Engine problems 1992 fzr1000 exup

[Eddie Hitler]

All started today. I think its down to the heavy rain last night, but could just be a coincidence.

Basically, the engine is spluttering and feels aweful when pulling away, but seems fine at 4k+. When idling, its almost as if it coughing, and theres an odd knock thats coming from a black circle type thing on the left side of the engine (uh oh?). It doesnt seem connected to the engine but, meh wtf.

Any ideas? Only happened today.

Cheers Ed

[N cee thirty]

spray the coils etc with wd40 if you think the water might have got in
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[Scotsman37]

Make & Model of bike

Sounds like the idle jet(s) maybe clogging up and so maybe add some petrol fuel system cleaner to the tank to avoid a possible carb cleaning job! Spraying carb cleaner with air filter off while the bike is running will also help in some way to hopefully clean the carbs!

Inspect your air filter in case rain water has seaped into the airbox.

The odd knock maybe down to a loose drive chain which means just adjusting the tension, but hopefully it's not internal to the engine itself otherwise it will be a mechanic's job.

[Eddie Hitler]

ok cheers guys, just parked it up and left it to look at tomorrow. dont have any carb cleaner, but will check the air box.

[Eddie Hitler]

Ok.

I wrote 2 huge replies last night but IE messed up. So i gave up. aha.

But yeh. I was up till 1.30am stripping the bike. Checked the air filter and it was totally free of water. Decided it was late so continued this morning.

I changed the oil and filter (as i had the part laying about so thought may aswell). The exup valve is almoist certainly to blame. It just wasnt moving as it should. I took it apart and as a test locked it to the fully off position (so its basically a 4-1 system). A bit boggy at low rpm but flies at 4k+. Completley cured the problem i had last night.

Are there any adverse affects at all doing this? Id rather leave as is as its working perfectly right now, and need it for a london trip tomorrow. Seeing as its jetted correctly anyway?

Eddie

[Pete.]

So long as the servo is not connected to the valve you'll be fine. If you keep the servo stalled it might overheat, just let it work away doing nothing.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Eddie Hitler]

Will sound dumb now. The servo is where theres a little black box with a pully type circle on it with the 2 cables? Seems electrical so do i need to turn it off as such?

[Eddie Hitler]

Blah, well the EXUP valve is now out of the exhaust. May aswell try to fix it proper.

[Kickstart]

Hi

That is the bit. Could try disconnecting it electrically, but probably easier just to disconnect the cables so the unit can happily turn to its hearts content without doing anything useful.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Scotsman37]

Here's a good site for finding info on how to do maintenance on the exup!

https://www.cartestsoftware.com/fz1/exupmaintenance.html

[Eddie Hitler]

Ahoy, scotsman thats a really helpful page

Cleaned all the unit up, copper greased it but it still seams to stick when i whack it all back together. Had a test ride and its riding better each time, but with the trip dooming im going to stick it all back together now.

What im going to do is set the valve so its fully open, but.. need to double check where to place it in the exhaust.

Usually (i think) it rests at the bottom (ie --- _ -- ) but i think i need to put it more like --- \ -- so its open?

Ahh weird question. Ill have a play.

Ed

[Eddie Hitler]

When im bolting the valve back up it for some reason gets stuck, but its nice and loose just before? Ahh help!

[Pete.]

Take it out, and shine a light into the hole. I haven't laid eyes on the 1000cc one but on my 400 there is a metal sleeve bearing at the back of the hole that had worn away causing the valve to rattle. Could be yours is falling apart too.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Kickstart]

Hi

There is a metal bush on the 1000 as well (and a right pain it was to get back in place on the bike).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Eddie Hitler]

Hey guys,

all fixed.

Was down to carbon build up causing friction when i was tightening the bolts back. Gave it a quick go with some sandpaper and copper greased it up, worked fine.

Also adjusted the cables, was too much slack.

All in all good day, oil and filter change, sorted battery eath terminal, EXUP valve stripped and fixed. My face is all sooty now though.

Some pictures.

https://img.photobucket.com/albums/v246/remoking/Photo0672.jpg
https://img.photobucket.com/albums/v246/remoking/Photo0673.jpg
https://img.photobucket.com/albums/v246/remoking/Photo0671.jpg

[Pete.]

I like your toolkit
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good