Yamaha V-Star 650 Multi Application Air Horns Installation Instructions

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Filed Under (Yamaha) by admin on 21-12-2010

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1. Remove the right side cover. 2. Unplug and remove the original horn. 3. Remove the bolt holding the rectifier to the frame and move it out of the way during installation. 4. Locate the hole in the frame shown in photo #4. This hole must be drilled out to 11/32″ for the compressor- mounting bolt. COMPRESSOR MOUNTING Before mounting the compressor it is necessary to install the hose and wires as follows, refer to photo #1 Cut one wire 30″ long. Crimp a female terminal to one end. Cut one wire 8″ long. Crimp a bare fork terminal to one end and a female blade to the other. 1. Attach the short wire to compressor (-), Long wire to compressor (+) 2. Lube one end of the hose with oil or WD-40 and attach to the compressor. 3. Using the bolt, nut, washer and lock washer provided slide the 8 X 16mm bolt in to the slot in the compressor. 4. Bolt the compressor between the frame and engine with the terminals facing down. 5. Re-Install the rectifier and attach the short (-) ground wire to the rectifier mounting bolt. HORN MOUNTING 1. Assemble the hose clamp onto the frame-mounting bracket as pictured in photo #2. 2. Attach the bracket to the frame as shown in photo #3 3. Attach the horn assembly to the bracket using the 5/16″ bolt nut and washers provided. Align the horns so that they are level or angled down slightly at the front and also so they are vertical when viewed from the front or rear. You may need to twist or bend the mounting bracket. Use 2 crescent wrenches to do so. 4. Tighten the hose clamp and 5/16″ bolt securely.

YAMAHA YZ250F ALUMINUM PRO SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING YOUR STOCK SYSTEM 1. Place the machine on a stable work stand. 2. If you are not familiar with removing the original exhaust refer to the owner’s manual before you start work. 3. Always allow your machine to cool down before attempting to remove the exhaust. 4. Remove the two bolts from the right side panel. Then remove the side panel. 5. Loosen the stock mid-pipe clamp, then remove the stand-off bolt and bracket bolt that supports the muffl er. 6. Remove stock muffl er and clamp from the stock head pipe. 7. Remove the stock head pipe at the cylinder head. NOTE: It may be necessary to use a penetrating lubricant on the fl ange nuts. INSTALLING THE NEW ALUMINUM PRO SYSTEM 1. Install Aluminum Pro head pipe onto cylinder head using stock nuts. Leave these fi nger tight for now. 2. Slide mid-pipe onto head pipe. Rotate the mid-pipe slightly to obtain proper alignment with sub-frame mount. 3. Install the OEM bolt through sub-frame into the stand-off mount on mid- pipe (Finger tight). 4. Slide the muffl er onto mid-pipe, align muffl er mount with the stock muffl er mount hole, and install and fi nger tighten the supplied M8x25mm bolt. 5. Once you have the system fully aligned, tighten all the bolts securely to factory specifi cations. NOTE: We recommend starting at the cylinder head and working backwards. 6. Replace the side panel and secure the mounting bolts. BEFORE YOU BEGIN MORE

YAMAHA VIRAGO 700/ 1100 2 into 2 EXHAUST SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8″ x 1″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16″ x 1 1/4″ bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time

