Stuck exup, grrrr!!

[fzrtim]

Well 500 miles now done on the 400 and its has been great up to this point. But at the weekend i noticed that the exup didnt move when i tuned the ignition on. Further investigation found the exup to be sticking in the fully closed position but free(ish) elsewhere. To my fustration when i tried to remove the securing bolts the first 2 snapped. I decided to put off the job until i have more time to completely remove the exhausts, exup valve and redrill/tap as required.
For now i have set the exup to fully open so i can still ride her until i find time.
How badder job is it removing the exup from the pipes??
Still love it tho!!!

[Phil Norton]

Biggest problem with the bloody exups is always the bolts seizing and the need to drill and re-tap. Had the same problem when the R1 exup went last year.

I was half inclined to remove the whole exup and just be done with it, but forked out to get it done in the end. Could of and should of done it myself, but have spent so much time and effort (and money) on the bike that I was to pissed off to be arsed. It's not a bad job once your in there, just don't have a smoke first, as Boris and I once did. It made a simple job into a real mess.

With the R1 you just leave the servo on there if you remove the exup, so the engine management system is fooled. Otherewise you get fault codes on the tacho and the engine management goes into safe mode. Don't think that you'd get those problems with a 400, but never had any probs with the fzr400 exup when I had that, so can't say for sure.

[Sligeach]

How badder job is it removing the exup from the pipes??

is that a word or a typo?
the FZR pipes are all one piece, so you cant just remove the exup.
in terms of just keeping the valve open, i rode mine for a few months that way until i sourced some cables. never caused excessive ballache. the scorpion can with no baffle and exup open did sound exceptionally loud at idle tho!!

[Evilchicken0]

He means remove the exup valve. Sounds like the bushes have worn and notched.

[plodder]

Maybe but the cover plate bush and exup valve rod corrode because they leak exhaust gas.

I used to refurb pipes for the 1000 EXUP and sell them, so here's how it goes...

Drill out with a M5. I use a brand new drill for each bolt because the bolts harden with the heat (and I once drilled my knuckle dicking about with old bits). 5 Ti coated bits are about £3 from screwfix, so it's not worth losing sleep over. (Too late but) don't try to undo the bolts as they ALWAYS snap and you get a better centre drilling straight through the bolt than the slug that gets left. Retap at M6.

Use some 240/400 wet & dry to clean up the outer rod of the exup valve and the inside of the outer bush. If I was you I would take a bit more material off than strictly required. You can stop the rattle by tensioning the cables correctly.

The inner bush is unlikely to require attention.

creedxup or yzfzr (same bloke) sells the high temperature nickel grease on ebay

Use stainless bolts (50 pk from screwfix is about £3).

I use the nickel grease to coat the hot end of the cables, all of the bolts and the manifold bolts (I bought a tin of the grease for £30 and used to do a kit with grease and bolts for £5 but don't any more).

You don't need to take the pipes off to do the job if you don;t mind lying on the floor.

Once fitted with the SS bolts and putting some of the grease on the threads, they will not snap next time and doing this service is a 30 minute job (which I do annually).

[fzrtim]

Cheers guys. Got all the tools, just need to find some time to get the job done.
Badder ,though not gramatically correct is a word i frequently use. Think it was also the name of a spitfire pilot....

[Evilchicken0]

Douglas Barder ???
He was the subject of the film "Reach for the Sky" .... not a nice giy by all acounts but then you can't be alll sweetness and light to do what he did.

[Alex.]

Oohh, so close!

It's Douglas Bader.

Alex.

[Evilchicken0]

yeah well Badder, Barder, Bader, Bladder, Badger, Bahgee .... it's all the same really

[sharpey]

on the r1 if it is fuel injected not sure if it would defo work but you could do like we used to have to do to suzuki's when fitting full race systems and do a pin out on the ecu so it doesnt register any of the exup, all ya do is get a wire diagram for the bike in question find out which pin of the ecu controls the exup and using the cprrect tool remove the pin from the connector, dont just cut it.