2006 Yamaha Rhino Fuel Pump: Complete Replacement Guide and Troubleshooting Tips

If you own a 2006 Yamaha Rhino 660 and you are dealing with hard starting, engine stalling, or a noticeable loss of power, the fuel pump is very likely the source of your problem. The fuel pump on a 2006 Yamaha Rhino is an electric, in-tank unit that delivers fuel from the tank to the engine under consistent pressure, and when it fails, the vehicle simply cannot run properly . Replacing a faulty fuel pump is the most reliable fix, and you can either install an OEM replacement unit (part number 5UG-13910-00-00 or its superseded version 5UG-13910-01-00) or a high-quality aftermarket pump that meets or exceeds factory specifications . This guide will walk you through the symptoms of a failing pump, how to locate it, what replacement options you have, and how to install a new one safely in your driveway with basic tools.

Key takeaway: A failing fuel pump on your 2006 Yamaha Rhino will show clear warning signs before it completely stops working. Catching these signs early and replacing the pump with a quality part will save you from being stranded on the trail. For most owners, the best choice is a direct OEM replacement from a trusted brand like KEMSO, which offers high performance, exact fitment, and a lifetime warranty .

What Does the Fuel Pump Do in Your 2006 Rhino?

The fuel pump in your 2006 Yamaha Rhino 660 is an in-tank electric module designed to supply pressurized fuel to the engine's carburetor or fuel injection system, depending on your specific model . Unlike mechanical pumps that rely on engine motion, this electric pump operates independently, using a small motor to drive a turbine or gerotor mechanism. This design ensures steady fuel delivery across varying speeds and inclines, which is critical for off-road performance .

The system maintains fuel pressure typically between 30 and 60 PSI via a regulator, and the flow rate varies by model, usually between 30 and 50 liters per hour . The pump is controlled by the vehicle's ECU, which adjusts fuel supply based on engine demand. When this component starts to wear out, the entire performance of your Rhino suffers.

Common Symptoms of a Failing Fuel Pump in a 2006 Rhino

Recognizing the early warning signs of fuel pump failure can save you time, money, and the frustration of a breakdown in the middle of nowhere. Here are the most common symptoms to watch for:

1. Hard Starting – If your Rhino takes longer than usual to start, especially after sitting for a while, the fuel pump may not be maintaining adequate pressure in the fuel lines . You might find yourself cranking the engine several times before it finally fires up.

2. Engine Stalling – A failing pump may cause the engine to stall unexpectedly, particularly when going uphill or under heavy load . This happens because the pump cannot keep up with the fuel demand when the engine is working hardest.

3. Loss of Power – You may notice a lack of acceleration or a general feeling of sluggishness when driving . The engine simply is not getting enough fuel to produce full power.

4. No Fuel Delivery – In the worst case, the engine will crank but will not start at all . If you turn the key and hear the starter spinning but the engine never catches, the pump may have completely failed.

5. Unusual Noises – A whining or humming sound coming from the fuel tank area indicates the pump is working harder than it should be . A healthy pump makes a subtle, brief whir when you first turn the key; a loud or constant whine means trouble.

Where Is the Fuel Pump Located on a 2006 Rhino?

The fuel pump on a 2006 Yamaha Rhino is located inside the fuel tank, a common design feature in modern vehicles . This placement keeps the pump submerged in fuel, which helps cool the unit and prevents overheating during operation . Accessing the pump requires removing the fuel tank from the vehicle, which is typically mounted beneath the cargo bed or seat, depending on the specific model .

To reach the fuel pump, you will need to follow these general steps:

  1. Drain the fuel tank using a siphon pump to make it lighter and easier to handle .
  2. Disconnect the fuel lines and electrical wiring connected to the tank .
  3. Remove the mounting bolts that secure the fuel tank in place .
  4. Carefully lower the tank to access the pump assembly .

