Adjusting the EXUP cable freeplay on an R1 98-2001

 

If the EXUP cable freeplay is out of specification then you will encounter power loss above 6-7000 revs,
rough idling and poor throttle response.
To adjust this you will first need to turn the ignition On then OFF(do not start the engine),this will reset the servo motor and pulley.
Then remove the petrol tank and the lower fairing.
Then remove the EXUP pulley cover, at the bottom of exhaust, see diagram 1:

diagram 1 pulley cover

Next you need to measure the amount of freeplay in each EXUP cable at the pulley end, at points "a", which should be 1.5mm, see diagram 2:

diagram 2 freeplay check

If this is not the case then, slacken the lock ring on the adjuster in each cable and turn the adjusters, these are situated under the tank, in to create freeplay in the cable, see diagram 3:

diagram 3 locknuts and adjusters

Now turn the pulley on the EXUP valve until the notch in the pulley aligns with the hole in the housing, then insert a 4mm pin into the hole,see diagram 2.
Turn each cable adjuster out until it becomes tight, then turn each in by half a turn and tighten the lock rings.
Remove the pin and check that the freeplay is as specified and equal for each cable.
If all is ok then apply some copper grease to the cover bolt threads. Install the cover and tighten the bolts to 10Nm.
Install the lower fairing and the tank and its job done!!!

 

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