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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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Yamaha Road Star EZ-Steer Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Champion Yamaha Road Star EZ-Steer Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamp of your Yamaha Road Star Motorcycle. Much of the OEM hardware is retained and reused. It is assumed that the installer has advanced and/or professional skills in motorcycle servicing. We recommend that you use an OEM service manual and follow the prescribed disassembly, installation and torque specifications for the upper and lower clamp assembly. Recommended Procedures • Remove headlight, windscreen (if so equipped) and brackets from motorcycle. • The wheel and fork assembly can be removed as one complete unit. Disconnect the master cylinder brake line from the tee fitting below the lower triple clamp. The caliper brake lines may be left in place on the tee fitting. • Install supplied extensions to fork tubes the supplied o-rings. Apply lubricant to o-rings and extensions prior to installing to fork tubes. • Install the lower fork tube covers to the lower clamp prior to installation to motorcycle using the longer screws supplied. The two longest screws are used in the outboard holes. • Replacing the upper OEM bearing and race with the Champion supplied bearing and race, install Champion lower triple clamp to motorcycle reusing original hardware as removed. Torque bearing lock nut to 30 lb. ft. • Slide fork tubes up through bottom of lower clamp approximately 6-8 inches. Install the OEM gaskets, washers and upper fork tube covers. Do not reinstall brake line holders at this time. • Install Champion upper clamp with OEM washer and dome nut. Leave loose. • Slide forks up and into the upper clamp until top of extension is flush with top surface of clamp. • Torque dome nut to 85 lb. ft. • Ensure that fork tube extensions are flush with top of upper clamp. Torque upper and lower clamp bolts to 35lb. ft. • Install handle bars to upper clamp using OEM bolt with supplied flat washers. One washer on top, two on bottom, both sides. • Reinstall brake line holders to the bottom of the lower triple clamp using the supplied M6 NyLoc nuts. • Reinstall all other OEM parts as removed. • Bleed brakes. EZ-Steer Maintenance

Harley Davidson Dakota Digital HLY-6000 Road Star Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The Road Star wiring is split into 2 different bundles with black connectors on the ends that were used to plug into the stock gauge cluster. Cut off both connectors. They are no longer needed The speed sensor wires on the HLY-6000 have a connector on the end that allows you to plug it directly into Harley Davidson speed sensors by using an appropriate adapter (sold separately). Luckily for us, the Road Star’s stock speed sensor will work just fine without an adapter so go ahead and cut off that connector, you don’t need it.
Ideally, the best location for the “brain box” unit of the HLY-6000 would be under the left side cover. Unfortunately, mine is full of other stuff so I had to improvise the location and decided to mount it to the back portion of the under-seat area. I would recommend that you mount yours under the left side cover though. The wires are the perfect length for that location. The brain box and wires could fit under the right side cover, but I don’t believe that the main gauge connector would reach. Using the wiring scheme on the last page of this guide, match up the wires on the Road Star with the corresponding wires on the HLY-6000 wiring harness and solder them together. Important Wiring Information: Both BLACK wires on the brain box need to be connected directly to the (-) terminal on the battery. Don’t connect them to anything else. The following wires from the Road Star are not used and can be taped off: • BLACK • RED / GREEN • BROWN The following wires from the HLY-6000 are not used and can be taped off: • GRAY • WHITE/ BLUE • WHITE (on main harness) • BROWN (*optional) The HLY-6000 has a “dimmer” function which is controlled by the BROWN wire. If you want the gauge to be bright all the time, then leave this wire disconnected. If you want the gauge to dim for night driving, then connect this wire to the GREEN Low Beam (+12v) wire

YAMAHA 1996-2003 Road Star BILLET TACH MOUNT KIT INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 12-01-2012

