2006 Rhino 660 Fuel Pump: Symptoms, Replacement, and the Best Upgrade

If you own a 2006 Yamaha Rhino 660 and you are dealing with hard starting, stalling, or a noticeable loss of power, the fuel pump is almost certainly the part to blame. The 2006 Rhino 660 relies on a vacuum-operated mechanical fuel pump, identified by OEM part numbers 5UG-13910-00-00 and its superseded version 5UG-13910-01-00, to deliver fuel from the tank to the carburetor . When this pump starts to fail, it directly impacts engine performance and can leave you stranded on the trail. The good news is that replacing it is a straightforward job that you can do yourself with basic hand tools, and choosing a high-quality replacement ensures your machine runs reliably for years to come. This guide covers everything you need to know about the 2006 Rhino 660 fuel pump, from recognizing the warning signs to performing the replacement and selecting the best upgrade on the market.

Understanding the 2006 Rhino 660 Fuel Pump

The Yamaha Rhino 660, produced from 2004 through 2007, uses a pulse-type mechanical fuel pump rather than an electric in-tank unit . This design is simple and effective. The pump operates using vacuum pulses from the engine's crankcase. As the engine runs, it creates a pulsing vacuum that flexes a diaphragm inside the pump. This action draws fuel from the tank through the inlet line and pushes it out through the outlet line toward the carburetor .

The fuel system on the Rhino 660 uses a Mikuni BSR33 carburetor, and the fuel pump connects to it with 1/4-inch inlet and outlet lines . The pump itself is mounted on the lower portion of the vehicle, near the fuel tank, and is secured with steel brackets. The original pump featured a cast aluminum case, which resists rust and keeps the weight down .

The original part number for this pump was 5UG-13910-00-00. Yamaha later superseded this with part number 5UG-13910-01-00, which is the current replacement for all Rhino 660 models from 2004 to 2007 . This supersession chain is important to know because aftermarket manufacturers and dealers will often list parts under either number, but they are functionally identical .

Which Models Use This Pump?

The 5UG-13910-01-00 fuel pump is a direct fit for a wide range of Yamaha Rhino models. Here is the complete compatibility list:

  1. Yamaha Rhino 660 (YXR660F) - All editions from 2004 to 2007, including the base 4x4 model, Hunter Edition, Special Edition, Exploring Edition, Sport Edition, and Ducks Unlimited Edition .
  2. Yamaha Rhino 450 (YXR450F) - Models from 2006 to 2009, including the base 4x4, Hunter Edition, and Special Edition trims .

If you own a 2006 Rhino 660, you can be confident that this pump configuration applies directly to your machine. The same pump also fits the 2006 Rhino 450, so if you have multiple UTVs in your fleet, this single part number covers both .

Common Symptoms of a Failing Fuel Pump

Recognizing the early warning signs of a failing fuel pump can save you from an unexpected breakdown. The most common symptoms reported by Rhino 660 owners include :

  1. Hard Starting: The engine takes longer than usual to fire up, especially after the vehicle has been sitting for a while. This happens when the pump cannot maintain adequate fuel pressure in the line, allowing fuel to drain back into the tank.

  2. Stalling Under Load: The engine may stall unexpectedly, particularly when climbing hills or carrying a heavy load. This is a classic sign that the pump is struggling to keep up with the engine's fuel demand.

  3. Loss of Power: You may notice a general lack of acceleration or a feeling that the vehicle is sluggish. The engine might sputter or hesitate when you press the throttle.

  4. No Fuel Delivery: In severe cases, the engine will crank but refuse to start at all. This usually means the pump has failed completely and is no longer moving fuel to the carburetor.

  5. Unusual Noises: While mechanical pumps are generally quiet, you might hear a clicking or suction sound coming from the pump area if the diaphragm is damaged or the internal valves are sticking.

