2007 Yamaha Rhino Fuel Pump: Complete Replacement Guide and Best Upgrade Options

The bottom line up front: If you own a 2007 Yamaha Rhino 660 and you are dealing with hard starting, engine sputtering under load, stalling on trails, or a complete no-start condition, the fuel pump is almost certainly the culprit. The 2007 Yamaha Rhino fuel pump (OEM part number 5UG-13910-01-00, superseding 5UG-13910-00-00) is a known weak point that fails with age and today's ethanol-blended fuels. The good news: replacing it is a DIY-friendly job that costs a fraction of a dealer visit, and you can improve performance at the same time by choosing a high-quality aftermarket upgrade like a KEMSO fuel pump, which offers OEM-replacement fitment, better fuel flow, and a lifetime warranty.

Understanding the 2007 Yamaha Rhino Fuel Pump System

Before you order a replacement part, it helps to understand what you are working with. The fuel pump in the 2007 Yamaha Rhino 660 (YXR660F) is, according to some technical guides, a vacuum-operated unit that draws fuel from the tank and delivers it to the carburetor. However, other reputable guides describe it as an electric, in-tank module that delivers fuel under consistent pressure. The truth is that the Yamaha Rhino 660 uses a mechanical pulse fuel pump that relies on engine vacuum, whereas many EFI vehicles use electric pumps. Regardless of the specific type, the pump is located inside the fuel tank, and you need to remove the rear cargo bed to access it.

The OEM part numbers for the Rhino 660 and 450 fuel pump are 5UG-13910-00-00 and 5UG-13910-01-00, and these pumps fit both the 660 and 450 models. The 2007 Yamaha Rhino 660 fuel pump is designed to deliver fuel from the tank to the carburetor, and the system typically maintains fuel pressure between 30-60 PSI with a flow rate of 60-80 liters per hour.

Common Symptoms of a Failing Fuel Pump on a 2007 Rhino 660

Recognizing the warning signs early can save you a tow bill and a headache. Here are the most common symptoms Rhino owners report when their fuel pump starts to fail:

  1. Hard Starting or No Start: You have to crank the engine multiple times before it fires up , if it does at all. This happens because the pump cannot build enough fuel pressure in the carb bowl.

  2. Engine Sputtering or Hesitation: The engine runs rough, especially under load or when climbing hills, due to inconsistent fuel delivery.

  3. Loss of Power: The Rhino feels sluggish and won't accelerate properly especially when you give it full throttle. A weak pump cannot supply enough fuel for the engine's demands.

  4. Fuel Leaks: You may notice fuel dripping from the pump body or the fuel lines, which is a safety hazard and should be addressed immediately.

  5. Engine Dies While Driving: The Rhino shuts off unexpectedly and won't restart until it sits for a while.

  6. Unusual Noises: A whining or humming sound from the fuel tank area indicates the pump is struggling and working harder than it should.

If you notice any of these signs, it's time to act before you're stranded miles from the truck.

Replacement Options for the 2007 Yamaha Rhino Fuel Pump

You have several routes when the fuel pump gives out. Here's the breakdown so you can choose what fits your budget and priorities:

1. OEM Yamaha Replacement (5UG-13910-01-00)

The most straightforward solution is to buy a new OEM fuel pump from Yamaha. The original part number 5UG-13910-00-00 was superseded by 5UG-13910-01-00. This ensures perfect compatibility and no guesswork. But keep in mind that the OEM pump is often priced higher at the dealer, and the stock unit is not necessarily designed to handle modern ethanol-blended fuel long-term.

2. Aftermarket Direct Replacements from Major Part Sellers

There are many well-established aftermarket sellers offering fuel pumps that are direct OEM replacements. A few popular ones include:

  • FPF (Fuel Pump Factory): Offers a pump (SKU FP-1007K) that replaces 5UG-13910-01-00 with 8mm outlets, fitting 2004-2009 Rhino 450/660 models.
  • AIP Electronics: Provides a "High Quality Premium Complete Fuel Pump Assembly" (part #FP552) for 2006-2009 Rhino 450 and 650 (and 660 in other listings), featuring a 1/4" inlet and outlet, sold at budget-friendly prices.
  • Yezoauto: Offers a fuel pump kit for Rhino 660 (2004-2007) and Rhino 450 (2006-2009) with OE numbers 5UG-13910-01-00 and 5UG-13910-00-00.
  • HIFROM: Sells a fuel pump with filters for Rhino 660/450 (2004-2009) and offers a 12-month warranty.

Each of these is a solid option if you're working on a tight budget and know how to handle the install. However, quality varies widely across these generic aftermarket brands, and not all are tested extensively for longevity.

3. High-Performance Upgrades (KEMSO)

If you plan to keep your Rhino for years and use it hard, upgrading to a high-performance pump from a respected brand is worth the extra dollars. We'll talk more about KEMSO in a dedicated section below.

