Replacing A Fuel Pump In A Yamaha Rhino: Step-By-Step Guide

If you're looking to replace the fuel pump on your Yamaha Rhino, you've come to the right place. This is a step-by-step guide on how to do it. First, make sure you have the necessary tools and parts, including a new fuel pump, socket set, and fuel line. Next, locate the fuel pump on your Yamaha Rhino, which is usually found near the engine. Disconnect the fuel lines and vacuum lines from the pump, being careful not to spill any fuel. Remove the old fuel pump by loosening the mounting bolts and lifting it out. Install the new fuel pump by bolting it into place and reconnecting the fuel and vacuum lines. Ensure all connections are secure to prevent leaks. Finally, start the engine and check for any leaks or issues. If everything looks good, you're done!

Disconnecting the fuel lines from the pump

• Remove the seats, engine cover, bed, and hood to access the fuel pump and related components.
• Locate the fuel lines connected to the pump. There should be two fuel lines attached to the pump.
• Before disconnecting the fuel lines, it is important to relieve the pressure in the fuel system. This can be done by relieving the pressure in the fuel rail or disconnecting the fuel pump fuse. Always refer to the vehicle's service manual for specific instructions.
• Once the pressure is relieved, carefully disconnect the fuel lines from the pump. You may need a fuel line disconnect tool or a pair of needle-nose pliers to do this. Be prepared to catch any residual fuel that may spill from the lines with a clean cloth or drip pan.
• After disconnecting the lines, it is a good idea to plug or cap the open ends of the fuel lines to prevent dirt or debris from entering the fuel system.
• Set the disconnected fuel lines aside, being careful not to kink or damage them.

Remember to work in a well-ventilated area and take the necessary precautions when working with fuel systems to avoid injury and ensure a safe working environment.

Removing the pump with a 5/16 socket

To remove the pump with a 5/16 socket, follow these steps:

First, remove the seats, engine cover, bed, and hood. Disconnect the fuel lines from the pump, but leave the vacuum line that leads to the intake manifold. Disconnect the vacuum line at the engine side. Now, use a 5/16 socket to remove the two bolts that hold the pump to the bracket. Save the pump.

At this point, you can install a new electric pump. Ensure that you install it in the correct direction.

Installing a new electric pump

Firstly, remove the seats, engine cover, bed and hood. Disconnect the fuel lines from the pump, but leave the vacuum line that leads to the intake manifold. Disconnect this at the engine side. Next, use a 5/16 socket to remove the two bolts that hold the pump on the bracket. Save the pump.

Now, take your red wire and thread it through the tunnel next to the engine, pulling it through under the hood and up to the battery box. This feeds the pump, so ensure it can be routed to the pump wires. You may need to zip tie it on.

Next, take another piece of red wire and measure how much you need, starting at the positive terminal and routing it to wherever you want your relay mounted. This is your power feed. Strip the ends and add a female flat connector to one end, and a ring terminal to the other. Set aside.

Repeat the above step with a black wire, starting at the negative terminal. This is your ground wire.

Now it's time to hook things up. Cut off the wacky plastic doodad on the end of the wires of the new pump. Cut and strip the wires. On the black wire, trim and add a split spade terminal. Loosen one of the mounting bolts and clamp the terminal between the bolt head and pump, then tighten the bolt. This is the pump ground.

Now, strip the end of the red wire you ran through the tunnel and add a butt connector, splicing it to the red wire on the pump. On the other end of this wire, strip and add another butt connector. Take the fuse holder and secure one of the wires with the butt connector. Add a female terminal to the other wire. Put the fuse in now, too.

Let's hook up the relay. Using the female terminals pre-installed, connect the pump feed wire via the fuse holder to pole 87, and then connect the red battery supply wire to pole 30. Connect the black ground wire to either 85 or 86. This leaves an empty terminal on the relay.

Locate the starter solenoid. It has two thick cables and three or four small wires coming out of it. Strip the black tape away from the small wires to give yourself enough to work with. Locate the small yellow wire with a blue stripe. Using yellow wire, measure a strip from the yellow solenoid wire to the relay location. Add a female terminal to one end. You now have two options: either use a quick splice connector or a wire nut. If using a wire nut, strip the other end. If using a quick splice, just leave it alone. If using a quick splice, place it over the solenoid wire, and insert the yellow wire you just made. Clamp it in and you're done! The wire nut method requires you to cut and strip the solenoid wire, and place both ends in a bundle with the new yellow wire, securing it with a wire nut.

Hook the other end of the yellow wire to the empty spot on the relay. Hook the black ground to the battery and turn the key on—the relay should click.

Hook the red battery feed to the battery and turn the key on. The pump should run. Don't leave it on for more than a few seconds.

Wrap up your relay and wires in electrical tape, and secure it to your mounting point.

Now, hook up the fuel lines. The line with the filter (supply line) goes on the bottom end of the pump. Use a new 6" line to go from the pump to the return tee. You will have to remove the existing line from the tee.

