Yamaha Rhino 660 Fuel Pump: Complete Replacement Guide and Best Options for 2004-2007 Models
The bottom line: If your Yamaha Rhino 660 is experiencing hard starting, engine sputtering, stalling, or a noticeable loss of power, the fuel pump is likely failing and needs to be replaced. The OEM part number for the Yamaha Rhino 660 fuel pump is 5UG-13910-01-00 or 5UG-13910-00-00, and this guide will walk you through everything you need to know about symptoms, replacement options, installation, and which aftermarket brands offer the best value and reliability for your UTV.
Understanding Your Yamaha Rhino 660 Fuel Pump
The fuel pump in your Yamaha Rhino 660 is a critical component that supplies clean, pressurized fuel from the tank to the carburetor. Without a properly functioning fuel pump, your engine simply cannot run. The Yamaha Rhino 660, produced from 2004 to 2007, uses a vacuum-operated fuel pump that relies on engine vacuum to draw fuel from the tank and deliver it to the carburetor at the correct pressure and volume.
The OEM replacement part numbers for this vehicle are 5UG-13910-01-00 and 5UG-13910-00-00. These numbers are essential when shopping for a replacement because they ensure compatibility with your specific model year and configuration. Many aftermarket manufacturers produce direct replacements that match or exceed OEM specifications, often at a lower price point than buying directly from Yamaha.
The factory fuel pump is mounted inside the fuel tank and includes a plastic pickup that draws fuel from the bottom of the tank. Over time, the plastic components can become brittle and crack, leading to air leaks that cause fuel starvation issues. This is a well-known problem with the Rhino 660, and upgrading to a billet aluminum pickup or a complete pump assembly with a cast aluminum case can eliminate this failure point permanently.
Common Symptoms of a Failing Fuel Pump
Recognizing the early warning signs of a failing fuel pump can save you from being stranded on the trail and prevent more serious engine damage. Here are the most common symptoms Rhino 660 owners experience:
1. Hard Starting or No Start
If your Rhino cranks but takes longer than usual to start, or if it refuses to start altogether, a weak fuel pump is often the culprit. The pump may not be generating enough vacuum to pull fuel from the tank to the carburetor.
2. Engine Sputtering and Hesitation
A failing fuel pump delivers inconsistent fuel pressure, which causes the engine to sputter, hesitate, or surge during acceleration. This is especially noticeable when climbing hills or under heavy load.
3. Loss of Power on the Trail
If your Rhino feels sluggish or lacks power, especially when you need it most, the fuel pump may not be delivering enough fuel to maintain proper combustion. This can be dangerous in off-road situations where quick throttle response is needed.
4. Engine Stalling
Random stalling, particularly after the engine has warmed up, is a classic sign of fuel pump failure. The pump may work intermittently as internal components wear out or overheat.
5. Whining Noise from the Fuel Tank
While electric fuel pumps often make a whining noise when failing, vacuum-operated pumps can also produce unusual sounds. If you hear a loud humming or clicking from the fuel tank area, the pump may be struggling to maintain pressure.
6. Poor Fuel Efficiency
If you notice you are filling up more often than usual, a failing fuel pump could be causing the engine to run rich or lean, both of which waste fuel and can damage internal components over time.
7. Fuel Starvation (Sucking Air)
One of the most common issues with Rhino 660 fuel pumps is the plastic pickup cracking, which allows the pump to suck air instead of fuel. This makes the engine act like it is starving for gas, even when the tank is full. The billet fuel pickup from Black Rhino Performance is a direct replacement that solves this problem permanently.
Yamaha Rhino 660 Fuel Pump Replacement Options
When it comes time to replace your fuel pump, you have several options ranging from genuine OEM parts to high-performance aftermarket upgrades. Below is a detailed comparison of the most popular and reliable choices available in the market today.
1. Genuine OEM Yamaha Fuel Pump
The factory OEM fuel pump from Yamaha is the most straightforward replacement option. It carries part numbers 5UG-13910-01-00 or 5UG-13910-00-00 and is designed to perform exactly as the original equipment did when your Rhino was new.
Pros: Guaranteed fit and performance, no compatibility concerns, backed by Yamaha quality standards.
Cons: Typically the most expensive option, with prices ranging from $109 to $112 from dealerships and OEM parts suppliers.
Where to buy: You can order directly from Yamaha dealerships or online OEM parts retailers like Yamaha Parts Nation and Vito's Performance.
