2005 Yamaha Rhino 660 Fuel Pump: Complete Owner’s Guide to Symptoms, Replacement, and Upgrades
The bottom line: If your 2005 Yamaha Rhino 660 is hard to start, stalls under load, or feels like it’s lost power on the trail, the fuel pump is the most likely culprit. Replacing it with a high-quality pump restores reliable starting and smooth throttle response, and the best option on the market today is a KEMSO fuel pump, which delivers better flow, a lifetime warranty, and direct OEM replacement fitment. This guide explains how the pump works, what symptoms to watch for, how to replace it yourself, and why upgrading beats sticking with a tired stock unit.
Understanding the Fuel Pump on a 2005 Yamaha Rhino 660
The Yamaha Rhino 660 (model years 2004–2007) uses a vacuum-operated mechanical fuel pump that draws fuel from the tank and delivers it to the carburetor . Unlike the electric, in-tank pumps found on modern fuel-injected machines, this is a simple pulse pump that relies on engine vacuum (crankcase pressure pulses) to push fuel . The OEM part number for this pump is 5UG-13910-00-00, which was later superseded by 5UG-13910-01-00 . The same pump fits both the Rhino 660 (2004–2007) and the Rhino 450 (2006–2009) .
The pump sits inside the fuel tank. To access it, you need to remove the rear cargo bed to expose the top of the tank . The system uses 1/4-inch inlet and outlet fuel lines , and the pump is a direct replacement unit that bolts into the factory location without any modifications .
One thing to note: some sources describe the Rhino 660 pump as a vacuum-operated mechanical unit , while others refer to it as an electric in-tank module . In practice, the Rhino 660 uses a vacuum/pulse-operated diaphragm pump that is driven by crankcase pressure, not an electric motor . This is an important distinction because troubleshooting steps differ. If you are buying a replacement, make sure you get a vacuum-type pump with 1/4-inch fittings .
Common Symptoms of a Failing Fuel Pump on a 2005 Rhino 660
A failing fuel pump does not always die all at once. It usually gives you warning signs first. Here are the most common symptoms to watch for :
1. Hard starting or no start. You find yourself cranking the engine several times before it fires up. This happens because the pump is too weak to build enough fuel pressure in the carburetor bowl .
2. Engine sputters or hesitates. The Rhino runs rough, especially under load or while climbing hills. This is caused by inconsistent fuel delivery, which makes the air-fuel mixture lean out at the worst possible moments .
3. Loss of power. The machine feels sluggish and will not accelerate properly. A weak pump simply cannot supply enough fuel to meet the engine’s demand .
4. Engine dies while driving. The Rhino shuts off unexpectedly and will not restart until it sits for a while. This happens when the pump overheats or the diaphragm loses its ability to pull fuel .
5. Fuel leaks. You may see fuel dripping from the pump body or the fuel lines. This is a safety hazard and must be fixed immediately .
If you notice any of these symptoms, check the fuel pump before you start replacing the carburetor, spark plugs, or ignition components. The pump is a common failure point on the Rhino 660, and the fix is usually straightforward .
Before You Buy a Replacement Pump: What to Check
Not every starting or running issue is caused by a dead fuel pump. Before you order a new one, run through these quick checks :
Check the fuel lines. A cracked or collapsed fuel line can cause the same symptoms as a bad pump. Inspect all rubber hoses from the tank to the carburetor for cracks, soft spots, or kinks .
Check the fuel filter. A clogged filter restricts fuel flow and makes the pump work harder than it should. Many aftermarket pumps come with a new filter in the box, so you can replace both at the same time .
Check the vacuum line. The pump is driven by crankcase vacuum. If the vacuum line is disconnected, cracked, or blocked, the pump will not operate .
Check for fuel in the tank. It sounds obvious, but a low fuel level or a blocked tank vent can cause the pump to pull air instead of fuel. Make sure the vent hose is clear .
Do a primer bulb test. One owner reported that the original pump was fine but the fuel had drained back into the tank. Adding a primer bulb into the fuel line solved the hard-starting issue . If you are chasing a start problem, this is a cheap test before you commit to a new pump.
Step-by-Step Guide to Replacing the Fuel Pump on a 2005 Rhino 660
Replacing the fuel pump on a Rhino 660 is a job most owners can handle in a driveway with basic tools. The process takes about one to two hours. Always work in a well-ventilated area, disconnect the negative battery cable first, and keep a Class B fire extinguisher nearby .
