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EXUP Instruction Guide

As Yamaha bikes tend to adopt most of the powervalve problems, these instructions are provided purely as a simple guide to suit motorbikes with mid-exhaust mounted, internal powervalve.

Pictures are taken from the YZF1000R but equally suit the 600, R6, R1 etc.

For EXUP owner / riders the first telltale sign that we have a powervalve issue is that dreaded "TICK!". In it's early stages this usually happens at a lower engine speed when under load. This can be a cause for real concern as it's possible to mistake the EXUP noise as coming from the engine itself rather than the belly of the exhaust.

We try to ignore it and convince ourselves it's just a bug bouncing off our 'crash hat' or we just think nothing of it and carry on your merry way (at the national speed limit of course ).

A week or so later, having forgotten all about it, you pop out to your local garage to pick up some american tan tights and a bar of chocolate when you hear a 'tick' - 'tick'!, your convinced that this time it was simply a pair of mating bugs & you carry on just praying it's not your turn!!

Things progress, and after a month or two you start to realise there aren't that many bugs in the world & your crash hats reasonably clean, so what can it be?

When you run out of ideas and start asking fellow riders who have suffered the dreaded 'tick' the answers come thick and fast, strangely though there are rarely any two explanations the same.

All I can put this down to is that one man's 'tick' is another man's 'knock' etc.

What were trying to achieve here is a simple step by step guide to help anyone wanting to remove the 'tick' - 'knock' - 'squeak' - 'clunk'.

So here goes - this is a typical Yamaha EXUP Valve

STEP 1

Your going to need a bag of spanners, a big hammer,
a little patience and...


(89p from your friendly local supermarket)


(essential fluids for human lubrication)

STEP 2

Remove the lower fairing and keep the nuts safe this time!

Remove the EXUP pulley cover completely by carefully
removing the three pulley cover screws (these are usually
quite easy to remove), unlike some face plate bolts!


When removed this will expose the EXUP pulley with centre
nut and the two EXUP cables (hopefully, gulp)?

STEP 3

Next unscrew and remove the two 10mm pulley bracket bolts
(only 1 viewable in photo) and the 8mm pulley bolt (with washer).

Now it's time for some human lube, have your coffee as it's
now that the fun can really start!

STEP 4

With the pulley bracket, pulley, bolts, cables and washer safely out of the
way you can now remove the remaining 10mm EXUP cover bolt(s).

Scrape off any old copper lubricant that's congealed.



(NOTE The two cable bracket bolts also act to hold
the EXUP valve faceplate to the exhaust unit - three
bolts hold the whole unit in place on this model).

The actual EXUP faceplate may be seized/rusted,
if so give a good squirt or two of DoubleTT or
similar pentrating fluid.


if you let it do it's magic then there's time for another...

(this is so easy!)

If you drink real slow, by the time you finished your coffee,
voila! pop! and out she comes but BEWARE!

!WARNING!
The faceplate metal is soft and can be brittle - try not to use a hammer if
you can avoid it. It's possible to put some light leverage on the left hand
side between the exhaust casing and the rear of the faceplate.

(I used the rubber handle of a hammer to good effect)

When EVENTUALLY! she breaks free you are likely to find that the actual
internal valve comes away attached to the faceplate. A bit like this...


Keep these parts, you will need them later ;o)

STEP 5

Now remove both little hex screws from the opposite side of the exhaust.

With the EXUP valve removed you can now help out the larger distal bearing
(if it hasn't already come away - see diagram above with collar in place).

!WARNING - IMPORTANT!
These pins must be removed before you attempt to re-install the EXUP unit.

STEP 6

It is important that you collect all the removed parts.

bolts, washers, spring, small collar & cover



EXUP valve, faceplate, small collar (as above)



spring, washer, centre bolt, faceplate
(old copper grease from previous owners)


small collar & large distal bearing/collar
(both dry as a bone on my bike)

Clean all individual parts thoroughly and take a
small wire brush to the back of the faceplate paying
particular attention to the slightly raised lip.

Whilst they dry out - have another coffee & perhaps a No.1


and admire the inside of your exhaust, ahhh...

STEP 7

Now's also a good time to think about cleaning off the mating surfaces
of the faceplate and the exhaust unit to give us a nice clean re-fit.

It is critically important to remove all old burnt on copper residue or
a nice tight re-fit will be impossible. Pay particular attention to the
recessed lip inside the exhaust unit with a firm wire brush or blade

(mmm not bad!)

STEP 8

When you finish your coffee and the No.1, make sure you wash
your hands and then check the entire inventory of parts are present, clean and completely dry.

Apply EXUP Juice to all bearings, shafts and matting surfaces

Getting good now isn't it! :o)

STEP 9

When your happy that all parts are well lubricated, re-install the EXUP unit
taking care to make sure that the collars locate correctly in the housing.

With the faceplate sat just proud make sure that the bolt holes line up properly with the exhaust unit and gently tap home if necessary.

Turn the pulley a few times with some small mole grips to make sure that the EXUP rotates freely through the whole of the EXUP rotation, if not remove
and re-clean / re-lube.

You should be able to turn the valve freely after all bolts are tightened, if this is stiff or stuck remove and re-clean / re-lube.

If you can't turn it freely the little servo unit hasn't got a chance!

STEP 10

Now it's time to re-assemble the pulley, cables and the cable bracket.

!REMEMBER!
The cable bracket bolts secure the faceplate too, so you need to thread the
cables back into place and finger tighten the two bracket bolts first.

STEP 11

Next identify the cables and use the following photo's to guide re-installation.

(pulley before cables removed)


(pulley with short cable removed)


(clean pulley, front face)


(clean pulley, rear face)

Now attach the third faceplate bolt and as you tighten each of the 3
faceplate bolts turn the EXUP with a small pair of mole grips a couple
of times to ensure it remains free moving.

STEP 12

Slot the pulley back onto the spindle and insert the 8mm washer and bolt.

Make sure all parts are lubricated and if possible squirt DoubleTT inside the cable sleeves and around the pulley cable recess itself.

Part 13

Replace the pulley cover with the three pulley bolts.


Replace the two small hex bolts on the far side of the exhaust.

STEP 14

Crank her up!

NO tick NO knock NO squeak NO clunk

One EXUP powervalve duly removed, repaired and lubricated.

Oh yeah and 'don't forget to put the lower fairing back on'

If anyone has repair instruction for other bike models and would like them
listed here, please email details click here, many thanks.

If you have problems with any re-installation procedure, please email.