exup valve motor problems HELP

[fzr400bill]

Hi this is my first post after buying an FZR 400 RR.

unfortunately dint realise it was sold without the exup valve working. After messing about on the bike .. it seems the motor isn't working.
Can anyone help. On ignition does the motor make a sound on all fzr 400rr, s? All that happens on my 400rr is you turn key and the the two cables move maybe 1cm if that? On you tube videos there seems to be more movement on ignition key and a long motor sound.? To confirm when bike is running no movement at all when throttle is turned. Hope someone can help guys. Also im not sure we have fitted the valve right to exhaust?

I have pics if that would help.

First post btw. Thank you Ben

[DonTZ125]

Hi, Ben - welcome to the madness!

Either the motor is seized, the valve's seized, or the cables are seized. Disconnect the cables, then key off and on - does the servo go through a relatively long open and shut cycle?.

Take a look at the best EXUP maintenance site out there.

[fzr400bill]

Thanks Don.

Good guide on the link thanks. I will try all things stated. Erm can the motor be un seized .? Also can the motor be electricly broken ? Thank you. Ben

[DonTZ125]

It's common for the motor windings to burn out, or for the gears to break and jam, especially when the valve or cables are seized - neither is particularly repairable. It's possible (but rare) for the gears to be just plain gummed up.

Like I said, pop the cables, start a cleaning cycle, and see what happens.

[Evilchicken0]

The servo motor should make a weep weep noise and the exup pulley will cycle back and then forwards.
Have a look at the exhaust down by the side stand and see the chrome cover take that off and you'll see the exup pulley.
Cycle the exup - you can flick the kill switch off then on to do this too. Check the pulley moves. If it doesn't check the cables they can fray where they come out of the sheath. Mark the cables top and bottom at the exup and the pulley before you take them off.
Venhill do a pair of cable cores as a kit or if its the servo I've got a spare

[fzr400bill]

Hey. Thanks for the advice don. Got the exup valve working this eve and looking good.the bracket was incorrectly fitted. Its now working correctly I hope.
The only issue is a rattle noise from the valve. Is there a reason for this and can it b overcome?

Thanks again . Great advice and guides.

Ben

[fzr400bill]

The servo motor should make a weep weep noise and the exup pulley will cycle back and then forwards.
Have a look at the exhaust down by the side stand and see the chrome cover take that off and you'll see the exup pulley.
Cycle the exup - you can flick the kill switch off then on to do this too. Check the pulley moves. If it doesn't check the cables they can fray where they come out of the sheath. Mark the cables top and bottom at the exup and the pulley before you take them off.
Venhill do a pair of cable cores as a kit or if its the servo I've got a spare

Thanks mate. Seem to have the exup working now. Will see how it goes on test run . Cheers all

Ben

[willandrip]

Rattle ?;
Tighten the cables somewhat .
There is a spring to take up sideplay fitted behind the pulley which usually goes astray.
You can advance the valve a little.
Bushes do wear out.

[GreyImport]

You need to pull the guts of it out of the headers and check , clean and wateva and check the bushings as mentioned and that its actually moving its full arc (with the cables off)

As mentioned the servo will cycle and obviously if the cables are adjusted correctly u will see the valve at the headers cycle as well (with the cover off)

Heres what it all looks like....(ignore the red marks)



And heres what its supposed to acheive ....

[Evilchicken0]

There isn't a spring on the 400, sounds like you need to adjust it.

Take the chrome cover off and have a look at the pulley, there are two tangs on there. If you look at the housing behind the tangs there's a hole ... stick a bolt, nail, or punch between the tangs and into the hole. Now go to the sevro end and find the adjusters on the cables. Undo the locknuts and adjust the tension, sometimes a cable is to tight so slacken them first then do them up but FINGER TIGHT ONLY. Down the bottom again, sweeze the cables together to check they're not tight, now take out the pin from the exup pulley.
Cycle the exup on the ignition a few times and check it moves freely and returns to the right place - that should sort it.
There should be a rubber that clips onto the cables, if yours is missing replace it, it keeps the crap off the cables, get one from Yamaha.

Run the engine, make tea dunk a digestive ....

[willandrip]

Nee the wonder they rattle then.!
Fit a spring and they are as smooth as .........

[fzr400bill]

Where would a spring fit guys?

Thanks again for replys

[willandrip]

Put a weak spring under part no. 10 on the valve spindle in the linked diagram.
If you look at an exup parts diagram for the fzr 1000 models;they have them std and is why that I use them.
The rattle can be either sideplay ,which this will prevent or the valve fluttering off the closed position stop,which can be prevented by advancing the valve slightly.

[DonTZ125]

It can also be excessive radial clearance caused by worn bushings; my inboard bush had a clearance of about 1/16" radial (!), and rattled like a handful of change in a clothes dryer ...

[fzr400bill]

Where can I get a spring and will it fit the 400? Thanks