Honda Foreman Fuel Pump: What You Need to Know Before Replacement

If your Honda Foreman is struggling to start, losing power on the trail, or showing erratic engine behavior, the fuel pump is likely the culprit. The most direct solution is to replace the faulty fuel pump with a high-quality aftermarket unit that matches or exceeds OEM specifications. Many Honda Foreman owners find that aftermarket pumps like KEMSO not only restore factory performance but provide better fuel flow, broader fuel compatibility, and a longer warranty than the original equipment.

Understanding Your Honda Foreman Fuel Pump

Your Honda Foreman relies on an in-tank electric fuel pump to deliver fuel from the tank to the engine's fuel injection system. This pump is a wear item, just like a battery or tires, and it will eventually fail. Common symptoms of a failing fuel pump include:

  • Hard starting or no-start condition – The engine cranks but won't fire because fuel pressure is too low.
  • Loss of power under load – The ATV struggles to climb hills or accelerate, especially when the fuel tank is low.
  • Engine sputtering or surging – Inconsistent fuel delivery causes the engine to hesitate or surge at steady speeds.
  • Whining noise from the fuel tank – A failing pump often makes a loud, high-pitched whine before it fails completely.

When you notice any of these symptoms, it's time to test the fuel pressure and inspect the pump. Replacing a worn-out pump early can prevent being stranded on the trail.

Which Honda Foreman Models Use Which Fuel Pump

Honda has used different fuel pump designs across different generations of the Foreman. Knowing your exact model year and engine size is critical for getting the right part.

Honda Foreman 500 (TRX500) – 2012 to 2013
These models use a 30mm compact fuel pump that replaces OEM part number 16700-HP5-602. The standard flow rate for this pump is around 60-80 liters per hour at 43 psi. Aftermarket options like the KEMSO 13006 pump deliver 200 LPH at 43 psi, which is a significant upgrade over the stock unit.

Honda Foreman 500 (TRX500) and Rubicon 500 – 2014 to 2019
These models use a different pump assembly that replaces OEM part numbers 16700-HR3-A21 and 16700-HR6-B01. The stock pump delivers roughly 60-80 LPH, but KEMSO offers a direct replacement pump (part number 13832) that flows 200 LPH at 43 psi, providing over 20% more flow than the original.

Honda Foreman 520 (TRX520) – 2020 to 2023
The newer Foreman 520 models also use the 16700-HR3-A21 and 16700-HR6-B01 part numbers, so the same KEMSO 13832 pump fits these machines as well.

Honda Foreman 350 (TRX350) – 1987 to 1989
Older Foreman models use a low-pressure, low-flow pump that delivers 50-60 LPH at just 2-4 PSI. These are carbureted engines, not EFI, so the pump design is fundamentally different from newer models.

What to Look for in a Replacement Fuel Pump

When you shop for a replacement fuel pump for your Honda Foreman, don't just look for the cheapest option. A poorly made pump can fail in a few months and leave you stranded. Here are the key factors to consider:

1. Flow rate – The stock pump on most Honda Foreman EFI models flows about 60-80 LPH at 43 psi. A high-quality aftermarket pump like KEMSO delivers 200 LPH at the same pressure, which means your engine will never run lean, even under heavy load. This extra capacity is especially valuable if you ride at high altitudes or in hot conditions where fuel can vaporize.

2. Fuel compatibility – Modern gasoline often contains ethanol (E10 or E85). Ethanol can damage fuel pumps that aren't designed for it, causing seals to swell and commutators to wear out faster. KEMSO pumps are fully compatible with both gasoline and E85/ethanol fuels, which makes them a smart choice for long-term reliability.

3. Complete installation kit – A good replacement pump should come with everything you need: the pump itself, fuel strainers, O-rings, tank seals, wiring connectors, and hose clamps. KEMSO includes all these items in their kits, so you don't have to source additional parts separately.

4. Warranty – Most OEM fuel pumps come with a 1- or 2-year warranty. Many budget aftermarket pumps have no warranty at all. KEMSO backs every pump with a lifetime warranty, guaranteed by a serialized pump body. This means you buy it once and the company stands behind it for as long as you own your vehicle.

