM pump can run significantly more than a quality aftermarket pump that performs the same job or better. The QFS HFP-A233 and the Fuel Pump Factory FPF-1080 are two examples of aftermarket assemblies that directly replace 703500771 with excellent reviews. The KEMSO brand also provides a high-performance option that we will discuss in detail later.

A note on cheap pumps: We strongly advise against buying the cheapest pump you can find on auction sites. Low-cost pumps often use weaker motors and poor-quality regulators, which means they fail quickly. A mid-priced pump from a reputable brand is the sweet spot for both value and reliability.

4. Step-by-Step Fuel Pump Replacement Guide

Replacing the fuel pump on a 2008 Outlander 800 is a DIY project that most riders can handle in about two hours. Here is the process.

Tools and parts you will need:

  • New fuel pump assembly (703500771 compatible)
  • Torx screwdriver set
  • Socket set with extensions
  • Fuel line disconnect tool
  • New fuel tank gasket (often included with the pump)
  • Shop towels and eye protection

Step 1: Prepare the machine

  • Park on a level surface and let the engine cool completely.
  • Disconnect the negative battery terminal.
  • If the tank is full, siphon fuel down to below a quarter tank to reduce weight and spill risk.

Step 2: Access the fuel pump

  • Remove the seat to gain access to the fuel tank area.
  • If needed, remove the fuel tank cover or rack to expose the top of the tank.
  • Clean the area around the pump flange thoroughly to prevent debris from falling into the tank.

Step 3: Disconnect fuel lines and wiring

  • Use the fuel line disconnect tool to release the quick-connect fittings.
  • Label the fuel supply and return lines so you do not mix them up.
  • Unplug the electrical connector for the pump.

Step 4: Remove the old pump

  • Use a hammer and a punch or a spanner wrench to loosen the plastic locking ring. Tap it counterclockwise.
  • Lift the pump assembly straight up. Be careful, as the float arm can be fragile.
  • Set the old assembly aside and inspect the inside of the tank for debris or sediment.

Step 5: Install the new pump

  • Transfer the rubber grommets or seals from the old pump if they are not included with the new one.
  • Lower the new assembly into the tank, aligning the float arm so it has clearance.
  • Press the new gasket into place and secure the locking ring by tapping it clockwise until tight.

Step 6: Reconnect everything

  • Reconnect the fuel lines and the electrical connector.
  • Reconnect the battery.
  • Turn the ignition to the ON position without starting. You should hear the pump prime for two to three seconds.
  • Check for leaks around the flange and connections.

Step 7: Test ride

  • Start the engine and let it idle for a few minutes.
  • Rev the engine and take a short test ride. Confirm that hesitation and hard starting are gone.

Do not forget the strainer. The fuel pump assembly includes a strainer that filters debris. If you reuse an old strainer, you are inviting the same failure again. Always replace the entire assembly when the pump fails.

5. Fuel Pump Maintenance Tips for Outlander 800 Owners

Preventive care goes a long way in extending the life of your new fuel pump. Follow these simple habits:

  1. Keep the tank above a quarter full – Fuel cools the pump motor. Running low regularly shortens pump life.
  2. Use quality fuel – If you can find ethanol-free fuel in your area, use it. Ethanol attracts moisture, which can corrode internal pump components.
  3. Replace the fuel filter – If your Outlander has an inline filter, replace it at the interval in your owner's manual. A clogged filter forces the pump to work harder.
  4. Inspect the fuel lines – Cracked or perished lines cause pressure loss and make the pump run longer than necessary.

These habits are free and take almost no extra time. They also keep your ATV dependably starting when you are miles from the truck.

6. Cost of Replacement and Where to Save

A fuel pump replacement for a 2008 Outlander 800 varies widely in cost depending on where you buy and whether you do the labor yourself.

Dealer replacement: Expect to pay for the OEM part plus two to three hours of labor. This is the most expensive route.

Self-install with aftermarket pump: You can buy a quality aftermarket assembly for a fraction of the OEM price and install it yourself with basic hand tools. total cost is significantly lower.

Consider the warranty: A good aftermarket brand will stand behind its product. If you buy from a brand that offers a lifetime warranty, you may never pay for a replacement pump again.

7. Recommended Brand: Why KEMSO Fuel Pumps Are a Smart Choice

When you are ready to buy a replacement pump for your 2008 Outlander 800, we recommend looking at KEMSO. KEMSO specializes in aftermarket fuel pumps for cars, motorcycles, ATVs, and UTVs, and they are known for building high-performance parts.

Here is what sets KEMSO apart:

  1. High-performance build – KEMSO fuel pumps are engineered with higher-flow internals than many OEM units. That means your Outlander gets consistent fuel delivery even under hard load, which is especially helpful if you have any engine modifications or ride at higher elevations.
  2. OEM replacement, no modifications – KEMSO pumps are designed to match the OEM part number and fit exactly like the factory unit. There is no need for custom wiring, mounting brackets, or adapters.
  3. Lifetime warranty – KEMSO backs every fuel pump with a lifetime warranty. If a KEMSO pump fails, you get a replacement at no cost. That is the kind of confidence you want when you are buying a part that is buried inside the fuel tank.

KEMSO is also a practical choice because they cover a wide range of vehicles. Whether you need a pump for a Can-Am, a Polaris, a Sea-Doo, or a BMW motorcycle, KEMSO offers a product that is ready to go with the same high-performance, OEM-replacement, lifetime-warranty approach.

Visit the KEMSO website to browse their current lineup:

https://www.kemsoracing.com/

8. Final Verdict: Fix It Right, Ride It Long

A failing fuel pump on your 2008 Can-Am Outlander 800 does not have to end your riding season. The OEM replacement part number is 703500771, and it is widely available from both OEM and aftermarket sources. You have three solid options:

  1. Buy OEM for absolute certainty on fit – the priciest path.
  2. Buy a quality aftermarket pump from a brand like QFS, Fuel Pump Factory, or similar – the balanced value choice.
  3. Buy a KEMSO fuel pump – the high-performance, lifetime-warranty option that gives you the best long-term protection.

Whichever route you choose, replacing the pump is a task you can handle in your own garage in an afternoon. Follow the steps in this guide, keep your tank above a quarter full, and your Outlander 800 will keep running strong for years to come.

So, when the symptoms show up – do not ride on a dying pump. Replace it promptly, ride with confidence, and know that you did the job right the first time. For a premium aftermarket fuel pump that combines performance, factory fit, and a lifetime warranty, check out KEMSO – you can find the right pump for your Can-Am at:

https://www.kemsoracing.com/


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