Fuel-pump replacement may be considered for hard starting, stalling or low power on a 2016 Polaris Outlaw 110 EFI with the 111 cc gasoline engine. Its owner troubleshooting instructions provide no dedicated pump-failure code; the check-engine lamp warns of an EFI fault or overheating. Neither these symptoms nor the warning lamp proves that the pump motor has failed. Check fuel delivery, electrical supply and other engine causes before buying an insert.
Application and repair overview
This guide concerns the 2016 Outlaw 110 EFI, model codes A16YAK11AD/AF: a youth ATV with an air-cooled four-stroke engine, automatic CVT and chain final drive. Its complete in-tank pump is secured by six flange screws. The featured part replaces only the internal motor, so a sound, compatible original carrier and a supported method of installing that motor are essential. It does not repair a damaged flange, regulator, float or electrical connector.
Gasoline and youth-ATV safety
This is adult service work. Keep children away from gasoline and the work area. Park level, apply the parking brake, switch the ignition off and allow the factory-recommended cooling period of at least one hour. Work outdoors or with adequate ventilation, away from flames, sparks and smoking; keep an appropriate extinguisher accessible. Wear eye protection and fuel-resistant gloves, and provide gasoline-compatible containment.
Cooling does not prove the EFI line is depressurized. Follow the contained coupling-opening method below, and disconnect battery negative and the pump harness before opening fuel connections. Do not energize an open system. Stop if you cannot contain fuel, the tank is contaminated or fuel would spill through its opening, a fitting is damaged, or the insert requires an unsupported internal adaptation. Never use a shop vacuum or mouth siphoning for gasoline.
Featured replacement: A-Premium APFP1438
ASIN: B0DT482ST8. Part number: APFP1438. Quantity: one boxed electric in-tank pump insert with strainers. The selected main image shows a cylindrical motor, two different strainer shapes and small retaining washers. The maker explicitly excludes the sending unit, float, pressure sensor and sealing ring. A complete tank flange, carrier, hose and regulator are not supplied as this kit.
View A-Premium pump motor and strainers
The seller specifies 12 V, a 30 mm motor diameter and an 8 mm outlet. Those component dimensions do not establish the correct immersed hose, terminal polarity or vehicle fuel-pressure target. Check the model code, VIN and actual original carrier before purchase; do not assume both strainers install together.
For this Outlaw, the OE catalog identifies complete pump 0455411, replacing 0455194, and separate flange gasket 0455146. These assembly references help identify the original installation; APFP1438 is not a complete 0455411 assembly. Seller reference 455157 corresponds to a Sportsman fuel tank, so it should not be treated as another pump part number.
Vehicle compatibility
| Vehicle | Catalog years | Engine/fuel version | Application limit |
|---|---|---|---|
| Polaris Outlaw 110 | 2016–2022 | EFI gasoline | Detailed scope: 2016 A16YAK11AD/AF, 111 cc. Match the existing carrier. |
| Polaris RZR 170 | 2015–2021 | EFI gasoline | Different youth side-by-side and complete-pump retention; its repair steps are not covered here. |
| Polaris Sportsman 110 | 2016–2022 | EFI gasoline | Different complete pump/carrier. Do not transfer the Outlaw procedure solely from shared insert fitment. |
These are the selected seller’s and exact maker’s EFI applications. They do not include carbureted models or later years. The A-Premium APFP1438 catalog gives the broader fitment; the original 2016 owner manual supplies the selected Outlaw’s 111 cc specification.
Symptoms and diagnostic checks
Hard starting, intermittent stalling and power loss can come from stale or contaminated gasoline, a restricted filter or tank vent, poor battery connections, ignition faults or an engine problem. Confirm actual fuel quantity and inspect accessible wiring, grounds and fuel lines. A pump sound alone does not establish correct pressure, and a silent pump may lack electrical power.
The steady check-engine light indicates an EFI fault; a flashing light indicates overheating and reduced power. Stop operation and resolve the indicated problem. Do not read this as a pump-specific blink code or assume a generic automotive code reader can communicate with this ATV.
Measure pressure with the correct inline equipment
Use the complete factory PU-43506-A pressure tester with PV-48656 adapter and matched hoses, couplings and relief/collection arrangement. Follow the cooling and isolation steps below. Wrap the pump-side quick connector with a shop towel and contain residual fuel. Fit the adapter between the pump outlet and original line, then attach the gauge hose to the adapter’s test valve. Route the equipment clear of hot or moving parts, and secure its drain hose in an approved gasoline receiver before the test.
