FZ1 ExUP Service

September 8, 2013

Tools Required

• 8mm socket and hex key
• Center punch or other small metal rod

Supplies

• Kerosene and tooth brush
• Contact cleaner 
• WD-40 
• Tri-Flow cable lube 

Pat's Motorcycle Page has an excellent and thorough write-up about Yamaha exhaust valve maintenance.  I don't have a lot to add to it, besides that the copper anti-seize I used for this service 12k miles ago was completely gone without a trace.  The valve wasn't seized but I expected the anti-seize to last longer than that.

The other thing is that the orientation of the valve is a bit counter intuitive.  During exhaust valve operation the curved valve faces toward the front of the bike, and rotates clockwise upwards as RPMs increase.  I would've thought it faced the rear of the bike and rotated the other way, but there are only so many ways it can go back in and that isn't one of them.

I started by putting WD-40 on all the bolts holding the valve in.  They are subject to heat and corrosion, and it would be a pain to snap one and get it stuck in there.

ExUP removed, seen from front.  Front of bike at left

To clean it I brushed everything with kerosene, then washed with contact cleaner and reassembled after the solvents had dried.

ExUP, top view.  Front of bike would be at right

ExUP rear view, front of bike at right

For completeness remove and clean the pulley, and use a clamp-on cable lube tool to shoot Tri-Flow into the cable housings. Spray contact cleaner into the header port where the far side of the valve seats, then dry with compressed air.

ExUP removed.  Valve is on left at reassembly

Post-cleaning Alignment

After reassembling and adjusting the cables, to ensure the ExUP is operating correctly run the bike with the ExUP cover off and observe whether the pulley can rotate freely.  If so, turn off the bike, then turn the key back to the ON position.  The servo motor should bring the pulley so that the alignment rods are centered over the alignment hole on the left side of the mounting bracket.  If the rods are not centered correctly adjust the cables (right side of bike under tank) and repeat the procedure.  Note that the cable housings are color-coded silver and black for easy identification.

Notes for Easier Reassembly

There are a few small parts that have to go together in the correct order. To reattach pulley: silver ExUp cable goes on top (over top of pulley), black cable goes on bottom (underside of pulley). Order of pulley parts: 1.) ExUp face plate, 2.) large washer, 2.) pulley spring with large side toward large washer, 3.) pulley, 4.) pulley washer, then bolt. Bolt pulley securely by putting a rod or hole punch between the U-shaped bracket that faces towards the front of the bike, into the alignment hole on the valve face plate. Then bolt can be tightened without moving the pulley.

Cable adjustment notes: to loosen cable turn adjuster towards front of bike - less adjuster threads showing. Tighten is opposite - more threads showing, adjuster moves toward rear of bike.