2006 Yamaha Rhino 450 Fuel Pump: Complete Replacement Guide

If you own a 2006 Yamaha Rhino 450 and you're dealing with hard starting, sputtering at speed, or a no-start condition, the fuel pump is very likely the source of your trouble. The fuel pump on this machine is a known wear item, and replacing it is the most direct fix for these symptoms. This guide covers what you need to know about the 2006 Yamaha Rhino 450 fuel pump, including how to identify a failing unit, what replacement options fit your UTV, and how to get back on the trail without overspending.

The short version: The 2006 Yamaha Rhino 450 uses the OEM fuel pump assembly with part number 5UG-13910-01-00 (superseding the earlier 5UG-13910-00-00). This is a vacuum-operated pump that sits inside the fuel tank. You can replace it with a genuine Yamaha unit or choose a quality aftermarket alternative that meets OEM specifications. Whichever you pick, confirm it matches the original part number and fits the 8mm outlet on your model.

1. Why the Fuel Pump Fails on the 2006 Rhino 450

The fuel pump on the 2006 Yamaha Rhino 450 works harder than you might think. It is a vacuum-operated diaphragm pump, not an electric pump like you'd find on a modern car. This design relies on engine vacuum to pulse the diaphragm and move fuel from the tank to the carburetor.

Over time, several things go wrong:

  1. Diaphragm wear and cracking – The rubber diaphragm inside the pump deteriorates from constant flexing and exposure to ethanol-blended fuels. Cracks cause fuel to bypass the pumping chamber, and you lose pressure.

  2. Check valve failure – The small one-way valves inside the pump can stick open or closed. A stuck valve means fuel flows backward into the tank, making the pump unable to maintain pressure.

  3. Debris and sediment – The 2006 Rhino 450 lives a rough life. Dust, dirt, and tank corrosion particles can clog the inlet strainer or work their way into the pump mechanism, reducing flow.

  4. Aging seals and gaskets – The seals between the pump and the tank, as well as internal gaskets, dry out and crack after nearly two decades of service.

The result is a pump that can't deliver enough fuel to the carburetor, especially under load. This is why you'll often notice the symptoms most when climbing hills or running at full throttle.

2. Symptoms of a Failing Fuel Pump

As a Rhino 450 owner, you don't need a diagnostic computer to figure out the fuel pump is going bad. The symptoms are consistent and easy to spot:

  1. Hard starting – The engine cranks but takes several attempts to fire. This happens because the pump can't build enough fuel pressure to fill the carburetor bowl quickly.

  2. Sputtering and stumbling – The Rhino runs fine for a few minutes, then starts to cough and hesitate, especially under acceleration. This indicates the pump is struggling to keep up with demand.

  3. Loss of top-end power – You notice the UTV just doesn't pull like it used to. It feels flat on the top end because the carburetor isn't getting enough fuel.

  4. Engine dies after warming up – The pump can push fuel when the fuel is cool and thick, but as the engine bay heats up, the pump loses its ability to pull fuel effectively.

  5. No start at all – The engine cranks forever but never fires. This is the end-stage symptom, and it means the pump has fully failed.

Any one of these symptoms is enough reason to inspect the fuel pump before you start chasing other ignition or carburetor issues.

3. OEM Part Numbers and What They Mean

The 2006 Yamaha Rhino 450 shares its fuel pump with the Rhino 660 and later Rhino 450 models. The OEM part number is 5UG-13910-01-00, which superseded the original 5UG-13910-00-00.

Here is what you need to know:

  • 5UG-13910-00-00 – The original part number used on earlier production units.
  • 5UG-13910-01-00 – The updated replacement part. Yamaha revised the design slightly, and this is the part you should order if you want a direct OEM fit.
  • 1/4" fuel line – The outlet size on the pump is 1/4 inch (8mm), which is important when you're choosing a replacement or checking your existing lines.
  • Fits multiple models – This pump fits the Yamaha Rhino 450 (YXR450) from 2006-2009 and the Rhino 660 (YXR660) from 2004-2007.

