Bike is just a hair away from 170000 kms now and for the past month it has been surging and idling a little rough, so decided to give the injectors a cleaning.
Before going into this, nearly every post I could find online states that you need to remove the throttle bodies to remove the injectors, Not true, and here's how I did it.
(I did snap these pics when putting it back together, thats why you see fresh o ring grease, You will need that on all seals to get everything to slip back together easilly without pinching them.)
First, Remove your seat, fuel tank and airbox. All easilly done with tools in the KTM kit.
Next, you will need to remove these 2 screws, they are in there good, and I needed to use an impact screwdriver to break the torque without stripping them.
![Image]()
Next, take a large flat blade screwdriver to seperate this crossover fuel tube between the injectors. once they are seperated, you can just pull upward on the injectors and it will pop out. this is what it looks like with one removed already. Refer to the pic above to see what they look like when joined, you can see I nicked the plastic a little bit with a small screwdriver, before I got a larger one that worked better.
![Image]()
Now, once you have them removed, you have to pull the injector out of the plastic housing thing, just a good tug and it will pop out, more orings that will require lube before re installing.
Before..
![Image]()
After...
![Image]()
Once you have the injector to this point, now you just need to give it power to open the lifter inside. I just made some jumpers with wire and small connectors, and attached them to the bikes battery. Once it's powered you will hear it click, then spray carb cleaner through the injector in the same direction that gas would normally flow, I just shoved a small straw on my carb cleaner can and poked it into the hole on the top of the injector, at first it looked like a forked piss stream, but in a couple seconds all the other holes opened up and it was a nice spray pattern. Dry with some compressed air, and re install.
If you want to see "how to vids" on fuel injector cleaning, just look on youtube, lots of vids, and all generally the same process no matter the vehicle. Also at first I tried using a AA battery, and it wasn't enough power, so hooked directly to the bikes batt, and worked great.
Hope this is helpful to some of you. It really made a huge difference in my bike today.
Before going into this, nearly every post I could find online states that you need to remove the throttle bodies to remove the injectors, Not true, and here's how I did it.
(I did snap these pics when putting it back together, thats why you see fresh o ring grease, You will need that on all seals to get everything to slip back together easilly without pinching them.)
First, Remove your seat, fuel tank and airbox. All easilly done with tools in the KTM kit.
Next, you will need to remove these 2 screws, they are in there good, and I needed to use an impact screwdriver to break the torque without stripping them.
Next, take a large flat blade screwdriver to seperate this crossover fuel tube between the injectors. once they are seperated, you can just pull upward on the injectors and it will pop out. this is what it looks like with one removed already. Refer to the pic above to see what they look like when joined, you can see I nicked the plastic a little bit with a small screwdriver, before I got a larger one that worked better.
Now, once you have them removed, you have to pull the injector out of the plastic housing thing, just a good tug and it will pop out, more orings that will require lube before re installing.
Before..
After...
Once you have the injector to this point, now you just need to give it power to open the lifter inside. I just made some jumpers with wire and small connectors, and attached them to the bikes battery. Once it's powered you will hear it click, then spray carb cleaner through the injector in the same direction that gas would normally flow, I just shoved a small straw on my carb cleaner can and poked it into the hole on the top of the injector, at first it looked like a forked piss stream, but in a couple seconds all the other holes opened up and it was a nice spray pattern. Dry with some compressed air, and re install.
If you want to see "how to vids" on fuel injector cleaning, just look on youtube, lots of vids, and all generally the same process no matter the vehicle. Also at first I tried using a AA battery, and it wasn't enough power, so hooked directly to the bikes batt, and worked great.
Hope this is helpful to some of you. It really made a huge difference in my bike today.