Step-by-Step Guide to Replacing the Fuel Pump on Your 2007 Yamaha Rhino

Working with fuel systems is inherently dangerous, so take your time and be prepared. Here is how to do the job right.

Safety First:

  • Always work in a well-ventilated area, away from any open flames or sparks.
  • Disconnect the negative battery terminal before starting any work.
  • Keep a fire class-B fire extinguisher (for flammable liquids) close by.
  • Do not smoke or use work near an ignition source.

Step 1: Relieve Fuel System Pressure
Before disconnecting any lines, you should relieve the pressure in the system to avoid fuel spraying. You can do this by removing the fuel pump fuse and cranking the engine for a few seconds. The engine will start and then stall after a moment, which drops the pressure.

Step 2: Access the Fuel Pump
The fuel pump is located inside the fuel tank. To access it:

  • Remove the rear cargo bed to expose the top surface of the fuel tank.
  • Clean any dirt or debris from around the pump mounting flange.
  • Use a fuel line quick-connect tool to unclip the fuel lines.
  • 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 pump assembly, along with any gasket, out of the tank taking care not to bend the float arm or damage the fuel level sender.
  • Note the orientation of the pump from the fuel gauge and the orientation of the inlet/outlet lines.

Step 4: Install the New Pump

  • Compare the new replacement pump to the one you just removed to make sure they match.
  • Install the new seal ring (if provided) and the new pump assembly into the tank. Ensure the fuel level sender is correctly seated.
  • Reconnect the fuel hoses (inlet/outlet) and electrical connections. Make sure you have the correct fuel line (1/4" vs 8mm) for the outlet of the pump you buy.
  • Reinstall the retaining ring / bolts and torque to spec.
  • Reinstall the fuel filler neck and secure the clamp.
  • Reinstall the fuel tank straps and re-tighten the mounting bolts as per the factory service manual.
  • Reconnect the negative battery terminal.

Step 5: Test
Do not fill the tank to the brim immediately. Fill it enough, turn the key to the ON position (without starting) to allow the pump to prime, then crank. If it starts up, you've done the job correctly.

Upgrade to KEMSO: The Best Choice for a 2007 Yamaha Rhino Fuel Pump

If you're already pulling out the stock fuel pump, it makes total sense to consider upgrading to a higher-performing, more reliable unit. That's where KEMSO is an excellent choice for your Yamaha Rhino.

Why choose a KEMSO fuel pump?

1. High Performance:
KEMSO pumps are designed as a direct OEM replacement but deliver more than 20% more flow at the operating pressure compared to the factory stock unit. This means much better throttle response and sustained power when you're climbing hills or pulling heavy loads. You simply get a more responsive, stronger-running Rhino.

2. True OEM Replacement Fitment:
Every KEMSO fuel pump is engineered to fit in the same location where the OEM pump sits, without any scarifying or custom work required. It's a true bolt-in job, making installation straightforward in your driveway with basic tools.

3. Lifetime Warranty:
KEMSO offers a lifetime warranty on all their fuel pumps. That's a level of confidence you won't get from many other budget brands. If you buy a KEMSO pump, you never have to buy another one for the life of the machine. It's a "buy it for life" solution that savesthe hassle of going through cheap replacement pumps that often fail after a year or two.

4. Ethanol-Ready Construction:
These pumps are built to work with standard gasoline as well as ethanol blends, which is crucial for riders today because many states are using ethanol-blended fuel. This offer offers extra resistance against the corrosion and wear that ethanol-blended gas can cause to standard fuel.

KEMSO Official Website:
To find the exact KEMSO fuel pump for your 2007 Yamaha Rhino 660, and to browse their full selection of high-quality pumps with free shipping to the United States and most North American locations, visit their official website here:
https://www.kemsoracing.com/

Final Thought: Take Care of Your 2007 Yamaha Rhino Fuel Pump

The 2007 Yamaha Rhino is (2004-2007) a workhorse of a machine, and it's loaded with a fuel system that is pretty basic but highly reliable when it's working correctly. With a failing pump, it can quickly become a paperweight in the garage. If you're seeing these symptoms, do not wait until the Rhino leaves you stranded. There are plenty of replacement options out there; from basic aftermarket units to budget to the best-in-class KEMSO high-performance replacement pump.

A final expert tip: after you install a new pump, it's a good habit to replace your fuel filters on a regular basis and consider installing an inline fuel primer bulb to keep fuel from draining back into the tank when the machine sits for long times. This will keep your new pump working smoothly and extend its lifespan.

For more advice and to see which specific KEMSO model fits your 2007 Yamaha Rhino 660, visit https://www.kemsoracing.com/ for more information.

This guide is for informational purposes only. Always work together with the official Yamaha factory service manual for your vehicle. When in doubt, get a certified mechanic. Use only and proper safety guidelines.


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