2006 Yamaha Rhino 660 Fuel Pump: The Complete Guide to Symptoms, Diagnosis, and Replacement

The bottom line: If your 2006 Yamaha Rhino 660 is hard to start, sputters during acceleration, or stalls unexpectedly, the fuel pump is almost certainly the culprit. The 2006 Rhino 660 uses a specific fuel pump assembly (part number 5UG-13910-00-00 or 5UG-13910-01-00) that is known to fail over time due to wear, ethanol-blended fuel damage, or debris clogging. Replacing it with a quality direct replacement—whether OEM or an upgraded aftermarket unit—is straightforward and will restore your UTV’s reliability. This guide covers everything you need to know: symptoms of a failing pump, how to test it, step-by-step replacement instructions, and the best replacement options available.

Why Your 2006 Rhino 660 Fuel Pump Fails

The 2006 Yamaha Rhino 660 (YXR660FA) comes with a factory fuel pump assembly mounted inside the fuel tank. The OEM part number is 5UG-13910-00-00, and later superseded by 5UG-13910-01-00 . These pumps are electrically operated and deliver fuel from the tank to the carburetor or fuel injection system, depending on your specific model.

Common causes of failure include:

Age and wear. The original pump is now over 20 years old. Internal brushes, seals, and bearings degrade over time, leading to reduced flow or complete failure.

Ethanol damage. Ethanol-blended gasoline (E10 or higher) is corrosive to rubber components and can cause the pump’s internal seals to swell, crack, or dissolve. Many aftermarket replacement pumps explicitly state they are not compatible with fuel containing more than 10% ethanol .

Debris and contamination. Over time, sediment and rust particles can accumulate in the fuel tank and clog the pump’s inlet strainer or internal passages.

Electrical issues. A failing relay, corroded connector, or broken wire can prevent the pump from receiving power.

Symptoms of a Bad Fuel Pump on a 2006 Rhino 660

A failing fuel pump will show one or more of these warning signs. If you notice any of them, inspect the pump immediately.

1. Hard starting or no start. The engine cranks but struggles to fire up, or it won’t start at all. This is often the first symptom, as the pump can no longer build adequate fuel pressure for the engine to start.

2. Engine sputters or hesitates under load. When you accelerate, especially going uphill or carrying a load, the engine stumbles or loses power. This indicates the pump can’t supply enough fuel to keep up with demand.

3. Sudden stalling. The engine runs fine for a while, then dies without warning. After a few minutes, it may restart, only to stall again. This is a classic sign of an overheating pump or a pump with intermittent electrical contact.

4. Whining or buzzing noise from the fuel tank. A healthy fuel pump makes a quiet hum. If you hear a loud, high-pitched whine, the pump is struggling and likely near failure.

5. Poor fuel economy. If you notice you’re filling up more often than usual, the pump may be leaking internally or running inefficiently, causing excessive fuel consumption.

Testing the Fuel Pump on a 2006 Rhino 660

Before you buy a new pump, it’s worth confirming the diagnosis. Here’s how to test the fuel pump system.

Check for power. Locate the fuel pump connector near the fuel tank. Using a multimeter, check for 12 volts at the connector when the ignition is turned on. If you have power, but the pump is silent, the pump itself is likely dead. If you have no power, check the fuse, relay, and wiring harness for damage.

Listen for the prime. Turn the ignition key to the “ON” position (without starting the engine). You should hear the fuel pump hum for 2-3 seconds as it pressurizes the system. If you hear nothing, the pump is not receiving power or is burned out.

Check fuel pressure. If you have a fuel pressure gauge, connect it to the fuel line. The Rhino 660’s fuel system typically operates at 43-68 psi, depending on the specific model . If the pressure is low or non-existent, the pump is failing.

Replacement Options for the 2006 Rhino 660 Fuel Pump

You have several choices when replacing the fuel pump on your 2006 Rhino 660. Here are the most common options, ranging from budget-friendly to high-performance.

1. OEM Yamaha Fuel Pump Assembly. The genuine Yamaha part (5UG-13910-01-00) is available from dealerships and online parts suppliers. It’s a direct fit, plug-and-play installation. The OEM pump is reliable but typically costs between $100 and $120 . It’s designed to meet OEM specifications and maintain stock flow rates.

2. Aftermarket Direct Replacement Assemblies. Brands like NICHE, JDLLONG, and Yezoauto offer complete fuel pump assemblies that are designed to replace the OEM unit. These are usually more affordable, ranging from $20 to $60, and include everything needed for installation: pump, fuel filter, fuel line, clamps, and seals . Some come with a cast aluminum case that prevents rust and reduces weight . However, quality varies—some aftermarket units may not flow as well as OEM or may have shorter lifespans. Many of these are vacuum-type pumps with 1/4-inch fuel lines and are not compatible with fuel containing more than 10% ethanol .

3. High-Performance Upgrades. If you use your Rhino for heavy-duty off-roading, towing, or racing, an upgraded fuel pump can provide more flow and better reliability. High-performance pumps deliver 200 liters per hour or more, compared to the stock pump’s 60-80 liters per hour . These pumps are designed for both gasoline and E85/ethanol, and they often include a bypass valve set at a higher pressure for enhanced performance .

Step-by-Step Fuel Pump Replacement for a 2006 Rhino 660

Replacing the fuel pump on a 2006 Yamaha Rhino 660 is a DIY-friendly job that most owners can complete in about 1-2 hours. Here’s a general overview of the process.

