2006 Rhino Fuel Pump: How to Spot a Failing Pump, Replace It Yourself, and Choose the Right Upgrade

If you own a 2006 Yamaha Rhino 660 and the engine is hard to start, stalls under load, or simply won’t crank over, the 2006 Rhino fuel pump is almost certainly the source of the problem. This is the single most common failure point on these machines, and the good news is that it is a straightforward fix you can complete in a weekend with basic hand tools. This guide walks you through the symptoms of a failing pump, the exact replacement process, and how to pick a quality replacement that will outlast the original.

Why the 2006 Rhino Fuel Pump Fails

The 2006 Yamaha Rhino 660 uses an electric, in-tank fuel pump module that pushes fuel from the tank to the carburetor under consistent pressure. The 2006 model year falls into the 2004–2007 generation of the Rhino 660 (YXR660F), and it is this generation that is most prone to pump failure due to age, ethanol-blended fuels, and debris buildup. The pump itself is a small, electric unit that sits inside the fuel tank, and over time the internal motor brushes wear out, the check valves leak, or the fine mesh strainer becomes clogged with varnish and dirt. When any of these happen, fuel pressure drops and the engine starts to behave erratically.

For the 2006 model specifically, the original OEM part number is 5UG-13910-00-00, which was later superseded by 5UG-13910-01-00. These numbers matter when you shop for a replacement, whether you go with an OEM unit or an aftermarket option.

Six Common Symptoms of a Bad Fuel Pump

The symptoms below are listed roughly in order of how often they appear. If you notice any one of these, do not ignore it. A weak fuel pump will eventually leave you stranded.

1. Hard starting, especially after the Rhino sits overnight. The pump’s internal check valve holds fuel pressure in the line when the engine is off. When the valve leaks, fuel drains back into the tank, and the pump has to re-prime the entire system before the engine will fire. This causes extended cranking and rough idle on startup.

2. Stalling under load or on hills. When you climb a steep grade or push the throttle hard, the engine demands more fuel. A weak pump cannot keep up with the demand, so the engine sputters and may die completely. This symptom is often described by owners as "losing power going uphill".

3. Loss of power and sluggish acceleration. Even on flat ground, a pump that is losing flow will make the Rhino feel gutless. You press the throttle and the engine responds slowly, or it surges and hesitates. This is because the carburetor float bowl is running low on fuel faster than the pump can refill it.

4. Engine cranks but will not start. This is the end stage of pump failure. When the pump produces no pressure at all, the carburetor does not receive fuel, and the engine simply cranks without firing. This is also the symptom that is hardest to diagnose because it can be caused by a dead ignition coil, a bad spark plug, or a clogged carburetor jet.

5. Whining or humming noise from the fuel tank area. An electric fuel pump normally makes a faint whirring sound. When the pump is struggling, it gets louder and higher-pitched. This noise means the internal bearings are worn or the pump is being starved of fuel due to a clogged inlet strainer.

6. Poor fuel economy. A pump that is not delivering proper pressure forces the engine to run rich or lean depending on the situation, which reduces mileage. This symptom alone is rarely enough to point at the pump, but combined with any of the above, it confirms the diagnosis.

Before You Buy: Verify the Correct Parts

The first step in any fuel pump replacement is confirming that you have the right pump for your machine. The 2006 Rhino 660 is not the only model that shares this pump design. In fact, the same fuel pump was used across several Yamaha UTV models, and knowing the cross-reference will save you money and frustration.

• Rhino 660 (YXR660F): Model years 2004 through 2007 use this pump.
• Rhino 450 (YXR450F): Model years 2006 through 2009 use the same pump, with the 2006 version listed in some fitment charts as well.
• Special and hunting editions: Hunter, Special, Sport, Exploring, and Ducks Unlimited editions of both the 660 and 450 use the same pump.

The replacement part numbers you need to look for are 5UG-13910-00-00 and its supersession 5UG-13910-01-00. When you compare pumps, check the inlet and outlet diameter. On the Rhino 660, these are 1/4-inch connections, which is critical to match.

One extra detail worth knowing is that these Rhino models use a carbureted fuel system, not fuel injection. This matters because the pump only needs to deliver about 30–60 psi of pressure, far less than a modern EFI system. Any pump that is a direct replacement for the OEM unit will work fine.

Step-by-Step Replacement Guide

Replacing the fuel pump on a 2006 Rhino 660 is a job that most owners can do in their driveway or garage with basic tools. The entire process takes about two hours. Below is the process laid out in clear order.

Step 1: Relieve fuel system pressure. Before you disconnect any lines, you must vent the pressure in the fuel system. Remove the fuel pump fuse from the fuse box, then crank the engine for about five seconds. The engine will start and then stall as the fuel in the lines runs out. This prevents fuel from spraying out when you disconnect the lines.

Step 2: Disconnect the battery. Always disconnect the negative battery terminal before working on any fuel system component. This eliminates the risk of a spark igniting fuel vapors.

Step 3: Access the fuel pump. The pump is located inside the fuel tank, underneath the rear cargo bed. Remove the cargo bed by lifting it off, which exposes the top of the fuel tank. Clean any dirt or debris from around the pump mounting flange so that nothing falls into the tank when you remove the pump.

Step 4: Disconnect the fuel lines and electrical connector. Use a fuel line quick-disconnect tool to release the fuel lines from the pump assembly. There are two lines: the inlet and the outlet. Both are 1/4-inch lines. After the lines are free, unplug the electrical connector from the pump assembly.