Only after all test joints are sealed, reconnect the pump harness and battery, turn the key on and inspect for leaks. The specified key-on, engine-off pressure is 39–45 psi. Compare the reading with that condition; low pressure still requires distinguishing poor electrical supply, restrictions and regulator/assembly faults. Do not substitute the seller’s flow-rate claim for this test.
Turn the key off and use the tester’s pressure-release button with the drain hose still contained. Confirm the gauge has fallen to zero, then isolate battery negative and the pump harness before disconnecting the test equipment. Catch residual fuel at each joint. Restore the original connection with its retainer fully engaged and a gentle pull check, and recheck that joint for leaks after the system is sealed and power is restored. Keep power isolated if continuing with pump removal. Do not ride with the tester installed.
Tools, parts and supplies
The table covers the exterior service and diagnostic work. Match actual fastener heads, connector shape and equipment attachments before starting. A motor insert also needs its exact internal installation materials and method; ordinary hose, loose blade connectors or an improvised carrier retainer are not substitutes.
| Tool or Supply | Exact Product | Product Link | Purpose and Selection Check |
|---|---|---|---|
| Hand driver, ratchet, bits and metric sockets | Wera 05056490001 Tool-Check PLUS Metric Set, 39 Pieces | View metric tool kit | Confirm each actual screw or bolt head before starting. Use the matching hand driver, ratchet, adapter, bit or socket for the body, battery and six-screw pump flange. The kit covers several head styles; stop if the needed size is absent. Keep screwdrivers away from the fuel coupling and do not force plastic locking tabs. |
| Low-range torque wrench and bit holder | TEKTON TRQ50402 1/4-Inch Drive Torque Wrench, 20–200 in-lb | View low-range torque wrench | Use the factory 26 in-lb (3 N·m) value for the six pump-flange screws. The selected range covers it. A matching 1/4-inch socket fits directly; use the wrench’s supplied 1/4-inch hex-bit holder for a correctly fitted bit. Hand-start the screws and keep the gasket and flange seated. |
| Inline fuel-pressure tester with controlled drain | Polaris PU-43506-A Fuel Pressure Gauge Kit with PV-48656 Inline Adapter | Source the matched item | Use the complete gauge kit, its matched hose and test-valve coupling, relief valve and clear drain hose. Fit PV-48656 inline between the pump outlet and original fuel line, then attach the gauge hose to its test valve. Secure the drain hose in an approved gasoline receiver; after the key-on test, switch OFF and use the tester’s relief button to contain the pressure release. |
| Digital multimeter | INNOVA 3320 Auto-Ranging Digital Multimeter | View multimeter | Use the supplied leads for the specified battery and pump-circuit voltage checks before opening the fuel system. Select DC voltage with leads in COM and V. Perform resistance checks only with power removed, and keep electrical probing away from exposed gasoline or vapor. |
| New pump-flange tank gasket | Genuine Polaris 0455146 Fuel Tank Gasket for the Selected 2016 Outlaw 110 | Source the matched item | Obtain the correct new tank gasket before opening the flange. Confirm the VIN and original six-screw assembly, clean and dry the sealing surfaces, and seat the gasket without damage. The featured motor kit does not supply this seal; no added gasket lubricant is specified here. |
| Motor-specific internal service parts | APFP1438-to-Original-Carrier Retention, Outlet Sealing and Electrical Parts Specified for the Exact Assembly | Source the matched item | Before opening the carrier, establish the motor-release and retention method, outlet-seal arrangement, terminal identification and polarity, and the correct supplied strainer with its retaining parts. Use only the components and installation method matched to this motor and original carrier. Do not cut, splice, force a strainer or improvise an outlet connection. |
| Wheel chocks | MaxxHaul 70472 Black Rubber Wheel Chocks, 2-Pack | View wheel chocks | Secure the ATV on a firm, level surface with the parking brake applied. Confirm that the chocks sit firmly against the actual tires. This pump-access procedure does not require vehicle lifting. |
| Chemical splash goggles | 3M 91252H1-DC-10 Chemical Splash Goggles, One Pair | View splash goggles | Wear fitted splash goggles when handling the pressure tester, fuel connector and wet assembly. Check lens condition and the face seal before work. |
| Chemical-barrier gloves | Honeywell North Silver Shield SSG/7, Size 7, Ten Gloves | View chemical-barrier gloves | Use intact gasoline-resistant barrier gloves that fit the wearer. This selected pack is size 7 with ten individual gloves, not ten pairs. Replace contaminated or damaged gloves. |
