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Bikes, Hints'n'Tips => Fazer 1000/FZ1 corner => Topic started by: Tefer on 16 April 2016, 05:37:15 pm

Title: EXUP Maintenance
Post by: Tefer on 16 April 2016, 05:37:15 pm

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.

Title: Re: EXUP Maintenance
Post by: Falcon 269 on 16 April 2016, 06:39:45 pm

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

Good luck! :)

Title: Re: EXUP Maintenance
Post by: Tefer on 17 April 2016, 09:35:11 am

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?

Title: Re: EXUP Maintenance
Post by: Tefer on 17 April 2016, 09:43:13 am

Some pics.

Title: Re: EXUP Maintenance
Post by: Falcon 269 on 17 April 2016, 11:04:43 am

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

Title: Re: EXUP Maintenance
Post by: robbo on 18 April 2016, 09:17:40 am

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.

Title: Re: EXUP Maintenance
Post by: Tefer on 18 April 2016, 10:17:10 am

Quote from: robbo on 18 April 2016, 09:17:40 am

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