Here are some of the maintenance methods we’ve received from the Webike Community "MOTO HACK Maintenance" campaign that we’d like to refer to. Maybe you have an idea you'd like to try!
In this article, I'm going to introduce the maintenance HACK from Chibi Buncho who rides FZR250!
Motorcycle introduction and its maintenance
About the motorcycle
Nearly 35 years old FZR250 2KR
Working process
Removing rust from the EXUP system valves that have rusted due to moisture in the exhaust system and greasing the bearings to ensure reliable operation and improved exhaust system efficiency.
Working hours
About 3 to 4 hours
Working difficulty
Relatively simple
Items to use
Brand: Loctite
Product name: C5-A Copper Anti Seize tube 28g Blister JP
Learn more about the work
- Remove the terminal from the battery.
- Remove the under-cowl and left tail cowl.
- The servo motor is located in the left rear tail cowl.
- Loosen and remove the two-wire length adjustment screws from the servo motor.
Check the wire number listed on the servo motor. In the photo, the top is No. 2 and the bottom is No. 1.
- Remove the silencer.
- Remove the exhaust pipe from the body.
- Remove the cover of the EXUP valve from the exhaust pipe.
- The wire is attached to the pulley in the cover and remove it. Check the wire bracket as the number is engraved on it.
- Remove the bracket mounting screws.
- The stainless steel gasket is located between the bracket and the exhaust system, so be careful not to deform it when you reuse it.
- This is the EXUP valve that was removed. Because it is located at the bottom of the exhaust pipe, rust has been generated by water from the exhaust.
- Use a wire brush to remove the rust. Since it is made of cast iron, you don't need to worry about scratches. Do not polish the bearing part too much. The gap becomes big and a clattering sound comes out when idling.
- After removing the rust from the EXUP valve, apply anti-carburizing copper grease to the bearing.
- Clean and grease the bushing side of the valve bearing. Since the bushing is soft and made of heat resistant and oilless material, do not make deep scratches. The bushing is also available in parts.
- You can also assemble the EXUP valve at 180 degrees in the opposite direction, so be careful which way it is facing.
- After assembling the bracket and pulley, install the exhaust system to the body. The cover is not yet installed.
- After assembling the wire to the servo motor, connect the battery and turn on the key. adjust the wire so that the holes in the bracket fit in the notched slot on the EXUP valve. (The wire will be placed in the pulley groove.)
Since the hole is 6mm in diameter, it is easy to adjust by inserting a drill or the like to stop it from moving around. - After adjusting the wire play, check the operation and complete the assembly of the EXUP cover, and removed the cowl.
Advice
The EXUP is a fun motorcycle to ride at high rpm. With regular maintenance, you can enjoy a motorcycle that is new to you.
Thanks for posting that valuable maintenance HACK, Chibi Buncho! You will receive 1,500 points to be used at Webike!
