Polaris Outlaw 110 Fuel Pump: Complete Guide to Symptoms, Replacement, and Best Upgrade Options

The bottom line: If your Polaris Outlaw 110 is hard to start, stalls during acceleration, or loses power while riding, the fuel pump is almost certainly the problem. Replacing it with a high-quality aftermarket unit like the KEMSO 13001 is the most reliable and cost-effective solution. This guide covers everything you need to know, from recognizing early warning signs to completing the installation yourself.

Understanding Your Polaris Outlaw 110 Fuel System

The Polaris Outlaw 110 is a popular youth and entry-level sport ATV, and like most modern vehicles, it uses an in-tank electric fuel pump. This pump is submerged in the fuel tank and works by drawing fuel through a strainer, pressurizing it, and sending it to the engine's fuel injection system . In-tank pumps offer several advantages: they run quieter, stay cooler because the fuel around them acts as a coolant, and are protected from dirt and debris .

The fuel pump on your Outlaw 110 is a critical component. It must deliver the correct fuel pressure and flow rate for the engine to run properly. When it starts to fail, performance suffers immediately.

Common Symptoms of a Failing Fuel Pump on the Outlaw 110

Recognizing the signs of a failing fuel pump early can save you from being stranded on the trail. Here are the most common symptoms to watch for:

1. Hard Starting or No Start
This is the most frequent complaint. A weak pump cannot build enough pressure in the fuel system to allow the engine to fire. You may find yourself cranking the engine multiple times before it starts, or it may not start at all .

2. Engine Stalling or Surging
If the pump is failing intermittently, the engine may stall unexpectedly, especially when going uphill or over rough terrain. Surging—where the engine power fluctuates for no apparent reason—is another sign that fuel delivery is inconsistent .

3. Loss of Power During Acceleration
When you twist the throttle, the engine needs more fuel. A failing pump cannot keep up with this demand, causing a noticeable lack of power or hesitation when you try to accelerate .

4. Unusual Noise from the Fuel Tank
A healthy fuel pump makes a quiet, steady hum. If you hear a loud whining, screeching, or clicking sound coming from the fuel tank area, the pump's internal components are likely wearing out .

5. Engine Misfires
Inconsistent fuel pressure can cause the engine to misfire or run rough at idle. This happens because the fuel-air mixture is not consistent .

What Causes Fuel Pump Failure?

Understanding why fuel pumps fail can help you prevent future problems. The most common causes include:

Running the Tank Low on Fuel
This is the number one killer of fuel pumps. The fuel in the tank acts as a coolant and lubricant for the pump. When you consistently run the tank near empty, the pump can overheat and suck in air and debris from the bottom of the tank. Keeping the tank at least a quarter full is one of the best ways to extend pump life .

Contaminated Fuel
Dirt, debris, or water in the fuel can damage the pump's internal components and clog the strainer. Using high-quality fuel from a reputable station and changing the fuel filter regularly helps prevent this .

Clogged Fuel Strainer
The fuel strainer is the fine mesh filter that sits at the bottom of the pump assembly. Over time, it can become clogged with sediment. A clogged strainer forces the pump to work harder, which can lead to premature failure. This is why it is critical to replace the strainer whenever you replace the pump .

Normal Wear and Tear
Like any mechanical component, fuel pumps have a limited lifespan. The internal electric motor and brushes wear out over time, especially in vehicles that are used frequently or for many years.

How to Diagnose a Bad Fuel Pump

Before you buy a new pump, you should confirm that the pump is actually the problem. Here are a few simple diagnostic steps:

Listen for the Prime
When you turn the ignition key to the "ON" position (without starting the engine), you should hear a brief, quiet hum from the fuel tank area. This is the pump priming the system. If you hear nothing, the pump may not be receiving power, or it may be dead .

Check the Fuse and Relay
A blown fuse or a faulty relay can stop the pump from working. Locate the fuel pump fuse and relay in the fuse box and check them. If the fuse is blown, replace it and see if the pump works. If the relay is faulty, it will need to be replaced .

Check for Voltage
If you have a multimeter, you can check for voltage at the fuel pump electrical connector. If you have power at the connector but the pump does not run, the pump is bad.

