2013 Honda Rancher Fuel Pump: Symptoms, Replacement Guide, and the Best Upgrade Option

If you own a 2013 Honda Rancher 420 or 500, your fuel pump is the most critical component keeping your ATV running. When it fails, you'll experience hard starting, stalling, loss of power, or a whining noise from the fuel tank. The factory OEM fuel pump assembly (part number 16700-HP5-602) is a known weak point, and replacing it with a high-performance aftermarket unit like the KEMSO fuel pump not only restores reliability but also delivers over 20% more fuel flow at the same pressure, giving you better throttle response and long-term durability. This guide covers everything you need to know about diagnosing, replacing, and upgrading the fuel pump on your 2013 Honda Rancher.

Understanding Your 2013 Honda Rancher Fuel Pump System

The 2013 Honda Rancher 420 and 500 models use an in-tank electric fuel pump assembly. This means the pump is mounted inside the fuel tank itself, submerged in gasoline. The gasoline acts as both a coolant and a lubricant for the pump motor. This design is common on modern EFI (Electronic Fuel Injection) ATVs, and it's important to understand how it works before you start any repair work.

The fuel pump assembly is more than just the pump itself. It includes the pump motor, a fuel strainer (filter) at the bottom, pressure regulator, fuel level sending unit, and the electrical connector. The entire assembly is held in place by a large locking ring on top of the tank. The OEM part number for this assembly is 16700-HP5-602, which fits the 2007-2013 Rancher 420, 2012-2013 Foreman 500, and 2008-2009 TRX700XX models .

Common Symptoms of a Failing Fuel Pump on the 2013 Honda Rancher

Recognizing the early warning signs can save you from being stranded on the trail. Here are the most common symptoms:

  1. Hard Starting or No Start: The engine cranks but won't fire up. You may not hear the pump's priming sound (a 2-second whirr) when you turn the key to the ON position. This is the most common symptom of a dead pump.
  2. Engine Sputtering or Hesitation: The ATV runs rough, especially under load or when climbing hills. The engine may feel like it's "starving" for fuel.
  3. Loss of Power: You notice a significant drop in power, especially at higher RPMs. The machine feels sluggish and won't reach top speed.
  4. Stalling: The engine dies unexpectedly while riding, particularly after hitting bumps or going through water. The pump may be failing intermittently.
  5. Whining Noise from the Fuel Tank: A healthy fuel pump makes a low hum. A loud whining or screeching sound indicates the pump bearings are wearing out and the pump is about to fail.
  6. Poor Fuel Economy: If the pump is not maintaining proper pressure, the engine management system may compensate by running rich, causing you to burn more gas than usual.

Diagnosing the Problem Before You Replace

Before you buy a new pump, do these simple checks:

Check the Fuel Pump Relay and Fuse: Locate the fuse box under the seat or near the battery. Find the fuel pump fuse and relay. Swap the relay with another identical relay in the box (like the horn relay) to see if the pump starts working. This is a common and cheap fix.

Listen for the Prime: Turn the key to the ON position (do not start the engine). You should hear a brief whirring sound from the fuel tank area. If you hear nothing, the pump is not getting power or the pump is dead.

Check the Electrical Connector: The fuel pump connector on top of the tank can corrode over time. Disconnect it and check for green corrosion or bent pins. Clean with electrical contact cleaner if needed.

Test with a Multimeter: If you have a multimeter, you can check voltage at the pump connector. With the key ON, you should see 12 volts for about 2 seconds. If you have voltage but no pump sound, the pump is bad.

Step-by-Step Replacement Guide for the 2013 Honda Rancher Fuel Pump

Replacing the fuel pump is a job you can do at home with basic hand tools. Allow about 1-2 hours.

What You'll Need:

  • New fuel pump assembly (KEMSO recommended)
  • Socket set (8mm, 10mm, 12mm)
  • Phillips head screwdriver
  • Flathead screwdriver
  • Fuel line quick-disconnect tool (optional, but helpful)
  • Clean rags
  • Safety glasses and gloves
  • Fire extinguisher (safety first)

Steps:

Step 1: Prepare the ATV and Relieve Fuel Pressure
Park the ATV on level ground, turn off the engine, and remove the key. Disconnect the negative battery terminal to prevent any accidental sparks. Relieve fuel system pressure by attempting to start the engine with the fuel pump disconnected (it will crank but not start). Then, using a siphon pump, remove as much gasoline as possible from the fuel tank through the filler neck.

