2006 Suzuki GSX-R750 Fuel Injectors: Disassembly, removal, rebuild, test

Spent some time removing the fuel rail from my 2006 Suzuki GSX-R750 to troubleshoot from rough running conditions. Note - removing the fuel rail itself is not an easy task due to the screw choice used on these bikes (Philips head screw, tightened on with extreme torque). In the end, I had to remove the entire throttle body assembly to be able to get access to the screws holding fuel rail down, in order to remove and inspect the 8 injectors. I ended up using a Dremel tool on the heads of the 4 screw fuel rail screw heads that refused to come out easily. Once the bolts were off, I decided to use 4 hex bolt on the fuel rail, to make it easy to remove fuel rail in future, without needing to remove entire throttle body assembly.
All 8 injectors were removed from the bike once fuel rail was removed from throttle body. The injectors were all inspected, cleaned and refitted with new o-rings and mini-filters after getting an injector rebuild kit from Ebay for about $20. All injectors were also electrically tested to make sure the solenoid inside them worked as expected before fitting the injectors back to the rail.
In order to avoid tearing the o-rings on installation, which would not seal the high pressure fuel properly, it is imperative to apply a small amount of grease to the o-ring before installing on the rail. This makes the installation a snap and only takes a few seconds/injector to do properly. Once the lube had been applied to each injector o-ring, they were installed on the fuel rail, one at a time, and the fuel rail re-installed on the bike with the new hex bolts.
Next steps were simple - reconnect all wiring for all injectors, re-connecting the throttle position sensor and motor for controlling intake air, attaching the fuel tank hose to the fuel rail, and fuel pump electrical connector. Lastly, the air box was re-installed, making sure to attach the 2 rubber hoses on the top and side. It's also important to make sure the air box to the 4 throttle body intakes are all tightened to form a good air tight seal.
Once all put back together, and all connections tightened the bike was fired up to see how it sounded. Sounds good!
Next steps are a test ride, but it seems like it's running way better with the injectors all cleaned now.
Link to injector rebuild kit I purchased on Ebay:
From user hot_rods_and_harleys: www.ebay.com/i...

[@Dunkensb]

Did you have to buy two kits or was the kit for all eight injectors?

[@nPlus.1]

I only purchased 1 kit. The kit is good for 4 injectors. The kit I purchased contains:
4 - Inlet screens
4 - Viton Upper O-rings
4 - Upper seals
4 - Lower seals
Total of 16 pieces

[@teamcru]

Where did you get the hex bolts from for the fuel rail ?

[@kuby999]

I had a few lying around that fit. But you can easily find something at any hardware store like Home Depot, Ace Hardware, or if you're in Canada, Canadian Tire. : )

[@cbx1168]

Great tutorial; any link to kit on ebay? Thanks

[@nPlus.1]

Thanks- hope it’s of help for you. Yep, details of kit are in the description. Cheers.

[@cbx1168]

Any tips on removing the injector harness 'plugs'? Thanks

[@nPlus.1]

@@cbx1168 - Do you mean the electrical plug to the injector or removing the injector from the rails? Both should be fairly straightforward.

[@cbx1168]

Removing the lower electrical plug from the injector

[@nPlus.1]

@@cbx1168 If I recall from when I did this, the lower ones have a similar style plastic connector holding them on to the injector; a small tab that needs to be depressed, before you can pull them off. They can be a bit stubborn to get off if you don't press it far enough. If you disconnect your fuel line from the fuel rail, and remove the screws holding the rail, it might be easier to disconnect them - as you can gain more access with your hands in the cramped space. You can also refer to the details I left in the video description when video was first posted.

[@rideritikkuning2373]

need dyno if change injector ?

[@kuby999]

if you care, sure. I didn't - I just wanted to get it functional again. i know how fast this bike is when it's working well. Broke it in on the track the day I bought it. :)