ZR900 Exhaust Value Cable Repplacment

[sir-switch]

While waiting for Mr. Winter to show up this season, I'd thought that I would do a bit more preventative wrenching. Pulled the cover off the servo motor for the exhaust value to inspect the cables and noticed that both cables were broken. Not exactly sure how long ago they broke, but both slides have considerable amounts carbon build up. currently soaking for a few days in mineral sprints loosen up to grud. Curious what the cable length spec is when installing the new cables. I'm assuming that I need to set the cable free length before installing to the servo. Also, how can I verfiy things working correctly after everything is put back together? My guess is to run the machine on a stand without the servo motor cover installed and look for the cable actuation. Not sure if the APV engages according to throtle position or RPM. Any other helpful hints/tips would be appreciated....thx

 

[G]

Used to have a ZR 800 and I am sure they are the same. Do not remember the free play amount but you can get on Arcticchat.com and somebody there will know. As far as checking operation once you get it back together you are on the right track. You can see what is going on with the little cover removed. If I remember right it is RPM triggered.

 

[markf419]

If you have your owners manual, it has the specs and adjustment procedure. Measure the cable length with valves and cables installed on the engine side only. Pull on the free end of the cable to check that the valves are moving freely. Then, with no tension on it, measure the exposed cable from the end of the sheathing to the inside of the ball end. On my "02 ZR800, the specs are from 29.6mm -31.6mm. The specs are several mm different from the 500 and 600cc twins that are also in my manual so yours my differ from the 800s.

 

[ezra]

also you can check if servo is working start it and servo should open and close 2 times fast with in a few seconds after starting