Removing Yamaha R6 Fuel Injectors
Removing the fuel injectors for service on a 2006 and up R6 won’t require any special tools, just a couple allen head wrenches, screwdrivers, and a pair of vice grips (not the tiny ones). R6s models or 2003-2005r6 will not have upper fuel injectors but the rest of the procedure for removing the lowers is about the same.
Start by removing the gas tank, and air box cover. The upper injectors (4 of them) are inside the cover. Remove the allen screws from the top that hold
the plastic underside to the cover. Then there are 2 allen screws holding the metal fuel rail on the inside. After disconnecting the wiring harness from the fuel injectors, remove the rail by rotating it forward. Be careful to not loose the rubber seals that hold the injectors in the air box cover. From there you need to begin removing the air box lower from the throttle body. There are allen screws you loosen at the base you access on the sides of the velocity stacks. After removing the breather hose on the back and disconnecting the wiring that controls the v-stacks, the air box will come off. Spray some brake clean around the base of the injectors to remove sand and dirt that could fall into the intake when removing the lower injectors.
Removing the fuel rail will require a good pair of vice grips, as the 2 screws that hold the rail in place are locktighted on from the factory. They will easily break loose with vice grips (no chance with a phillips screwdriver and I don’t bother with an impact driver, but that is what some use). Disconnect the injector connectors and remove the fuel rail. Some injectors will pull out of the throttle body while doing this, and again, be careful to not loose the rubber seals that hold the injectors in the throttle body. Shake any fuel out of the injectors, and carefully wrap them up, and prepare for shipping.
Send the injectors to ProFlow for ultrasonic cleaning and service
Here is a step by step tutorial.
remove the gas tank, have a rag under the fuel line. The 03-05r6 (and r6s) has 1 bolt at the front and one bolt at the rear that attaches to the subframe. The 06 and newer "race" model has those 2 but also one on each side behind the plastic side panel. the plastic side panels are held on with 1 small screw then slide forward.
disconnect the air box wires and breather hose. The multi-pin plug that goes to the airbox cover is tricky to undo, but actually only has 1 tab holding it in. It is not the outer tabs that you see. Figure this out and it comes apart easily.
unscrew the allen head screws that hold the air box bottom to the throttle body
the 2 fuel rail bolts have loctite from the factory, get a good bite on the phillips head with a pair of vice grips (much easier than pounding on it with an impact driver). they come right out.
after spraying the base of the injectors with brake clean to remove sand and dirt. Disconnect the electrical leads, carefully raise the fuel rail. Some of the injectors will want to come out with the rail. This is fine, but don't loose the rubber base gaskets that hold them in the throttle body. Some will come with the fuel injector, some will stay in the throttle body, but often at least 1 will fall out and on top of the engine into a tight spot.
Begin to take out the upper injectors, by removing the 4 allen head bolts on top of the air box cover.
With the air box cover upside down, There is a rubber cover for the injector wires and for the fuel rail. Push these inward. When putting this plastic part back, it is important to ensure it is seated in the cover properly before you tighten the 4 allen screws.
unbolt the upper fuel rail and roll it outward.
Remove the upper fuel rail and disconnect the wire leads. When removing the injectors, do not loose the rubber gaskets that hold them in place.
Obviously do the reverse when reinstalling the injectors, and be sure to have a light film of grease on the rubber o-rings. Be careful when rocking the fuel rails back on. Ensure you don’t have leaks by priming the fuel pump prior to putting the gas tank down.