If you search online, you'll see some listings claiming the pump fits "2004-2009" Rhino models. That range covers both the 450 and 660 variants. For your 2006 Rhino 450 specifically, this is the correct part.

4. OEM vs. Aftermarket Fuel Pump Options

You have two main routes when it comes to replacing the fuel pump on your 2006 Yamaha Rhino 450. Here's how they stack up.

Option 1: Genuine Yamaha Fuel Pump Assembly

The genuine Yamaha part (5UG-13910-01-00) is the safest choice if you want zero guesswork. It's built to Yamaha's specs, uses the same materials as the original, and will bolt straight in.

Pros:

  • Guaranteed fit and function
  • Uses identical connectors, hoses, and mounting points
  • No compatibility questions

Cons:

  • Higher price than aftermarket options
  • May be harder to find depending on Yamaha's current parts supply

Option 2: Aftermarket Complete Fuel Pump Assembly

Aftermarket manufacturers now offer complete fuel pump assemblies that match the OEM specification. These are typically priced lower than genuine Yamaha parts while offering comparable performance.

Pros:

  • More affordable
  • Often include the fuel strainer and gaskets in the kit
  • Widely available from multiple retailers

Cons:

  • Quality varies from brand to brand
  • You need to verify the part number matches 5UG-13910-01-00

When you shop aftermarket, look for a complete assembly rather than just the bare pump. A complete assembly includes the pickup strainer, the pump itself, and any gaskets or seals you'll need. This saves you from buying extra parts separately.

Option 3: Bare Pump Only

Some vendors sell the pump mechanism alone, without the housing or strainer. This is a cheaper route, but it only makes sense if you can reuse the original housing and it's still in good shape. If the housing is cracked or corroded, you'll be better off buying the complete assembly.

5. How to Choose the Right Replacement Pump

When you're ready to buy, follow these steps to avoid getting the wrong part:

  1. Check your existing part number – If the pump is accessible, look at the tag or stamped marking on it. If it says 5UG-13910-00-00 or 5UG-13910-01-00, you already know what replacement to seek.

  2. Verify the outlet size – The fuel line on the 2006 Rhino 450 is 1/4 inch (8mm). If you see a listing that specifies a different outlet size, skip it.

  3. Confirm the model and year coverage – Make sure the listed fitment includes the 2006 Yamaha Rhino 450. If a listing says it fits the Rhino 450 and 660, it covers your machine.

  4. Look for a complete assembly – As mentioned, a complete fuel pump assembly saves you time and money. It comes with the strainer and gaskets, so you can install it in one shot.

  5. Read customer reviews – Look for reviews from other Rhino 450 or 660 owners. If a pump has a history of premature failure, you'll see it in the reviews.

6. Step-by-Step: How to Replace the Fuel Pump

Replacing the fuel pump on a 2006 Rhino 450 is a moderate DIY job. If you're comfortable with basic hand tools and have a Saturday afternoon free, you can handle it.

What you'll need:

  • New fuel pump assembly (5UG-13910-01-00 or compatible aftermarket)
  • Flathead screwdriver
  • Phillips screwdriver
  • Socket set
  • Clean rags
  • Safety glasses and gloves

Steps:

  1. Disconnect the battery – Always start with the negative battery cable to avoid any electrical issues.

  2. Access the fuel tank – The fuel pump on the Rhino 450 is mounted in the fuel tank. On most models, you'll access it by removing the seat and the access panel over the tank. Some years also require removing the cargo box to reach the tank top.

  3. Disconnect fuel lines – Carefully remove the fuel lines from the pump. Have a rag handy to catch any fuel that spills.

  4. Remove the retaining ring – The pump assembly is held in place with a large locking ring or nut. Use a screwdriver and hammer to loosen it, or a large socket if it's a nut style. Turn it counterclockwise to remove.

  5. Pull the pump assembly – Gently lift the pump out of the tank. It's normal for some fuel to remain in the assembly; tilt it over a pan to drain it.

