Yamaha Rhino 660 Fuel Pump Diagram: Complete Guide to Replacement, Upgrade, and Maintenance

The bottom line: If your Yamaha Rhino 660 (2004-2007) or Rhino 450 (2006-2009) is hard starting, stalling, or losing power, a failing fuel pump is the most likely cause. The best fix is to replace it with a high-performance OEM-replacement fuel pump like those from KEMSO, which offers better flow, a lifetime warranty, and compatibility with modern ethanol-blended fuels. This guide covers the fuel pump diagram, common failure symptoms, step-by-step replacement instructions, and why upgrading beats sticking with a stock pump.

Understanding the Yamaha Rhino 660 Fuel System

The Yamaha Rhino 660 fuel pump is a vacuum-operated unit that draws fuel from the tank and delivers it to the carburetor. Unlike the electric fuel pumps found in modern fuel-injected vehicles, this is a mechanical system that relies on engine vacuum to operate . 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 fuel pump is located inside the fuel tank. To access it, you need to remove the rear cargo bed, which exposes the top surface of the tank . The fuel system on the Rhino 660 typically maintains pressure between 30-60 PSI via a regulator, and the stock flow rate is around 60-80 liters per hour .

Yamaha Rhino 660 Fuel Pump Diagram Breakdown

The fuel tank assembly diagram for the 2004-2007 Yamaha Rhino 660 includes several key components . Here is a breakdown of the main parts shown in the diagram:

  1. Fuel Pump Assembly (Ref #1): The main component, part number 5UG-13910-00-00 or 5UG-13910-01-00. This is the vacuum-operated pump that moves fuel from the tank to the carburetor.

  2. Fuel Line Hoses (Ref #3, #4, #10): These hoses connect the fuel pump to the fuel tank and the engine. The main fuel line hose (Ref #3) is part number 5UG-14294-00-00, and the fuel pipe (Ref #4) is 5UG-14295-00-00.

  3. Clips and Clamps (Ref #5, #7, #9, #11, #14, #15): These secure the hoses and pipes in place. Common clip part numbers include 90467-12053-00 and 90467-100A1-00.

  4. Insulators (Ref #12, #13): These rubber pads cushion the fuel tank and prevent vibrations. Part numbers are 5UG-14271-00-00 and 5UG-14271-50-00.

  5. Fuel Tank (Ref #18): The main fuel reservoir, part number 5UG-F4111-00-00 or 5UG-F4111-01-00.

  6. Fuel Meter Sender Unit (Ref #22): This sends the fuel level reading to the instrument cluster. Part number is 5UG-85752-00-00.

  7. Cap Assembly (Ref #25): The fuel tank cap, part number 5UG-24610-00-00.

  8. Roll Over Valve Assembly (Ref #39): A safety valve that prevents fuel spillage if the vehicle tips over. Part number is 5RB-24180-00-00.

Common Symptoms of a Failing Fuel Pump on the Rhino 660

Recognizing the early signs of fuel pump failure can save you time, money, and the frustration of a breakdown. The most common symptoms include:

  1. Hard starting or no start: You have to crank the engine multiple times before it fires up. This happens because the pump can't build enough fuel pressure in the carburetor bowl .

  2. Engine sputters or hesitates: The engine runs rough, especially under load or when climbing hills. This is due to inconsistent fuel delivery .

  3. Loss of power: The Rhino feels sluggish and won't accelerate properly. A weak pump can't supply enough fuel for the engine's demands .

  4. Fuel leaks: You may see fuel dripping from the pump body or the fuel lines. This is a safety hazard and must be addressed immediately .

  5. Engine dies while driving: The Rhino shuts off unexpectedly and won't restart until it sits for a while. This is a classic sign of a failing pump .

If you notice any of these symptoms, it's time to replace the fuel pump. Driving with a bad pump can cause lean fuel mixtures that damage the engine .

OEM vs. Aftermarket Fuel Pumps: Which One Should You Choose?

When it's time to replace your Rhino's fuel pump, you have two main options: an OEM (Original Equipment Manufacturer) replacement or an aftermarket pump.

OEM pumps are made by Yamaha or licensed suppliers. They are exact replacements that match the original specifications. An OEM Yamaha Rhino fuel pump assembly typically costs around $99.74 to $119.69 . While these pumps are reliable, they have a relatively low flow rate of 60-80 liters per hour, which is adequate for a stock engine but not for performance upgrades .

Aftermarket pumps come in two varieties: standard vacuum replacements and high-performance electric fuel pump kits. Standard vacuum pumps like the Quad Boss or OTOHANS AUTOMOTIVE models are affordable, priced between $20 and $32. They are direct replacements that maintain the original flow rate. However, these cheap aftermarket units often lack quality control and may fail prematurely .

