FZRSupport: the FZROnline Archive

Hi Everyone, just bought a 1990 Exup yesterday, my first litre bike .. however the exup valve is stuck in the closed position. It pulls well up to 4-5 k then really struggles. Beyond 8 k its gets a little better and goes on to 11 k. I have managed after much WD40 to get the valve out, but the valve is ceased to the external plate in the closed position. Before I try to hammer it out tomorrow, does anyone know the best way to get the valve out of the external plate, or is it possible to get a replacement?

The previous owner said it kept seizing on him and he used copper lube, though I see the haynes manual says to use molybdenum disulphide grease..

I have had a look and cant find any part on ebay. Has anyone had any luck finding a replacement?

I'd really love to the the valve working and any help/advice is appreciated.

Thanks in advance, Gareth

Theres a soft carbon type bush in the outer cover that gets gauled up with soot from the exhaust. Best way is to hold the valve itself in the vice, flood the endshaft with WD40 etc and keep rotating the end plate around whist trying to lift it off the shaft. I had the same issue a while back on a spare that i bought, took a bit of time and patience but gets there in the end

Valves do come up occasionally but fetch good money. Theres several thats interchangeable too but the early R1 is a fraction longer on the far shaft and would need to be shortened before fitting. YZF750 and thunderace are a straight swap

As for lube, use this stuff. Its miles better than copperslip and lasts longer



When you come to re-assemble, make sure the valve spins freely between fingers....if it doesnt theres a good chance it may be slightly bent (seen this a few times). A bit of selective tweeking sorts it out by using a steel rule across the ends.

If you DO find you need a replacement valve and cant find one, get in touch with creedexup over at EXUP1000.co.uk. He breaks them and sometimes has spares in stock

BTW, where abouts in the uK are you?

Hi Stig, many thanks for the reply, Ill keep giving it a go with the WD40 and vice as you suggested. I think its been seized for a while, so it may take some time. Once (if) I get it unstuck Ill get some of that lube too.

Would you think soaking it in a rust dissolver like Jenolite would do it any good?

I am based in Salisbury, picked up the bike from Gosport from someone who has had it for 11 years. Its an import thats just gone roung the clock, 102 k km - 63k miles. It does burn a bit of oil under acceleration, but I can live with that for a bike of this age and miles. Otherwise its in quite good condition.
Ill post some pics tonight.

Jenolite just converts rust to a non oxide state.....sending the rust black. I personally havent tried it as a releasing agent. It may be worth a try if all else fails

I kept flooding the shaft/faceplate joint with WD40 to wash out the rust as I kept rotating the plate around the clamped vavle. Rotate it a full 360 so it goes past its normal run...it helps clear the stubborn particles.
Once completed I cleaned the shaft ends with some fine emery cloth and then greased them

Got the bugger unstuck.. after heat gunning and WD40 as a quencher.. . I had to screw a large piece of wood to the outer plate, put the valve in a vice, and kept turning. Took about 20 mins.. bent the valve, but its now straight.
Ive had a look for that lube. It seems to be nuclear priced as well as grade..

Yeah ... copper slip (different brands, same idea) may not be as good, but you can get it more places and for less money. Include it as part of your annual maintenance, and you'll be fine.

What about Moly grease as the haynes manual says.. ?
I was thinking this stuff:
http://www.wilcodirect.co.uk/index.php? ... ts_id=3373
or this:
http://www.halfords.com/webapp/wcs/stor ... pping#tab4
or this:
http://www.opieoils.co.uk/pv-1232-fuchs ... ntent=1232

Though from what I've read, the collective wisdom seems to think copper grease is ok, and that's sitting in the garage...

I can't find that nuclear stuff.. Stig if you'd like to put it in 100g pots and sell it on ebay that'd be lovely..

I dont have enough to be able to sell it off. The non nuclear stuff of a similar type can be got from RS online

i have one id part with cheap, PM me