Exup Problem

[pearson*]

I've had a few problems with the bike while i've been away, looks like it's a mixture of a few things:
- Exup valve fully seized, cover, screws, unit, the lot.
- Bolts sized to attach the exhaust to engine (so no easy replacement option)
- Theres also a 4k rev limiter on the bike in all gears, this could either be caused by the exup or an electrical problem.

Does anyone firstly have any suggestions on what to do with the exup, can replacement valve units be bought as i havent found any as of yet. Already got new cables and a new servo so its just the problem of the valve itself.

Thanks for any help.

[Evilchicken0]

It's a bit of shitey job, but lets start with the easy bit.
The rev limiter is because the exup is closed and is strangling the engine, cure the exup and that will go.

The exup bushes have seized, you can get new ones but as you can see fitting them is difficult if you don't have the right tools, so have a word with a garage explain the job fully and ask for a fixed quote.

You need to get the exhaust off - take off the front mudguard and then the radiator, so you get room to work. use some penetrating oil over a couple of days, tap the nuts a bit when you spay them and spray the stud where it goes into the block too. You can use a blow torch (get a small one) on the nuts to get them to expand too.
If you can get one of the nuts undone put a little copper slip on it and do it up again bfeore you try the next one. You don't want to take the weight of the pipes off the next nut.

The bolts for the exup will probably need drilling out which is why I said it might be better to take it to a garage.

[pearson*]

waheyy!

finally got the exhaust off of the engine, took oil, a bit of drilling and some pulling but we got there.

now the clamp has a stud siezed into it so i dont know how i can re-use that. question is, can replacement clamps be sourced (i havent seen any so far and cant find the part in my catalogue) and i cant figure out how to get the clamp off the exhaust... any pointers?

[Evilchicken0]

Do you mean in the middle of the system between the silver pup and from behind the exup ? That one's attached to the silver pipe. Undo it and wiggle them apart.

[pearson*]

err im on about the ones that attach the 4 ends of the downpipes to each cylinder, the 4 silver coloured clamps that look like they are made of some cast metal.

[Evilchicken0]

Ahh - Collars.
You can't take them off the pipes - it's quite rare that the stud would seize in, usually they sieze to the nuts. Put 2 nuts onto the sdu and tighten them against each other then "undo" the lower one or get some mole grips on the collar and gently heat it with a blow torch then put some ice onto the stud then penetrating oil and see if it shifts

[pearson*]

its in the garage at the moment, it got a lil brutalised when wrenching it off and drilling the top off the stud to get it out.

now im left with a bit of the top drilled off the collar (it was weaker than the stud so it got caught a bit), and as it came off the screw in the engine snapped out, leaving a little screw but not much to help with the stud.

if i cant replace it il have to look at removing the stud when i get the pipes back from the garage (took your advice and sent them away to be done) and use a washer over the top or something to keep that level surface.

and also thanks for all the help so far

[Evilchicken0]

No probsthe easiest way is to get some hex steel tag weld you should be able to get it yoga garage or welded with 7 studs in the pipes ed to the stub and use a scanner.

[pearson*]

Heard back from the garage... it's bad news.

From what it sounds like, everything has rusted together inside the downpipes.

Now they quote around 300 or so to do everything (175 at a best case scenario).

Do I look for a new set of downpipes or is there anything I can look at doing?

[Evilchicken0]

Well there is a set on ebay but they're not particularly cheap. They look like they could do with cleaning up and painting but it will get you on the road again with the least pain.

Other than that you're looking at running the bike without an exup, you'll need to to rev it a bit and slip the clutch to pull away and it would be best if the carbs were tuned to compensate

Or put a 600 engine in the bike