Kawasaki J300 - Service manual > Fuel Injector Removal

WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTICE Never drop the fuel injector especially on a hard surface. Such a shock to the injector can damage it.

NOTE

• Ensure the fuel hose without any pressure, and then remove the fuel injector.

STEP 1: Disconnect the fuel pump connector.
STEP 2: Turn the ignition switch on. Starting the engine until the engine stop working.

• Remove the storage box (see Storage Box Removal in the Frame chapter).
• Disconnect the fuel injector connector [A].
• Remove the fuel injector mounting bolt [B].

• Remove the fuel injector [A] from the fuel pipe [B].

Fuel Injector Installation

• Replace the O-ring [A] and dust seal [B] with new ones.

• Apply engine oil to the O-ring and dust seal.
• Install the fuel injector to the fuel pipe.
• Install the fuel injector to the intake manifold so that the tabs [A] fit the fuel injector [B] and the projection [C] inserts into the hole [D].
• Tighten:
  Torque - Fuel Injector Mounting Bolt: 9.8 N*m (1.0 kgf*m, 87 in*lb)

Fuel Injector Audible Inspection

NOTE

• Be sure the battery is fully charged.

 

• Remove the storage box (see Storage Box Removal in the Frame chapter).
• Start the engine, and let it idle.
• Apply the tip of a screwdriver [A] to the fuel injector. Put the grip end into your ear, and listen whether the fuel injector is clicking or not.
  • A sound scope can also be used.
  • The click interval becomes shorter as the engine speed rises.

  If the injector click at a regular intervals, the injector is normal.

• Turn the ignition switch off.

  If fuel injector dose not click, check the fuel injector resistance (see Fuel Injector Resistance Inspection).

Fuel Injector Resistance Inspection

• Turn the ignition switch off.
• Remove the storage box (see Storage Box Removal in the Frame chapter).
• Disconnect the injector connector.
• Connect a digital meter [A] to the injector terminal.
• Measure the fuel injector resistance.

  Fuel Injector Resistance
   Standard: About 10.5 +-0.53 Ω @20ºC (68ºF)

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