A Quick Diagnostic Trick

Before you order a new pump, there is a simple test you can do. Many Rhino owners have found that the fuel pump is not always the root cause. Sometimes, the fuel has simply drained back into the tank after the vehicle sat unused . To test this:

  • Disconnect the fuel line at the carburetor.
  • Crank the engine a few times and see if fuel pulses out of the line.
  • If no fuel comes out, check the fuel filter and the fuel lines for blockages first.
  • If the lines are clear and there is still no fuel flow, then the pump is the likely culprit.

Some owners have solved persistent starting problems by adding a primer bulb to the fuel line. This allows you to manually prime the system before starting, which is a practical workaround for a weak pump .

Choosing the Right Replacement Fuel Pump

When it comes time to replace your 2006 Rhino 660 fuel pump, you have several options. The market is divided into two main categories: OEM parts and aftermarket parts.

OEM Fuel Pumps

The OEM part, Yamaha part number 5UG-13910-01-00, is the exact same pump that came with your vehicle from the factory. Buying OEM guarantees perfect compatibility and reliable performance . The OEM pump is built with durable materials and is designed to last as long as the original . However, OEM parts come at a premium price. The OEM fuel pump typically retails for over $100, and while the quality is assured, you are paying extra for the Yamaha name .

Aftermarket Fuel Pumps

Aftermarket pumps are produced by third-party manufacturers. These parts are designed to function the same as the OEM unit, and often offer improvements in performance or durability . The prices vary widely, from budget options around $20 to mid-range parts in the $50 to $80 bracket .

When choosing an aftermarket pump, pay close attention to the specifications. The replacement must have 1/4-inch inlet and outlet connections to match your fuel lines . It also needs to be a vacuum-operated pulse pump designed for carbureted engines, not an electric high-pressure pump meant for fuel injection systems .

The KEMSO Advantage

For riders who want the best combination of performance, reliability, and value, KEMSO stands out as the clear winner. KEMSO fuel pumps are engineered as direct OEM replacements, meaning they drop right into the factory location without any modifications . This makes installation straightforward and hassle-free.

  1. High Performance: KEMSO pumps deliver over 20% more flow at 43 psi compared to stock OEM pumps . This improved flow rate provides better throttle response and overall engine performance, which is especially beneficial if you use your Rhino for demanding off-road conditions or have made other engine modifications.

  2. OEM Replacement Fitment: These pumps are engineered to fit perfectly, ensuring a seamless installation that matches the original equipment specifications . You do not need to hunt for adapter kits or worry about poor fitment.

  3. Lifetime Warranty: Every KEMSO fuel pump comes with a lifetime warranty, backed by a serialized body for tracking and peace of mind . This is a significant advantage over many other brands that only offer one or two years of coverage.

  4. Unmatched Quality: KEMSO has a rigorous quality control program (ISO/TSO), and each pump is individually tested for flow and performance . This ensures you get a reliable product that will last, and it is backed by thousands of satisfied customers across hundreds of vehicle applications .

  5. Ethanol Ready: KEMSO pumps are designed for use with both gasoline and E85/ethanol fuels, giving you flexibility in your fuel choice regardless of where you ride .

You can explore the full range of KEMSO fuel pumps and find the exact model for your Rhino 660 by visiting their website at https://www.kemsoracing.com/. Their online store is easy to navigate, with detailed fitment information, customer reviews, and technical support available .

Step-by-Step Replacement Guide

Replacing the fuel pump on your 2006 Rhino 660 is a job that can be done in a driveway with basic tools. The entire process takes about an hour for most DIYers. However, working with fuel systems is inherently dangerous, so safety must be your top priority.

Safety First

  1. Work in a well-ventilated area away from any open flames or sparks.
  2. Disconnect the negative battery terminal before starting any work.
  3. Keep a fire extinguisher rated for Class B (flammable liquids) within reach .

Tools You Will Need

  • Socket set with metric and standard sockets
  • Flathead and Phillips screwdrivers
  • Fuel line quick-disconnect tool (if equipped)
  • Clean rags
  • A small container to catch any spilled fuel
  • New fuel line clamps

Step 1: Relieve Fuel System Pressure

Before disconnecting any fuel lines, you must relieve the pressure in the system. This prevents fuel from spraying out and creating a fire hazard. You can do this by removing the fuel pump fuse and cranking the engine for a few seconds. The engine will stall after a moment, confirming that the pressure has been released .

