RIP EXUP!

[Andy W]

All things must pass..  :'(


A few hours spent trying to get the EXUP valve to operate but it must be slightly warped - cleaned it all, copper greased it all as I always do but this time...nada!


Removed it, blanked the hole in the mounting plate with nut/bolt/washers so running on full bore now!


I wonder how many other Fokkers are riding likewise?  :biker

[Falcon 269]

If it's warped it can be straightened.  Not difficult, just have to be patient and careful.  Might need a few goes to get it right but use a straight edge to eyeball the spindles and gently bend it back in line.  Grip one spindle in a vise and gently apply pressure with your hand.

Much better to have a working EXUP than an empty one.

[b1k3rdude]

If it's warped it can be straightened.  Not difficult, just have to be patient and careful. 
Much better to have a working EXUP than an empty one.

Super easy, I straighened my by placing it in the chuck of a drill, slowley rotated it to see which way it was bent and hit it carefully with a rubber mallet, did this untill as far as I could tell the valve was straight. Then flipped it around and put the other end in the drill and did the same again. End result, pretty straight exup valve.

Or just take it to a machine shop, it will take them a few minutes and they will be able to get it dead straight with within a few fractions of a milimeter.

[Andy W]

I'll give it a go......unless I set fire to the damn bike first....after a run of problems & lots of £ spent I am currently broken down at side of road at 7.00am waiting for AA...total electrical failure! ???

[SkidT]

Oh bugger. Sorry to hear that Andy.
Hope you get sorted quickly and it’s something simple. ?

[Andy W]

5 hours tracing & testing electrics for a fault that took 4 mins to fix! ?
Oh well, at least I'm back on the road!


Also - fixed the EXUP - a vice, heat gun, straight edge & a hammer did the trick! ??

[SkidT]

Fantastic, glad you’re back on the road and got the EXUP valve sorted. Out of interest, what was the electrical cause?

[bigfootpete]

My Exup seized a long time ago, the bike still runs fine so I'm not bothered :lol  Although I think my biking days are coming to an end, I rarely use it any more  :\

[Andy W]

Fantastic, glad you’re back on the road and got the EXUP valve sorted. Out of interest, what was the electrical cause?

Fault was the live feed connector under the tank - the one in the plastic cone type cover with a bunch of others!
(Stop me if I'm getting too technical..!  )

[Andy W]

Freaking EXUP gone again ...........a job for another day when I actually have some time! 

[SkidT]

Fantastic, glad you’re back on the road and got the EXUP valve sorted. Out of interest, what was the electrical cause?

Fault was the live feed connector under the tank - the one in the plastic cone type cover with a bunch of others!
(Stop me if I'm getting too technical..!  )

? Thanks for the update. Im sure that will be useful for others in the future.

[Andy W]

Fekking bike runs raggedly as feck without the EXUp valve there at all....Had one last go at sorting it but the cables are pretty stuffed, the valve won't budge if the Allen bolts are done up tight & none of the parts are available any more so........Fuck It!.....Bike runs better with the EXUp valve in place & around 1/2 open (but not moving) so I'll leave it alone........
A nice but flawed concept I reckon & without parts being available then it's yet another warning that a change of bike is in the pipeline.......sadly I am utterly boracic so what that bike will be & when is anyone's guess!   
What the next bike won't have is carbs & strange exhaust valves! 

[Andy W]

Hmm...I'm watching a set of downpipes-collector on Fleabay but rather a lot of £s.....if anyone has a set for sale it may be easier for me to get my ExUp back by replacing the lot!

[Falcon 269]

You can pick up a decent used set of EXUP cables from a breaker for not much money.

The valve is still slightly bent if it binds when you tighten the cover bolts. You just need to persist with adjustments to straighten it. You have to ensure that both spindles are parallel with each other. Use a straight edge and eyeball them carefully. Concentrate on the spindles, not on the blade part of the valve. All it will cost you is an hour's worth of patience - a lot cheaper and easier to find than a working EXUP in used headers!

[unfazed]

You could always take it to a machine shop, they would sort it quickly enough

[RMT1983]

Andy W that set on ebay for silly money is mine...

Message me and we can talk a more sensible figure lol

[PieEater]

I literally had this exact same problem, fit everything together, the valve rotated perfectly until the bolts were tightened and then the valve was stuck in place. I believe that it was the end stops in the cover pressing down on the valve and by re-assembling with the valve in the alternate orientation the issue went away. I can only refer back to Pat's page for photo's that might demonstrate how this can happen - https://www.cartestsoftware.com/fz1/exup...nance.html

I just went to service mine and noticed one of the cables had snapped, no OEM replacements so went for the Wemoto SlinkyGlide ones, will post back when fitted.

[Andy W]

Thanks for the info PJ,
I'll get back on it as soon as I have a free moment!
?‍?

[Andy W]

I literally had this exact same problem, fit everything together, the valve rotated perfectly until the bolts were tightened and then the valve was stuck in place. I believe that it was the end stops in the cover pressing down on the valve and by re-assembling with the valve in the alternate orientation the issue went away. I can only refer back to Pat's page for photo's that might demonstrate how this can happen - https://www.cartestsoftware.com/fz1/exup...nance.html

I just went to service mine and noticed one of the cables had snapped, no OEM replacements so went for the Wemoto SlinkyGlide ones, will post back when fitted.

I just went to service mine and noticed one of the cables had snapped, no OEM replacements so went for the Wemoto SlinkyGlide ones, will post back when fitted.

Any updates on this?

[PieEater]

I literally had this exact same problem, fit everything together, the valve rotated perfectly until the bolts were tightened and then the valve was stuck in place. I believe that it was the end stops in the cover pressing down on the valve and by re-assembling with the valve in the alternate orientation the issue went away. I can only refer back to Pat's page for photo's that might demonstrate how this can happen - https://www.cartestsoftware.com/fz1/exup...nance.html

I just went to service mine and noticed one of the cables had snapped, no OEM replacements so went for the Wemoto SlinkyGlide ones, will post back when fitted.

I just went to service mine and noticed one of the cables had snapped, no OEM replacements so went for the Wemoto SlinkyGlide ones, will post back when fitted.

Any updates on this?

Yeah, sorry forgot I said I'd update the thread. Visually cables were pretty much a match for the OEM ones, I cable tied the end of the old set to the new set and pulled them through so the routing was the same. The fiddliest bit was hooking the ends up to the servo until I figured out that once I had one cable in I had to manually move the servo so the other end could reach. I'd got the adjusters fully wound in so once fitted they just needed to be adjusted to take up the slack with the valve in the correct position and that was that. I cant speak for the longevity of the cables but they aren't under much load so I can't see that being a problem, so would happily recommend them.