EXUP Maintenance

[Tefer]

Hi, I got my FZS1000 last year and have not really done a lot of miles so far. I have been dreading the exup maintenance as I am not that great with a scanner but have been trying more and more lately.
Today I got the cover of to show me the cables and pulley. I tried to remove the Allen bolts to all me to look at the valve but they are stuck solid. I have sprayed some WD40 on them and will continue too, is there anything else I can do? I only have an Allen key rather than a Allen socket. I am scared to shear a bolt. Can I heat these?

I have been reading the guide from Pats site and this is helpful.

P.s one of the 8mm bolts is missing, where can I source a replacement.

[Falcon 269]

Full marks for having a go but this isn't a task to take on without the right tools and - if the bolts are seized - perhaps a bit of prior experience of dealing with difficult extractions.

WD40 isn't good enough as a penetrating oil and even with the right stuff, you still will need a proper-fitting socket head wrench.  The odds are still pretty high that you'll troubles with sheared off bolt heads.

Lots of 'how to' posts on the forums - here's one I made earlier dealing with two very recalcitrant R1 EXUPs, which are identical to the Fazer's:

http://fazerowners.yuku.com/topic/21517

Good luck!

[Tefer]

Hi Mike,

Thanks ordered some plusgas and will use this to soak the stuff over a prolonged period. Partners brother is a motor mechanic so will have better tools and knowledge of problematic extractions.

I see in some of the comments in the link you posted it mentions replacing the old and replacing with stainless, top of your head any sizes and  types so I can order too?

[Tefer]

Some pics.

[Falcon 269]

Top of my head?  M6 x 10mm should be about right for the pulley cover, maybe a bit longer for the valve end plate. 

[robbo]

Measured the necessary bolts only the other week.The cover is M6 x 10mm the valve M6 x 16mm the pulley centre is M5 x 12mm and the cover on the other end of the valve (RH side of the bike) is M4 x 6mm.

[Tefer]

Measured the necessary bolts only the other week.The cover is M6 x 10mm the valve M6 x 16mm the pulley centre is M5 x 12mm and the cover on the other end of the valve (RH side of the bike) is M4 x 6mm.

Thanks man