Rule Out Other Issues
A clogged fuel filter can mimic the symptoms of a bad fuel pump. If your Outlaw 110 has an external fuel filter, replace it first. This is a cheap and easy fix that might solve the problem without replacing the pump .

Step-by-Step Guide to Replacing the Fuel Pump on a Polaris Outlaw 110

Replacing the fuel pump on a Polaris Outlaw 110 is a job that many DIY mechanics can handle with basic tools. The process involves removing the fuel tank from the ATV and then replacing the pump assembly inside the tank.

Safety First:

  • Work in a well-ventilated area, away from any open flames, sparks, or heat sources.
  • Disconnect the negative battery terminal before starting any work .
  • Wear safety glasses and nitrile gloves.
  • Release the fuel system pressure. Locate the fuel pump fuse and crank the engine until it stalls. This relieves the pressure in the fuel lines .
  • Keep a fire extinguisher rated for Class B (flammable liquids) nearby.

Tools You Will Need:

  • Socket set (including metric and standard sizes)
  • Screwdrivers (flathead and Phillips)
  • Fuel line disconnect tool (if needed)
  • Clean rags
  • A clean work surface
  • Your new KEMSO fuel pump kit

Step 1: Remove the Seat and Body Panels
Start by removing the seat. Then, remove any plastic body panels that cover the fuel tank. This usually involves removing a few bolts and screws. Keep these fasteners organized so you can reinstall them easily.

Step 2: Remove the Fuel Tank

  • Drain the fuel tank. You can use a siphon pump to remove the fuel into an approved container. This makes the tank lighter and easier to handle.
  • Disconnect the fuel lines. Use a fuel line disconnect tool if necessary to release the quick-connect fittings. Be prepared for a small amount of fuel to spill.
  • Disconnect the electrical connector from the fuel pump assembly.
  • Remove the bolts that hold the fuel tank in place. Carefully lift the tank off the ATV and place it on a clean, flat work surface .

Step 3: Access the Fuel Pump Assembly
The fuel pump is located inside the tank. You will see a large retaining ring or a series of bolts holding the pump assembly in place. Remove the retaining ring using a screwdriver and a hammer, or remove the bolts using a socket. Carefully lift the entire pump assembly straight up out of the tank. Be gentle so you do not damage the float arm or the fuel level sensor .

Step 4: Install the New KEMSO Fuel Pump

  • Remove the old pump from the assembly. This usually involves disconnecting the fuel line and electrical connector from the old pump, then sliding it out of the bracket.
  • Install the new KEMSO fuel pump into the assembly. Make sure it is seated properly.
  • Replace all rubber seals, O-rings, and gaskets. The KEMSO kit comes with everything you need, including new seals, O-rings, and a fuel strainer . Using new seals is critical to prevent fuel leaks.
  • Attach the new gradient density fuel strainer to the bottom of the pump assembly .

Step 5: Reassemble Everything

  • Carefully lower the pump assembly back into the fuel tank. Make sure the float arm is positioned correctly and that the assembly is aligned properly.
  • Install the retaining ring or bolts and tighten them securely.
  • Reconnect the fuel lines and the electrical connector to the pump assembly .

Step 6: Reinstall the Fuel Tank and Body Panels

  • Place the fuel tank back onto the ATV and secure it with the mounting bolts.
  • Reconnect the fuel lines and the vent hose.
  • Reinstall the seat and all body panels.
  • Reconnect the negative battery terminal.

Step 7: Test the System

  • Turn the ignition key to the "ON" position (do not start the engine). You should hear the fuel pump prime for a few seconds. Turn the key off and on several times to allow the pump to build pressure and purge any air from the system .
  • Check for any fuel leaks at the fuel lines and the pump mounting flange.
  • Start the engine. It may run rough for a few seconds as the last of the air is purged from the fuel lines. Let it idle and verify that the engine runs smoothly.
  • Take the ATV for a short test ride to ensure everything is working properly.

Why Choose KEMSO Fuel Pumps for Your Polaris Outlaw 110

When it comes time to buy a replacement fuel pump, you have several options. You can buy a cheap, no-name pump from an online marketplace, an expensive OEM pump from a dealer, or a high-quality aftermarket pump from a trusted brand. For most Outlaw 110 owners, the KEMSO fuel pump is the clear best choice.