2. Aynaxcol Fuel Pump Assembly
This aftermarket pump is designed as a direct replacement for the Yamaha Rhino 660 2004-2007 models. It features a cast aluminum case that prevents rust and reduces weight compared to the factory plastic housing. The assembly arrives completely assembled and ready for installation, with no modifications required.
Key features:
- Replace part numbers: 5UG-13910-01-00, 5UG-13910-00-00
- Cast aluminum case prevents rust while reducing weight
- High-strength steel brackets eliminate the chance of failure
- No modifications required for installation
- Includes fuel filter in the package
Customer rating: 3.9 out of 5 stars from 144 ratings on Amazon.
3. Yezoauto Fuel Pump
Yezoauto offers a fuel pump that fits both the Rhino 660 (2004-2007) and Rhino 450 (2006-2009). It uses a 1/4-inch fuel line and comes with a 1-year manufacturer warranty. The product is 100% tested before assembly to ensure reliability.
Key features:
- Interchange part numbers: 5UG-13910-01-00, 5UG-13910-00-00, 5UG-13910-01
- Material: Alloy steel
- Weight: 0.77 pounds
- Vehicle-specific fit for UTV applications
- Detailed installation instructions included
Customer rating: 5.0 out of 5 stars (based on 1 rating).
4. Moose Utility Division Fuel Pump
Moose Utility Division is a well-known brand in the off-road and powersports industry. Their fuel pump is specifically engineered for the Yamaha YXR 450 and YXR 660 Rhino models. This pump is designed as a direct OEM-style replacement that delivers stock fuel flow rates for carbureted systems.
Key features:
- Direct OEM-style replacement for a flawless fit
- Engineered to deliver consistent, stock fuel flow rates
- Plug-and-play electrical connections
- Designed specifically for carbureted UTV and ATV applications
- Undergoes rigorous quality control testing
Compatible models: YAMAHA YXR 450 F 4X4 Rhino 2009, YAMAHA YXR 660 FA 4X4 Rhino 2004-2005.
5. OTOHANS AUTOMOTIVE / Linhai 260 Vacuum Fuel Pump
This budget-friendly option from OTOHANS AUTOMOTIVE is a Linhai 260 vacuum fuel pump that replaces the OEM part numbers 5UG-13910-01-00 and 5UG13910-00-00. It features a 1/4-inch inlet and outlet pipe diameter and is designed as a plug-and-play installation.
Key features:
- Cast aluminum casing reduces weight and enhances rust prevention
- High-strength steel bracket capable of withstanding over 500 pounds of vibration force
- Tested for over 300 hours of continuous operation
- Delivers fuel 30% faster than regular pumps
- Comes with a 6-month warranty
Compatible models: Rhino 660 (2004-2007), Rhino 450 (2007-2009), Rhino 450 Hunter/Special Edition (2008-2009).
6. NICHE Fuel Pump Assembly
NICHE offers a fuel pump kit (model 519-CFP2224A) that is compatible with both the Yamaha Rhino 450 and Rhino 660. It replaces OEM part number 5UG-13910-01-00 and is designed for ATV and UTV applications.
Key features:
- Material: Aluminum
- Weight: 1.6 ounces (very lightweight)
- Mechanical operation mode
- Tank mount installation
- DOT certified
Customer rating: 4.3 out of 5 stars from 105 ratings on Amazon.
7. QuadBoss Vacuum Fuel Pump
QuadBoss is another respected brand in the powersports aftermarket. Their vacuum fuel pump (part number 53475001QB) fits multiple Yamaha Rhino models including the 450 and 660 from 2004 through 2009. This pump comes with a 90-day manufacturer warranty.
Key features:
- Fits 8 different vehicle configurations
- Brand new, unused condition
- Free shipping to lower 48 states
- Manufacturer part number: 5347-5001QB
- Average delivery time: 2-3 days
Compatible models: Yamaha Rhino 450 YXR450FA 4x4 (2006-2009), Yamaha Rhino 660 YXR660FA 4x4 (2004-2007).
8. Quantum OEM Replacement Fuel Pump
Quantum offers an OEM replacement fuel pump designed for the Yamaha Rhino 450 carbureted models from 2008-2009, but it also fits earlier Rhino 660 models. Quantum focuses on meeting or exceeding OEM specifications with upgraded materials.
