Exup Value problems......

[the_ferret82]

Before I start yes I know these have been done to death...... but...

I have recently purchased a 2003 Fazer 1000 with around 25k on the clock. In loving the bike but I noticed that when I looked the bike over it was giving the 7k rpm error when the ignition is on. I knew this to be a fault with the EXUP valve and had already searched this forum for the EXUP maintenance guide and was confident that with a few hours i could fix it. But sadly this was not the case.

Upon beginning to strip the valve down I noticed there was a missing bolt on the EXUP cover (the one that hides the pulley) I thought nothing of it and carried on taking the valve apart. Once the cover was off I noticed that the bolt that holds on the pulley was missing so obviously someone has been in here before. As I removed the bolts that hold on the valve cover one snapped off (or so I thought) but the other 2 came out clean. I then extracted the end plate after a few taps with a mallet.

Now with the value out I can have a proper look, first off that snapped bolt, did turn out to be a snapped bolt but one someone had welded into place prior my ownership. oh great (this is where I should have stopped) but I cracked on and punched and drilled out the old bolt and retapped the hole and now on to the valve...

we the thing is stuck fast it does not turn or move in any direction the valve its self is bent and the end where the missing screw for the pulley should be is deformed... so someone has been in here before trying to make it work and done it very heavy handed. With this damage already I thought hell well in for a penny in for a pound and set about trying to free the plate and the valve. first off I took the easy option, cleaning everything the best I can and then submerged the valve and cover in penetrating fluid overnight and nope they didn’t help so I then set about heating the end plate to an inch of its life and this had no effect I then tried freezing it for half a day (after it had cooled) and no that didn’t help. So I thought sod it and put it all back together and tried to retap the end of the valve so I could get a bolt in and the bloody tap snapped off in the valve. So now it’s even more buggered.

I phoned Yamaha to find out how much a new valve and cover was and had to take a seat when the price came back at over £450..... [img alt=http://foc-u.co.uk/Smileys/efocicon/shocked.gif height=18 width=18]http://foc-u.co.uk/file:///C:\Users\Nikolaj\AppData\Local\Temp\msohtmlclip1\01\clip_image001.gif[/img]

So anyone got any idea's how I could separate / fix mine of know where I can get a reasonable priced working second had unit from?

[shrekster]

Hi, I think most owners have had ths problem to some degree, some like me get lucky when taking the old bolts out. I replaced all the bolts with stainless and lube them a couple of times a year.The exup is a great idea if only all the bolts and various parts were stainless steel but Yamaha decided mild steel would be sufficient.


Extracting the old bolts shouldn't be too much of a problem but the broken tap is more of a challenge, if the valve is not damaged beyond repair you could get the tap spark eroded at an engineering shop. From experience trying to drill it out is just a waste of drill bits.


You could look for one second hand on eBay but they are very rare on their own, a better bet is to look for an exhaust complete with valve from either a Fazer or R1 '98-'01. You might find one for under £100 if your lucky.
Best of luck.
Jim.

[PieEater]

As Shrekster says look for a breaker that has a header section or Exup valve, in the UK there are some part-search utilities that charge you a couple of quid but search a good number of breakers catalogues for what you're looking for. If you do buy a header then explain that you are only really interested in the exup valve and assembly so ask for pictures of this in and out of the header so you know you're not buying another seized one. Take your time and something decent should come up. Obviously check Ebay, I had a look but could only see ones in the states one was really grotty and the other was overpriced as it included an end can.


The valve hasn't been working since you've had the bike so you could just refit it and be in no worse situation whilst you look for a replacement. I'd not bother refitting the cables though and I'd make sure the servo is still operating by checking that the cables are moving when the ignition is turned on, the servo will have had a hard time trying to operate with a seized valve. What position is the valve stuck in, is it against the stops or somewhere inbetween? Taking a hacksaw to the valve and removing it from the equation is an option just so you know you're getting full power but if you're used to the bike like it is then maybe don't bother.

[tex]

this was on ebay, don't think it sold, contact the seller ,he might still have it, 

  http://www.ebay.co.uk/itm/390954772144?_...EBIDX%3AIT

[the_ferret82]

Thanks for the help guys,

I’m 99% sure that my valve is beyond saving.

If I’m honest I had not thought about getting a scrap set of down pipes with a good value I shall keep my eyes peeled on eBay.

For now I have done what has been suggest I have managed to get my valve back in the bike and replaced all the bolts with stainless steel bolts and put them in with anti-seize grease. altho i have not check the servo is fine, i shall do that once it stops raining

As for where my value is stuck it’s about half way as it’s not on any of the stops and just slight off centre.

Thanks for the link tax I have messaged the seller and I’ll see what comes of that.

[stevierst]

You can release the valve from the outer bearing when they're seized, it just takes a bit of time and patience.

I soaked mine in wd40 for a few days, then heated up the bearing with a blowtorch. Tried turning it in a vice with a large adjustable spanner.

I kept doing this until it eventually started to move. I took it apart and sanded the bearings/valve shaft smooth, and it's good as new now.

Just don't bend the exup valve, the metal is a bit soft.

[the_ferret82]

good news everybody....... i have managed to track down a exup valve in great condition from a 99 YZF R1. it is fully disabled and when assembles it spins freely it just needs a clean and some lube and it will be good to fit. and i found this on ebay this morning by pure luck as the advert was badly spelt. and all for the sum total of £36 inc postage..

i just need to wait for the item to arrive i will update once i have the new unit and post a pic of my stuffed one...

[shrekster]

Well done you jammy #### ! Make sure you replace all the bolts for A4 stainless and lube the valve spindle and bolts with copper grease or equivalent anti seize compound.
I lube mine twice a year to keep it free, I can do it in less than 15 minutes now so it's no great hassle.


Jim.

[the_ferret82]

i have already replaced all bolts with Stainless steel ones and have lubed them with copper grease, but i will lube them again upon fitting the new value. as for the valve i will be lubing that with more lube than the tax man uses just to make sure the dam thing does not stick again and i will be keeping a close eye on it and redoing it at least one a year or once a oil change.. all i need is the postman to deliver it first....