| Flammable-liquid fire extinguisher | First Alert HOME1 / FE1A10GR195, 1-A:10-B:C, One Pack | View fire extinguisher | Keep a serviceable extinguisher accessible before opening the fuel system. Its Class B rating covers flammable-liquid fires; check its gauge, pin, seal and inspection condition. Keep ignition sources away from the work area. |
| Clean low-lint wiping cloths | WypAll X60 54015 White Brag Box, 236 Sheets | View wiping cloths | Wrap the fuel connection with a clean cloth for contained disconnection and use fresh cloths on exterior sealing surfaces. Keep fibers and dirt out of the tank, and move fuel-wet cloths to the covered waste can. |
| Gasoline-compatible residual catch pan | Lumax LX-1629 Black 5-Gallon Catch Pan | View fuel catch pan | Catch residual fuel and place the removed wet assembly over stable gasoline-compatible containment. The maker expressly permits gasoline contact. Transfer collected fuel to the approved closed safety can; the open pan is not a storage container. |
| Approved gasoline receiver | Eagle UI50FS Red 5-Gallon Type I Safety Can with Funnel | View gasoline safety can | Use the approved receiver for the tester’s clear drain hose and recovered liquid fuel. Maintain adequate free capacity and headspace, secure the hose against escape, and close the can after transfer. Do not drain gasoline onto the ATV or ground. |
| Covered container for fuel-wet cloths | Justrite 09200 Red 2-Gallon Countertop Oily Waste Can | View cloth waste can | Collect contaminated wiping cloths in this self-closing container and arrange appropriate disposal. Store free liquid gasoline in the separate approved fuel receiver. |
DIY versus professional cost
Use $110–$180 as a planning allowance: roughly $30–$60 for the insert, $50–$70 for the correct separate gasket and $30–$50 for routine materials. Filling gaps in an existing hand-tool kit may add $75–$175; the complete pressure tester and any full replacement pump assembly are additional.
As an illustrative shop calculation, 1.5–3 labor hours at an assumed $100–$175 per hour gives $150–$525 labor, or approximately $260–$705 with the above parts allowance. These are editorial estimates, not a published labor-time standard, current retail quotes or a guaranteed conversion price. They assume an approved motor-installation method and a reusable carrier. A shop may instead recommend a complete assembly; price that job separately.
Step-by-step repair overview — 2016 Outlaw 110 EFI
1. Prepare, cool and isolate the vehicle
Confirm A16YAK11AD/AF and compare the existing pump with the intended replacement. Before dismantling the ATV, obtain the complete carrier-specific motor-installation method and materials described in step 4; stop if these are unavailable. Have the new 0455146 gasket and correct service equipment ready. Park level with the parking brake applied and chock the wheels, turn the key off and let the vehicle cool for at least one hour. If fuel reaches the pump opening or is contaminated, arrange safe fuel recovery before removal; do not assume a low-fuel lamp proves a safe working level.
Release the single seat using the latch at its left rear and lift it off. Disconnect the battery negative cable and keep it from contacting the terminal. Discharge personal static to the vehicle frame before fuel work. Record routing and connector positions for reassembly.
2. Expose the Outlaw pump flange
Remove the side panels: each side has two front insert fasteners and one rear screw insert. Lift the front cover from its tabs. Remove the two screw inserts joining the front cab and tank cover, then the two lower front-cab bolts; release the cab locking tabs carefully. Temporarily remove the fuel cap to lift the tank cover, then immediately reinstall the cap. Keep dirt out of the filler and clean around the still-closed pump flange. With the flange exposed and the battery still isolated, disconnect the pump harness before opening any fuel connection.
3. Contain line fuel and remove the whole pump assembly
Treat the line as pressurized even after cooling or a no-start. Wrap the pump-side quick connector in a shop towel and put fuel-compatible containment beneath it. Release the connector’s retainer and separate it carefully while controlling residual fuel. Do not pull on the hose or force a damaged coupling. Protect disconnected connections from dirt.
Remove the six pump flange screws and lift the complete assembly carefully through the opening. Preserve the existing float arm, strainer and carrier; the absence of a new float in the insert kit does not mean the original assembly has none. Catch retained gasoline, cover the tank opening against contamination, and remove the old flange gasket.