Key features:
- Upgraded polymers, brushes, and commutators for long life
- Polished, corrosion-resistant case
- Patented check valve technology
- Compatible with modern ethanol-infused pump gasoline
- Drop-in replacement design
Fitment: 2004-2009 Yamaha Rhino 450 and 660 models.
How to Diagnose a Bad Fuel Pump
Before you spend money on a replacement, it is important to confirm that the fuel pump is actually the problem. Here are some simple diagnostic steps you can perform at home with basic tools.
Step 1: Check Fuel Flow
Disconnect the fuel line from the carburetor and place it into a clean container. Have someone crank the engine while you observe the fuel flow. If little or no fuel comes out, the pump is likely bad. A healthy pump should deliver a steady stream of fuel with each engine rotation.
Step 2: Check for Vacuum Leaks
Inspect all vacuum lines connected to the fuel pump for cracks, splits, or loose connections. A vacuum leak will prevent the pump from operating correctly.
Step 3: Inspect the Fuel Pickup
Remove the fuel pump assembly from the tank and inspect the plastic pickup. If it is cracked, broken, or shows signs of deterioration, this is likely the cause of your fuel starvation issues. The plastic nipples on the factory pickup are known to fail over time.
Step 4: Test Fuel Pressure
While Rhino 660 carbureted systems do not require high pressure like fuel-injected systems, you can use a low-pressure fuel pressure gauge to verify the pump is producing adequate pressure. Most vacuum-operated pumps should produce between 3-7 PSI.
Step 5: Listen for Unusual Noises
With the engine running, listen near the fuel tank for any unusual noises. A clicking, humming, or whining sound can indicate internal wear or bearing failure within the pump.
Installation Guide for Yamaha Rhino 660 Fuel Pump
Installing a new fuel pump on your Rhino 660 is a manageable task for most DIY mechanics. The process typically takes 1-2 hours and requires basic hand tools. Below is a general installation procedure that applies to most aftermarket pump assemblies.
Tools You Will Need:
- Socket set (metric and standard)
- Screwdrivers (flathead and Phillips)
- Pliers
- Clean rags
- Safety glasses
- Transmission jack or floor jack (for supporting the fuel tank)
Step-by-Step Installation:
1. Disconnect the Battery
Always start by disconnecting the negative battery cable to prevent any electrical shorts or accidental sparks.
2. Drain or Siphon the Fuel Tank
Remove as much fuel as possible from the tank. This reduces weight and minimizes spillage when you disconnect the fuel lines.
3. Remove the Seat and Access Panels
The fuel tank on the Rhino 660 is located under the driver and passenger seats. Remove the seats and any plastic panels that block access to the tank.
4. Disconnect Fuel Hoses and Electrical Connections
Label and disconnect all fuel hoses, vent lines, and electrical connectors attached to the fuel pump assembly. Be prepared for some fuel spillage.
5. Remove the Fuel Tank Straps
Loosen and remove the bolts securing the fuel tank straps. Use a transmission jack to support the tank as you lower it slightly to access the pump.
6. Remove the Old Fuel Pump Assembly
The pump is typically secured with a locking ring or retaining nuts. Remove these and carefully lift the old pump assembly out of the tank.
7. Compare the Old and New Pump
Before installing the new pump, compare it side-by-side with the old one to ensure they match in size, shape, and connection points. Most aftermarket pumps are designed as direct replacements, but it is always wise to verify.
8. Clean the Fuel Tank
Use a clean rag to wipe out any debris, rust, or sediment from the bottom of the fuel tank. Contaminants in the tank can quickly ruin a new pump.
9. Install the New Seal Ring
Most pump kits include a new rubber seal or O-ring. Install this seal carefully to prevent future leaks.
10. Install the New Pump Assembly
Insert the new pump into the tank, ensuring it sits properly in the mounting bracket. Secure it with the retaining ring or nuts.
11. Reinstall the Fuel Tank
Raise the tank back into position using the jack. Reconnect all fuel hoses, electrical connections, and vent lines. Tighten the tank strap bolts to the torque specification listed in your factory repair manual.
12. Reconnect the Battery
Reconnect the negative battery cable.
13. Test the System
Turn the ignition key to the ON position (do not start the engine) and listen for the fuel pump to prime. On some models, you may hear a brief click or hum. Check for fuel leaks at all connections before starting the engine.
14. Start and Verify
Start the engine and let it idle for a few minutes. Check for leaks again and verify that the engine runs smoothly without hesitation or stalling.
