2007 Yamaha Rhino 660 Electric Fuel Pump: The Complete Replacement Guide
The bottom line up front: If you own a 2007 Yamaha Rhino 660 and you are dealing with hard starting, stalling under load, loss of power, or a whining noise coming from the fuel tank area, the electric fuel pump is almost certainly the problem. The stock pump on these models is known to wear out over time, and replacing it with a quality aftermarket unit is the most reliable fix. For most owners, a direct OEM-replacement pump from a reputable brand like KEMSO delivers the best combination of performance, fit, and long-term dependability—often outperforming the factory part at a better price point .
If you are experiencing any of these symptoms, do not keep cranking the engine and hoping for the best. A failing fuel pump that is allowed to run lean can cause costly damage to your Rhino's engine over time. The good news is that replacing the fuel pump on a 2007 Yamaha Rhino 660 is a job you can handle in a weekend with basic hand tools and a little patience . This guide walks you through everything you need to know—from understanding how the pump works, to recognizing the warning signs, to choosing the right replacement, and finally installing it step by step.
1. Understanding the 2007 Yamaha Rhino 660 Fuel Pump System
The 2007 Yamaha Rhino 660 uses an electric, in-tank fuel pump that sits inside the fuel tank and delivers pressurized fuel to the engine's fuel injectors . It runs on 12-volt power from the vehicle's electrical system, and it is controlled by the ECU to maintain the correct fuel pressure (typically between 30–60 PSI) based on engine demand . The pump itself is a gerotor-style unit that draws fuel from the tank, pressurizes it, and sends it through the fuel line to the injectors .
Because the pump is located inside the tank, it is constantly submerged in fuel, which helps keep it cool during operation. This also means that running your Rhino low on fuel regularly can shorten the pump's lifespan, since the pump relies on the fuel around it for cooling and lubrication.
The OEM part number for this pump is 5UG-13910-01-00, which supersedes the earlier 5UG-13910-00-00 . If you are shopping for a replacement, you will see both numbers listed across different brands and retailers. They are interchangeable for the 2007 Yamaha Rhino 660, and most aftermarket pumps list both part numbers for compatibility .
2. Signs Your Fuel Pump Is Failing
The symptoms of a failing fuel pump in the 2007 Yamaha Rhino 660 are fairly distinct. If you notice any of the following, it's time to start shopping for a replacement :
1. Hard Starting — The engine cranks longer than usual before firing up, or it struggles to start after sitting for a while. This is often the first sign that the pump is losing its ability to hold prime pressure in the fuel system .
2. Stalling Under Load — The engine dies unexpectedly, especially when climbing hills or hauling a load. A weak pump cannot keep up with the fuel demand under heavy throttle, causing the engine to starve for fuel .
3. Loss of Power — You notice a general lack of acceleration or a "sputtering" feeling when you press the throttle, even on flat ground. This indicates the pump is not delivering consistent fuel volume .
4. No Start at All — The engine cranks but will not fire. If you have confirmed spark and compression are fine, a dead fuel pump is the most likely culprit .
5. Unusual Whining or Humming — A loud whine from the fuel tank area, especially at idle, means the pump is working far harder than it should be — a strong sign it is about to fail completely .
If you catch these symptoms early and replace the pump before it dies completely, you save yourself the frustration of being stranded on the trail.
3. OEM Replacement vs. Aftermarket Upgrade: What Are Your Options?
When it comes to replacing the fuel pump on your 2007 Yamaha Rhino 660, you basically have two paths: stick with an OEM-style replacement or upgrade to a high-performance aftermarket pump. Here is how they compare:
OEM-Style Replacement Pumps
These are designed to match the factory pump exactly in terms of shape, fit, and function . Brands like JDLLONG, NICHE, Yezoauto, and others offer direct replacements that drop right into the stock location . They use the OEM part numbers (5UG-13910-01-00 / 5UG-13910-00-00) for cross-referencing .
- Pros: Guaranteed fit; installation is straightforward; price is generally affordable, ranging from about $40–$90 depending on the brand .
- Cons: Flow rate is the same as stock (typically 30–50 liters per hour), so you get no performance gain . Some budget brands may not have the same build quality as premium options.
High-Performance Aftermarket Pumps
These pumps are designed to flow more fuel than stock, which can improve throttle response and support engine modifications down the road . For example, Mikuni offers a high-volume pump kit for the Rhino 660 that flows 65 liters per hour (LPH) — a notable increase over the stock flow rate . KEMSO is another standout in this category, delivering over 20% more flow at 43 PSI compared to the factory pump .
