Removal and installationsk

A Warning: If the engine has been running the exhaust system will be very hot. Allow the system to cool before carrying out any work.

Silencer

Removal

1 On YZF750R and SP models, for improved clearance and to avoid the possibility of damage, remove the lower fairing (see Chapter 8). Slacken the clamp bolt securing the silencer pipe to the downpipe assembly. Unscrew and remove the silencer mounting bolt, then release the silencer pipe from the downpipe assembly. Remove the sealing ring from the end of the silencer or downpipe assembly and discard it as a new one should be used.

2 On YZF1000R models, unscrew the three flange bolts securing the silencer to the downpipe assembly, noting the guard where fitted (see illustration). Unscrew the nut on the silencer mounting bolt, then withdraw the bolt and remove the silencer (see illustration). Remove the sealing ring from the end of the silencer or downpipe assembly and discard it as a new one should be used.

Installation

3 On YZF750R and SP models, fit the new

12.4b Remove the choke lever and cable elbow from the housing ...

Installation

5 Install the cable making sure it is correctly routed. The cable must not interfere with any other component and should not be kinked or bent sharply.

6 On YZF750R and SP models, lubricate the cable nipple with multi-purpose grease and fit it into the lever, then fit the outer cable end into its socket (see illustrations 12.3c and b). Mount the bracket onto the frame and tighten the bolt securely (see illustration 12.3a).

7 On YZF1000R models, lubricate the cable nipple with multi-purpose grease and attach it to the choke lever (see illustrations 12.4c). Fit the lever and cable elbow into the housing (see illustration 12.4b), then fit the two halves of the housing onto the handlebar, making sure the lever fits correctly, and the pin in the front half locates in the hole in the front of the handlebar (see illustration). Install the screws and tighten them securely (see illustration 12.4aV

8 Lubricate the cable nipple with multipurpose grease and attach it to the choke linkage bar on the carburettor (see illustration 12.2c). Fit the outer cable into its bracket, making sure there is a small amount of freeplay in the inner cable, and tighten the screw (see illustrations 12.2b and a).

9 Check the operation of the choke cable (see Chapter 1).

10 Install the air filter housing and the fuel tank (see Sections 4 and 2). On YZF750R and SP models, install the left-hand fairing side panel (see Chapter 8).

13.2a Remove the bolts (arrowed) and the guard (where fitted)

13.2b Unscrew the nut (A), withdraw the bolt (B) and remove the silencer

12.7 Make sure the pin (A) in the housing locates in the hole (B) in the handlebar sealing ring into the silencer pipe. Fit the silencer onto the downpipe assembly, making sure it is pushed fully home. Align the silencer mounting bracket at the rear and install the bolt, but do not yet tighten it. Tighten the clamp bolt securely, but not overtight, then tighten the silencer mounting bolt to the torque setting specified at the beginning of the Chapter.

4 On YZF1000R models, fit the new sealing ring into the silencer. Fit the silencer onto the downpipe assembly, making sure it locates correctly against the flange, not forgetting the guard where fitted. Align the silencer mounting bracket at the rear and install the bolt, but do not yet tighten it. Tighten the silencer flange bolts to the torque setting specified at the beginning of the Chapter, then tighten the silencer mounting bolt nut to the specified torque (see illustrations 13.2a and b).

5 Run the engine and check the system for leaks.

Complete system Removal

6 Remove the lower fairing and the fairing side panels (see Chapter 8).

7 Detach the cables from the EXUP valve (see Section 14).

8 Slacken the silencer mounting bolt but do not yet remove it (see illustration 13.2b). Unscrew the bolt securing the rear of the downpipe assembly to the frame (see illustration).

13.8 Unscrew the bolt (arrowed)...

13.9 ... and the nuts (arrowed)...

9 Unscrew the eight downpipe flange nuts and draw the flanges off the studs (see illustration).

10 Supporting the system, remove the silencer mounting bolt, then detach the downpipes from the cylinder head and remove the system (see illustration).

11 Remove the gasket from each port in the cylinder head and discard them as new ones must be fitted.

Installation

12 Fit a new gasket into each of the cylinder head ports (see illustration). Apply a smear of grease to the gaskets to keep them in place whilst fitting the downpipe if necessary.

13 Manoeuvre the assembly into position so that the head of each downpipe is located in its port in the cylinder head (see illustration 13.10), then install the silencer mounting bolt and the downpipe assembly rear bolt, but do not yet tighten them (see illustrations 13.2b and 13.8).