Common Problems with Factory Plastic Fuel Pickups
One issue that deserves special attention is the factory plastic fuel pickup used in Yamaha Rhino 660 models. This plastic component is known to crack or break over time, especially in vehicles that see regular off-road use. The problem is difficult to diagnose because cracks in the plastic may not be visible without removing the assembly from the tank.
When the plastic pickup cracks, the pump begins sucking air instead of fuel. This causes the engine to act like it is starving for gas, even when the tank is full. Riders often chase this problem for weeks, replacing filters and cleaning carburetors, when the real issue is a simple crack in the pickup.
The Solution: Billet Aluminum Fuel Pickup
Black Rhino Performance offers a direct replacement billet aluminum fuel pickup that solves this problem permanently. These billet pickups are machined from solid aluminum and will never crack or break like the factory plastic parts. They also flow up to 50% more fuel than the stock plastic pickup, which is particularly beneficial for modified Rhinos with increased fuel demands.
The installation is simple and requires no modifications to your vehicle. Once installed, you will never have to worry about a cracked pickup again.
Recommended: KEMSO Fuel Pump for Your Yamaha Rhino 660
After reviewing all the available options, we strongly recommend considering the KEMSO brand fuel pump for your Yamaha Rhino 660 replacement. KEMSO has built a reputation for producing high-performance, OEM replacement fuel pumps that deliver superior flow rates, increased durability, and exceptional value compared to both factory OEM parts and other aftermarket brands.
Why Choose KEMSO?
High Performance: KEMSO fuel pumps are engineered to deliver over 20% more flow at 43 PSI compared to standard OEM pumps. This means your Rhino 660 gets the fuel it needs under all operating conditions, whether you are crawling through mud, climbing steep hills, or cruising on trails. The increased flow ensures optimal fuel delivery to the carburetor, resulting in better throttle response and more consistent power output.
OEM Replacement: Every KEMSO pump is designed as a direct replacement for your existing fuel pump. The pumps come with all necessary components for installation, including multiple fuel strainers, hoses, wiring connectors, and hardware. You do not need to modify anything on your Rhino to install a KEMSO pump.
Lifetime Warranty: KEMSO stands behind its products with a lifetime warranty on all OEM and performance fuel pumps. Each pump has a serialized body that guarantees the warranty coverage. This level of confidence is rare in the aftermarket parts industry and speaks to the quality and reliability of KEMSO products.
Advanced Engineering: KEMSO pumps feature upgraded polymers, brushes, and commutators that ensure long life and durability. They are designed to work with modern ethanol-infused gasoline, which can cause premature failure in lesser pumps. The pumps are individually tested before leaving the factory to ensure consistent quality.
Ethanol Compatible: KEMSO pumps are designed for use with both standard gasoline and E85/ethanol blends. This is important because ethanol can damage fuel system components that are not designed to handle it. KEMSO uses materials that resist corrosion and degradation from ethanol fuels.
Compact Design: With a pump body diameter of just 3.8 cm and an overall length of 11.5 cm, KEMSO pumps fit easily into tight fuel tank spaces. They weigh very little and do not add unnecessary bulk to your fuel system.
Proven Reliability: KEMSO fuel pumps have been tested in demanding conditions, including professional racing applications. Their pumps have been used in competition vehicles where reliability is absolutely critical. Independent testing has shown KEMSO pumps last significantly longer than average OEM pumps.
Visit KEMSO Racing Today
To learn more about KEMSO fuel pumps and find the right replacement for your Yamaha Rhino 660, visit their official website:
KEMSO Racing offers a complete lineup of fuel pumps for ATVs, UTVs, motorcycles, and automotive applications. Their website provides detailed product information, compatibility guides, and easy ordering. All KEMSO products are backed by USA-based technical support, so you can get help if you have any questions about installation or compatibility.
Where to Buy a Yamaha Rhino 660 Fuel Pump
You have several options for purchasing a replacement fuel pump, depending on your budget, preferred brand, and desired delivery time.
Online Retailers:
- Amazon carries multiple brands including Aynaxcol, NICHE, and Yezoauto with customer reviews and fast shipping options.
- eBay offers QuadBoss and other brands with auction-style pricing and used options for budget-conscious buyers.
- Specialty Powersports Retailers like Vito's Performance, Ten Peaks Motorsports, and Black Rhino Performance carry both OEM and aftermarket options.