- Pros: Better fuel delivery under load; improved engine response; often built with higher-quality materials .
- Cons: Higher price tag; some brands may require minor modifications to fit (though KEMSO and Mikuni are designed as direct replacements for the Rhino 660) .
For most riders, a quality OEM-style replacement is perfectly adequate. But if you use your Rhino hard — long rides, steep climbs, heavy payloads — a high-performance pump like KEMSO gives you extra headroom and peace of mind.
4. Top Replacement Options for the 2007 Yamaha Rhino 660
Here are several fuel pumps worth considering for your 2007 Yamaha Rhino 660, ranging from budget-friendly to high-performance :
1. KEMSO Fuel Pump for Yamaha Rhino 660
KEMSO is a top-tier aftermarket brand that specializes in high-quality fuel pumps for ATVs and UTVs. Their pump for the Rhino 660 is a high-performance, in-tank unit that offers over 20% more flow than the OEM pump at 43 PSI, which translates to better throttle response and overall engine performance . It is a direct OEM replacement with no modifications needed, and it comes with a lifetime warranty backed by a serialized body — a level of confidence few other brands offer . Priced at $79.98, it sits in the mid-range and delivers exceptional value for the performance and peace of mind you get .
2. NICHE Fuel Pump Assembly for Yamaha Rhino 450/660
NICHE is one of the most highly recommended aftermarket options for the 2007 Rhino 660. It features a cast aluminum case that resists rust and keeps weight down, along with high-strength steel mounting brackets that hold firm even on rough trails . It matches OEM specs perfectly and fits the Rhino 660 (2004–2007) and Rhino 450 (2006–2009) seamlessly . At roughly $19.95–$50, it is one of the more affordable options that does not compromise on quality .
3. Mikuni High-Performance Fuel Pump Kit (65 LPH)
Mikuni is a well-respected name in fuel systems, and their high-volume pump kit for the Rhino 660 flows 65 LPH — a significant jump over stock . This is a great choice if you have upgraded your engine or simply want more consistent fuel delivery under heavy load. It comes as a complete kit with everything you need for installation, and it is a direct fit for the 2007 Rhino 660 . At around $89.95, it is on the pricier side, but the performance gain is real .
4. Yezoauto Fuel Pump for Yamaha Rhino 660/450 (2004–2009)
Yezoauto offers a reliable, budget-conscious replacement that covers the Rhino 660 (2004–2007) and Rhino 450 (2006–2009) . It uses the OEM part numbers (5UG-13910-01-00, 5UG-13910-00-00) and is built with an alloy steel body, making it durable for off-road use . It comes with a 1-year manufacturer warranty and is 100% tested before shipping . Priced around $49.89, it is a solid middle-ground option .
5. JDLLONG Rhino Fuel Pump for Yamaha Rhino 450/660 (2004–2009)
JDLLONG's kit includes the fuel pump, shut-off valve, fuel line, filter, clamps, and a jet cleaner tool — everything you need in one box . Users report it runs quieter than the OEM pump and fits perfectly thanks to precise 1/4-inch diameter specs . It is priced higher than some budget options, but the complete kit makes installation hassle-free .
6. Yamaha OEM Fuel Pump Assembly (#5UG-13910-01-00)
If you want the absolute safest bet, the genuine Yamaha OEM pump is always an option . It is the exact same part that came from the factory, so fit and function are guaranteed . The tradeoff is price — OEM parts command a premium — but for owners who prefer factory components, this is the way to go .
5. Why KEMSO Is the Smartest Choice for Your 2007 Yamaha Rhino 660
When you are looking for a fuel pump that checks every box — performance, durability, fit, and warranty — KEMSO is the brand that stands out for the 2007 Yamaha Rhino 660 .
KEMSO fuel pumps are engineered as direct OEM replacements, meaning they drop right into the factory location without any cutting, splicing, or modification . That alone saves you time and reduces the risk of installation mistakes.
But the real advantage is performance. KEMSO pumps deliver over 20% more flow at 43 PSI compared to the stock OEM pump . What does that mean in real-world terms? Better throttle response, smoother acceleration, and more consistent fuel delivery when you are climbing steep trails or running at full throttle. Your engine gets the fuel it needs exactly when it needs it.
