f***ing exup valve

[bluethou]

Exup valve working fine, removed it for routine maintenance put it all back together again with a little copperease and wallop the bloody thing wont move jammed solid so rinse and repeat same story the valve seems to work fine right up until I tighten the bolts it'll turn then stick as if its bent or off centre somehow.
I've checked all the positions of the bushes, I laid them in order as I removed them cleaned them all with a little emery cloth and some brake cleaner, then a dousing with the old WD40, another wipe then a little copperease and back in, cant see what I've done wrong?????? :'( :wall

stupid design. What's wrong with a single flap in the link pipe??
has anyone thought of butchering an FZ1 link pipe and fusing it onto a 4-1 after market job??[size=78%] [/size]

[eddie]

sorry to hear this tale of exup woe...but the old syaing ...if not broke dont fix it.....springs to mind...hope you sort it before the sun returns

[bluethou]

Need to sort it before monday mate shes my daily workhorse

[bluethou]

sorry to hear this tale of exup woe...but the old syaing ...if not broke dont fix it.....springs to mind...hope you sort it before the sun returns

An old wise man once told me "Son if you ain't got nothing constructive to contribute then keep it shut cos no-one likes a smartsrse"

[Falcon 269]

The valve can be bent quite easily, although odd that yours was fine until refitted.

Obvious question first, you do have the valve orientated correctly?  Sorry, got to ask just in case ...

Use a straight edge to check the alignment of the spindles.  If necessary, bend carefully back using a vise ... do this by hand, not by hammer!

You may have to go through several dry refits before you eventually get it free enough to flip-flop with a finger and thumb on the spindle end. 

Don't despair, it will work in the end.

[brooker81]

Also I know it's your workhorse but can be ridden without completely just a little grumpy at low revs but can ride around it I rode mine for a month without it u get used to it. Also when it's working again feels like a new bike again either way good luck fella

[Captain Haddock]

I'd take it out and check for crud in the end bush stopping the valve going fully in, a bit of grit in the copperrease could do that.

[bluethou]

Thanks chaps, after consulting my engineer grease monkey brother he asked me one question, did i take it apart while it was hot and the answer was yes and I dropped it as a result of the hotness, I thought the bolts would come out easier while the heat was still in them but got carried away and dismantled the whole shebang doh!
so I'm to heat it up and see if that corrects it ( something to do with metal memory??) and /or give it a little persuasion with a vice/hide mallet!
then as I was earlier advised leave the blooming thing alone until it stops working.

[kebab19]

No, mine also did that & I found the valve was slightly warped. No matter how I tried to reassemble it, it always jammed once I tightened up the bolts.
I ended up having an engineer bend it back into shape & also file some metal off the end prong. It was a fraction loose afterwards & I could hear it rattling in the exhaust, but at least it worked fine.

[unfazed]

It is possible to fit the valve slightly off in that the housing does not sit properly on the exhaust due to the two stops on the housing, see picture. If you tighten it in that position it will seize solid . Loosen the housing and rotate it until is sits flush on the exhaust and now tighten the bolts.
Alternatively set the valve on the housing and do up the bolt on the pulley to keep it in place and then feed it info the exhause to fit into the bush on the inside of the exhaust. Before this make sure that the internal bush is seated properly,

[bluethou]

I would like to firstly wish you all a happy new year and thank you all for your advice.
I took the offending valve out snapped a bolt in the chamber while I was at it.
so with a drill and a tap and some bending and patience its re assembled and operating correctly until it gets warm then the bloody thing starts to rattle like a stone in a can all the bushes are in the correct positions there's plenty of grease my cables are adjusted and oiled I have no warning codes.
can anyone tell me the correct way to re-assemble the washer spring arrangement on the cable carrier on the downpipe just in case I've done it wrong.




Many thanks for all your help.



Dave.  :'(

[PieEater]

This should help - see picture labelled Photo 4 for the correct order - http://www.cartestsoftware.com/fz1/exupmaintenance.html

[unfazed]

Check that the spacer on the inner side did not fall off when you were reassembling.

[unfazed]

Yamaha Exup1000.co.uk exup valve rant

[Anquetil]

Absolutely hilarious ! My wife and I are still laughing. Brilliant ! I'll never be able to watch that film again without remembering this. Thank-you.

                                            Mike and Karen