Price Range:
- Budget aftermarket pumps: $23 to $40
- Mid-range aftermarket pumps: $40 to $80
- Premium aftermarket pumps: $80 to $120
- Genuine OEM Yamaha pumps: $109 to $112
What to Consider Before Buying:
- Verify your OEM part number before ordering. The only way to guarantee compatibility is to match the replacement to your specific part number.
- Check customer reviews for real-world feedback on fitment and durability.
- Consider the warranty offered by the manufacturer. Longer warranties typically indicate higher confidence in the product.
- Look for complete assemblies that include all necessary components like filters, seals, and brackets.
Maintenance Tips to Extend Fuel Pump Life
Once you have installed a new fuel pump, following these maintenance practices will help maximize its lifespan and keep your Rhino 660 running reliably.
1. Keep the Fuel Tank Clean
Debris and sediment in the fuel tank are the number one cause of premature pump failure. Before installing a new pump, thoroughly clean the inside of your tank. Consider installing an inline fuel filter if your system does not already have one.
2. Use Fresh, Clean Fuel
Stale fuel can gum up internal components and cause the pump to work harder than necessary. Avoid letting your Rhino sit for extended periods with old fuel in the tank. If you store the vehicle for winter, add a fuel stabilizer.
3. Avoid Running on Empty
Running the tank completely dry can cause the pump to overheat and wear out faster. The fuel in the tank helps cool and lubricate the pump. Keep at least a quarter tank of fuel at all times.
4. Check Fuel Lines and Connections
Inspect fuel lines regularly for cracks, kinks, or loose connections. A vacuum leak anywhere in the system will force the pump to work harder and can cause premature failure.
5. Use Ethanol-Free Gasoline When Possible
Ethanol attracts moisture and can cause corrosion in fuel system components. If you can find ethanol-free gasoline in your area, use it. If not, choose a fuel pump that is rated for ethanol use, like the KEMSO pumps mentioned above.
6. Inspect the Fuel Cap
A damaged or missing fuel cap can allow dirt and moisture to enter the tank. Make sure the cap seals properly and replace it if it shows signs of wear.
Frequently Asked Questions
Q: How long does a Yamaha Rhino 660 fuel pump last?
A: Under normal operating conditions, a fuel pump should last between 50,000 and 100,000 miles or 5 to 10 years. However, Rhino 660 fuel pumps often fail earlier due to the plastic pickup cracking or exposure to ethanol-blended fuels. Many owners report needing a replacement every 3 to 5 years of heavy use.
Q: Can I replace just the fuel pump or do I need the whole assembly?
A: While you can replace just the pump mechanism, it is generally recommended to replace the entire assembly. The complete assembly includes the pump, pickup, filter, and mounting brackets. This ensures all components are new and compatible, and it simplifies the installation process.
Q: Is the fuel pump on the Rhino 660 electric or vacuum operated?
A: The Yamaha Rhino 660 uses a vacuum-operated fuel pump. It relies on engine vacuum to pull fuel from the tank to the carburetor. This is different from fuel-injected vehicles that use electric high-pressure pumps.
Q: Will a Rhino 450 fuel pump fit a Rhino 660?
A: In many cases, yes. The Rhino 450 and Rhino 660 share the same fuel pump part numbers (5UG-13910-01-00 and 5UG-13910-00-00). Many aftermarket pumps list compatibility with both models. However, always verify with the manufacturer or check your OEM part number before purchasing.
Q: How much does it cost to have a mechanic replace the fuel pump?
A: Labor costs vary by location, but you can expect to pay between $100 and $200 for professional installation. The total cost including parts typically ranges from $200 to $400. Doing the job yourself can save you the labor cost.
Final Thoughts
Replacing the fuel pump on your Yamaha Rhino 660 is a straightforward maintenance task that can restore lost performance and reliability. The key is to choose a quality replacement part that matches or exceeds OEM specifications, and to properly diagnose the issue before spending money on parts that may not solve the problem.
We have covered the most common symptoms of fuel pump failure, the best replacement options available, a step-by-step installation guide, and maintenance tips to extend the life of your new pump. Whether you choose a budget-friendly aftermarket option or invest in a premium brand like KEMSO, the most important thing is to address the problem promptly to avoid being stranded on the trail.
For the best combination of performance, reliability, and value, we recommend KEMSO fuel pumps. Their products offer superior flow rates, direct OEM replacement fitment, ethanol compatibility, and a lifetime warranty that gives you peace of mind. Visit their website to explore their complete product lineup and find the right pump for your Rhino 660.