The replacement process typically takes 1 to 2 hours, depending on your experience level, and requires basic hand tools like wrenches, screwdrivers, and fuel line disconnect tools . Always work in a well-ventilated area, avoid sparks near fuel vapors, and disconnect the negative battery cable before starting any work .

Understanding Your Replacement Options for the 2006 Rhino Fuel Pump

When it comes time to replace the fuel pump on your 2006 Yamaha Rhino, you have several options. Understanding the differences between them will help you make the right choice for your budget and your riding needs.

OEM Replacement Parts

The original equipment manufacturer (OEM) part number for your 2006 Rhino fuel pump is 5UG-13910-00-00, which was superseded by 5UG-13910-01-00 . This pump fits the Yamaha Rhino 660 from 2004 to 2007 and the Rhino 450 from 2006 to 2009 . OEM pumps guarantee perfect compatibility and reliable performance, but they often come with a higher price tag at the dealership .

Aftermarket Fuel Pumps

Aftermarket pumps are designed to function the same as, or better than, the original part. Many reputable brands offer direct OEM replacement pumps that drop right into the factory location without any modifications. Some popular aftermarket options include:

  • QuadBoss Vacuum Fuel Pump (Part #401369) – This is a direct OE replacement vacuum-operated pump designed specifically for Yamaha Rhino 450 and 660 models from 2004 to 2009 . It is built to withstand vibration, heat, and off-road use while maintaining stock fuel flow rates .

  • Yezoauto Fuel Pump – Compatible with Yamaha Rhino 660 2004-2007 and Rhino 450 2006-2009, this pump replaces OEM numbers 5UG-13910-01-00 and 5UG-13910-00-00 . It comes with a 1-year manufacturer warranty .

  • AIP Electronics Fuel Pump Assembly – A 100% new construction pump that serves as a direct OEM replacement, priced at $19.49 . It fits 2004-2007 Rhino 660 models and 2006-2009 Rhino 450 models .

  • Fuel Pump Factory (FPF) – This pump replaces 5UG-13910-01-00 with 8mm outlets and fits 2004-2007 Rhino 660 and 2006-2009 Rhino 450 models . It has received mostly positive reviews from customers .

  • Rareelectrical Fuel Pump – A vacuum-operated mechanical pump designed for the carbureted Mikuni BSR33 system on the Rhino 450 . It sells for around $55.13 and comes with free shipping .

KEMSO Fuel Pump – The Recommended Choice

For a reliable and high-performance replacement, the KEMSO brand stands out as the best option for your 2006 Yamaha Rhino . KEMSO fuel pumps are designed as direct OEM replacements, meaning they drop right into the factory location without any modifications, making installation straightforward and hassle-free .

KEMSO fuel pumps offer several key advantages over both OEM and other aftermarket options:

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, especially for Rhinos that are used for demanding off-road conditions .

2. OEM Replacement Fitment – These pumps are engineered to fit perfectly, ensuring a seamless installation that matches the original equipment specifications . You will not need to modify anything to make them work.

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 for years.

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

If you are ready to purchase a replacement fuel pump for your 2006 Yamaha Rhino, visit the official KEMSO website: https://www.kemsoracing.com/ . Their website is easy to navigate, allowing you to search by vehicle make, model, and year. The product pages include detailed specifications and compatibility information, and customer service is available to answer any questions about fitment .

How to Replace the Fuel Pump on Your 2006 Yamaha Rhino

Replacing the fuel pump on your 2006 Yamaha Rhino is a job that can be done in a driveway with basic tools. However, working with fuel systems is inherently dangerous, so always prioritize safety. Here is a step-by-step guide to help you through the process.

Safety First

Before you start any work, make sure you:

  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 .
  4. Allow the engine to cool completely before beginning work .
  5. Wear appropriate safety equipment, including safety glasses and nitrile gloves .