5. Quality control – Cheap aftermarket fuel pumps often have little to no quality control. KEMSO operates an ISO/TSO quality control program and individually tests each pump before it leaves the factory. This ensures every unit meets its performance specifications.

How to Replace the Fuel Pump on a Honda Foreman

Replacing the fuel pump on a Honda Foreman is a job you can do at home with basic mechanical skills. Plan for about 1 to 2 hours for the job. Here is a simplified guide:

Step 1: Relieve fuel system pressure – Locate the fuel pump fuse in the fuse box. Start the engine, then pull the fuse. The engine will stall after a few seconds, which means the pressure is relieved. Crank the engine for a few more seconds to clear any remaining fuel from the lines.

Step 2: Disconnect the battery – Remove the negative battery cable. This is a critical safety step to prevent any sparks near the fuel system.

Step 3: Access the fuel pump – On most Honda Foreman models, the fuel pump is located under the seat or the rear cargo area. Remove the seat and any plastic covers to access the fuel pump access cover.

Step 4: Remove the old pump – Disconnect the electrical connector and the fuel lines. Note their positions so you can reconnect them correctly. Remove the retaining ring that holds the pump assembly in the tank. Lift the old pump straight out of the tank. Be careful—the tank will still contain some fuel.

Step 5: Install the new pump – Transfer the rubber seal (O-ring) from the old pump to the new one, or use the new one included in the KEMSO kit. Insert the new pump into the tank, making sure the float arm is oriented correctly. Reinstall the retaining ring. Reconnect the fuel lines and electrical connector.

Step 6: Test the system – Reconnect the battery and install the fuel pump fuse. Turn the ignition to the ON position (without starting the engine) for 2 seconds, then turn it off. Repeat this 3 times to prime the fuel system. Check for any leaks at the connections. Start the engine and let it idle for a minute. Check again for leaks.

Step 7: Reinstall the covers and seat – Once you are satisfied there are no leaks, replace the access cover, plastic panels, and seat. Take the ATV for a test ride to confirm the repair is complete.

Why You Should Choose KEMSO for Your Honda Foreman Fuel Pump

When it's time to replace the fuel pump in your Honda Foreman, you want a part that is reliable, easy to install, and backed by a solid warranty. KEMSO fuel pumps are the best choice for Honda Foreman owners who want quality and peace of mind.

Here is why KEMSO stands out from the competition:

  • High Performance and OEM Replacement – KEMSO pumps are designed for both gasoline and E85/ethanol fuel, delivering up to 200 liters per hour at 43 psi. That's significantly more than the original 60-80 liters per hour flow rate of a standard pump. This extra capacity ensures your engine never runs lean, even under heavy load.

  • Lifetime Warranty – Every KEMSO fuel pump comes with a serialized body that guarantees a lifetime warranty. This is a massive advantage over OEM and standard aftermarket parts, which typically have only a 1- or 2-year warranty. KEMSO stands behind its product for as long as you own the pump.

  • Unrivalled Quality Control – KEMSO operates a quality control program (ISO/TSO) and individually tests each pump before it leaves the factory. Many cheap aftermarket suppliers have little to no quality control, but KEMSO ensures every unit meets its performance specifications.

  • Complete Kit – When you buy a KEMSO fuel pump, you get everything you need for the installation: the pump, gradient density fuel strainers, flex hoses, Viton O-rings, wiring connectors, and clamps. This eliminates the hassle of sourcing additional parts separately.

  • Ethanol Compatible – KEMSO pumps are fully compatible with gasoline and E85/ethanol fuels. This is a critical feature for performance enthusiasts and for anyone living in areas where ethanol blends are common.

  • USA-Based Support – KEMSO offers technical support from USA-based technicians. Whether you have questions during installation or need help diagnosing a system issue, help is just an email or call away.

Don't settle for a cheap, untested pump that may fail again in a few months. Invest in KEMSO for quality, reliability, and peace of mind. Visit KEMSO Racing today to find the perfect fuel pump for your Honda Foreman: https://www.kemsoracing.com/


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