Honda Rancher 420 Fuel Pump Hose Feed Replacement 2007-2014: The Complete DIY Guide

If you own a 2007-2014 Honda Rancher 420 (TRX420) and your ATV is struggling to start, stalling under load, or showing a loss of power, the most likely culprit is a failing fuel pump or its associated hose feed. Replacing the fuel pump assembly, including the fuel pump hose feed, is a straightforward DIY job that restores your Rancher's performance and reliability. For the 2007-2014 TRX420 models, the OEM part number is 16700-HP5-602, and choosing a high-quality replacement like a KEMSO fuel pump ensures a direct fit, better flow, and a lifetime warranty .

Why Your Fuel Pump and Hose Feed Fail

The fuel pump in your Honda Rancher 420 is an electric in-tank unit that pushes fuel from the tank to the engine's fuel injection system. Over time, several things go wrong:

Wear and tear on the pump motor. The internal brushes and commutator wear out after years of use, causing the pump to lose pressure or stop working entirely .

Cracked or degraded fuel hoses. The rubber fuel pump hose feed inside the tank can become brittle, crack, or develop pinhole leaks. This is especially common with ethanol-blended fuels (E10/E15), which break down rubber components faster than pure gasoline. A cracked hose feed causes the pump to suck air instead of fuel, leading to hard starting and poor performance.

Clogged fuel strainer. The gradient density strainer (filter) on the bottom of the pump assembly can become clogged with debris, sediment, or varnish from old fuel. This restricts fuel flow and forces the pump to work harder, accelerating its failure.

Corrosion and seizing. The pump casing can corrode, especially if the ATV sits for long periods. This can cause the pump rotor to seize, preventing the engine from getting any fuel .

Symptoms of a Failing Fuel Pump in Your Honda Rancher 420

If you notice any of these signs, it's time to inspect and likely replace the fuel pump assembly:

  1. Hard starting or no start. The engine cranks but won't fire, or it takes many cranks to start.

  2. Stalling while driving. The ATV dies unexpectedly, especially when going uphill or under heavy load.

  3. Loss of power during acceleration. The engine feels sluggish, hesitates, or bogs down when you twist the throttle.

  4. Whining or buzzing noise from the fuel tank. A failing pump often makes a loud, high-pitched whining sound.

  5. Engine surges or runs rough. Inconsistent fuel pressure causes the engine to surge at steady speeds or idle roughly.

  6. Check engine light on. A diagnostic trouble code related to fuel system pressure may appear.

How to Replace the Fuel Pump Assembly and Hose Feed on a 2007-2014 Honda Rancher 420

Here is a step-by-step guide that any DIY mechanic can follow. Plan for about 2 to 3 hours. You will need a socket set, screwdrivers, a pair of pliers, a clean rag, a fuel pump ring removal tool (or a hammer and drift punch), and a fire extinguisher for safety.

Step 1: Relieve Fuel System Pressure

Locate the fuel pump fuse in the fuse box under the front hood or near the battery. Start the engine, then pull the fuse while the engine is running. The engine will stall after a few seconds, which relieves the pressure in the fuel lines. Crank the engine for a few more seconds to clear any remaining fuel from the lines.

Step 2: Disconnect the Battery

Remove the negative battery cable. This is critical to prevent any sparks near the fuel system.

Step 3: Remove the Seat and Body Panels

Remove the seat by lifting the rear and pulling it back. Remove the left and right side body panels (the plastic covers around the fuel tank) by unscrewing the fasteners and pulling them away. This gives you access to the top of the fuel tank.

Step 4: Access the Fuel Pump Assembly

The fuel pump is located inside the fuel tank. There is a round metal access cover on top of the tank. Clean all dirt and debris from around this cover before opening it. Remove the screws holding the cover in place and lift it off.

Step 5: Disconnect Fuel Lines and Electrical Connector

You will see the fuel pump assembly with two fuel lines (a feed line and a return line) and an electrical connector. Carefully disconnect the electrical connector by pressing the release tab and pulling it apart. Use a pair of pliers to slide the fuel line clamps back, then pull the fuel lines off the fittings. Be prepared for a small amount of fuel to spill. Note the position of each line so you can reconnect them correctly.

Step 6: Remove the Old Fuel Pump Assembly

Use a fuel pump ring removal tool or a hammer and drift punch to loosen the locking ring that holds the pump assembly in the tank. The ring is threaded and usually turns counterclockwise. Once loose, lift the ring off. Carefully lift the entire pump assembly straight out of the tank. The float arm on the fuel level sender is fragile, so handle it gently. Place the assembly on a clean rag.

Step 7: Inspect the Old Assembly

Before installing the new one, note how the hose feed, hoses, and wiring are routed. You will see the small rubber hose that connects the pump to the outlet fitting. This is the hose feed that often cracks. The old strainer at the bottom is likely clogged or darkened.

