fzr400 exup

**imdying** · 20th June 2007, 12:27

I can show you how to make them stronger than standard if you like... pretty overkill, but...

**Paul in NZ** · 20th June 2007, 13:03

Originally Posted by imdying

I can show you how to make them stronger than standard if you like... pretty overkill, but...

Can't do easily if it means making the cables bigger as they have to fit into cast ends / recievers at the servo and exhaust. Nylon lined? Maybe not as i think they get hot at the exup end... Looks like I CAN buy new now (argh)

**imdying** · 20th June 2007, 13:51

Naw, it's all in how you attach the ends. If you open the end piece a little (you can buy some pre done), then you can flare the cable before you solder it up. Ain't no way that will ever pull out

**Paul in NZ** · 20th June 2007, 15:12

Originally Posted by imdying

Naw, it's all in how you attach the ends. If you open the end piece a little (you can buy some pre done), then you can flare the cable before you solder it up. Ain't no way that will ever pull out

They didn't pull out - they snapped off. I think the nipples seized in the pulley.

Cheers

**imdying** · 20th June 2007, 16:10

Ok, two things too watch out for:
- Hold the cable upside down when you solder it, and only feed in as much solder as you need... otherwise it'll feed up the cable, and create a hard point that'll snap off
- Make sure you end actually fits the thing you're fitting it into. And when you grind any excess solder off, make sure it's still round afterwards

A little dab of grease on the end bit pivot point (the hole it goes in) doesn't go astray either

**Paul in NZ** · 30th June 2007, 20:34

Right - progress at last!

I now have nice rebuilt EXUP cables... Fitted to the servo and while I was in there I noticed the rear brake master cylinder was floating free so a spare bolt from the collection of spare bolts sorted that.. nooice..... Pictures crap but losts of hi temp grease on servo nipples

I have fitted new grips (I got bored).....

I have cleaned up the rusty bolts holding the sub frame and engine in (rust killer) and will give em a shot of zinc tomorrow... shiney....

Swing arm bobbins are fitted and one of Frosty's race stand hold it up.. mmmm.. stable... (Tony send me your bleeding account details already!)

I have new gaskets and new rings! Yes they have arrived from the USA so we can now rebuild the head (valve stem seals) and gap the piston rings in the bores and once I've cleaned up the pistons I can start engine reassembly...

Woo hoo....

**Paul in NZ** · 30th June 2007, 20:37

Oh - I've started on the exhaust system too - bleugh - 'orrible job!

**FROSTY:Me** · 1st July 2007, 12:04

Paul---Save yaself a bit of work--remember the way we used to clean out 2 smoke zorsts--Blow torch -Itll wok in thie innards of the exup casing too

**Paul in NZ** · 1st July 2007, 13:33

Originally Posted by FROSTY

Paul---Save yaself a bit of work--remember the way we used to clean out 2 smoke zorsts--Blow torch -Itll wok in thie innards of the exup casing too

Yup - done that - bleugh! Cleaning up the outside too for a paint..... Muffler looks OK (ish) inside....

**Paul in NZ** · 1st July 2007, 19:06

Argh - bloody weather - wot a pain in the bum...

Spent a bit of time this morning pruning trees, triming the hedge etc when it was not raining too badly.. (sigh) but I'd have liked it fine so I could clean up the pipes and paint stuff outside...

Not to be!

Headers are cleaned up and painted. Worst of the soot cleaned out!

Mufflers cleaned inside (a bit) and out... (a bit more)

Various frame bolts that were munted got the rust killer treatment and a shot of zinc paint to protect em. Really should have plated them but the paint was already there as was the rust killer and I'd rather spend the $$ on the gaskets etc....

The tube is a water pipe that was fairly corroded and now - it is not.....

All lookin good and only a couple of really messy jobs to do and then we can get to the fun stuff - reassembly... (ah hem)

**Paul in NZ** · 2nd July 2007, 08:49

Dropped the NEW valve seals (for head reassembly) and the NEW piston rings (gap checking in bores) off at the engine reconditioners... Woo hoo...

**xwhatsit** · 2nd July 2007, 12:50

Originally Posted by Paul in NZ

Argh - bloody weather - wot a pain in the bum...

Spent a bit of time this morning pruning trees, triming the hedge etc when it was not raining too badly.. (sigh) but I'd have liked it fine so I could clean up the pipes and paint stuff outside...

Not to be!

Headers are cleaned up and painted. Worst of the soot cleaned out!

Mufflers cleaned inside (a bit) and out... (a bit more)

Various frame bolts that were munted got the rust killer treatment and a shot of zinc paint to protect em. Really should have plated them but the paint was already there as was the rust killer and I'd rather spend the $$ on the gaskets etc....

The tube is a water pipe that was fairly corroded and now - it is not.....

All lookin good and only a couple of really messy jobs to do and then we can get to the fun stuff - reassembly... (ah hem)

Those pipes look very good. How did you get them like that? My headers look absolutely awful where they exit the engine, probably a bit worse than yours were originally, but I'd like an alternative to exhaust tape or brand new ones.

**Paul in NZ** · 2nd July 2007, 12:56

Originally Posted by xerxesdaphat

Those pipes look very good. How did you get them like that? My headers look absolutely awful where they exit the engine, probably a bit worse than yours were originally, but I'd like an alternative to exhaust tape or brand new ones.

A good scrub with a wire brush to remove the worst of it... Several applications of rust killer, washing, scrubbing, wire brush, emery paper, sand paper anything abrasive left on the bench followed by a spray with VHT Hi-Temp exhaust paint which is good stuff! (once its painted, keep it nice with pot belly stove polish)

They were pretty rusty so this will make em last a little longer I hope?

Cheers

**Paul in NZ** · 11th July 2007, 21:53

Remember this thread?? Sadly work is the curse of the workshop man and I have been waiting on bits as well.

The heads done and barrels are back (pictures later - it's staying wrapped up at the moment). Rings sized up well so it's all go.

Second lot of parts arrived coutesy of jeaves on KB who is a genuine good bastard and saved me a small fortune with his fledgling (ah hem) service - I shall be using him again and I suggest you do too.... 1 genuine air filter, muffler bolt / nut (a bit of vanity) and exup valve gasket and bush.

Big news - I welded up the engine cover myself using the stuff on trademe Frosty and Pantah Pete recommended. It was relatively easy (er - less said the better) but practise is recommended. Its now sound but will address the cosmetics this weekend and seal the inside as well (non oil retention cover so all sweet)

Next job (started tonight) it to remove the gunk from the pistons and fit the new rings.

QUESTION - the base gasket seems to have had some sort of sealant applied at the factory? Anyone know what it is? I've heard of 'Yamabond'. it that it? (must check manual)

As usual - pictures...