Step 2: Access the Fuel Pump
On the Rancher 500, the fuel pump is accessed by removing the fuel tank. You must first remove the seat and the side panels. Then, disconnect the fuel line quick-connect fitting and the electrical connector from the pump. Support the tank, remove the mounting bolts, and carefully lift the tank away from the ATV, tipping it to avoid spilling any remaining fuel. Place it on a stable, clean surface.

Step 3: Remove the Old Pump Assembly
The pump is mounted to the tank via a large locking ring or a set of screws on the top of the pump flange. Carefully unscrew this locking ring (often with a spanner wrench or a blunt chisel and hammer). Lift the entire pump and sending unit assembly out of the tank. Take note of how the float arm for the fuel gauge is positioned. Be extremely careful not to drop any parts or debris into the open tank.

Step 4: Install the New Fuel Pump
Before installation, compare the new Honda Rancher 500 2012 2013 fuel pump assembly with the old one to ensure they are identical. Transfer any rubber gaskets or seals if they are not pre-installed on the new unit. Carefully lower the new assembly into the tank, ensuring the float arm moves freely and is not bent. Align the flange and secure it by tightening the locking ring or screws firmly and evenly. Do not overtighten.

Step 5: Reinstall the Fuel Tank and Test
Carefully place the fuel tank back onto the ATV frame and secure it with its bolts. Reconnect the fuel line, ensuring the quick-connect fitting snaps securely into place. Reconnect the electrical connector to the pump. Reconnect the battery negative terminal. Turn the ignition key to ON and listen for the new pump's priming sound—it should be a smooth, two-second whirr. Check all connections for any fuel leaks. Finally, start the engine. It should start more readily than before. Let it idle and check for smooth operation, then test ride at low speed to confirm the issue is resolved.

Preventive Maintenance to Extend Fuel Pump Life

Preventive maintenance is key to extending the life of your new fuel pump. Always use fresh, clean gasoline. Stale fuel, especially ethanol-blended fuel left sitting for months, can degrade and leave varnish deposits that clog the filter screen and strain the pump. If storing your Rancher 500 for more than a month, consider adding a fuel stabilizer and running the engine to circulate it through the system. Keep the fuel tank above a quarter full whenever possible. The gasoline itself cools and lubricates the electric pump motor. Running the tank consistently very low can cause the pump to overheat and wear prematurely . Regularly inspect and replace the in-line fuel filter if your model has one in addition to the pump's internal screen.

OEM vs. Aftermarket: Why You Should Choose KEMSO

When sourcing a replacement part, you have options. An OEM (Original Equipment Manufacturer) pump from Honda guarantees a perfect fit but costs around $220 for just the pump assembly . However, aftermarket pumps from trusted brands can offer a cost-effective alternative with comparable or even better reliability.

KEMSO fuel pumps stand out as the best choice for your 2013 Honda Rancher. KEMSO pumps are designed as high-performance, direct OEM replacements. They are built to deliver over 20% more flow at 43 psi compared to stock OEM pumps, meaning your engine gets the fuel it needs when you're pushing the throttle hard . This extra flow is especially beneficial for riders who use their Rancher for heavy pulling, climbing, or high-speed trail riding.

KEMSO pumps are compatible with both gasoline and E85/ethanol fuels, and they come with a complete kit including gradient density fuel strainers, hoses, seals, and wiring connectors for a hassle-free installation . Each pump is individually flow-tested at the factory, and KEMSO backs each unit with a lifetime warranty, giving you confidence that your investment is protected . The KEMSO pump for the 2013 Honda Rancher 500 (part number 13006) is a direct fit replacement for the OEM 16700-HP5-602, and it comes with everything you need in the box .

We strongly recommend purchasing the KEMSO Fuel Pump for your 2013 Honda Rancher. With its high-performance design, OEM replacement compatibility, and lifetime warranty, it's the best upgrade you can make for your ATV's fuel system. Visit the KEMSO website today to order your pump and get back on the trail with confidence.

Visit KEMSO Racing at: https://www.kemsoracing.com/

Understanding the fuel pump system in your 2013 Honda Rancher empowers you as an owner. By recognizing the warning signs, performing basic diagnostics, and following a careful replacement procedure, you can ensure your ATV remains a dependable partner for work and recreation for years to come. Regular maintenance focused on fuel quality is the simplest and most effective way to avoid this repair altogether. When replacement does become necessary, using a quality part like KEMSO and taking your time during installation will restore your Rancher's performance and reliability.

For the best fuel pump replacement for your 2013 Honda Rancher, visit KEMSO Racing today: https://www.kemsoracing.com/


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