4. Resolve the motor-to-carrier installation before disassembly
A motor-only repair requires a method matched to this carrier: how the motor is released and retained, how its submerged outlet is sealed, which blade terminal is positive, and which strainer and retaining washer fit without obstructing the float or tank. Do not open or modify the carrier without that complete installation information. If it is absent, have the assembly serviced by an equipped EFI specialist or select the correct complete pump assembly. Do not cut a sealed carrier, guess polarity, push on an unmatched strainer or improvise an immersed hose connection.
5. Seal and secure a correctly serviced assembly
Once a correctly matched, sound assembly is ready, inspect and clean the tank and flange sealing surfaces. Fit a new 0455146 gasket, lower the pump without bending the float arm and center the flange. Align the triangle marks on the flange and tank. Tighten the six flange screws to 3 N·m / 26 in-lb with a suitable low-range torque wrench. Do not apply a threaded-ring procedure or a high automotive fastener torque to this flange.
6. Reconnect, prime and check before closing the bodywork
Reconnect the fuel coupling until its retainer snaps into position, then gently pull to confirm retention. Restore the harness routing and connector. With every fuel joint sealed, reconnect battery negative and secure the terminal connection. Cycle the key to prime, inspect the flange and line joints, and check again during controlled engine operation in a ventilated area. If you find wetness, fuel odor or leakage, switch off and do not restart until the cause is corrected.
Reinstall the tank cover, fuel cap, front cab, front cover and side panels with all tabs and fasteners correctly located. Check that no hose or wire is trapped. Refit and latch the seat, then pull up to verify it is secure. Resolve warning lamps and confirm normal starting and idle before any riding check. Keep any final operation off-road, with an appropriately trained rider within the ATV’s rating; this youth ATV is not intended for a public-road test.
Understand the insert and complete assembly
Common mistakes
- Replacing the motor because of a warning lamp without testing fuel pressure and electrical supply.
- Confusing a motor-and-strainers kit with a complete pump, or treating a tank reference as a pump interchange.
- Copying RZR two-seat access or threaded-retainer instructions onto the six-screw Outlaw flange.
- Assuming cooling or a no-start removes line pressure, or reconnecting power while fuel joints are open.
- Damaging the original float, reusing a compressed flange gasket or applying the wrong screw torque.
- Guessing internal polarity, immersed-hose construction, motor retention or strainer orientation.
- Closing the bodywork before a leak check or allowing a child to handle gasoline.
Frequently asked questions
Does this kit include everything in the original pump assembly?
No. APFP1438 supplies a motor and strainers. The flange, carrier, original float/sender and other assembly components must remain serviceable, and the tank gasket is separate.
Can I use this on a carbureted Outlaw or RZR?
The selected product lists only the stated EFI applications. A similar model name or engine size does not establish carbureted fitment.
Does the six-screw flange make this an easy motor swap?
No. The exterior assembly removal and the internal motor installation are different operations. A complete, carrier-specific retention, sealing and wiring method is required before an insert repair is attempted.
Can a bad regulator or float be fixed by changing only the motor?
A motor replacement does not renew those components. Diagnose the failed part; a damaged or unsuitable carrier may make a correctly matched complete assembly the appropriate repair.
Should the ATV be ridden to confirm the repair?
First confirm sealed fuel joints, secure bodywork and seat, normal starting/idle and no unresolved warning lamp. Any later functional check must follow the owner manual’s off-road, rider-rating and supervision requirements.
Sources and further reading
- Original Polaris 2016 Outlaw 110 / Sportsman 110 owner manual, P/N 9925741 — vehicle identity, lamp meanings, battery and seat operation, fuel safety and troubleshooting.
- Polaris 2016–2019 Youth ATV 110 EFI service manual, P/N 9929401 R01 — Outlaw body access, six-screw pump figures, pressure-test equipment, flange alignment and tightening.
- Polaris 2016 Outlaw 110 A16YAK11AD/AF fuel-tank parts fiche — complete pump, separate gasket and flange fasteners.
- A-Premium APFP1438 product and EFI compatibility catalog — insert identity, package exclusions and application range.
- Polaris 2016 Sportsman 110 fuel-tank parts fiche — distinguishes tank 0455157 from its separate pump assembly.
- Equipment references: Torque; Extinguisher.