Odd rattle

[Rooster]

Could end play in the exup valve cause a rattle when letting out the clutch from a stop?

If the clutch is all new and theoretically installed right according to the Yamaha diagram.

2nd gear was fixed when all the pieces came to me and were assembled.

Also what are the odd's there is something in the transmission that would account for the rattling that only is noticeable when trying to launch the bike at low revs?

When rocking the bike forward and back engine not running and transmission in first gear with clutch lever pulled in I can hear a rattling noise of some kind.

Is there any chance one of you has had this happen or heard of it happening?

[Stig]

check sprocket nuts tight? Exup valve rattling against its stop maybe?

[Rooster]

Gonna check both of those tonight.

[Rooster]

so the exup valve has some end play and there is no stop that I can see, it slides in and out at least a couple mm. Also just resealed the valve cover from checking for loose cam chain and nope its not loose but I found the source of my oil leak from the half circle plugs, i forgot to silicone them according to the install instructions. The rattle may indeed be the exup valve being poorly adjusted and missing pieces, anyone have a good picture of the valve without the chrome cover over the workings of it?

[willandrip]

You won't learn much from a pic. The pulley obscures the parts behind it.
There is a washer and a spring behind the pulley that is designed to prevent excess axial play and the valve from banging end to end.(10 & 16 on the fiche)
The stop referred to in previous posts is internal to the valve chamber; you cannot see it.

Take the chrome cover off, turn on the ignition and manipulate the pulley manually in radial and axial planes to determine if adjustment is required. The cable adjustment stops the radial play; the spring/washer the axial.
It should not really "bang" off anything.
A 5mm drill bit placed in the location dowel on the faceplate aligns the fork in the pulley for correct timing; It may be advanced a little to take up wear.
http://www.cmsnl.com/yamaha-fzr1000w-19 ... ml#results

[DonTZ125]

The best EXUP maintenance site out there.

[Rooster]

Thanks gentleman, it turns out I'm missing the spring and the centre bolt.

[willandrip]

Did you do the cable tensions ?
( the 5mm drill bit from my earlier post is too big; I think its only 3 or 4 mm)

Did you replace the sprung plate with a normal friction plate when you built the clutch. ?

[Rooster]

Clutch was all OEM Yamaha parts because the original had come apart and broke friction disc's etc. It is all 100% new except for the star plate and springs, now if I down shift at too high of revs it does not slip it'll just drag the back tire.

Cable tension is adjusted, the exup valve however is missing the spring that goes behind the pulley down at the collector.

[willandrip]

What I meant was; did you substitute part nos. 8 & 13 on the fiche with one no.7 (ordinary friction plate).
[ the 8 & 13 usually disintegrate and destroy the assy. if abused].

Any light duty generic compression spring can be cut down for the exup valve.- it just prevents axial play.

You say the drum is new . (was it you asking on another forum where the shock absorber springs in the rear of the drum were mentioned ?)

You might have to do the oilway drilling mod to the clutch drum if you were going to try to launch off the line at high revs.

Cannot think of owt else for your noise with the engine off ; just the plates grating with each other.

[Rooster]

alright well I will add the spring on the Exup valve and the clutch or whatever noise it is is actually at relatively low rpm's like trying to not spin the tire while on sand and gravel which is my drive way.

[glenstrachan]

rattle only when you go to take off or put load could also be the starter chain in g/box that has stretched and rubbing against case.??

[Rooster]

only when letting out the clutch and not giving it a lot of revs