High Performance OEM Replacement
The KEMSO fuel pump for the Polaris Outlaw 110 (part number 13001) is designed as a direct OEM replacement. It fits perfectly into the stock fuel pump assembly without any modifications. This is a crucial advantage over generic pumps that may require cutting, splicing, or jury-rigging to fit. It is made to drop right in and work.

Superior Flow Rate
Compared to the stock OEM fuel pump, the KEMSO pump delivers over 20% more flow at 43 psi . This means better throttle response, more consistent fuel pressure, and improved overall engine performance. Even if your Outlaw 110 is stock, this extra flow provides a margin of safety and ensures the engine always gets the fuel it needs.

Complete Installation Kit
One of the biggest frustrations of replacing a fuel pump is realizing you need a small O-ring or a specific hose that you do not have. The KEMSO 13001 kit comes with everything you need for a successful installation:

  • 1 x Genuine KEMSO 13001 fuel pump
  • 4 x gradient density fuel strainers (to cover different models)
  • 1 x 7mm by 280mm flex hose
  • 2 x rubber hoses
  • 1 x Viton O-ring
  • 1 x wiring connector
  • 2 x crimp connectors
  • 4 x metal clamps
  • 2 x zip-ties

Having four strainers and multiple seals included means you can cover your specific model without having to buy additional parts .

E85 and Ethanol Compatible
KEMSO pumps are built with ethanol-resistant materials, including Viton seals and O-rings. This makes them safe to use with standard gasoline, E10, and even E85 fuel blends. Many cheap aftermarket pumps will degrade quickly when exposed to ethanol, but KEMSO pumps are designed for long-term reliability .

Lifetime Warranty
KEMSO stands behind the quality of their products with a lifetime warranty. This is a significant advantage over most other brands. If your pump fails for any reason, KEMSO will replace it. This level of confidence comes from manufacturing a superior product and gives you complete peace of mind .

USA-Based Technical Support
KEMSO offers technical support from USA-based technicians who understand American vehicles and performance requirements. If you have questions during installation or need help determining compatibility, their team is ready to help. This is a valuable resource that you will not get from a generic overseas seller .

Unmatched Quality Control
KEMSO has a rigorous quality control program (ISO/TSO), and each pump is individually tested for flow and performance before it leaves the factory. This ensures that every pump you buy meets the highest standards of reliability and performance. Do not compare KEMSO to cheap, unbranded units—there is simply no comparison .

Affordable Price
At a regular price of $79.98, the KEMSO fuel pump for the Polaris Outlaw 110 is competitively priced compared to other aftermarket options and significantly cheaper than OEM replacements. You get premium performance, a complete installation kit, and a lifetime warranty at a reasonable cost .

To order your KEMSO fuel pump and get your Polaris Outlaw 110 back on the trail with reliable performance, visit the official KEMSO website today: https://www.kemsoracing.com/

Maintenance Tips to Extend Fuel Pump Life

Once you have installed a new fuel pump, a few simple habits can help it last longer:

Use fresh fuel. Stale fuel can leave deposits that clog the pump and strainer. If you store your ATV for long periods, use a fuel stabilizer.

Keep the tank full. Running the tank low frequently can cause the pump to suck in air and debris from the bottom of the tank. A full tank also reduces condensation, which can contaminate the fuel.

Change the fuel filter regularly. If your ATV has an external fuel filter, replace it according to the manufacturer's schedule. This protects the pump from contamination.

Avoid running on empty. The fuel pump relies on gasoline for cooling and lubrication. Running the tank dry can overheat the pump and cause premature failure .

Final Thoughts

A failing fuel pump is one of the most frustrating issues you can experience with your Polaris Outlaw 110, but it is also one of the most straightforward to fix. By recognizing the symptoms early, choosing a high-quality replacement like the KEMSO fuel pump, and following the proper installation steps, you can restore your ATV's performance and reliability quickly and affordably.

The KEMSO fuel pump for the Polaris Outlaw 110 (part number 13001) is the ideal solution. It offers superior flow, a complete installation kit, and a lifetime warranty at a price that makes sense for any ATV owner. Do not settle for a cheap, untested pump that may fail again in a few months. Invest in KEMSO quality and enjoy the peace of mind that comes with a product backed by a lifetime of confidence.

For more information or to purchase your KEMSO fuel pump, visit: https://www.kemsoracing.com/


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