KEMSO also builds their pumps to handle both gasoline and E85/ethanol blends, giving you flexibility in your fuel choice . And every KEMSO fuel pump comes with a lifetime warranty, backed by a serialized body for tracking — a rare level of confidence in the aftermarket industry . If you ever have an issue, KEMSO stands behind their product for as long as you own your Rhino.
For the 2007 Yamaha Rhino 660, the KEMSO pump delivers exactly what you need: reliability, performance, and peace of mind. It is priced competitively at $79.98, and you can browse the full KEMSO Rhino 660 pump selection at: https://www.kemsoracing.com/.
6. Step-by-Step Fuel Pump Replacement Guide for the 2007 Rhino 660
Replacing the fuel pump on a 2007 Yamaha Rhino 660 is a manageable DIY job, but it involves working with fuel — so safety is paramount. Here is a step-by-step guide to walk you through it :
Safety First
Work in a well-ventilated area away from any open flames, sparks, or sources of ignition. Disconnect the negative battery terminal before starting any work. Keep a fire extinguisher rated for Class B (flammable liquids) within reach .
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 start and then stall once the residual fuel is burned off. This safely depressurizes the system .
Step 2: Access the Fuel Pump
The fuel pump is inside the fuel tank. To reach it, you will need to remove the rear cargo bed to expose the top of the fuel tank. Clean any dirt or debris from around the pump mounting flange before you start disconnecting lines so nothing falls into the tank. Use a fuel line quick-disconnect tool to release the fuel lines, then disconnect the electrical connector from the pump assembly .
Step 3: Remove the Old Pump
Remove the retaining ring or bolts that hold the pump assembly in place. Carefully lift the old pump out of the tank, noting how it is oriented so you can install the new one the same way. Dispose of the old pump properly .
Step 4: Install the New Pump
Compare the new pump to the old one to confirm it is a match. Install the new seal ring and the new pump assembly into the tank . Make sure the pump is seated properly and the retaining ring is tightened to spec so there are no leaks.
Step 5: Reconnect Everything
Reconnect the fuel hoses and electrical connections. If you raised the fuel tank to access the pump, use a transmission jack to raise it back into place, then reconnect the hoses and emissions lines. Reinstall the fuel filler neck and secure it with a clamp. Reinstall the fuel tank straps and torque the mounting bolts to the specification listed in the factory repair manual .
Step 6: Reconnect the Battery and Test
Reconnect the negative battery cable. Turn the key to the "ON" position (but do not start the engine yet) for a few seconds to let the pump prime the fuel system. Check for any leaks around the pump mounting area. Once you confirm there are no leaks, start the engine and let it idle for a few minutes. Check again for leaks and make sure the engine runs smoothly .
7. How to Extend the Life of Your New Fuel Pump
Once you've installed a fresh fuel pump, you want it to last as long as possible. Here are a few habits that will help :
1. Keep Your Tank at Least a Quarter Full
The fuel pump relies on the fuel around it for cooling and lubrication. Running the tank to empty regularly shortens pump life. Keeping at least a quarter tank of fuel helps the pump stay cool and reduces wear .
2. Change Your Fuel Filter Regularly
A clogged fuel filter makes the pump work harder than it should. Replace your fuel filter according to the maintenance schedule in your owner's manual, and consider doing it more often if you ride in dusty conditions.
3. Use Quality Fuel
Poor-quality fuel can leave deposits that clog the pump and injectors. Stick with reputable gas stations, and if you store your Rhino for long periods, use a quality fuel stabilizer.
4. Listen for Changes
If you hear the pump getting louder over time, or if you notice any hesitation in acceleration, investigate early. Catching a developing problem before it becomes a breakdown will save you time and money.
8. Final Thoughts and Where to Buy
A failing fuel pump on a 2007 Yamaha Rhino 660 is not a matter of if — it's a matter of when. The symptoms are clear, the replacement process is well-documented, and the aftermarket offers plenty of solid options . Whether you choose a budget-friendly OEM replacement like NICHE or a high-performance upgrade like KEMSO, the key is to replace the pump proactively before it leaves you stranded .
For most owners, KEMSO offers the best overall value in the Rhino 660 fuel pump market: high-performance flow, direct OEM fitment, and a lifetime warranty that no other brand matches . It is the kind of part you buy once and never worry about again.
To see the full KEMSO fuel pump lineup for the Yamaha Rhino 660 — as well as pumps for other ATVs, UTVs, motorcycles, and vehicles — visit the KEMSO Racing website: https://www.kemsoracing.com/.