Got my full 3tj exhaust system, hints tips on fitting??

[spadey99]

Hi guys

ok so I got a full system off e bay for £50 (looks mint too_) I can work out how to put the front headers on and until I get a nice tail pipe and link pipe will pop the original on, might keep it like that if it runs ok!!!!!!

But my exup servo is there and moves on turning the key, I have some cables but how do I connect them? Which cable goes where?
Do and how do I adjust them?
Shall I grease the exup valve before putting the headers on...

etc etc

you get the idea guys, just want to do it right..

Steve

[Evilchicken0]

Have a read of the manual first.

Spray the exhast nuts with penetrating oil a few times and leave it overnight befor you start. When you undo them undo them all about a 1/4 turn first then start taking them off. There's another mount near the back I think (or it might just be the 1WG).
Fit up the headers - the bike will run with the EXUP cables disconnected.
The cables go with the adjusters near the servo. They're easier to fit if you take the servo off the subframe. Fit them up to the servo then the EXUP ... they can only go on one way round. Take the wheel off the exup fit the cables then refit the wheel.
Check it all opens and closes on the ignition.

Adjust the cables
with the exup cover off you'll see the pulley it has two prongs that face forward and there's a hole in the casing at the back. Put a small bolt or pin between the prongs and into the hole so you lock it in the forward position. Slacken off the lock nuts at the servo end and adjust them finger tight, only. You should be able to wiggle the cables a few millimetres at the exup end.
Take out the pin - the pulley shouldn't move then turn the ignition on and watch the open and close the exup, it should have the prongs forward again.

Start the bike and watch the exup move when the throttle is opened ... put the case on and see what it's like to ride.

[spadey99]

Thanks evil... Sprayed the studs and going to have a go in the morning..... Just wanted to make sure I knew what I was doing with the EXUP valve,,,,

Steve

[Evilchicken0]

Cool - remember to use some copperslip on the exhaust nuts.

[spadey99]

Ok quick update...... 2 broken studs........Dohhhh, best way to get them out please guys? Few tools on e bay, are they worth investing in?

Also was lubing up the exup cables and working out where the valve would be and because it didnt have cables on how the hell do I route them? Any specific way?

Steve

[spadey99]

Also guys the stainless pipes I took off had Yamaha 5 SL-1 stamped on them so was wondering what they are from and are they any use to anyone before flea bay gets them??????

[Evilchicken0]

Get a garage to do the studs for you.

[spadey99]

Thanks evil, not sure what to do as bike in my garage, other garage 2 miles away........ Any tips on the EXUP cables routing, how they go round the pulleys etc??

Steve

[Evilchicken0]

To get the studs out give your local garage a ring and see if they can do it. Did they break flush with the head or is there enough to get hold of ??? It's probably better to go ahaed and fit the new headers first and go there with a blowing exhaust. Are the other studs in good nick ??? if so give them a bit of a clean with a wire brush.

I think the cables drop down the back of the engine then underneath - I'll have a look and see if I've got a picture

[spadey99]

Cheers evil, studs broke at the unthreaded part so loads to get hold of. Ive soaked them about 10 times now with thread ease stuff so hopefully soaked in. Im tempted with a tool off e bay as I need one for the workshop anyway....... But the other studs are absolutely fine so could fit it and go to the garage....

My biggest concern is how the cables go into each part of the exup motor as in do they go round the disc thing and then into the hole? then feed them underneath and into the exup valve on exhaust and again feed them round the disc and into the holes in the disc..... Sorry mate just want to make sure I get it back together right... It will be then totally standard and pretty mint and ready for a spin when the weather allows........

Steve