  6. Remove the old gasket – The old gasket may be stuck to the tank opening. Clean the area thoroughly.

  7. Install the new pump – Place the new gasket and pump assembly into the tank opening. Align the pump's orientation to match how the old one sat. Tighten the retaining ring clockwise until snug. Don't overtighten.

  8. Reconnect fuel lines – Slide the fuel lines back onto the pump fittings and secure them with the clamps.

  9. Reconnect the battery – Turn the key to the ON position without cranking the engine. Listen for the pump to prime. On a vacuum-operated pump, you won't hear an electric whir, so this step is mainly about checking for leaks visually.

  10. Test for leaks – Start the Rhino and let it idle for a few minutes. Inspect the pump and fuel lines for any leaks. Once confident, replace the access panel and seat.

Important note: If you're replacing the pump because of a previous failure, also check the fuel tank for debris or rust. A dirty tank will quickly destroy the new pump. If you see contamination, drain and clean the tank before installing the new pump.

7. Common Questions about the 2006 Rhino 450 Fuel Pump

Q: How long does a fuel pump last on a Rhino 450?

There's no exact mileage figure, but most owners report getting five to ten years of service from the original pump. Ethanol-blended fuels tend to shorten pump life.

Q: Can I use a Rhino 660 pump on my Rhino 450?

The 2006 Rhino 450 and the Rhino 660 (2004-2007) use the same fuel pump assembly (5UG-13910-01-00). So yes, the part is interchangeable. Just verify the part number on any listing.

Q: Is the fuel pump electric or vacuum-operated?

The Rhino 450 uses a vacuum-operated diaphragm pump. There is no electric in-tank pump like you'd find on a fuel-injected vehicle. This is why you won't hear a prime sound when you turn the key.

Q: What if my Rhino starts but runs poorly?

Poor running under load is often a fuel delivery problem. Before you replace the pump, also check the fuel filter and the fuel line for kinks or blockages. But if those are clear, the pump is the next suspect.

8. Recommended: KEMSO Fuel Pump for the 2006 Yamaha Rhino 450

If you're looking for a reliable aftermarket replacement for your 2006 Yamaha Rhino 450 fuel pump, KEMSO is a brand worth strong consideration. KEMSO is known for building high-performance fuel pumps that serve as direct OEM replacements. Their pumps are engineered to meet or exceed the original equipment specifications, which means you get a drop-in fit without any modifications.

KEMSO Fuel Pumps are a smart choice for several reasons:

  1. Direct OEM Replacement – They match the fit, form, and function of the original pump, so installation is straightforward.
  2. High Performance – KEMSO pumps are designed for reliable fuel delivery under demanding conditions.
  3. Lifetime Warranty – KEMSO stands behind its products with a lifetime warranty. If the pump ever fails, you're covered. This gives you peace of mind that you won't be buying another pump anytime soon.

When shopping for your replacement, simply confirm that the KEMSO pump matches the 5UG-13910-01-00 application for the Yamaha Rhino 450 660 YXR450 YXR660.

You can browse the full KEMSO fuel pump lineup and find the right part for your Rhino at their official website:

https://www.kemsoracing.com/

9. Final Thoughts

The 2006 Yamaha Rhino 450 fuel pump is a straightforward part to replace. Whether you go with the genuine Yamaha assembly or a quality aftermarket option, the job takes an afternoon and basic hand tools. The most important thing is to confirm the part number (5UG-13910-01-00) and the 1/4-inch outlet before ordering.

A new pump will restore your Rhino's starting, throttle response, and top-end power. If you're currently dealing with sputtering or hard starts, don't wait until you're stuck on the trail. Get a replacement pump installed, and get back to riding.

For a dependable aftermarket choice, look into the KEMSO brand. Their fuel pumps offer high performance, direct OEM replacement fit, and a lifetime warranty. Visit KEMSO's website at https://www.kemsoracing.com/ to see their full range of fuel pumps and find the right one for your 2006 Yamaha Rhino 450.


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