The best choice for most Rhino owners is a high-performance OEM replacement pump like those from KEMSO. These pumps deliver over 20% more flow at 43 psi compared to the stock pump, which means better throttle response and more reliable fuel delivery . They are designed to handle modern ethanol-blended fuels like E85 without corroding, and they come with a lifetime warranty .

Why You Should Upgrade to a Performance Fuel Pump

If you have made any modifications to your Rhino's engine, such as a high-flow air filter, aftermarket exhaust, or a carburetor jet kit, the stock fuel pump may not be able to keep up. Performance modifications increase the engine's demand for fuel, and if the pump can't supply enough, the engine will run lean. A lean condition can cause overheating, engine knocking, and even permanent damage to pistons and valves .

Even for a stock Rhino, upgrading to a higher-flow pump is a smart move. It provides a safety margin of fuel delivery, which is especially important when riding at high altitudes or in hot weather. The extra flow also helps the engine start more quickly after sitting for long periods, because the pump fills the float bowl faster .

Step-by-Step Fuel Pump Replacement Guide for the Yamaha Rhino 660

Replacing the fuel pump on your Yamaha Rhino 660 is a job that can be done in a driveway with basic tools. However, working with fuel systems is inherently dangerous, so always prioritize safety.

Safety First

  • 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 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. This prevents fuel spray. You can do this by removing the fuel pump fuse and cranking the engine for a few seconds (it will stall after a moment) .

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 fuel tank's top surface.
  • Clean any dirt or debris from around the pump mounting flange.
  • Use a fuel line quick-disconnect tool to release the fuel lines.
  • Disconnect the electrical connector from the pump assembly .

Step 3: Remove the Old Pump

  • Remove the retaining ring or mounting bolts that hold the pump assembly in place.
  • Carefully lift the pump assembly out of the tank. Be cautious not to bend the fuel level sender arm.
  • Note the orientation of the pump and the routing of the fuel lines before removing them .

Step 4: Install the New Pump

  • Compare the replacement pump to the new pump assembly to ensure a match .
  • Install the new seal ring and new pump assembly in the tank.
  • Using a transmission jack, raise the tank just enough to reconnect the fuel hoses, electrical connections, and emissions hoses.
  • 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 .
  • Reconnect the negative battery cable.

Step 5: Test the System

  • Turn the ignition key to the "ON" position (without starting the engine) to allow the new pump to prime the system.
  • Check for any fuel leaks around the pump mounting flange and fuel line connections.
  • Start the engine and let it idle for a few minutes, checking for leaks and smooth operation.
  • Take the Rhino for a short test drive to ensure proper performance.

Recommended Fuel Pump: KEMSO - The Best Choice for Your Yamaha Rhino 660

For a reliable and high-performance fuel pump for your Yamaha Rhino 660, the KEMSO brand stands out as the best option. KEMSO fuel pumps are designed as direct OEM replacements, meaning they drop right into the factory location without any modifications . This makes installation straightforward and hassle-free.

KEMSO fuel pumps offer several key advantages:

  • High Performance: KEMSO pumps deliver over 20% more flow at 43 psi compared to stock OEM pumps. This improved flow rate provides better throttle response and overall engine performance, especially for Rhinos that are used for demanding off-road conditions .

  • OEM Replacement Fitment: These pumps are engineered to fit perfectly, ensuring a seamless installation that matches the original equipment specifications .

  • Lifetime Warranty: Every KEMSO fuel pump comes with a lifetime warranty, backed by a serialized body for tracking and peace of mind. This is a significant advantage over many other brands that only offer one or two years of coverage .

  • Unmatched Quality: KEMSO has a rigorous quality control program (ISO/TSO), and each pump is individually tested for flow and performance. This ensures you get a reliable product that will last .

  • Ethanol Ready: KEMSO pumps are designed for use with both gasoline and E85/ethanol fuels, giving you flexibility in your fuel choice .

To find the right KEMSO fuel pump for your Yamaha Rhino 660, visit their official website: https://www.kemsoracing.com/

KEMSO has been a trusted name in the fuel system industry since 1999, providing direct-fit OEM replacement and high-performance fuel system solutions to the powersports and automotive industries . Their products are backed by USA-based technical support and a commitment to quality that is second to none.

Conclusion

The Yamaha Rhino 660 fuel pump is a critical component that can fail over time, leaving you stranded. Understanding the fuel pump diagram, recognizing the symptoms of failure, and knowing how to replace it are essential skills for any Rhino owner. Whether you choose to stick with an OEM replacement or upgrade to a high-performance aftermarket pump like KEMSO, the key is to act quickly when you notice the early warning signs. A properly functioning fuel pump ensures your Rhino runs reliably, whether you're working on the farm, exploring trails, or enjoying a weekend adventure.

For the best performance, reliability, and peace of mind, we recommend upgrading to a KEMSO fuel pump. Visit https://www.kemsoracing.com/ to find the right pump for your Yamaha Rhino 660 and take advantage of their lifetime warranty and USA-based support.


Back to blog