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YAMAHA V-STAR 650 EXHAUST SYSTEM REMOVAL AND INSTALLATION

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Filed Under (Yamaha) by admin on 18-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the right hand frame cover to avoid scratching it. 2. Remove the nuts that mount the rear header to the cylinder head. 3. Loosen the pinch clamp on the inlet end of the lower muffler. 4. Remove the two bolts that mount the mufflers to the muffler bracket, located between the two mufflers. Save the hardware for reuse. 5. Pull the rear head pipe out of the exhaust port. Slide the muffler assembly with the rear head pipe attached, rearward, disconnecting it from the front head pipe. Set the assembly aside. Note: Keep the front head pipe attached to the motorcycle, it will integrated with the new exhaust system. 6. Remove the muffler mounting bracket from the frame and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the V&H muffler mounting bracket (stamped 272) to the frame using the stock hardware and mounting location. Refer to figure 1 2. Slip the T-bolt band clamp (supplied) over the straight pipe that is welded to the front muffler. 3. Slip the front muffler assembly over the stock head pipe. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 4. Install the rear header assembly to the exhaust port using the stock 8mm nuts, but leave them loose at this time. 5. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the rear muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 6. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of both heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 7. Align the mufflers so they are parallel when viewing from the right side of the bike, and tighten the 5/16″ flange bolts on the back side of both mufflers. 8. Tighten the two header flange nuts on the rear head pipe. 9. Tighten the T-bolt clamp at the slip joint of the front muffler. 10. Rotate the hose clamps on both heat shields so they are accessible with a screw driver and tighten each of them evenly. Note: The edge of the heat shield should just cover the weld on the inlet of each muffler, if not, adjust the heat shield for correct alignment

YAMAHA FJR1300N PERIODIC MAINTENANCE AND MINOR REPAIR

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Filed Under (Yamaha) by admin on 17-12-2010

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Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU04076* Replacing the fuses The fuse box, which contains the fuses for the individual circuits, is located under panel D. The fuel injection system fuse box is located under panel D. The main fuse box is also located under panel D, beside the battery. (See page 6-7 for panel removal and installation procedures.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. Fuel injection system fuse 2. Spare fuel injection system fuse 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Windshield motor fuse 5. Radiator fan fuse 6. Backup fuse (odometer and clock) 7. Spare fuse (〈 4)
PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU04099 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B (if replacing the left headlight bulb) or panel C (if replacing the right headlight bulb). (See page 6-7 for panel removal and installation procedures.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cove

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Hot-Start Kit For Yamaha YZ/ WR 400F

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Filed Under (Yamaha) by admin on 16-12-2010

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Blaster Rear Brake Kits 121-01298 • YFS200 Blaster ’88-’98 • This cable will eliminate the stock cable from the handlebar. Cable will go from the rear brake pedal to the caliper. 121-01299 • Same as 121-01298 +4″ • Cable is 4″ longer for extended swingarms. 121-01027 Replacement Ratchet Spark Plug Wrench 121-08147 • Designed specifically to fit where there is limited space • Ratchet mechanism works one way • Fits standard 13/16″ plugs
INDEX PAINT HANDLEBARS STREET LEVERS FORK SEALS CABLES SUSPENSION ELECTRICAL FILTERS BRAKE LINES BRAKES CABLE MAKING SUPPLIES CONTROLS DUAL SPORT MANUALS FSO PRODUCTS EMGO DRIVE DISPLAY JETS BEARINGS EYEWEAR VINTAGE MIRRORS EUROPEAN KICKERS SHIFTERS MISC HARD PARTS SHOP TOOLS CHEMICALS TOOLS R . 03-15-06 21 (626) 792-7384 www.FlandersCompany.com Fax: (626) 792-5341 www.FlandersCo.com Specialty Tools Swingarm Bearing Tool 121-080213 • Designed for installation of the swing arm bearings on late model Japanese motorcycles • Using the correct size insert (various sizes included in kit) and the puller, the mechanic can draw the bearing into the swingarm without beating on it with a hammer Main Jet Wrenches • High-quality die cast construction • 6mm round and hex jets and 8mm round • Cap holds a few spare main jets • Sold each 121-08023 6mm Hex (Fits 6mm hex main jets) 121-08024 8mm Round (Fits 8mm round main jets) 121-08025 6mm Round (Fits 6mm round main and pilot) Allen Extension 121-080184 • 5mm allen on a 6.25″ long, 3⁄8-drive extension for hard-to-reach case bolts • Designed for use with air tools • Great for splitting engine cases

Yamaha XVS 650AN Supplementary Service Manual

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Filed Under (Yamaha) by admin on 15-12-2010

