2004 bandit 1590 running out of fuel under hard load

[Jstihl]

Glad to hear it’s running so well for you now, cheap fixes are always nice!

The age of the injectors will determine whether they need replaced or not, a good diesel shop can pop test them for you and will be able to see if they’re working correctly. If they’re original though, it’s probably about time to think about changing them if they’re in the 5000 hour range.

Changing the injectors on that engine should be fairly easy, but you will need a slide hammer, if I remember correctly. (It may be possible to pull them with a prybar, but it definitely won’t be nearly as easy!) We have an 07 1590 with the same engine, so I presume the change is similar. Our diesel shop can change them in about two hours, so it’s worth the labor to us to have them done professionally.

I can’t speak to the AutoFeed, I don’t know much about those, unfortunately.

I was just looking through the manual for my chipper and turns out it's much more extensive than most manuals. These injectors have a gland nut at the top to hold them in place. The manual doesn't mention a slide hammer for removal or install, does your injectors have a nut at the top?

 

[Reach]

I was just looking through the manual for my chipper and turns out it's much more extensive than most manuals. These injectors have a gland nut at the top to hold them in place. The manual doesn't mention a slide hammer for removal or install, does your injectors have a nut at the top?

I should remember, but I don’t. I believe they have a retaining bolt instead, and then are popped out with a slide hammer. Pulling the valve cover should not be too hard, if you’re a competent diesel mechanic, you should be able to find out pretty quickly if it can be done without a slide hammer. And if it can’t be, Advanced Auto or Harbor Freight should have a cheap slide hammer for you. Advanced may even have a loaner, but that’s hard to say for sure.