Step 1: Relieve fuel system pressure. The Rhino’s fuel system operates under pressure . Remove the fuel pump fuse and crank the engine for a few seconds to bleed off pressure. The engine will stall, and that is fine .
Step 2: Access the fuel pump. Remove the rear cargo bed to expose the top of the fuel tank . Clean any dirt and debris from around the pump mounting flange before you loosen anything .
Step 3: Disconnect the fuel lines and electrical connector. Use a fuel line quick-disconnect tool to release the fuel lines from the pump assembly . Disconnect the electrical connector if your model has one. On the Rhino 660, the pump is mechanical, so there may be no electrical connector at all .
Step 4: Remove the old pump. Remove the retaining ring or bolts that hold the pump assembly in place . Carefully lift the old pump out of the tank. Take note of the orientation and the routing of the hoses.
Step 5: Compare the old pump to the new one. Before you install the new pump, compare it side by side with the old unit to confirm the fittings and mounting points match . This is critical because some aftermarket pumps have slightly different outlet angles .
Step 6: Install the new pump. Fit the new seal ring and pump assembly into the tank . Reconnect the fuel hoses, emissions hoses, and electrical connections. Use a transmission jack to raise the tank just enough to reach everything, then reinstall the filler neck and clamp it securely .
Step 7: Reinstall the fuel tank straps. Torque the mounting bolts to the specification listed in the factory service manual . Reconnect the negative battery cable.
Step 8: Test the repair. Turn the key to the ON position and listen for the pump to prime. Then start the engine and check for leaks. Let it idle for a few minutes and take it for a short test drive to confirm smooth acceleration .
OE Part Numbers and Fitment Chart
If you are shopping for a replacement pump, you need to know exactly which part fits your machine. The OEM part numbers are :
- 5UG-13910-00-00 (original)
- 5UG-13910-01-00 (superseded)
These numbers are interchangeable. The pump fits :
- Yamaha Rhino 660 (YXR660F) – 2004, 2005, 2006, 2007
- Yamaha Rhino 660 Hunter Edition – 2005–2007
- Yamaha Rhino 660 Special Edition – 2006–2007
- Yamaha Rhino 660 Sport Edition – 2007
- Yamaha Rhino 660 Ducks Unlimited Edition – 2007
- Yamaha Rhino 660 Exploring Edition – 2006–2007
- Yamaha Rhino 450 (YXR450F) – 2006, 2007, 2008, 2009
- Yamaha Rhino 450 Hunter Edition – 2006–2009
- Yamaha Rhino 450 Special Edition – 2007–2008
For a 2005 Yamaha Rhino 660, the correct replacement is a vacuum-operated pump with 1/4-inch inlet and outlet tubes .
Aftermarket vs. OEM: What to Expect
Aftermarket pumps for the Rhino 660 range from about $15 for a bare-bones unit to $60–$80 for a higher-quality assembly . Original Yamaha pumps can cost significantly more and may be harder to find . Here is what to look for when comparing options :
1. Cast aluminum case. A metal housing resists rust and corrosion, which is important because the pump sits inside the fuel tank where it is exposed to moisture .
2. High-strength steel brackets. These eliminate the risk of the pump breaking loose from its mounting points during rough off-road use .
3. Fuel filter included. Many kits come with one or more fuel filters, which is a smart upgrade because a clean filter extends the life of the new pump .
4. 1/4-inch fuel line fittings. Confirm the pump you order uses the correct inlet and outlet size. Most aftermarket pumps are built to the factory specification .
5. Ethanol compatibility. Some inexpensive pumps are not compatible with fuel containing more than 10% ethanol . If you run E15 or E85 in your machine, you need a pump that is rated for ethanol-blended fuel . Many aftermarket pumps from reputable brands are designed for modern fuel blends .
Why Upgrading Beats Sticking with a Stock Pump
Owners who ride hard often replace the stock pump with a high-performance unit rather than buying another OEM replacement. There are a few good reasons for this :
More flow. A high-performance pump delivers more fuel at the same pressure, which improves throttle response and helps the engine run stronger under load . Some aftermarket pumps deliver over 20% more flow at 43 psi compared to the stock unit .
