4.31
Fuel Systems
4
3. Remove the hex screws securing the fuel rail it to the
cylinders.
4. If replacing a lower injector, remove the two bottom screws
bolts from the lower fuel rail.
5. Remove the failed injector(s).
NOTE: Make sure that the green rubber washer
comes out with the failed injector(s).
6. Measure from the end of the injector (as shown below)
3" (76.2mm) and cut the injector off.
7. Strip the harness end injector wire covering .25" - .375"
(6.35 - 9.525mm).
8. Crimp the ends of the new injector firmly on to the wire
harness.
9. Tape exposed wire and splices (11).
10. Apply 2-stroke oil to the fuel injector o-rings, seal and
mating surfaces (fuel rail & case sides).
11. Remove the fuel injector cap.
12. Insert the fuel rail, with injectors into the engine.
13. Apply a light amount of 262 Loctite® to the fuel rail
fasteners and torque to specification.
14. Replace the harness to the original routing and apply
panduit straps back to the original locations, making sure
they are not applied over any mesh part of the fuel rail.
NOTE: Refer to Step 2 for proper routing and strap
location.
15. Install the engine if it was removed.
16. If different color injectors were installed you will need to
re-flash the ECU to accept the new colors.
WASHER
3” (76.2mm)
= T
Fuel Rail Hex Screw Torque: 9 ft-lb (12N-m)
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