Arctic Cat 700 EFI Fuel Pump Replacement: A Step-by-Step Guide

Replacing the fuel pump in your Arctic Cat 700 EFI ATV is a critical repair when experiencing starting issues or engine performance problems. This straightforward task requires basic mechanical skills, common hand tools, and can often be completed in under two hours. Performing the replacement yourself saves significant money compared to shop costs and restores your ATV's reliable fuel delivery system. The process involves locating the pump assembly, carefully disconnecting fuel lines and electrical connectors, removing the old pump, installing the new unit correctly, and verifying operation. Always prioritize safety by working in a well-ventilated area away from ignition sources and properly relieving fuel system pressure before starting. Following these steps precisely ensures your Arctic Cat 700 EFI runs smoothly for seasons to come.

Symptoms Indicating a Fuel Pump Failure
Several telltale signs point to a failing fuel pump on the Arctic Cat 700 EFI. Difficulty starting the engine, especially when cold, is a primary indicator. The engine may crank normally but fail to ignite or start after extended cranking. Hesitation, sputtering, or power loss during acceleration or under load suggests the pump cannot maintain sufficient fuel pressure. An intermittent loss of power that resolves itself after the ATV rests for a few minutes signals a weakening pump. In severe cases, the engine may stall completely during operation and refuse to restart. Unusual whining or buzzing noises emanating from the fuel tank area when the key is turned on (before starting) strongly indicate pump motor wear.

Necessary Parts and Tools for Replacement
Gather all required materials before beginning the Arctic Cat 700 EFI fuel pump replacement. Purchase a replacement fuel pump assembly specifically designed for the 700 EFI model year. Using an incorrect pump causes improper pressure or fitment issues. An Arctic Cat OEM pump offers guaranteed compatibility. Quality aftermarket options from reputable brands like Quantum or Delphi provide reliable alternatives. You’ll need a replacement in-tank fuel pump strainer, even if the kit includes one, as the old strainer is typically clogged or degraded. High-quality submersible fuel injection hose clamps resistant to ethanol fuel are essential. Basic tools include standard sockets (commonly 10mm, 8mm), screwdrivers (flathead and Phillips), pliers, safety glasses, nitrile gloves, and a drain pan. Have clean shop rags available to absorb spilled fuel.

Critical Safety Preparations
Safety is paramount when replacing the Arctic Cat 700 EFI fuel pump due to flammable fuel hazards. Perform the replacement outdoors or in a well-ventilated garage with open doors. Ensure no sparks, open flames, pilot lights, or potential ignition sources exist nearby. Disconnect the ATV's negative (-) battery cable first to eliminate electrical risks and accidental starting. Wear safety glasses throughout the process to protect eyes from fuel splashes or debris. Use nitrile gloves to shield skin from gasoline exposure and prevent contamination inside the fuel tank. Position the ATV on a level surface and engage the parking brake securely. Relieve residual fuel pressure by removing the fuel pump relay (often located under the seat or near the battery) and attempting to start the engine until it stalls and no longer fires. This simple step prevents pressurized fuel spray when disconnecting lines.

Step-by-Step Fuel Pump Removal Process

1. Access the Fuel Tank: Remove the seat to access the top of the fuel tank. Locate the fuel pump access panel secured by several screws on top of the tank. Carefully remove the screws and lift the panel away.
2. Disconnect Electrical & Vent Lines: Identify the electrical connector plugged into the pump module. Depress the locking tab and unplug it. Gently detach any smaller vent hoses connected to the pump assembly by loosening their clamps with pliers.
3. Label and Disconnect Fuel Lines: Note the routing of the supply (high pressure) and return fuel lines attached to the pump module top plate. Label them if necessary. Use pliers to carefully squeeze the spring clamps and slide them back along the hose. Gently twist and pull the hoses off the metal pump nipples.
4. Extract the Pump Assembly: Carefully lift the entire fuel pump assembly straight up and out of the fuel tank. Tip it slightly to clear the tank opening. Watch for any remaining fuel draining back into the tank or hose drips. Set the assembly on a clean surface protected by rags.
5. Remove Old Pump from Module: Observe how the pump is secured within the plastic module carrier. Typically, it’s held by rubber straps or cushioned brackets. Note the orientation of the strainer on the pump inlet. Release any retaining straps or brackets and lift the old pump out.