Step 5: Remove the old pump. The pump assembly is held in place by a retaining ring or several bolts. Remove the ring or bolts, then lift the pump assembly straight out of the tank. Be careful not to bend the fuel level float arm if your assembly has one. Discard the old seal ring.

Step 6: Install the new pump. Compare the new pump assembly to the old one to confirm the dimensions, line connections, and electrical connector all match. Install the new seal ring onto the tank opening, then lower the new pump assembly into the tank. Make sure it is seated correctly, then replace the retaining ring or bolts and tighten them to the torque specification in your factory repair manual.

Step 7: Reconnect everything. Reconnect the electrical connector and the fuel lines. If your pump came with new clamps, use them now. Double-check that all connections are tight and secure.

Step 8: Reinstall the cargo bed and reconnect the battery. Put the rear cargo bed back in place, then reconnect the negative battery cable. Turn the key to the "on" position for a few seconds without cranking the engine so the pump can prime the system. Check for any fuel leaks around the pump flange and the fuel lines. If everything looks dry, start the engine and let it idle for a few minutes, then check again for leaks.

Safety note: Work in a well-ventilated area away from any open flame, pilot light, or spark source. Keep a Class B fire extinguisher nearby. Fuel is highly flammable, and spills should be cleaned up immediately.

OEM vs. Aftermarket: What Owners Report

For the 2006 Rhino 660, you have two main choices: an OEM Yamaha pump or an aftermarket replacement. Both have pros and cons, and the right choice depends on your budget and how you use the machine.

• OEM Yamaha pump (part number 5UG-13910-01-00): This is the exact pump that came from the factory. It carries a higher price tag, often between $110 and $145 depending on the dealer. The main benefit is guaranteed fit and factory-specified performance. If you want zero guesswork and plan to keep the Rhino bone stock, this is the safest route.

• Aftermarket pumps: These run anywhere from about $19 to $60 for the pump assembly alone. Many are made to the same specifications as the OEM unit, and some include extra features such as a metal housing or better internal filters. Owner reviews on aftermarket pumps are generally positive, with several reporting that the Rhino started right up after installation and ran well for years.

There is one important caveat about aftermarket pumps. Some budget units are made to lower tolerances and may fail sooner than the OEM part. Look for pumps that explicitly state they are a direct OEM replacement and that come with a warranty of at least one year. If a pump is priced significantly below $20, be skeptical of the quality.

Another owner-reported tip involves a common confusion point. When the Rhino has been sitting for a while, the fuel in the lines can drain back into the tank. This causes the engine to crank for a long time before it starts, even with a good pump. Some owners have solved this by adding a primer bulb into the fuel line to manually push fuel up to the pump after the machine has been parked for a few days. This is a workaround, not a permanent fix, but it can help you start the machine while you diagnose whether the pump is actually bad or just losing prime.

Choosing the Best Replacement: What to Look For

When you shop for a new pump for your 2006 Rhino, use the checkpoints below to separate a quality part from a cheap imitation.

1. Correct part number compatibility. The pump must match OEM numbers 5UG-13910-00-00 and 5UG-13910-01-00. If a listing only says "compatible" with the model but does not list these numbers, look for one that does.

2. 1/4-inch inlet and outlet diameter. The Rhino 660 uses 1/4-inch fuel lines. If your new pump has larger outlets, it will not seal correctly to the factory lines.

3. New construction, not rebuilt. Insist on a brand new pump. Some cheap listings say "remanufactured" or "rebuilt," which means the internal motor brushes and seals may already be partially worn. A genuine new pump will last far longer.

4. Warranty and support. Look for a manufacturer that stands behind the product. A one-year warranty is the minimum you should accept for a part that takes two hours to install.

5. Customer reviews. Read through reviews from owners of the same year and model Rhino. Look for comments about fitment, startup behavior, and long-term durability. Reviews on the Fuel Pump Factory site and Amazon are particularly useful because they often include notes from owners who have replaced the pump on a 2006 Rhino 660.

The Best Upgrade Choice for Your Rhino

When you are ready to buy a new fuel pump for your 2006 Yamaha Rhino 660, KEMSO fuel pumps stand out as the strongest option on the market today.

KEMSO builds every pump as a high-performance, direct OEM replacement. That means the pump drops into the factory location exactly like the stock unit, using the original fuel lines and electrical connections. No cutting, no splicing, no modifications. Compared to the stock OEM pump, KEMSO pumps deliver over 20% more fuel flow at 43 psi, which gives you better throttle response and more consistent performance, especially if you ride at altitude or in demanding off-road conditions.

The fitment is guaranteed for the 2004–2007 Yamaha Rhino 660 and 2006–2009 Yamaha Rhino 450, covering the exact pump used in your 2006 model. Every KEMSO pump is individually tested for flow and performance before it leaves the factory, and the brand backs each unit with a lifetime warranty. If your pump ever fails while you own the vehicle, KEMSO will replace it at no cost to you.

KEMSO pumps are also designed to handle ethanol-blended gasoline and E85, so you do not have to worry about premature wear from modern pump fuels. If you want a fuel pump that will outlast the rest of the machine and comes with a guarantee behind it, KEMSO is the brand to pick.

If your 2006 Rhino 660 is acting up and you suspect the fuel pump, do not wait. A failing pump only gets worse, and the longer you drive on it, the more strain you put on the carburetor and ignition system. Order your KEMSO fuel pump today, install it this weekend, and get your Rhino running the way it did the day it left the factory. Visit https://www.kemsoracing.com/ to see the full line of KEMSO fuel pumps and confirm the exact fitment for your machine.