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September 6th, 2011, 07:22 PM   #1
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How do you replace the injector?

I need to replace or clean my injector (2010 FE450). I can't seem to find instructions on how to do so. Are there any published instructions or photos anywhere? If not, can someone list the basic steps along with any tips on how to do the job without introducing new dirt?

It seems that I got something in the line while replacing the fuel pump and/or installing the in-line filter.
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September 7th, 2011, 01:14 AM   #2
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Re: How do you replace the injector?

The procedure is virtually the same as checking your valve lash check it here big shout out to Davo for putting in the hard yards viewtopic.php?f=5&t=14416. When you get the tank off seal everything up and clean thoroughly avoid using pressure cleaners or high pressure air.
remove the air box and this will give you access to the throttle body. You will need to remove the wiring plug to the TPS, injector and the Map sensor, then loosen the hose clamp holding the throttle body to the spigot. You can then swing the TB clear with the trottle cables still connected, its a matter of removing the phillips head screw holding the fuel rail on and then the injector will come out with a little force as the o-ring is a snug fit.
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September 15th, 2011, 07:56 AM   #3
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Re: How do you replace the injector?

Do I really need to pull the whole throttle body off to swap out the injector?

When I installed (and later removed) the in-line KTM filter, I just tipped the bike onto the right side and pulled the fuel rail off. Can I get the injector out this way as well? Or do I really need to disconnect the TPS and map sensor and pull the throttle body off the boot.

I have the tank and radiators off already and my replacement injector came yesterday, so I am hoping to swap the injector tonight.
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September 16th, 2011, 03:47 AM   #4
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Re: How do you replace the injector?

from memeroy yes you do have to remove the TB, at any rate it would be a good opportunity to to inspect the TB and also apply a lillle di-electric grease to the electrical connections for added reliabillity and peace of mind. As long as the frame and harness/hoses are sanitary there should be no dramas with ingress of foreign material.
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September 16th, 2011, 04:31 AM   #5
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Re: How do you replace the injector?

I swapped out the injector last night, and yes, I did have to partially remove the throttle body. What a pain that was. I made the mistake of loosening the bottom boot clamp first, which made it really hard to get the air box off. And I couldn't figure out how to get the electrical connectors off. The latches often seem to elude me.

I tried cleaning the bike good before starting, but there was still a fair amount of dirt stuck to everything. I then used a contact cleaner and paper towel to clean it up more, but it was still kind of dirty. I hope I didn't get any dirt in the system or damage the electrical connections. I haven't yet put it all back together for a test.
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September 17th, 2011, 04:23 AM   #6
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Re: How do you replace the injector?

hope you had a win mate. I know how frustrating it can be to deal with injector dramas. Could you possibly have the old injector serviced and share the before and after test results ? And perhaps post up how she runs with the new unit installed ?
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September 17th, 2011, 08:26 AM   #7
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Re: How do you replace the injector?

This morning I temporarily hooked up my fuel tank so I could test it. It fired right up and ran great. I couldn't ride it, but I let it run without airflow for quite some time. It took a long time for the fan to come on. On my last ride the fan was on almost all the time. My newly installed temperature gauge indicated the fan came on at about 215 degrees F. My max temp was 217. I am sure it was much hotter than that on my last ride.

Since I changed the fuel pump, the inline filter, and the injector, it is hard to be certain that the injector was the problem, but I suspect it was. I will see if I can get it tested, but it may be fixed now anyway. When I took it out I tapped it above a paper towel. A few small black chunks fell out. I am not certain they came from the inside, but I wonder if they were small bits of fuel line from when I cut the hose to install the CanAm filter. Although that was long ago.
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November 12th, 2011, 09:56 AM   #8
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Re: How do you replace the injector?

Hi,

i'll have to do the same operation, how did you clean the injector? Could you please provide some details?

Thanks a lot
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November 12th, 2011, 04:55 PM   #9
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Re: How do you replace the injector?

I had a friend that is an amateur auto mechanic clean mine. Some auto shops can do it. Or you can do it yourself. I watched some YouTube videos that showed how to hook up a test jig. You need to power the injector to get it to open up, and then spray some cleaner through it.
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November 12th, 2011, 05:59 PM   #10
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Re: How do you replace the injector?

Originally Posted by DeeG
I had a friend that is an amateur auto mechanic clean mine. Some auto shops can do it. Or you can do it yourself. I watched some YouTube videos that showed how to hook up a test jig. You need to power the injector to get it to open up, and then spray some cleaner through it.
I did the same thing 40 hours ago (run-time) and haven't had a problem since...
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