You need a pressure regulator. You can find your own or do what the writer of this guide did and use the old pump backwards. Locate the line coming from the carb and cut it in half. Install the old pump with the right-angle fitting on the supply side (from the new pump) and the straight side to the carb. Failure to do this correctly will result in all fuel going back to the tank and not reaching the carb. Please verify the flow before you go further.

Finally, you MUST use a small self-tapping screw to plug the vacuum port on the intake or it WILL NOT RUN CORRECTLY. Secure everything with zip ties to your satisfaction.

Routing wires to the pump

To replace the fuel pump on a Yamaha Rhino, you will need to route wires to the pump. Here is a detailed, step-by-step guide on how to do this:

Start by removing the seats, engine cover, bed, and hood. Disconnect the fuel lines from the pump, but leave the vacuum line that leads to the intake manifold. Disconnect this line at the engine side. Use a 5/16 socket to remove the two bolts holding the pump to the bracket. Save the pump, as you will need it later.

Next, take a red wire and thread it through the tunnel next to the engine, starting on the passenger side. Pull it through under the hood and up to the battery box. Ensure that this wire can be routed to the pump wires, as it feeds the pump. Secure the wire with zip ties where necessary.

Now, take another piece of red wire and measure how much you need, starting at the positive terminal. Route it to wherever you plan to mount the relay. This is your power feed. Strip the ends and add a female flat connector to one end and a ring terminal to the other.

Repeat the previous step with a black wire, starting at the negative terminal. This will be the ground for the relay.

Now it's time to connect everything. First, cut off the plastic doodad on the end of the pump wires and strip the wires. Trim the black wire and add a split spade terminal. Loosen one of the mounting bolts, clamp the terminal between the bolt head and the pump, and tighten the bolt. This is the pump ground.

Next, strip the end of the red wire you ran through the tunnel and add a butt connector to splice it to the red wire on the pump. On the other end of this wire, add another butt connector. Take the fuse holder and secure one of the wires with the butt connector. Add a female terminal to the other wire and insert the fuse.

Now, it's time to connect the relay. Using the female terminals provided, connect the pump feed wire via the fuse holder to pole 87, and then connect the red battery supply wire to pole 30. Connect the black ground wire to either pole 85 or 86.

Locate the starter solenoid, which has two thick cables and three or four small wires coming out of it. Strip the black tape away from the small wires to give yourself enough length to work with. Locate the small yellow wire with a blue stripe. Using yellow wire, measure the length from the yellow solenoid wire to the relay location, and add a female terminal to one end.

At this point, you have two options for connecting the wires: using a quick splice connector or a wire nut. If using a wire nut, strip the other end of the yellow wire. If using a quick splice, leave it alone. If using a quick splice, place it over the solenoid wire and clamp it in. If using a wire nut, strip the solenoid wire, and place both ends in a bundle with the new yellow wire, securing it with a wire nut.

Hook the other end of the yellow wire to the empty spot on the relay. Connect the black ground wire to the battery and turn the key on – the relay should click.

Finally, connect the red battery feed wire to the battery and turn on the key. The pump should run, but don't leave it on for more than a few seconds. Secure the relay and wires with electrical tape and mount it in your desired location.

By following these steps, you will have successfully routed the wires to the fuel pump on your Yamaha Rhino.

Testing the new pump

Now that you've installed the new fuel pump, it's time to test it to ensure it's functioning correctly. Here are the steps you should follow:

• Reconnect the Battery: Ensure the battery is connected and turn the key to the "On" position.
• Listen for the Pump: With the key on, you should be able to hear the fuel pump running. It will only run for a few seconds, so don't worry if it stops after a brief period.
• Check for Fuel Leaks: Inspect all the fuel lines and connections you've made to ensure there are no leaks.
• Crank the Engine: Try to start the engine. If it doesn't start right away, don't worry. Starting issues are common after replacing the fuel pump, and further adjustments may be needed.
• Check Fuel Flow: If the engine doesn't start, ensure that fuel is reaching the carburetor. You may need to crank the engine over several times to build up fuel pressure. Check the fuel filter and lines for any blockages.
• Adjust the Carburetor: If the engine starts but won't idle properly, you may need to adjust the carburetor. This can involve making adjustments to the idle screw, checking for air leaks, and ensuring proper throttle cable function.
• Test Drive: Once the engine is running smoothly, take the Yamaha Rhino for a test drive. Ensure that it accelerates, idles, and runs consistently.
• Monitor Fuel Consumption: Keep an eye on your fuel consumption during the initial test drives. A faulty fuel pump can lead to increased fuel consumption, so ensure that your fuel economy returns to normal levels.
• Regular Maintenance: Regularly check the fuel pump and lines for any signs of wear or damage. This will help prevent future issues and ensure the long-term reliability of your Yamaha Rhino.

Remember, safety should always be a priority when working on your Yamaha Rhino. If you're unsure about any aspects of the fuel pump replacement or testing process, don't hesitate to consult a qualified mechanic.

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