After getting error code 7 on the rev counter, I've done the EXUP valve service as described on the excellent website here (http://www.cartestsoftware.com/fz1/exupmaintenance.html), but am still getting the same error code.
I've had the valve out, it was slightly sticky around the bracket, nothing major, and wasn't returning to the correct position - but now it's all greased up and moving great, I can rotate the valve fully by hand, the servo returns it to the correct position on turning the key. No major corrosion down there - all looks pretty good. Only I'm still getting the error code 7. Just ridden it for two hours. Still getting code 7.
When I start it up the valve moves open by about 10-15 degress or so, on tickover. Rev it up to about 6-7000 on the centre stand in neutral and it moves a little bit further - at most about 30- degees from the starting position (11 o'clock), moves quite slowly, nowhere near the maximum I can move it by hand (to about the 2 o'clock position), though I don't know how far it's supposed to turn itself. Turn the engine off and it stays slightly open, but then returns back to line up with the hole again next time I turn on the ignition.
Only thing I can think of is cable tightness - I can tighten them more, but then the servo struggles to move it. I am getting near the end of the adjusters, so wondering whether the cables can't get quite tight enough. I've tried tightening more, and loosening off, but still getting number 7 on the rev counter.
The only way I can test the tightness is by pinching the two cables together on the pulley - they both move about 1mm at most, which I thought was supposed to be about right.
Any ideas? Don't really want to resort to taking it to a garage!