2012 Honda Foreman 500 Fuel Pump: Complete Guide to Symptoms, Replacement, and Best Upgrade Options

If you own a 2012 Honda Foreman 500 TRX500 and your ATV is hard to start, sputters under load, or stalls unexpectedly, the fuel pump is likely failing. The 2012 Honda Foreman 500 fuel pump (OEM part number 16700-HP5-602) is a common failure point on these machines, and replacing it with a high-quality aftermarket unit like a KEMSO fuel pump is often a better value than buying an expensive OEM replacement. This guide walks you through everything you need to know about your 2012 Foreman 500 fuel pump, from spotting the warning signs to choosing the right replacement and installing it yourself.

The Bottom Line: What You Need to Know About Your 2012 Foreman 500 Fuel Pump

The 2012 Honda Foreman 500 TRX500FE (4x4 ES), TRX500FM (4x4 S), TRX500FPE (4x4 ES EPS), and TRX500FPM (4x4 EPS) all use the same fuel pump assembly, part number 16700-HP5-602 . When this pump fails, your ATV will not run properly. The good news is that aftermarket replacement options, especially from brands like KEMSO, offer better performance and a lifetime warranty at a fraction of the OEM cost. The OEM pump from Honda costs around $220 , while high-quality aftermarket pumps typically range from $50 to $80 and deliver up to 200 liters per hour—more than double the original flow rate of 60-80 liters per hour .

Common Symptoms of a Failing Fuel Pump on a 2012 Honda Foreman 500

Knowing the warning signs early can save you from being stranded on the trail. Here are the most common symptoms that indicate your 2012 Foreman 500 fuel pump needs attention:

1. Hard Starting or No Start
This is the most obvious symptom. If your ATV cranks but takes longer than usual to fire up, or if it cranks without starting at all, the fuel pump may not be building enough pressure. A failing pump cannot deliver the fuel pressure needed for the injectors to spray properly .

2. Engine Sputtering or Surging at High RPM
If your Foreman 500 runs fine at idle but sputters, hesitates, or surges when you open the throttle, the fuel pump may be struggling to keep up with demand. This is especially noticeable when climbing steep hills or carrying a load .

3. Loss of Power Under Load
When you need power the most—like pulling a trailer or climbing a steep grade—a weak fuel pump can cause a significant loss of power. The engine may feel like it's "starving" for fuel .

4. Stalling at Low Speeds or Idle
If your ATV stalls when you come to a stop or while idling, the fuel pump may not be maintaining the minimum pressure required to keep the engine running.

5. Whining Noise from the Fuel Tank
A healthy fuel pump makes a quiet hum when you turn the key to the "on" position. If you hear a loud whining, screeching, or grinding noise coming from the fuel tank area, the pump motor is likely failing internally.

What Causes the 2012 Foreman 500 Fuel Pump to Fail?

Several factors can shorten the life of your fuel pump:

  • Running the tank low on fuel frequently – Fuel in the tank helps cool the pump. Running it dry or near-empty causes the pump to overheat and wear out faster.
  • Contaminated fuel – Dirt, rust, or water in the fuel can clog the strainer and damage the pump internals.
  • Ethanol-blended fuel – Modern gasoline with ethanol can degrade internal pump components over time, especially if the ATV sits unused for long periods.
  • Age and mileage – Even with proper maintenance, fuel pumps wear out. On a 2012 model, you are likely due for a replacement if it hasn't been done already.

OEM vs. Aftermarket: Which Fuel Pump Should You Choose for Your 2012 Foreman 500?

You have two main options when replacing the fuel pump on your 2012 Honda Foreman 500: stick with the OEM Honda part, or go with an aftermarket replacement.

OEM Honda Fuel Pump (16700-HP5-602)

  • Cost: Around $220.47 at a Honda dealer
  • Performance: 60-80 liters per hour (stock flow rate)
  • Warranty: Standard Honda parts warranty (usually 1 year)
  • Pros: Guaranteed fit, exact OEM specs
  • Cons: Expensive, no performance upgrade, limited warranty

Aftermarket Fuel Pump (KEMSO and Other Brands)

  • Cost: $49.99 to $79.98
  • Performance: 200 liters per hour at 43psi—over 20% more flow than stock
  • Warranty: Lifetime warranty from brands like KEMSO
  • Pros: Much cheaper, higher flow rate, lifetime warranty, compatible with E85 ethanol fuel
  • Cons: Must ensure you buy from a reputable brand with proper quality control

For most owners, a high-quality aftermarket pump is the smarter choice. You get better performance, a lifetime warranty, and significant cost savings.