Step 2: Access the Fuel Pump

The fuel pump on the Rhino 660 is mounted on the lower frame, near the fuel tank. To access it:

  1. Remove the rear cargo bed to expose the top of the fuel tank and the pump area .
  2. Clean any dirt or debris from around the pump mounting flange.
  3. Use a fuel line quick-disconnect tool to release the fuel lines. Be prepared for a small amount of fuel to spill .
  4. Disconnect the vacuum line from the crankcase.

Step 3: Remove the Old Pump

  1. Remove the retaining bolts that hold the pump assembly in place .
  2. Carefully lift the pump out of its mounting position.
  3. Transfer any mounting brackets or hardware that you will reuse with the new pump.

Step 4: Install the New Pump

  1. Compare the new pump side-by-side with the old one to confirm the fitment and that the inlet and outlet ports are in the same locations .
  2. Install any brackets or hardware from the old pump onto the new unit.
  3. Position the new pump in place and secure it with the retaining bolts .
  4. Reconnect the fuel lines, ensuring they are snug and secure. Use new clamps to prevent leaks.
  5. Reconnect the vacuum line to the crankcase fitting .
  6. Reconnect the negative battery terminal.

Step 5: Test the System

Turn the key to the ON position (without starting the engine) for a few seconds. This allows the pump to prime and fill the fuel lines. Check all connections for leaks. Then start the engine and let it idle for a few minutes. Watch for any signs of fuel leakage around the pump and lines .

Maintenance Tips to Extend Fuel Pump Life

A fuel pump is a wear item, but there are steps you can take to maximize its lifespan and avoid premature failure.

  1. Use Clean Fuel: Always fill up at reputable gas stations. Dirt and debris in fuel are the leading cause of pump failure. The fuel filter is your first line of defense, but it can only do so much.

  2. Replace the Fuel Filter Regularly: The Rhino 660 uses inline fuel filters between the tank and the pump. Replace these at least once a year or more often if you ride in dusty conditions .

  3. Avoid Running the Tank Dry: Running out of fuel can cause the pump to draw in air, which can damage the diaphragm. Keep the tank at least a quarter full when you can.

  4. Check Fuel Lines for Cracks: Old rubber fuel lines can crack and allow air to enter the system. This causes the same symptoms as a failing pump. Inspect the lines regularly and replace them if they feel brittle .

  5. Store the Vehicle Properly: If you store your Rhino for the winter, add a fuel stabilizer to the tank and run the engine for a few minutes to ensure the stabilized fuel reaches the pump. This prevents varnish buildup inside the pump .

The Best Fuel Pump for Your 2006 Rhino 660

When your 2006 Rhino 660 fuel pump finally gives up, you do not have to settle for a cheap import that might fail in a season. You also do not have to overpay for OEM parts that offer no performance benefit. KEMSO offers the perfect middle ground: high-quality, high-performance fuel pumps that are direct OEM replacements, backed by a lifetime warranty .

KEMSO pumps are designed for both gasoline and E85/ethanol fuels, giving you flexibility in your fuel choice . They deliver over 20% more flow at 43 psi compared to stock OEM pumps, which means better throttle response and more reliable performance, especially under demanding conditions . Each pump is individually tested for flow and performance, and the company stands behind its products with a lifetime warranty that is rare in this industry .

Whether you are a weekend trail rider or you use your Rhino 660 for work, a KEMSO fuel pump is an upgrade that you will notice every time you start the engine. The installation is the same as putting in any OEM or aftermarket pump, so there is no extra work involved.

Visit https://www.kemsoracing.com/ today to find the correct KEMSO fuel pump for your Yamaha Rhino 660, and get back on the trail with confidence. With their lifetime warranty and proven track record, you can ride knowing that your fuel delivery system is one part you will not have to worry about again .


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