What you’ll need: New fuel pump assembly, new fuel filter (if not included), new seal ring, basic hand tools (socket set, screwdrivers, pliers), a transmission jack or floor jack, safety glasses, and a fire extinguisher (working with fuel requires caution).

Procedure:

1. Disconnect the battery. Always disconnect the negative battery cable before working on any fuel system component. This prevents accidental sparks and electrical shorts.

2. Relieve fuel pressure. Locate the fuel pump fuse or relay and remove it. Crank the engine for a few seconds to relieve pressure in the fuel lines. Alternatively, you can carefully loosen the fuel line at the carburetor or injector rail.

3. Remove the seat and cargo bed. The Rhino 660’s fuel tank is located under the cargo bed. Remove the seat and then remove the bolts securing the cargo bed. Lift the bed off carefully.

4. Access the fuel pump. The fuel pump is mounted on top of the fuel tank. You’ll see a large plastic retaining ring or a metal ring holding the pump assembly in place. Clean the area around the pump to prevent dirt from falling into the tank.

5. Disconnect fuel lines and electrical connector. Label or take a photo of the fuel lines before disconnecting them. Use a line disconnect tool if necessary. Disconnect the electrical connector.

6. Remove the pump assembly. Use a spanner wrench or a large screwdriver and hammer to loosen the retaining ring. Turn it counterclockwise. Lift the pump assembly out of the tank. Be careful not to damage the fuel level sender float.

7. Compare the old and new pump. Place the new pump assembly next to the old one to ensure they are the same size and configuration. Make sure the fuel line connections, electrical connector, and mounting ring match.

8. Install the new pump assembly. Lower the new pump assembly into the tank, making sure the gasket seal is properly seated. Tighten the retaining ring clockwise.

9. Reconnect fuel lines and electrical connector. Reconnect the fuel lines, ensuring they are securely fastened. Use new clamps if needed. Reconnect the electrical connector.

10. Reinstall the cargo bed and seat. Lower the cargo bed back into place and tighten the bolts. Reinstall the seat.

11. Reconnect the battery. Reconnect the negative battery cable.

12. Test the system. Turn the ignition key to the “ON” position and listen for the fuel pump to prime. Check for any fuel leaks at the connections. Start the engine and let it idle for a few minutes. Check for leaks again. Take the Rhino for a short test drive to ensure smooth operation.

Important safety note: Work in a well-ventilated area, away from open flames or sparks. Have a fire extinguisher nearby. If you smell fuel or see a leak, stop immediately and address the issue.

Why You Should Choose KEMSO Fuel Pumps for Your Rhino 660

If you’re looking for a fuel pump that combines OEM-level reliability with high-performance upgrades, KEMSO is the clear choice. KEMSO fuel pumps are designed as direct OEM replacements for stock pumps that have failed, meaning they fit perfectly in your 2006 Rhino 660 without any modifications. They are true high-performance units that deliver over 20% more flow at 43 psi compared to the original factory pump, which translates to better throttle response, smoother acceleration, and more reliable performance under load.

KEMSO pumps are built with unrivaled quality. Each pump is individually tested for flow and performance, and the company operates under a strict Quality Control Program (ISO/TSO). Unlike many cheap aftermarket units that have little or no quality control, KEMSO ensures every pump meets professional specifications. The pump body is serialized, and KEMSO backs it with a lifetime warranty, giving you complete peace of mind . They are designed for both gasoline and E85/ethanol, so you don’t have to worry about fuel compatibility issues .

Whether you use your Rhino 660 for daily chores, weekend trail riding, or heavy-duty work, a KEMSO fuel pump will restore your machine’s performance and keep it running reliably for years to come. Visit the KEMSO website to find the exact pump for your 2006 Yamaha Rhino 660 and other models: https://www.kemsoracing.com/

Preventive Maintenance Tips for Your Rhino 660 Fuel System

Once you’ve replaced the fuel pump, a few simple habits can extend the life of your new pump.

Use fresh, quality fuel. Old or contaminated fuel is the number one cause of pump failure. Always use fresh gasoline from a reputable station. If you store the Rhino for more than 30 days, add a fuel stabilizer to prevent ethanol damage and gumming.

Keep the tank full. A full fuel tank reduces condensation and helps keep the pump submerged in fuel, which cools it and prevents overheating. Running the tank low frequently can cause the pump to overheat and wear out faster.

Replace the fuel filter regularly. A clogged fuel filter puts extra strain on the pump. Check your owner’s manual for the recommended replacement interval, or replace it every season.

Avoid ethanol-heavy fuel. If possible, use ethanol-free gasoline. If you must use ethanol-blended fuel, keep it at E10 or lower. Pumps that are not designed for high ethanol content will fail prematurely .

Inspect electrical connections. Corroded or loose connectors can cause voltage drops that damage the pump. Clean and tighten all connections periodically.

Final Thoughts

The fuel pump on your 2006 Yamaha Rhino 660 is a critical component that can fail without warning, leaving you stranded on the trail. Recognizing the symptoms early—hard starting, sputtering, stalling, or a whining noise—can save you from a breakdown. Testing the pump is simple, and replacement is a manageable DIY project for most owners.

For the best combination of reliability, performance, and peace of mind, choose a KEMSO fuel pump. With its high-performance flow, OEM-grade fit, and lifetime warranty, it’s a smart investment for your Rhino 660. Don’t settle for a cheap generic pump that may not last. Trust KEMSO to keep your fuel system running strong.

For more information and to order the right pump for your 2006 Yamaha Rhino 660, visit: https://www.kemsoracing.com/