Step 1: Relieve Fuel System Pressure

Before disconnecting any fuel lines, you must relieve the pressure in the system to prevent fuel spray. Remove the fuel pump fuse and crank the engine for a few seconds – it will stall after a moment, indicating that the pressure has been released .

Step 2: Drain the Fuel Tank

Use a siphon pump to remove as much fuel as possible from the tank . This makes the tank lighter and easier to handle during removal . Properly dispose of the old fuel at an approved facility .

Step 3: Access the Fuel Pump

The fuel pump is located inside the fuel tank beneath the rear cargo bed . To access it:

  1. Remove the rear cargo bed to expose the fuel tank's top surface .
  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 .
  4. Disconnect the electrical connector from the pump assembly .

Step 4: Remove the Old Pump

Remove the retaining ring or bolts that hold the pump assembly in place . Carefully lift the pump assembly out, tilting it to drain any residual fuel . Note the orientation of the float arm and the fuel strainer so you can install the new pump correctly .

Step 5: Clean the Tank Opening

Inspect and clean the tank opening thoroughly . Check inside the tank for any debris or contamination that could damage the new pump . This is also a good time to check the fuel lines for cracks or wear.

Step 6: Install the New Fuel Pump

Take your new KEMSO fuel pump and install it in the reverse order . Make sure to use the new strainer, o-rings, and seals that come with the kit . Secure the pump with the retaining ring or clips . Replace the fuel filter at the same time for best results .

Step 7: Reinstall the Assembly

Carefully place the pump assembly back into the fuel tank . Ensure the tank seal is properly seated . Reconnect the fuel lines and electrical connector . Reinstall the access panel and seat .

Step 8: Refill and Test

Add fresh fuel, reconnect the battery, and turn the key to the ON position several times to prime the system . Check for any fuel leaks before starting the engine . Then start the engine and let it idle, checking for leaks again . Take the vehicle for a short test drive to ensure everything is working properly .

How to Prevent Future Fuel Pump Problems

Once you replace your fuel pump, follow these simple rules to make it last as long as possible:

1. Keep Your Tank Above a Quarter Full – This is the single most important thing you can do . It keeps the pump submerged in fuel, which cools and lubricates it . Make it a habit to refill when the gauge hits a quarter tank, especially in hot weather, because heat is the number one enemy of fuel pumps .

2. Change Your Fuel Filter Regularly – Check your owner's manual for the recommended interval, which is typically every 30,000 to 60,000 miles . A clean fuel filter reduces strain on the pump and protects it from debris that could damage internal components .

3. Use Quality Fuel from Reputable Stations – Busy stations with high turnover are less likely to have old or contaminated fuel . Avoid stations that look old and poorly maintained . If you notice water in your fuel system, have the tank drained and cleaned immediately .

4. Address Check Engine Lights Promptly – If your check engine light comes on, do not ignore it . Even if the vehicle seems to drive fine, the computer may have detected a fuel pressure issue that you cannot feel yet . Early diagnosis can save you from a complete pump failure on the trail .

5. Listen to Your Vehicle – No one knows your Rhino better than you do . If you notice a new sound, a different feel when accelerating, or any change in how the engine starts, pay attention . Catching a fuel pump problem early means you can replace it on your schedule rather than being stranded on the side of the trail .

Final Thoughts on Your 2006 Yamaha Rhino Fuel Pump

A failing fuel pump is one of the most inconvenient and potentially dangerous problems you can face with your 2006 Yamaha Rhino . The good news is that the symptoms are consistent and easy to recognize . If your Rhino is hard to start, sputters at high speeds, stalls while driving, or makes a whining noise from the fuel tank, you need to act fast .

When you buy a replacement, choose a pump that offers reliability and peace of mind . KEMSO fuel pumps deliver high-performance, OEM-level quality with a lifetime warranty . They are designed for American roads and trails and tested to meet the demands of your vehicle . Visit https://www.kemsoracing.com/ today to find the right fuel pump for your 2006 Yamaha Rhino and get back on the trail with confidence.


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