New Fuel Pump Installation Steps

1. Transfer Components: Install the new strainer securely onto the inlet port of the brand-new fuel pump. Transfer any isolators, cushions, or brackets from the old assembly onto the new pump body. Ensure no rubber parts are cracked or damaged; replace them if necessary.
2. Mount Pump in Carrier: Place the new fuel pump into the existing plastic module carrier in the exact same position and orientation as the old pump. Secure it firmly using the original rubber straps, brackets, or retaining ring. Avoid kinking fuel lines.
3. Reinstall Module Assembly: Slowly lower the complete pump module assembly straight down into the fuel tank, aligning it properly with the opening. Ensure the rubber gasket on the top plate is seated correctly within the groove. Reconnect the fuel hoses to their corresponding metal nipples on the top plate, verifying the supply and return lines match your earlier labeling. Slide the spring clamps back into their original positions to secure the hoses firmly.
4. Reconnect Electrical and Vent Lines: Plug the electrical connector firmly back into the pump module until the locking tab clicks. Reattach any vent hoses, securing their clamps tightly.
5. Reseal the Tank: Place the access panel back onto the tank opening, ensuring the gasket is clean and aligned. Reinstall and tighten the panel screws securely, but avoid over-tightening which can crack the plastic.
6. Reconnect Battery: Connect the negative (-) battery cable.

Testing and Post-Installation Verification
After replacing the fuel pump and reconnecting the battery, perform thorough operational checks. Turn the ignition key to the "ON" position (without cranking) and listen for a distinct humming or buzzing sound from the fuel tank area. This confirms the pump is priming the system correctly. Listen for a smooth motor sound lasting 2-3 seconds; unusual grinding or a failure to prime indicates an electrical connection problem or faulty part. Start the engine. It should crank and fire promptly. Observe the ATV at idle; engine speed should be steady with no hesitation or stumbling. Take the Arctic Cat 700 EFI for a short test ride. Pay close attention to acceleration from low RPMs and performance under moderate load (like climbing a small incline). It should respond smoothly without any hesitation, surging, or power loss. Visually inspect the pump access panel, all hose connections, and the area under the tank for any signs of fuel leaks after the ride. Address any leaks immediately by rechecking hose clamps and the access panel seal.

Troubleshooting Post-Replacement Problems
If the Arctic Cat 700 EFI doesn't start or runs poorly after a new fuel pump is installed, systematically troubleshoot. Double-check all electrical connections, especially the main harness plug at the pump module, ensuring it's fully seated and locked. Verify every fuel hose connection is tight and secured with its clamp correctly positioned over the hose barb. Inspect inside the tank to ensure the pump strainer is correctly attached to the pump inlet and not blocked by debris from the old pump failure. Confirm the pump itself is correctly secured and oriented within its carrier; a loose pump can vibrate excessively. Ensure the access panel gasket is undamaged, properly seated in its groove, and that the panel screws are tightened evenly. Very rarely, a new pump can be defective; verify fuel pressure at the fuel rail using a gauge if possible, or consider swapping relays/fuses as a potential alternative issue. Re-check the battery connection strength.

Maintenance Tips to Prevent Future Fuel Pump Failures
Prolong the life of your new Arctic Cat 700 EFI fuel pump with proactive maintenance. Always refuel with clean, high-quality gasoline meeting the octane rating specified in the owner's manual. Avoid purchasing fuel from stations with recently replenished underground tanks, as this stirs up sediment. Replace the external inline fuel filter (if equipped) according to the manufacturer’s schedule, typically every 100 hours or annually. Consider adding a specialized in-line fuel filter designed for EFI systems if one isn't present. Keep the fuel tank at least a quarter full whenever possible; running very low increases the pump's workload and exposes it to accumulated tank sludge. Use a fuel stabilizer like STA-BIL whenever storing the ATV for periods exceeding 30 days, especially if containing ethanol-blended fuel which can degrade and leave deposits. Avoid operating the ATV through deep water which could potentially submerge electrical connections near the pump assembly. Store the ATV in a dry, protected environment.