Replacing Fuel Injection In A 2005 Gsr750: Step-By-Step Guide

The fuel filter on a 2005 GSR750 is located inside the fuel tank at the base of the fuel pump. To replace the fuel injection, you will need to remove the pump to access the filter. It is important to note that contamination is the leading cause of premature fuel injector failures, so it is crucial to work in a clean space and carefully follow the manufacturer's recommendations during the replacement process.

Prepare your service area

Having a spotless service area is essential when replacing fuel injectors. Contamination is the leading cause of premature fuel injector failure, and it can occur at many points during installation. Here are some steps to prepare your service area:

• Ensure your service area is clean and free of contaminants.
• Have all the necessary tools easily accessible. This includes specialty tools designed for injector replacements and multi-use torque wrenches.
• Do not unbox the new injectors until you are ready to install them.
• Have a clean space available to unbox and prepare the new injectors for installation.
• Make sure you have the correct replacement injectors for the specific engine and vehicle.
• If possible, have a second technician assist you during the replacement process to ensure accuracy and efficiency.

By following these steps, you will help ensure that the fuel injector replacement process goes smoothly and reduce the risk of contamination or damage to the new injectors.

Remove the old injectors

To remove the old injectors from your 2005 GSR750, you will need to first remove the fuel tank. This will give you access to the fuel pump and filter, which are located inside the fuel tank at the base of the fuel pump.

Once you have located the fuel pump, you will need to disconnect the two fuel lines, the supply and return lines. These can be challenging to disconnect, so it is recommended to use a specialised tool such as a 5/16 inch scissor-type locking tab fuel line separator tool.

Next, you will need to remove the electrical connectors from the injectors. There is a plastic locking clip on each connector that you will need to carefully unhook. Do not pull the plastic locking clip all the way out, as this is not necessary and may cause damage.

At this point, you should be able to remove the fuel injectors. It is recommended to take note of the order and orientation of the O-rings and spacers, as these will need to be re-installed correctly when installing the new injectors.

Finally, once the old injectors have been removed, it is a good idea to clean the injectors and the fuel system to remove any built-up deposits or contaminants. This can be done using a specialised fuel injector cleaning solution or by sending the injectors to a professional cleaning service.

Clean the engine and prepare new injectors

Clean the Engine

Before you begin, ensure your engine is cool to the touch. You don't want to risk burning yourself. Next, cover any sensitive areas, such as the air intake and electrical components. Then, use compressed air to blow away loose dirt and grime.

Now, it's time to degrease. Spray a motorcycle-specific degreaser generously on areas with a buildup of grease and grime. Allow the degreaser to sit for a few minutes before moving on to the next step.

Use a soft-bristled brush to scrub away at the degreased areas, focusing on those hard-to-reach spots. Continue scrubbing and washing until all grease and grime are removed.

Once you're satisfied, give your engine a thorough rinse with clean water to ensure all degreaser and soap residue is removed.

Finally, dry your engine with microfiber cloths. You can use compressed air for hard-to-reach areas. If you wish, apply polish to any chrome or metal surfaces for added shine and protection.

Prepare New Injectors

Retrieve your new injectors and carefully remove them from their packaging. Lubricate each injector in advance of installation.

It's important to note that you should only unbox your new injectors when you're ready to install them, as contamination is the leading cause of premature fuel injector failure.

Before installing the new injectors, ensure that the seating area for the injector and the hold-down bolts are clean.

Additionally, consider replacing the O-rings during installation, as they can become damaged in the process, leading to poor injector performance.

Install the new injectors

To install the new injectors on your 2005 GSR750, you should begin by carefully removing them from their packaging and lubricating them in advance of installation. It is important to note that injector nozzle tips are microscopically small, so you should be careful to avoid any contact or contamination that could impact their functionality.

Once ready, delicately press each new injector into its cylinder by hand, guiding it carefully to ensure the injector tip doesn't encounter anything that could cause damage. The injectors should fit firmly into the cylinder with minimal effort. If they do not, do not use a hammer or any other blunt instrument to force them into place.

After an injector is positioned, use a hold-down clamp to lock it into the cylinder. You can use a specialty torque wrench to torque the bolt of the hold-down clamp and ensure proper torque and torque angle.

Finally, follow any manufacturer recommendations for additional steps or components that may need to be replaced during the installation process.

Secure the injectors

To secure the injectors, technicians should ensure that the injectors fit firmly into the cylinder with minimal effort. No hammer or other blunt instrument should be used to force the injector into place. Instead, technicians should delicately press the injectors into the cylinder by hand, being careful to guide the component and avoid any potential damage to the injector tip. Injector nozzle tips are microscopically small, so it doesn't take much contact or contamination to impact their functionality.

Once the injector is positioned, a hold-down clamp should be used to lock the injector into the cylinder. A specialty torque wrench is recommended to torque the bolt of the hold-down clamp and ensure proper torque and torque angle. It is important to follow the manufacturer's recommendations during this process, as different engines and injector systems may require additional steps or component replacements.

O-rings, for example, are prone to damage during installation and can lead to poor injector performance if not lined up properly. Therefore, it is crucial to follow the manufacturer's guidelines and take extra care when securing the injectors to avoid any potential issues.

Frequently asked questions