Wasn't planning on a dyno but will set up the bike the best I can without meddling too much and see how it goes.

I'm not convinced they have given me the right plugs either.

Managed to remove the fairings tonight and have a look at the exup valve. It's still juddering after lubing it up so I removed the chrome cover plate and watched the cycle. The fork on the pulley rests after the cycle 180 degrees in the wrong direction so I'm assuming something has snapped or somebody adjusted it and didn't have a clue what they were doing.
There also seems to be a lot of play in the pulley so I'm going to dismantle the lot tomorrow and see what's happened.

Will try and bung a few pics up too.

The 2 prongs face forward with ignition off. There's a hole there put a pin in it and then adjust the cables finger tight.

Maybe the cables have been crossed so the pull is push

Evilchicken0 wrote:The 2 prongs face forward with ignition off. There's a hole there put a pin in it and then adjust the cables finger tight.

Maybe the cables have been crossed so the pull is push

The chrome cable is on top and the black cable underneath which I believe is correct.

that sounds right.

"The chrome cable is on top and the black cable underneath which I believe is correct."

This will only apply if the cables are fitted to the correct slots in the servo.

It is also often the case that P.O's refit the valve pulley 180 degrees out.
Also there are different offset pulleys for the valve which fit but are not possible to set correctly using the pin method and do not fully open the valve.This usually occurs with a s/h valve assy. fitted from another model.

Stripping and refurbing EXUP valves is very theraputic.

Quick pic of the freshly sprayed yoke,new bolts and new ignition. it looks a lot better than it did.





Ive removed the EXUP valve and had a look at it. looks like the outer bush is badly worn and the spring is missing.

Ive quickly cleaned the exup valve and noticed a bit wear and pitting on the outer spigot where the outer bush sits, is this going to cause a problem?





when i removed the exup valve and pulley i thought i would turn the ignition on to see if the juddering was coming from the servo, but the servo isn't working at all now, any ideas?

You're lucky to get the valve out so easily - I'd take a gamble on the pitting but renew the bushes. the servo sounds odd maybe it's thrown in the towel.

You have done well ibby.!
There is little to be done with the pitted shaft economically,bushes are circa £20 +vat.
Carefull when you press it in,its quite delicate.Pressing the old one out often destroys the "dust shield" which is just a flimsy spacer.
Plenty of coppaslip grease.
It is not a highly stressed bearing.
It appears from a 400 manual no spring is required to prevent excess sideplay and rattles as on the 1000 models !
Sometimes the plastic servo gears strip when the cables/valve is seized but you should still hear the motor cycling.
Unplug the motor and check the connections.
You can turn the servo by hand with ignition off.

Cheers. to be honest the valve was pretty loose. slightly concerned about the servo now though.

I'm a bit confused by what i should have in the EXUP assembly looking at the parts manual it shows a further bush on the left of the valve and another spacer to the right of the valve and no spring washer.

http://www.400greybike.com/files/FZRRRSP.pdf


I need to get these ordered from Fowlers as i'm sure it will be a 4 week wait if available at all.