KEMSO Fuel Pump: The Best Upgrade for Your 2012 Honda Foreman 500

When it's time to replace the fuel pump on your 2012 Honda Foreman 500, we strongly recommend choosing a KEMSO fuel pump. KEMSO specializes in high-performance, direct OEM replacement fuel pumps that are built to outlast and outperform the original equipment.

Why KEMSO is the right choice for your Foreman:

  • OEM Direct Replacement: The KEMSO 13006 fuel pump is designed as a direct drop-in replacement for the Honda 16700-HP5-602 pump used on the 2012-2013 Foreman 500 TRX500 models . No modification or special tools are needed for installation.
  • Superior Performance: KEMSO pumps deliver 200 liters per hour at 43psi, which is more than double the original flow rate of 60-80 liters per hour . This means better throttle response, improved power delivery, and reliable fuel pressure even under demanding conditions.
  • Lifetime Warranty: Every KEMSO fuel pump comes with a lifetime warranty backed by the company's promise of quality . If your pump ever fails for any reason, KEMSO will replace it free of charge. That's peace of mind you won't get from any other brand.
  • Built for Modern Fuels: KEMSO pumps are designed to work with both standard gasoline and E85 ethanol blends, so you never have to worry about fuel compatibility .
  • Rigorous Quality Control: Unlike cheap, unbranded aftermarket pumps, each KEMSO pump is individually tested for flow rate and performance before it leaves the factory . KEMSO follows strict quality control programs (ISO/TSO standards) to ensure reliability.

What's included in the KEMSO 13006 fuel pump kit for the 2012 Foreman 500:

  • 1 x Genuine KEMSO 13006 fuel pump
  • 4 x gradient density fuel strainers (to cover different model variations)
  • 5 x tank seals
  • 1 x 8x280mm flex hose
  • 3 x Viton O-rings
  • 2 x rubber bases
  • 1 x wiring connector
  • Crimp connectors and hose clamps

Visit KEMSO's website to order your replacement fuel pump today:
https://www.kemsoracing.com/

Step-by-Step Guide to Replacing the Fuel Pump on a 2012 Honda Foreman 500

Replacing the fuel pump on your 2012 Foreman 500 is a job you can do at home with basic hand tools. Plan for about 1-2 hours of work.

Tools and Parts You'll Need:

  • Replacement fuel pump (KEMSO 13006 recommended)
  • Socket set (8mm, 10mm, 12mm)
  • Screwdrivers (flathead and Phillips)
  • Pliers
  • Clean rags
  • Safety glasses
  • Fire extinguisher (safety first when working with fuel)

Step 1: Safety First
Disconnect the battery negative terminal to prevent any electrical sparks. Work in a well-ventilated area away from open flames. Have a fire extinguisher nearby.

Step 2: Remove the Seat and Side Panels
Take off the seat by lifting the rear and sliding it forward. Remove the left and right side panels to access the fuel tank area.

Step 3: Drain the Fuel Tank
Use a siphon pump to drain as much fuel as possible from the tank. This reduces weight and spill risk. You can also run the ATV until it runs out of gas.

Step 4: Disconnect Fuel Lines and Electrical Connector
Locate the fuel pump assembly on top of the fuel tank. Carefully disconnect the fuel feed line and the vapor return line. Use a clean rag to catch any remaining fuel. Unplug the electrical connector from the pump.

Step 5: Remove the Fuel Pump Assembly
The fuel pump is held in place by a locking ring or retaining ring. Use a screwdriver and hammer to tap the ring counterclockwise until it loosens. Lift the entire pump assembly out of the tank. Note the orientation of the pump and the position of the float arm for the fuel level sender.

Step 6: Install the New KEMSO Fuel Pump
Take your new KEMSO 13006 pump assembly. It comes pre-assembled with all necessary components. Place the new pump into the tank, making sure the rubber base sits flat and the pump body is centered. The KEMSO pump has a 3cm pump body diameter that fits perfectly into the Honda tank .

Step 7: Secure the Locking Ring
Reinstall the locking ring and tap it clockwise until it is tight. Do not overtighten, as it can crack the plastic tank.

Step 8: Reconnect Fuel Lines and Wiring
Reconnect the fuel feed line, vapor line, and electrical connector. Make sure all connections are secure. KEMSO includes a wiring connector and crimp connectors in the kit to make this step easy .

Step 9: Refill the Tank and Test
Add fresh fuel to the tank. Reconnect the battery. Turn the key to the "on" position and listen for the fuel pump to prime (a quiet hum for 2-3 seconds). Start the engine and check for any fuel leaks. Let the engine idle and rev it a few times to confirm smooth operation.