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Remove and retain the (4) chrome caps from the handlebar clamps. Remove and retain the (4) stock allen head bolts. This hardware will be re-used with the new Billet Tach Mount Kit. Carefully remove the stock handlebar clamps while supporting the handlebars. INSTALLATION: 2. Slide the Electronic Tachometer (#6) into the Billet Tach Mount (#2) and secure with the 10-24 X 1/4″ Socket Set Screw (#10) supplied. Carefully pull the tachometer wire harness through the larger hole in the Billet Tach Cup (#3) and secure the Billet Tach Cup with the 10-24 X 1/8″ Socket Set Screw supplied. (The additional holes in the tach cup are for air circulation). Attach the Billet Tach Mount to the Billet Handlebar Clamp (#1) with the two 10-24 X 1-3/4″ Socket Head Screws (#4) supplied. Install the Billet Tach Mount assembly with the four stock allen head bolts and chrome caps removed in step 1 above. Adjust handlebars to desired height and torque bolts to factory specs. WIRING INSTRUCTIONS: 3. Refer to FIG. #1 . Remove Seat. Disconnect negative cable from battery. Remove fuel tank retaining bolts. Raise fuel tank about 3″-4″ to expose the Left Side Ignition Coil. It is not necessary to completely remove the gas tank on the Road Star. (V-Star 1100 applications use the right front coil and require fuel tank removal.) TIP: Long needle nose pliers are useful in removing and re-installing the coil wires. If desired, tach wire loom may be shortened as necessary. Using an appropriate crimping tool, connect the Tachometer wires in the following manner: Cut Shrink Tubing (#9) into two 1″ pieces

Yamaha Road Star NEEDLE/ JET KIT INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 10-11-2010

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1. Remove the vacuum slide from the carburetor. 2. Remove the OEM needle, spacer and washers, noting order of assembly. 3. Counting from the top to the bottom, install the new Baron needle clip on groove #4 for 04-07 models and on groove #5 for 99-03 models of the replacement. NOTE: Baron adjustable needle – The top is the blunt end of the needle. 4. Reinstall the OEM spacer and washers as shown in this diagram. 5. Reinstall the vacuum slide along with the diaphragm spring. 6. Reattach the diaphragm cover back and tighten screws. NOTE: Verify that the slide maintains its full range of movement. 7. Drain the fuel from the float bowl and remove the bowl cover. 8. Remove the OEM main jet and replace it with a Barons genuine Mikuni main jet. Install the correct main jet as indicated in JET SELECTION area above on this page. Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Page: 2 BA-2420RD NEEDLE/JET KIT – Yamaha Road Star (99-07) 9. Thoroughly clean the inside of the float bowl prior to reinstalling it. 10. Reassemble the carburetor by reversing the order of step #1 through step #10. Use the new cap head allen screws in place of the OEM phillips head screws. 11. Locate the fuel mixture screw – it will either be a screw head or a brass plug. If it is a screw head, skip to step #11c. 11c. If you see a brass plug with a small hole in the center, proceed as follows: With the drill bit, carefully and slowly drill through the fuel mixture plug. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. Insert the self-tapping sheet metal screw into the drilled hole and remove the plug. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 1/2 turns. Refer to step #16 for assistance in fine tuning the setting of the air/fuel adjustment screw. 12. Reinstall the carburetor. We strongly suggest that you attach the throttle cables prior to mounting to intake manifold. 13. Reconnect the fuel line, ensuring the clamp is firmly in place. 14. Reinstall all vent hoses and electrical connectors that were previously removed, checking for any obstructions or blockage. 15. Reinstall the OEM air filter assembly or, if you are installing our Big Air Kit (BAK), follow the instructions that accompany that kit, then continue with next step. NOTES: When the BAK is installed, the vent hose that terminated on the rear of the OEM airbox can be relocated in any safe position that does not kink or pinch it. It is important to verify proper throttle operation before starting the engine.