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MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in) -4- MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer 182 222 Ω at 20C (68F)/Gray – Black J4T088/MITSUBISHI (U.S.A) J4T128/MITSUBISHI (CAL) Ignition coil: Model /manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance F6T541/MITSUBISHI 6 mm (0.24 in) 3.6 4.8 Ω at 20C (68F) 10.7 14.5 kΩ at 20C (68F) Voltage regulator: Type Model /manufacturer No load regulated voltage Semi-conductor, short-circuit type SH650C-11/SHINDENGEN 14.1 14.9 V Rectifier: Model /manufacturer Capacity Withstand voltage SH650C-11/SHINDENGEN 18 A 200 V Electric starter system: Type Starter motor: Model /manufacturer I.D. number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model /manufacturer Amperage rating Constant mesh type SM-13/MITSUBA SM-13 0.7 kW 10 mm (0.39 in) 28 mm (1.10 in) 0.7 mm (0.08 in) MS-5F-441/JIDECO 180 A 4 mm (0.16 in) 27 mm (1.06 in) Flasher relay: Type Model /manufacturer Self cancelling device Flasher frequency Wattage Semi transistor type FB257H/DENSO Yes 75 95 cycle/min 27 W 2 + 3.4 W Fuel pump relay: Model /manufacturer G8R-30Y-Q/OMRON

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YAMAHA YBR250 OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 15-12-2010

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Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. To increase the spring preload and thereby harden the suspension, turn the adjusting ring on each shock absorber assembly in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring on each shock absorber assembly in direction (b). Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Spring preload setting: Minimum (soft): 1 Standard: 3 Maximum (hard): 5 EAU36700 Luggage strap holders 1. Luggage strap holder There are four luggage strap holders on the bottom of the seat. To use the strap holders, remove the seat, unhook the straps from the hooks, and then install the seat with the straps hanging out from under the seat. (See page 3-9.) EAU15301 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) EWA10240 The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described

Yamaha VMX12/ VMX12C Owner's Manual

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Filed Under (Yamaha) by admin on 14-12-2010

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Main switch EAUO0028 The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU00032 ON All electrical systems are supplied with power, the headlight, meter lighting, taillight and front position lights come on, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed. 1. Push. 2. Release. 3. Turn P (Parking) The meter light, taillight and position lights are on, but all other electrical sys- tems are off. The key can be removed. The key must be pushed in from the “OFF” position to be turned to “P”. ECA00043 Do not use the parking position for an extended length of time, otherwise the battery may discharge. 1. Neutral indicator light ‘NEUTRAL’ 2. Turn signal indicator light ‘TURN’ 3. Fuel level warning light ‘FUEL’ 4. High beam indicator light ‘HIGH BEAM’ 5. Oil level warning light ‘OIL LEVEL’ EAU03034 Indicator and warning lights EAU00062 Neutral indicator light “NEUTRAL” This indicator light comes on when the transmission is in the neutral position. EAU00059 Turn signal indicator light “TURN” This indicator light flashes when the turn signal switch is pushed to the left or right. his warning light comes on when the fuel level drops below approximately 3 L (0.7 Imp gal, 0.8 US gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Turn the key to “ON”. 2. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. Oil level warning light “OIL LEVEL” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked according to the following procedure. 1. Turn the key to “ON”. 2. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: EAU00064 High beam indicator light “HIGH BEAM” This indicator light comes on when the high beam of the headlight is switched on. Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a mal- function

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YAMAHA FJR1300N OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 12-12-2010

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3-2 3 EAU03034 Indicator and warning lights EAU04121 Turn signal indicator lights “” a n d “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU00061 Neutral indicator light ” ” This indicator light comes on when the transmission is in the neutral position. EAU00063 High beam indicator light ” ” This indicator light comes on when the high beam of the headlight is switched on. EAU03201 Oil level warning light ” ” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Set the engine stop switch to ” ” and turn the key to “ON”. 2. Shift the transmission into the neu- tral position or pull the clutch lever. 3. Push the start switch. If the warning light does not come on while push- ing the start switch, have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a mal- function. EAU03192 Engine trouble warning light ” ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this oc- curs, have the Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Set the engine stop switch to ” “. 2. Turn the key to “ON”. If the warn- ing light does not come on, have a Yamaha dealer check the

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