Exup servo motor probs today..

[Tefer]

I have removed the AIS, and going to change the cables in my exup, do you think i would be better to remove the servo to fit cables or try and fit in place?

[unfazed]

It is easier with the servo off, but do not remove it from its location, rotate the unit to make fitting the cables easier and then put it back on. It
Take note of which cable is which and how they are routed to make replacement easier. Servo is easy to take off by slipping the rubber off the mount instead of undoing the mounting bolts.

[ogri48]

Had a similar issue a few years ago. Exup valve free as a bird, cables looked fine but changed them for slinky glide ones. Intermittent 7K on the tacho. In the end I bought a second hand servo and fitted it, no more 7K on the Tacho. :woot

I noticed the pulley on the old servo was much harder to turn than it was in the replacement.
Dismantled it and cleaned it up, everything moving freely. Reassembled it still the same.
Pulley would move freely when disassembled, but not when assembled.
Took it apart a few times, but could find absolutely nothing wrong anywhere on the gear system.  :rolleyes
I even tested the motor and it was spinning freely. Totally baffled, I put it in a box in the garage and it is still there :lol

I have the AIS removed which made replacing the EXUP Servo easier.

Take pictures of the way things are routed and how they are located before you dismantle anything.

Cheers mate pics are a good idea. Been laying stone today will give it a go tomorrow, be interesting to see if my problems is the same as what happened to you. It seems to work intermittently, though mike did tell me it doesn't take a lot of resistance anywhere in the system for it to register the fault and essentially put the servo in safe mode. I havnt got a warm garage I've got a cold container....:-(

[ogri48]

:'(

[robbo]

Oh wow, that must be cold in there. The very best of luck  .

[tommyardin]

Oh wow, that must be cold in there. The very best of luck  .

Cold in there FFS it's a monster walk in freezer in this this weather, and non fan assisted oven in the summer with the sun on it.
My mate Dazzer (Darron) has one and its so cold in there, we left a bottle of coke in there the other day/night and by morning it was mahoosive coke lolly.


Much to cold to work in there, Duck Fat  :lol

[ogri48]

Huge thanks again to RMT1984, the servo works perfectly.
It wasn't too cold today, fortunately ,but I had a big stone pier to build for my brother in law and didn't get done till two this afternoon, so with no leccy I had to get a wriggle on...
It was fiddly. Bloody fiddly. Spent more time scratching my head and looking at it than I did spannering. Does it come out this side, that side, from the top, have I gotta take the radiator off etc..that sorta thing. It came out the top, having cut several cable ties and moved wires an that about, but it was tight, I'm talking  another coat of paint on the frame and it wouldn't have come out tight lol.
Took me two hours, but it's one of them jobs that if I did it again it would take 30-45 minutes because I'd know what I was doing next time around. As long as the bike, like mine, didn't still have the AIS fitted.....
I knew I was onto a winner when I got the old one out, I couldn't turn it by hand at all had to get pliers on it to make it move, whereas the second hand spare I can turn fairly easy by hand.
Took it out for a short run to check it was ok and ended up doing the Wye valley in the dark and cold, it was brilliant. I'd forgotten how good a thou with everything working properly is. I know the exup v exup removed argument will go on forever, but perhaps it's bike specific, I certainly wouldn't be without mine, Low down flexibility counts for a helluva lot this time of year :-)

[ogri48]

And I'm selling me zzr1100 come spring, it's a lovely low miles minter, but I can't think of any occasion I'd use it over the fazer.

[unfazed]

Another happy Fazer owner

[RMT1983]

Huge thanks again to RMT1984, the servo works perfectly.
It wasn't too cold today, fortunately ,but I had a big stone pier to build for my brother in law and didn't get done till two this afternoon, so with no leccy I had to get a wriggle on...
It was fiddly. Bloody fiddly. Spent more time scratching my head and looking at it than I did spannering. Does it come out this side, that side, from the top, have I gotta take the radiator off etc..that sorta thing. It came out the top, having cut several cable ties and moved wires an that about, but it was tight, I'm talking  another coat of paint on the frame and it wouldn't have come out tight lol.
Took me two hours, but it's one of them jobs that if I did it again it would take 30-45 minutes because I'd know what I was doing next time around. As long as the bike, like mine, didn't still have the AIS fitted.....
I knew I was onto a winner when I got the old one out, I couldn't turn it by hand at all had to get pliers on it to make it move, whereas the second hand spare I can turn fairly easy by hand.
Took it out for a short run to check it was ok and ended up doing the Wye valley in the dark and cold, it was brilliant. I'd forgotten how good a thou with everything working properly is. I know the exup v exup removed argument will go on forever, but perhaps it's bike specific, I certainly wouldn't be without mine, Low down flexibility counts for a helluva lot this time of year :-)

Glad I could help mate!

[Tefer]

It is easier with the servo off, but do not remove it from its location, rotate the unit to make fitting the cables easier and then put it back on. It
Take note of which cable is which and how they are routed to make replacement easier. Servo is easy to take off by slipping the rubber off the mount instead of undoing the mounting bolts.

Do i can slip this round without undoing any bolts? I have seen a few things about the valve but little about the servo motor and how its mounted to the bike?

[ogri48]

You can. I unbolted the clamp because it made it far easier to get out, it's pretty tight in there. Just take it slow mate, note where cables etc run, take pics, it's not that bad a job in truth

[unfazed]

If AIS is removed no, just slip it off the mount, but if AIS is still in place probably easier to remove the bolts

[hambone]

hello could I ask when you turn on the ignition is the servo motor supposed to cycle[ mine does not]. The valve is all greased and very free the cables are not frayed or binding.  If I turn the pulley on the exhaust to its stop ie opposite to the hole where the slot lines up and then turn on the ignition the servo turns it back to the start position and that's it oh and I get the 7000 code. hopefully someone can offer a solution. thankyou for any help.  hambone

[robbo]

Hi Hambone,
The fact you've got a 7000 code means you've got some exup related grief.Regarding the servo cycling.If the engine has run and you've turned it off with key it should cycle the next time the ignition is switched on.However if you don't start the engine it won't cycle anymore until the engines been run.If you stopped the engine using the kill switch you'd hear it cycle then and not when you next operated the key.

[hambone]

thanks for that robbo.  No cycling at all seems like motor buggered .

[Falcon 269]

The fact that the valve is moving back to what you describe as the start position says the servo is probably fine.  I suspect the cables are too tight or not correctly adjusted. 

Start by removing the chrome valve cover.  Then, with the ignition OFF, use an 8mm socket on the pulley bolt to turn the valve fully clockwise.  Turn the ignition ON now and the valve should cycle back so that the fork is lined up with the alignment hole.  Ignition OFF now.

If the fork is not precisely aligned, turn the pulley to the desired position over the hole and then pin the pulley in place with a drill bit or whatever.  Now adjust the cables using the adjusters mid-way along them.  You'll find these behind the top right frame rail. 

With the valve pinned in place, you should have 1.5 - 2.0mm freeplay in each cable. 

Unpin the valve, rotate it back to fully clockwise again and turn on the ignition.  If correctly adjusted, it should now rotate back to put the fork over the hole.  If it doesn't, repeat the process.  It may take a few goes to get the idea of how to alter the valve position with the cable adjusters.

If you still get the 7k error code, either the cables are too tight (slacken a little more) or the valve isn't moving as freely as it should.

[hambone]

ok will do what you suggest thanks for info falcon.  hambone.

[hambone]

hi exup valve is now sorted turns out it was my mistake. I stripped the valve to grease and free it a bit when I assembled it I put the pulley on 180 deg out so could not line up cables. thanks for help.  hambone