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Yamaha Road Star Warrior Fuel Injected Models INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and fuel tank. 2. Remove airbox and left airbox cover. We highly recommend you consult the factory service manual for proper removal of airbox. 3. Route wiring harness under frame bracket towards airbox. (Fig 1) 4. Unplug stock black connector for fuel injectors. (Fig 2) 5. Plug Fuelpak 4-pin connectors in-line with the connectors from step 4. 6. Unplug the TPS connector and attach T-tap connector to the center wire (yellow). (Fig 3) 7. Route the Fuelpak violet wire to T-tap. (Fig 4) 8. Reattach the TPS connector. 9. Route black wire to the front of engine and down to the horn. (Fig 5) 10. Disconnect the factory black/white wire from horn. Plug Fuelpak into horn and plug Fuelpak black/white wire to Fuelpak connector. 11. Route black and green wires to battery negative. 12. Attach Fuelpak to Fuelpak harness and mount under seat as shown. (Fig 6) 13. Before reassembling the bike, make sure handlebar switch is in the engine-not-running position and turn the key on. Fuelpak should light up. Sound the horn. If Fuelpak turns off when the horn is sounded, recheck the black wire connection on the horn and that it is connected to the correct wire from the factory harness. 14. Follow the service manual to reinstall the airbox and gas tank. INSTALLATION INSTRUCTIONS FOR P/N 65005 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION FUEL INJECTION MANAGEMENT SYSTEM ROAD STAR WARRIOR NOTICE: Fuelpak is intended for racing or off-highway use only, and is not legal for sale or use in California on pollution-controlled vehicles. PLEASE NOTE: FUELPAK USE REQUIRES A HIGH PERFORMANCE AIR FILTER. HOW IT WORKS ENTERING VALUES 1. Remove Fuelpak clear case cover by removing all four screws, save hardware . 2. Turn on main power with key, but do not start engine. Fuelpak display should light up, if not, turn power off and verify the connectors are fully seated. 3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071. 4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct value as indicated in your Setting Value. After entering your first value, press the mode select button to move to mode 2 and enter the value. Continue until you have entered the value for each of the first 18 mode positions. Each time the value (+) is pressed, the value increases by one number. Each time the value (-) is pressed, the value decreases by one number. (Please refer to the “How It Works” section directly above if you have questions about this step. 5. As the next procedure, after you have entered in your values for the first 18 modes, press the mode select button to move to mode 19. Fully twist open the throttle and return to idle position to calibrate the Fuelpak to your bike. 6. By pressing the mode select button twice, move to mode 21 and verify that it reads “0″ with the throttle closed, “50″ at approximately half-throttle and “99″ when fully opened; if not, repeat step 5. Do not proceed to step 7 until mode 21 is verified. 7. Enter any other mode values as required for your application. 8. Turn off power. 9. Reinstall clear cover, tuck Fuelpak under seat area and reinstall seat. 10. You are now ready to ride.

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V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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Yamaha XVS650 and 1100 Drag Star/V-Star Service and Repair Manual

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Filed Under (Yamaha) by admin on 27-04-2011

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Fortunately, Haynes cruises to the rescue with the introduction of its new Service and Repair Manual for all Yamaha XVS650 and 1100 models – XVS650 (‘97-’05), XVS650A Classic (‘98-’05), XVS1100 (‘99–’05) and XVS1100A Classic (‘00–’05). Hailed as “… essential reading for any biker tackling his own servicing…” by Motor Cycle News, Haynes manuals have an enviable reputation. The new manual provides fully illustrated, step-by-step instructions for DIY servicing, overhaul and repairs of the engine and transmission, fuel and ignition systems, suspension and steering, the braking system and the electrical system. Each task is given a spanner rating for complexity and experience required. Checking and adjusting the valve clearances is rated as three spanners out of five. There are full-colour sections on the history of the models, on daily preride hecks and those all-important wiring diagrams, plus tools required and Haynes Hints. For instance, when changing the brake fluid how to tell when all the old fluid has been displaced The section guiding readers

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Honda Shadow A.C.E. v. Yamaha V-Star 1100 Middleweight Import Cruiser Shootout

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Filed Under (Tips and Review) by admin on 25-11-2010

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You want a big cruiser but you don’t need a large 1500 cc behemoth that weighs close to half-a-ton fully loaded. You want something you can cruise down the boulevard on but you want to be able to handle a corner or two. You want classic styling but you insist on reliability as well. If these are your guidelines, then Honda and Yamaha might have what you’re looking for in the guise of the Honda Shadow American Classic Edition and Yamaha V-Star 1100. Shadow ACE 1100 The ACE and V-Star have a few things in common: Both sport requisite V-twin powerplants (75° for the V-Star and 45° for the ACE) and both possess typical Japanese refinement. Aside from these similarities, the two rides are very different machines. While both machines are shaft driven, the ACE uses the shaft housing as the swingarm. Although this arrangement is effective, it’s a bit lacking style-wise. However, the whitewall tires and the classic fenders and tank help to create a traditional design that turns heads when you’re out and about. The V-Star uses a different approach, utilizing a pivoting sub-frame design with a hidden mono-shock that keeps the lines fluid and consistent with the rest of the bike. Although this beast isn’t equipped with whitewall tires, it still cuts a graceful, glittering profile. The only flaw we noticed was the small headlight that

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YAMAHA Road Star Fuel Pump Relocation Kit INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)

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