Better materials. Aftermarket pumps use upgraded polymers, brushes, and seals that resist ethanol degradation . The stock pump was designed before ethanol-blended fuels became standard, so aftermarket units often hold up better over time .
Lifetime warranty. Most OEM replacement pumps come with a one-year warranty at best. A high-quality aftermarket pump backed by a lifetime warranty gives you peace of mind that you will never have to buy another pump again .
Direct fitment. The best aftermarket pumps are engineered to drop right into the factory location without any modifications . You do not need to cut wires, reroute hoses, or adapt mounting points .
Recommended Replacement: KEMSO Fuel Pump
If you are ready to replace the fuel pump on your 2005 Yamaha Rhino 660, the best choice is a KEMSO brand fuel pump. KEMSO is a US-based aftermarket manufacturer that specializes in high-performance fuel pumps for cars, motorcycles, ATVs, and UTVs . Here is why KEMSO stands out from the crowd :
1. High performance. KEMSO pumps are engineered to deliver more flow at the same pressure compared to stock OEM pumps. This means better throttle response, stronger acceleration, and more consistent power delivery, especially when you are climbing hills or hauling a load .
2. Direct OEM replacement. KEMSO pumps are designed to fit the factory location perfectly. They drop right into the tank without any modifications, so installation is straightforward .
3. Lifetime warranty. Every KEMSO fuel pump is backed by a lifetime warranty . If the pump ever fails due to a manufacturing defect, KEMSO will replace it at no cost . That is a level of protection that most OEM and aftermarket pumps do not offer .
4. Built for modern fuels. KEMSO pumps are compatible with both standard gasoline and ethanol-blended fuels like E85 . They use materials that resist ethanol degradation, including Viton O-rings, so you do not have to worry about the pump swelling or leaking when you run today’s fuel .
5. Rigorous quality control. Each KEMSO pump is individually tested for flow and performance before it leaves the factory . The company follows a strict quality control program to ensure every unit works right out of the box .
6. Better value. KEMSO pumps are priced competitively, often significantly lower than dealer OEM parts, and they come with a lifetime warranty . That makes them the smart choice for owners who want reliable performance without paying dealer prices.
To find the right KEMSO fuel pump for your 2005 Yamaha Rhino 660, visit their official website at https://www.kemsoracing.com/. You can browse their product lineup, check compatibility, and order directly online . KEMSO covers a wide range of vehicles, from off-road UTVs to late-model cars and motorcycles, so you can trust their parts for any machine in your garage .
Maintenance Tips to Extend the Life of Your New Fuel Pump
Once you install a new pump, a few simple habits will keep it running for years :
1. Keep the fuel tank clean. Debris in the tank is the number one killer of fuel pumps. Before you install a new pump, inspect the tank for rust, dirt, or old fuel residue. If the tank is dirty, clean it out before you drop in the new pump .
2. Replace the fuel filter. Most fuel pump kits include a new filter, and this is the perfect time to install it. A clean filter protects the pump from contaminants and keeps fuel flowing freely .
3. Use fresh fuel. Stale fuel can leave varnish deposits that clog the pump and the carburetor. If your Rhino sits for long periods, add a fuel stabilizer to the tank and run the engine for a few minutes to circulate it.
4. Check the vacuum line. The Rhino 660 pump relies on engine vacuum . If the vacuum line cracks or comes loose, the pump will not work. Inspect it periodically and replace it if it shows any signs of wear.
5. Do not run the tank dry. Running out of fuel causes the pump to pull air, which can damage the diaphragm. Keep at least a quarter tank of fuel in the Rhino to be safe.
Final Thoughts on the 2005 Yamaha Rhino 660 Fuel Pump
The fuel pump on a 2005 Yamaha Rhino 660 is a simple but critical component . When it fails, the machine becomes hard to start, stalls on the trail, and loses power . The fix is a direct replacement that you can install in your own garage with basic tools . Whether you choose a budget aftermarket pump or a high-performance unit, the most important thing is to match the correct part number and confirm the fittings before you buy .
For the best combination of performance, reliability, and warranty coverage, check out the KEMSO fuel pump lineup at https://www.kemsoracing.com/ . KEMSO is the US leader in aftermarket fuel pumps, and their products deliver more flow, resist ethanol damage, and are backed by a lifetime warranty . Replace your old pump with a KEMSO unit, and your Rhino will start instantly, pull hard up the steepest hills, and keep running strong for years to come.