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+--- Thread: Exup seized solid...HELP! (/showthread.php?tid=63825)
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Exup seized solid...HELP! - nickodemon - 07-06-13
My mate just bought a fazer 1000 gen 1 from barnowl, as it was advertised with a low mileage, new oil and filter and service to exup valve, so i sent him to England to pick it up. He contacted me not far from where he bought the bike to tell me there was a 7000rpm fault code. I told him the exup valve must be sticking. He brought the bike round tonight, so i could free off the valve, but it was seized solid. I removed the valve with the housing attached and soaked in penetrating fluid. It wouldn't rotate, so i used a blow torch more penetrating fluid, freeze spray, rubber mallet, but it wouldn't budge a mm. The valve and the housing plate are totally fused together. Any suggestions to getting it free from the housing plate? Can i drill out the collar between the valve and the housing plate, so it will seperate and buy a new collar?
Re: Exup seized solid...HELP! - steeeve66 - 07-06-13
Your best, and safest, option might be to take the unit to an engineering outfit with a workshop to sort it for you? Could be as little as 50 quid and prob no more than 100. It's a pain but its better than damaging the valve.
S
Re: Exup seized solid...HELP! - nickodemon - 07-06-13
The exup valve comes out the collector box. It wont come off the plate, which holds the cable holder in place with an 8mm nut.
Re: Exup seized solid...HELP! - unfazed - 07-06-13
Why remove the headers when he already has the valve out? :rolleyes :lol
I presume you have removed the pulley?
Immerse the housing plate in penentrating fluid and leave it overnight.
Heat the housing but keep the heat away from the valve shaft and when it cools down immerse it in penetrating fluid again overnight if possible. Do not cool it with the fluid.
Now immerse the valve in ice, leave it immersed for an hour and then heat the housing only. That should get it moving. If not repeat the process. It is important to let the heated itms cool naturally.
You can always try the local machine shop if the above does not work. I have freed most thing as described but it is very time consuming.
Take care not to distort the valve. Remember the valve, housing, collar and bushes are over £250 new to buy. which is your final option.
Re: Exup seized solid...HELP! - steeeve66 - 07-06-13
(07-06-13, 11:29 PM)unfazed link Wrote: Why remove the headers when he already has the valve out? :rolleyes :lol
I presume you have removed the pulley?
Immerse the housing plate in penentrating fluid and leave it overnight.
Heat the housing but keep the heat away from the valve shaft and when it cools down immerse it in penetrating fluid again overnight if possible. Do not cool it with the fluid.
Now immerse the valve in ice, leave it immersed for an hour and then heat the housing only. That should get it moving. If not repeat the process. It is important to let the heated itms cool naturally.
You can always try the local machine shop if the above does not work. I have freed most thing as described but it is very time consuming.
Take care not to distort the valve. Remember the valve, housing, collar and bushes are over £250 new to buy. which is your final option.
It was the beer talking, not reading rather - amended now...
Re: Exup seized solid...HELP! - unfazed - 07-06-13
Guessed as much but could not resist the comment :rollin
Re: Exup seized solid...HELP! - Dave48 - 08-06-13
As said-repeated cycles of heating housing, cooling & penetrating fluid should free it eventually. Otherwise engineering shop visit. Yamaha certainly know how to "Add Value" to metal- £250! :eek
Re: Exup seized solid...HELP! - Falcon 269 - 08-06-13
Don't despair and start doing radical stuff just yet, Nick.
I had the same problem with a couple of R1 EXUPs a few years ago. Freeze, heat, pen fluid, repeat.
http://fazerowners.yuku.com/topic/21517/EXUP?page=2
If that proves inadequate, take it to an engineering shop who have the gear to do the same but to an industrial scale.
Re: Exup seized solid...HELP! - nickodemon - 08-06-13
I have done heat, freeze, silkopen fer a few hours last night to no avail, so he's off to bike shop with it. They will be able to put more heat on it and will no doubt have a better vice than my one. Let you know how he gets on. Will he need to replace the collar if it free's off? Can a good clean and a bit of emery paper do the job?
Re: Exup seized solid...HELP! - nick crisp - 08-06-13
I would have thought that you might as well replace the bushes anyway while it's all apart?
Re: Exup seized solid...HELP! - sirgalahad3 - 08-06-13
Leave valve in a bucket of diesel for a week then use the heat/cold technique. That will do it.
Re: Exup seized solid...HELP! - Falcon 269 - 08-06-13
Both the R1 valves shown in the link above went back together with the original parts and they work fine.
Re: Exup seized solid...HELP! - nickodemon - 08-06-13
Bike shop heated it to an inch of its life and did whatever to get it to come out and it eventually freed off, but it is apparently slightly bent, so when fitted it won't rotate. Don't know if it can be straightened or better getting a new one :'( Next question - has anyone got one?
Re: Exup seized solid...HELP! - Falcon 269 - 08-06-13
It will straighten. I've done a few. Just have to be patient and keep easing it straight while ensuring the spindles are aligned with each other.
You don't want to be buying a replacement just yet.
Re: Exup seized solid...HELP! - nickodemon - 09-06-13
Cheers Mike, i will take a look at it.
Re: Exup seized solid...HELP! - nickodemon - 09-06-13
- I have checked online for new exup valves 4SV-14821-00-00 and i can get one from america for $240 'ron ayers' , which is approx £150. Are all fazer 1000 gen 1 exup valves the same in UK as USA? I will try to straighten the original valve first.
Re: Exup seized solid...HELP! - b1k3rdude - 09-06-13
(09-06-13, 12:56 PM)nickodemon link Wrote: [size=1em] I will try to straighten the original valve first.[/size]This is very easy, just get a drill (with speed control) and a rubber mallet.
1. put the valve in the the drill and then slow rotate the valve looking for worst off-set point.
2. give the valve a gentle wack with the mallet in the opposite direction to the offset, repeat this untill its as good as you can get.
3. take the valve out and turn it around putting the oppsite end in the drill
4. do everything in part 2.
The above only works in the exup valve is only offset but small/medium amount, if its more then take it to an engineering shop witht thay will do the above method bu using an overhead drill (which is fixed so valve is easier to wack with mallet etc)
I have done this a few times for people.
Re: Exup seized solid...HELP! - Tmation - 09-06-13
I straightened mine between soft jaws in a vice. I just tightened the vice a bit , released it and checked for straightness. Repeated until straight. I cleaned the spindle ends with emery paper until they were a slightly loose fit, copper greased it all up and bobs your aunty.
I first serviced mine at about 1500 miles and it came out bent, since I put it right its been fine since.
Re: Exup seized solid...HELP! - nickodemon - 09-06-13
(09-06-13, 04:25 PM)Tmation link Wrote: I straightened mine between soft jaws in a vice. I just tightened the vice a bit , released it and checked for straightness. Repeated until straight. I cleaned the spindle ends with emery paper until they were a slightly loose fit, copper greased it all up and bobs your aunty.
I first serviced mine at about 1500 miles and it came out bent, since I put it right its been fine since.
Thats exactly what i did and it's now working. The thing i forgot to mention was the collar no 13 in diagram part no 90387-106U7-00 http://www.ronayers.com/EXHAUST-C116896.aspx was missing when i stripped it, so he will need to order one.. I wonder if that was also an issue with it not rotating when tightened?
Re: Exup seized solid...HELP! - nickodemon - 09-06-13
He has just contacted me. It's sticking again...