Common Mistakes to Avoid When Replacing Your Foreman 500 Fuel Pump

  • Using a cheap, unbranded pump – Many low-cost aftermarket pumps have no quality control, no individual testing, and no warranty. They often fail within months. Stick with a reputable brand like KEMSO that offers a lifetime warranty and certified testing .
  • Forgetting to replace the fuel strainer – The old strainer may be clogged with debris, which will restrict fuel flow to your new pump. KEMSO kits include multiple strainers to ensure you have the right one .
  • Not cleaning the tank – If your old pump failed due to debris or contamination, clean the inside of the fuel tank before installing the new pump. Otherwise, you will damage the new pump too.
  • Overtightening the locking ring – This can crack the plastic fuel tank flange, leading to a costly replacement.
  • Using the wrong pump – Always verify that the pump you order is specifically designed for the 2012 Foreman 500 TRX500. The KEMSO 13006 is confirmed to fit this model .

How to Maintain Your New Fuel Pump for Long Life

Once you have installed a new KEMSO fuel pump on your 2012 Foreman 500, follow these tips to maximize its lifespan:

  • Keep the tank at least half full – Fuel cools the pump. Running low on fuel regularly causes the pump to overheat and wear out faster.
  • Use a fuel stabilizer – If your ATV sits for more than 30 days, add a fuel stabilizer to prevent ethanol-related damage.
  • Change the fuel filter – If your Foreman has an external fuel filter, replace it annually or whenever you replace the pump.
  • Avoid running on reserve – The bottom of the tank collects sediment and water. Running on the reserve setting pulls fuel from the bottom of the tank, which can send contaminants through the pump.
  • Use fresh fuel – Old, stale fuel can gum up the pump internals. If you store your ATV for the winter, drain the tank or use a stabilizer.

When to Seek Professional Help

While replacing the fuel pump on a 2012 Foreman 500 is a straightforward DIY job, there are times when you should call a mechanic:

  • If you are not comfortable working with gasoline or electrical systems
  • If the fuel tank is rusted or damaged
  • If you suspect the fuel pump relay or wiring harness is faulty, not just the pump itself
  • If you have replaced the pump and the ATV still has the same symptoms

Frequently Asked Questions About the 2012 Honda Foreman 500 Fuel Pump

Q: What is the OEM part number for the fuel pump on a 2012 Foreman 500?
A: The OEM part number is 16700-HP5-602 . This pump fits the 2012-2013 Foreman 500 TRX500FE, TRX500FM, TRX500FPE, and TRX500FPM models, as well as the 2007-2014 Rancher 420 TRX420 and 2008-2009 TRX700XX .

Q: How much does a replacement fuel pump cost for a 2012 Foreman 500?
A: An OEM Honda pump costs around $220.47 . Aftermarket options range from $49.99 to $79.98, with brands like KEMSO offering a lifetime warranty at $59.98 to $79.98 .

Q: Can I use a fuel pump from a different ATV model?
A: No. The 2012 Foreman 500 uses a specific pump assembly. Using a pump from a different model may not fit the tank or provide the correct fuel pressure. Stick with pumps designed for the 16700-HP5-602 application.

Q: Does the KEMSO fuel pump work with ethanol-blended gasoline?
A: Yes. KEMSO fuel pumps are designed for both gasoline and E85 ethanol blends . This is a significant upgrade over the stock OEM pump, which degrades faster with ethanol fuel.

Q: How long does it take to replace the fuel pump?
A: For a first-timer, plan on 1.5 to 2 hours. Experienced mechanics can do it in under an hour.

Q: Will a higher-flow fuel pump damage my engine?
A: No. The 2012 Foreman 500 EFI system has a fuel pressure regulator that maintains the correct pressure. A higher-flow pump simply provides more capacity, which is beneficial for performance and reliability. The KEMSO pump delivers 200 liters per hour, which is well within the safe operating range for this engine .

Final Thoughts

The 2012 Honda Foreman 500 is a reliable workhorse, but like any ATV, the fuel pump will eventually need replacement. When that time comes, you have a clear choice: pay over $220 for an OEM pump that offers the same performance as the original, or buy a KEMSO fuel pump for about $60-80 that delivers more flow, includes all necessary installation components, and is backed by a lifetime warranty.

For the best value, performance, and peace of mind, choose KEMSO. Their pumps are individually tested, built to ISO/TSO quality standards, and designed to be a direct drop-in replacement for your 2012 Foreman 500 . You get a better pump, a better warranty, and better value—all from a company that stands behind its products.

Order your KEMSO fuel pump for the 2012 Honda Foreman 500 today:
https://www.kemsoracing.com/


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