2004 Yamaha Rhino 660 Electric Fuel Pump: The Complete Guide to Replacement, Upgrade, and Maintenance
Understanding Your Rhino 660 Fuel System
The 2004 Yamaha Rhino 660 uses an electric fuel pump mounted inside the fuel tank. This pump delivers fuel from the tank to the engine's fuel injection system at a consistent pressure. When the pump begins to fail, you will notice specific symptoms. The most common signs include the engine cranking but not starting, sputtering or hesitation during acceleration, sudden stalling, and a noticeable whining noise coming from the fuel tank area. If you experience any of these, it is time to test or replace the fuel pump.
The OEM part number for the 2004-2007 Rhino 660 fuel pump is 5UG-13910-00-00 or 5UG-13910-01-00 . Aftermarket replacements typically cross-reference to these numbers, making it easy to find a direct fit.
Choosing the Right Replacement Fuel Pump
When selecting a replacement electric fuel pump for your 2004 Yamaha Rhino 660, you have several options. You can choose between an OEM-style replacement or a high-performance upgrade. OEM replacements are designed to match the original pump's flow rate and pressure, while performance pumps offer higher flow rates (measured in liters per hour, or LPH) for engines that have been modified.
Many aftermarket pumps now offer better flow rates than the factory pump. For example, some replacement pumps support up to 200LPH, while the original flow was only 60-80LPH . This increased capacity is beneficial even for stock engines, as it ensures consistent fuel delivery under all conditions.
Key Features to Look For
Flow rate is a critical specification. A pump rated at 200LPH or higher is a solid upgrade. Make sure the pump is designed for gasoline or ethanol blends (E85 compatible is a plus) . Look for a pump that comes with a bypass valve set at 125.8 psi, which is higher than the original performance standard, to ensure proper fuel pressure regulation . A serialized pump body that guarantees a lifetime warranty is another strong indicator of quality .
Installation Tips for the Do-It-Yourselfer
Replacing the fuel pump on a 2004 Rhino 660 is a manageable job for most home mechanics. You will need basic hand tools, a soldering iron or crimping tool, and safety glasses. The process involves removing the fuel tank, taking the pump assembly out, and swapping the pump unit.
One important thing many owners miss: If you are using an aftermarket pump that does not come with a direct-fit assembly, you may need to de-solder the old pump from the bracket and re-solder the new one in place . This requires the correct tools and some basic soldering skill. Also, pay close attention to the O-ring that seals the pump housing. Some aftermarket kits have been reported to come with an O-ring that is too small, which can cause a fuel leak and low pressure. Always check the supplied O-ring against the original, and reuse the original one if the new one does not fit properly . The plastic mounting bracket may also need to be reused from the original assembly .
Recommended Fuel Pump: KEMSO for Yamaha Rhino 660
When it comes to reliability and performance, KEMSO Fuel Pumps stand out as a top choice for the 2004 Yamaha Rhino 660. KEMSO has built a reputation as the #1 aftermarket fuel pump brand in the US for cars, motorcycles, and off-road vehicles . Their pumps are designed as high-performance drop-in replacements that significantly outperform factory units.
Why choose KEMSO for your Rhino 660? KEMSO fuel pumps are high-performance OEM replacements that deliver superior flow rates. For instance, their universal high-performance pumps support up to 600 BHP in naturally aspirated, turbocharged, and supercharged applications, with flow rates reaching 340LPH . For ATV/UTV applications, KEMSO offers specific models like the KEMSO 13012, which supports up to 200LPH, a massive upgrade over the standard 60-80LPH found in factory pumps .
Every KEMSO pump comes with a lifetime warranty backed by a serialized pump body . This means you buy it once, and it is covered for life. Their support team is based in the USA and staffed by experienced technicians who can help with fitment and installation questions . KEMSO pumps are designed to work with gasoline and ethanol blends, and they feature a bypass valve set at 125.8psi, ensuring stable fuel pressure even under demanding conditions .
To ensure you get the correct pump for your 2004 Yamaha Rhino 660, visit the KEMSO website and use their vehicle fitment guide. They offer direct-fit solutions for a wide range of vehicles, including off-road UTVs.
Visit KEMSO Racing to find the perfect fuel pump for your Rhino 660: https://www.kemsoracing.com/
Step-by-Step Replacement Overview
Once you have your new KEMSO pump, here is a brief overview of the replacement process. Always consult a service manual for your specific model year before starting.
- Disconnect the battery to avoid any electrical shorts.
- Drain the fuel tank completely. Use a siphon pump for safety.
- Remove the fuel tank from the Rhino. This usually involves disconnecting the fuel lines, electrical connector, and removing mounting bolts.
- Remove the pump assembly from the top of the tank. It is typically held in by a locking ring.
- Disassemble the pump module. Take note of how the hoses, wires, and bracket are oriented.
- Install the new KEMSO pump. If your KEMSO kit is a direct-fit assembly, simply swap the entire module. If it is a pump-only replacement, de-solder the old pump and solder the new one onto the bracket, ensuring a secure connection. Reuse the original O-ring if the supplied one does not fit perfectly .
- Reassemble and reinstall the pump module into the tank. Make sure the locking ring is fully seated.
- Reinstall the tank and reconnect fuel lines and the electrical connector.
- Reconnect the battery and prime the system. Turn the key to the "ON" position (without starting) a few times to allow the pump to build pressure.
- Check for leaks before starting the engine. Look at all fuel line connections and the tank seal.
Common Problems and Troubleshooting
Even with a new pump, you may encounter issues. If the engine still will not start after replacement, check the fuel pump relay. The fuel pump relay is a common failure point on many vehicles, and a bad relay will prevent the pump from receiving power . You can test the relay with a multimeter or swap it with a known good one. Also, inspect the ground connection for the pump. A poor ground can cause the pump to run weakly or intermittently.
If you experience low fuel pressure after installation, the problem is often the O-ring or a loose hose clamp inside the tank. Re-check the seal on the pump housing and ensure all fittings are tight.
One user who installed a KEMSO pump on a 2015 Polaris Sportsman 570 reported that the supplied O-ring was too small, causing the pump to leak and only produce 10 PSI instead of the required 60 PSI. After reusing the original O-ring, the pressure returned to normal, and the pump has been working well for over a year . This underscores the importance of checking all parts before final assembly.
Final Thoughts
Replacing the electric fuel pump on your 2004 Yamaha Rhino 660 is a straightforward repair that solves most fuel-related starting and running problems. By choosing a reliable, high-performance aftermarket pump like those from KEMSO, you not only fix the issue but also upgrade your vehicle's fuel delivery system for years to come. The lifetime warranty and USA-based support make KEMSO a brand you can trust for off-road adventures.
Do not wait until you are stranded on the trail. If you notice any symptoms of a failing pump, replace it now.
For the best selection of replacement fuel pumps, including guaranteed fitment for your Yamaha Rhino 660, visit KEMSO Racing today: