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Go Back   FZ1OA Message Board > FZ1 & Fazer Owners Association > Service & Maintenance > Gen 1 Service & Maintenance

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Old 06-13-2019, 03:10 PM   #21
oldjeep
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Quote:
Originally Posted by longeze View Post
Apologies to OldJeep, no harm intended.
No need to apologize, I've been on pirate4x4 for nearly 20 years - you are not capable of offending me. Been working on old jeeps for longer than that, so I'm not going to learn much more about rusty bolts either ;)
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Old 06-13-2019, 03:46 PM   #22
longeze
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Clearly ;)
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Old 06-13-2019, 05:27 PM   #23
oldjeep
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All back together but the cover. It is no longer throwing a 7K code at idle but is when revving it in neutral. Need to go over the cable adjustments again in a bit. Worst case is that the servo has issues, but I have an extra one that I could try. (bottom pic is pre adjustment - so don't glean anything from its position)
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Old 06-13-2019, 05:32 PM   #24
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Question - from Pats page

Underneath the cover is the Exhaust Valve pulley. It is controlled by two cables. The free play in each cable should not exceed 1.5 mm (0.06 in.). That 1.5 mm is free slack, movement without any pressure at all, not as far as you can push it. Mine were very loose. The 'fork' in the pulley should line up over the hole as shown. If it does not then it may be 30 degrees or more advanced. Turn the ignition ON then OFF. The pulley fork should now be aligned over the hole.

How exactly is the 1.5mm measured - is this push pull or side to side? I suspect that maybe the cables are just too tight.
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Old 06-13-2019, 06:50 PM   #25
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After a bunch more screwing around I am becoming convinced that the servo isn't able to pull full range. Could be a result of the valve being jammed up before, who knows. Looks like I'll be figuring out how to get at the servo. looks like maybe part of the fairing needs to come off
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Old 06-13-2019, 07:58 PM   #26
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Turned out to be a problem with the return cable that was binding in the jacket. So for now the valve is wide open until I get some new cables.
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Old 06-14-2019, 01:01 PM   #27
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Last update on this. I wound up safety wiring the valve full open and what a difference. Couldn't figure out why the bike seemed to be working so much better until I went back to the old seized valve and realized that it was seized less than 1/2 open.
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Old 06-14-2019, 02:13 PM   #28
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Haha...wait until you get itI working as it should.
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Old 06-14-2019, 02:20 PM   #29
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Originally Posted by old77zrider View Post
Haha...wait until you get itI working as it should.
Have a set of replacement cables coming from Germany, so eventually I'll get it all set up properly. $50 seemed better than the $200 OEM I could get around here.

https://www.ebay.com/itm/EXUP-CABLE-...0/273553692166
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Old 06-14-2019, 10:39 PM   #30
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Quote:
Originally Posted by oldjeep View Post
Last update on this. I wound up safety wiring the valve full open and what a difference. Couldn't figure out why the bike seemed to be working so much better until I went back to the old seized valve and realized that it was seized less than 1/2 open.
I am having that 7rpm code, are you saying if you keep the valve open the bike runs better?
thanks for providing a link to new cables, I think mine are frayed, just hope its not the servo motor.
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Old 06-15-2019, 02:02 AM   #31
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With the EXUP tied open, you will lose some bottom end grunt. I don't know how much, but it is noticeable from what I understand. I know with it stuck closed, the bike feels like it hits a wall from about 6K on up depending on valve position.
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Old 06-15-2019, 03:57 AM   #32
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Originally Posted by firefly View Post
I am having that 7rpm code, are you saying if you keep the valve open the bike runs better?
thanks for providing a link to new cables, I think mine are frayed, just hope its not the servo motor.
It is running better than when the valve was stuck mostly closed. I've never experienced a working exup, so I don't know how much better it could be. As for the servo, I got a spare off ebay used for. $20 just in case.
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Old 06-15-2019, 09:35 AM   #33
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Originally Posted by oldjeep View Post
It is running better than when the valve was stuck mostly closed. I've never experienced a working exup, so I don't know how much better it could be.
You will be impressed how much better it sounds/runs when it is functional.
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