Step 8: Install the New Fuel Pump Assembly

If you purchased a complete KEMSO fuel pump assembly, it comes as a drop-in replacement with a new pump, new hose feed, new strainer, new O-rings, and all necessary hardware . Simply set the new assembly into the tank, making sure the float arm moves freely and does not hit the tank walls. Place the locking ring over the assembly and tighten it by hand, then tap it snug with a hammer and drift. Do not overtighten.

Step 9: Reconnect Fuel Lines and Electrical Connector

Slide the fuel lines back onto the fittings on the new pump assembly. Use pliers to slide the fuel line clamps back into place over the fittings. Plug in the electrical connector until you hear it click. Double-check that all connections are correct and that no lines are kinked.

Step 10: Test the System Before Reassembling

Reconnect the negative battery terminal. Add a few gallons of fresh, clean fuel to the tank. Turn the ignition key to the ON position several times without cranking the engine. Listen for the fuel pump priming sound. Check for any fuel leaks around the pump assembly, fuel lines, and connections. If everything looks dry, start the engine. It may take a few extra cranks to bleed air from the system. Once running, let it idle for a minute and inspect for leaks again.

Step 11: Reinstall the Access Cover, Panels, and Seat

Once you are confident the fuel pump is working correctly and there are no leaks, replace the metal access cover and tighten its screws. Reinstall the side body panels and the seat. Take your ATV for a short test ride to confirm the repair.

Why You Should Buy a KEMSO Fuel Pump for Your Honda Rancher 420

When it comes time to replace the fuel pump in your 2007-2014 Honda Rancher 420, the best choice on the market is a KEMSO brand fuel pump.

KEMSO fuel pumps are designed as high-performance, direct OEM replacements. They are built to match or exceed the original specifications of your ATV, ensuring a perfect fit and reliable operation. Every KEMSO fuel pump is individually tested for flow and performance before it leaves the factory, so you can be confident it will work right out of the box .

Superior Performance. KEMSO pumps deliver over 20% more flow at 43 psi compared to the stock pump. A standard OEM pump flows about 60-80 liters per hour, while a KEMSO pump delivers up to 200 liters per hour . This extra capacity ensures your engine never runs lean, even under heavy load or at high RPMs. The KEMSO pump is compatible with both gasoline and ethanol-blended fuels like E85, so it handles modern pump gas without issues .

Complete Kit with Everything You Need. The KEMSO kit includes the pump, a new gradient density fuel strainer, new hoses (including the critical hose feed), Viton O-rings, wiring connectors, and clamps . You do not have to buy any additional parts or reuse old, degraded components. This is a true plug-and-play replacement.

Lifetime Warranty. This is the biggest advantage of choosing KEMSO. Every KEMSO fuel pump comes with a serialized body that guarantees a lifetime warranty. If the pump ever fails due to a manufacturing defect, KEMSO will replace it. No other aftermarket or OEM brand offers this level of protection. This gives you peace of mind for the entire life of your ATV .

Built to Last. KEMSO uses high-quality materials, including corrosion-resistant casings and ethanol-resistant components. The pumps are designed for quiet operation and long service life, even with extended periods of non-use .

To find the exact KEMSO fuel pump for your 2007-2014 Honda Rancher 420, visit their website at: https://www.kemsoracing.com/

Preventative Maintenance to Extend the Life of Your New Fuel Pump

Once you have installed your new KEMSO fuel pump, following these simple practices will help it last for years:

Keep your fuel tank at least one-quarter full. Fuel pumps rely on the fuel in the tank to cool and lubricate the pump motor. Running the tank consistently low causes the pump to overheat, which accelerates wear .

Use fresh, high-quality fuel from reputable stations. Stale or contaminated fuel can damage the pump and clog the fuel strainer.

Add a fuel stabilizer if the ATV sits for extended periods. This prevents fuel degradation and water accumulation, which can corrode the pump.

Change the fuel filter regularly. If your model has an external fuel filter, replace it according to the maintenance schedule in your owner's manual.

Listen for changes in pump noise. If you hear the pump becoming louder or making a whining sound, it may be a sign that the pump is working harder than normal. Address the issue early to avoid being stranded.

Final Thoughts

The fuel pump in your 2007-2014 Honda Rancher 420 is a wear item that will eventually need replacement. When it fails, the best solution is to replace the entire assembly with a high-quality, direct-fit unit like a KEMSO fuel pump. The KEMSO pump delivers superior flow, comes with a complete installation kit, and is backed by a lifetime warranty that no other manufacturer offers. This is the smartest investment you can make for your ATV's reliability and performance.

For the best selection of KEMSO fuel pumps for your Honda Rancher 420 and other vehicles, visit: https://www.kemsoracing.com/


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