14 Locate the downpipe flanges onto the studs, then fit the nuts and tighten them to the torque setting specified at the beginning of the Chapter (see illustration). Now tighten the other bolts to the specified torque.

15 Attach the cables to the EXUP valve (see Section 14).

13.10 ... and remove the exhaust
secure them with the nuts

pulley cover on the exhaust and remove the cover (see illustration). 3 Unscrew the bolt securing the cable pulley and remove the washer, using a suitable bolt or screw located as shown to stop the pulley turning (see illustration). Draw the pulley off the shaft and detach the cable ends from it, noting which fits where (see illustration). Draw the cables out of the bracket, noting which fits where (see illustration). Note the spring and washer fitted on the valve shaft and remove them for safekeeping if required (see illustration 14.7a).

13.12 Fit a new gasket into each port

16 Run the engine and check the system for leaks.

14 EXUP system - S

cable renewal, check, Sv removal and installation Sc

Cable renewal

1 Remove the fuel tank (see Chapter 4) and the lower fairing (see Chapter 8).

2 Unscrew the bolts securing the EXUP

14.2 Unscrew the bolts (arrowed) and 14.3a Unscrew the bolt, securing the 14.3b Draw the pulley off the shaft and remove the cover pulley as shown detach the cable nipples ...

14.2 Unscrew the bolts (arrowed) and 14.3a Unscrew the bolt, securing the 14.3b Draw the pulley off the shaft and remove the cover pulley as shown detach the cable nipples ...

14.3c ... then free the cables from the bracket from the pulley (B). Servo mounting bolts (C)

14.7a Fit the washer and spring if removed

14.3c ... then free the cables from the bracket from the pulley (B). Servo mounting bolts (C)

7 Fit the outer cable ends into the bracket, then fit the nipples into the pulley (see illustrations 14.3c and b). If removed, slide the washer and spring onto the shaft, then locate the pulley and secure it with the bolt, not forgetting its washer (see illustrations). Check and adjust cable freeplay (see Chapter 1), then install the cover and tighten the bolts to the torque setting specified at the beginning of the Chapter.

Check

8 Trace the wiring from the EXUP system servo motor and disconnect it at the connectors (see illustration). Using a fully charged 12V battery and some jumper leads, connect the positive (+ve) terminal of the battery to the black/yellow wire terminal on the servo side of the connector, and the negative (-ve) terminal to the black/red wire terminal. When the battery is connected, the servo should operate. Disconnect the battery immediately after the test.

Caution: Disconnect the battery immediately after the test to prevent possible damage to the servo motor.

9 If the servo now operates, yet did not beforehand, check for voltage at the wiring connector using a voltmeter - connect the positive (+ve) probe of the meter to the black/red wire terminal on the loom side of the connector, and the negative (-ve) terminal to the black/yellow wire terminal. Battery voltage should be present. If not, check the connector for loose or corroded terminals, then check the fuse and the battery, and then the wiring between the connector and the ignition control unit, referring to the test procedures and Wiring Diagrams in Chapter 9.

10 If the servo does not operate, check the static resistance between the white/black wire terminal and the yellow/blue wire terminal on the servo side of the connector using an ohmmeter or multimeter set to the K-ohms scale. Compare the reading to that specified at the beginning of the Chapter. Disconnect the single white/red wire bullet connector (see illustration 14.8). Now check the variable resistance between the white/black wire terminal and the white/red wire terminal on the servo side of the connectors while turning the servo pulley by hand. Compare the reading to that specified at the beginning of the Chapter. If either reading is not within the range specified, replace the servo with a new one.

11 If the operation of the valve has been sticky, remove it as described below, then check the valve shaft, face, cover and housing for any corrosion or dirt which may be causing

4 Free the top ends of the outer cables from their holders on the servo housing, noting their location, and detach the cable nipples from the pulley (see illustration). Withdraw the cables from the machine noting the correct routing of each cable.

5 Lubricate the cable nipples with multipurpose grease and install them into the servo pulley (see illustration 14.4). Fit the outer cable ends into their holders, making sure they locate correctly.

6 Feed the cables through to the exhaust, making sure they are correctly routed. The cables must not interfere with any other component and should not be kinked or bent sharply.

14.7a Fit the washer and spring if removed llpPPI

14.7b Fit the pulley onto the shaft.

14.8 EXUP system wiring connectors

14.7b Fit the pulley onto the shaft.

14.8 EXUP system wiring connectors the problem. Also check the shaft collars in which the valve turns - one in the housing and one in the cover. Clean of all dirt and corrosion and check the operation of the valve. If the shaft ends or collars are worn, replace them with new ones.

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