My 02 cbr600 f4i is leaking fuel from where the fuel injector and fuel rail meet. It is leaking on all 4 injectors. I have replaced the o-rings on the bottom of the injectors (part# 16472-MCF-003), as well as the cushion rings (part# 16473-P10-A01) on the top of the injectors. I took off the fuel rail because I thought maybe the fuel rail was bent or cracked but it all looks fine. There are 4 notches on the top of each cushion ring that are causing the leak. When the fuel rail is tight, the injectors spin with a little force required similar to good fuel injectors in a car. The bike didn't leak fuel before it was all taken apart. I've attached pictures of the fuel injectors. The notches in the top o-ring are at 12, 3, 6, and 9 oclock.

Any advice? Thanks

 

Is return-line from FPR back to tank working?
If return isn't free & clear, pump will build excess pressure that'll force petrol through every O-ring and seal.

 

The hose is brand new and wasn't kinked when I stood the fuel tank up. The first time I set it all up, I never even primed the fuel tank. Fuel just ran into the hose and then leaked out when I tilted the fuel tank forwards. The FPR is a new honda part as well.
Is it possible that the injectors are stuck closed causing the leak to be through the path of least resistance? I wouldnt think thats the case because the bike was running before...

 

You don't mention replacing the o-rings on the top of the injectors, only the cusion ring? The o-ring is what's making the seal with the fuel rail.

91301-P2F-A01

https://www.hondasportpartswarehouse.../throttle-body

 

https://www.partzilla.com/catalog/ho.../throttle-body

In the diagram at that link, I replaced part #16 and #17 on each injector. I replaced them all because on each injector because I lost one of each.

Thanks

 

Part 22 is the important one - that's the actual seal. It sits in a ring on the injector. The o-ring in this image.

 

Wow, I think thats it. I cant remember exactly what mine looks like but I think it doesnt have the o-ring on there. I will recheck when I get home.

Thanks

 

Sometimes they get stuck in the fuel rail when you pull it off the injectors - they won't seal if they are simply pushed in the hole in the rail thought, they need to be in that groove.

 

I think I have them in the box with all the parts in it, I will check and update tonight.
Thanks