'04 xb9sl fuel pump or electronics?

[Cooter]

Yes, just pull up. The injector o-rings can be stiff. I twist each injector a little bit to break the seal first.

Be aware the front and rear injectors are different so put a mark on one:eagerness:

 

[Barrett]

Yes, just pull up. The injector o-rings can be stiff. I twist each injector a little bit to break the seal first.

Be aware the front and rear injectors are different so put a mark on one:eagerness:

Be aware the front and rear injectors are different so put a mark on one


Why? Marked from factory. Red banded injector is front cylinder-----------white banded injector is rear cylinder.

 

[drootang]

To be safe I will mark them both since I don't see any red and white bands on mine.
Thanks for the tips on pulling the injectors. I rotated them, and pull/wiggled.

Here are a couple pics of the inlet and nozzle:




I was hoping it would be more obvious how to clean these, but after some digging it seems it not as simple as soaking in PB Blaster.

 

[Kurlon]

There is a place you can mail them to in Florida IIRC that does a great job testing, cleaning, re-testing and sending back with results/diags in a decent turn around time. I'll dig through my email later to try and remember who it was. Short form, it's hard to really clean them properly without being able to put them under working pressure and fire 'em.

 

[Cooter]

The home-brew way is to power them on and off with a 9V battery while spraying cleaner through them. Otherwise any 1/2 way decent auto shop near you should offer the service, especially a diesel shop. The small cost to have them cleaned by a pro seems worth it to me considering the effort to R&R them.

 

[Barrett]

Jeff: Your injectors are color coded as I mentioned. Clearly visible in your pics. They obviously need to be restored to factory efficiency. Use the link below and contact Chaz Aagaard to have them professionally serviced and brought back to new. He is a wonderful guy....he knows what he's doing and has been doing it a very long time. Integrity, quality work, reasonably priced. Tell him I sent you. Contact him on his site link.

https://aagaardmotofoundry.bigcartel...d-moto-foundry

 

[drootang]

I picked some alligator clip leads and manually pulsed each injector. I could not hear or feel any actuation. Sprayed them both with a little bit of carb cleaner and let it sit inside then tried again and I could clearly hear the solenoid in both of them. I wanted to be sure there was no major malfunction before getting them cleaned. Since they appear to be working its worth a good cleaning, filter basket replacement and proper o-rings.

Considering they did not feel functional before the carb cleaner I'm extremely optimistic this was the last major hurdle to get the motor started.

Will report back once the clean injectors are in and everything is reinstalled.

Thanks

 

[Cooter]

Try to have them under pressure (a tube from the cleaner) while activating them to get the pintle as clean as possible. IMO still worth a pro cleaning.

 

[drootang]

I had the injectors cleaned by Aagard Moto Foundry. Getting the fuel rail bolts back in and tightened without rotating the engine was extremely challenging. I hope to never do that again.

With the new battery, rebuilt pump, restored injectors, and new plugs (original OEM H-D plugs I bought back in 2007 and never used), she started right up!

Thank you so much to all who offered help! I'll surely be posting a few more threads on here at some point as there is likely a lot of work left to be done. Tomorrow I'll do a light road test and see how the brakes, clutch, gearbox, etc are working.

 

[Cooter]

So happy for you, glad we could help and I hope the test ride goes well:angel: