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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

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Yamaha V-Star 650 Engine Guard Installation Manual

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

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1. Protect the rear portion of the front fender with a towel or other thick, soft cloth. Remove the OEM engine guards if they have been installed on the motorcycle. Your new Barons engine guard will fasten to the frame at the same points as the OEM guard and will use the same hardware. 2. Or, if OEM engine guards are not present, remove the 14mm bolts from the underside of the drivers footpeg mounts. 3. Remove the 12mm upper engine mount bolts located on both sides of the frame. Replacement bolts are included with your new engine guard. 4. Position the engine guard so that the lower brackets point towards the rear of the motorcycle, and slide the engine guard into the space between the front wheel and the frame. 5. Raise the guard until the holes in the lower mounting brackets align with the vacated bolt holes beneath the drivers footpegs. Due to production line tolerances in both the motorcycle and the engine guard, the mounting brackets may be too wide or too narrow for the frame. If this is the case, remove the guard from the motorcycle. Place the guard on a flat, firm surface. Insert a towel or other protective material between the guard and the surface. Using a rubber mallet or a block of wood and a hammer, tap the lower brackets until they are correctly spaced. 6. Insert the large washers (supplied with the guard) between the rear face of the lower bracket and the frame. The washer fills the space between the lower mounting bracket and the footpeg mount. Reinsert the 14mm bolts and finger tighten. 7. Rotate the guard until the holes in the upper mounting brackets align with the empty holes on each side of the frame. 8. Insert the replacement 13mm bolts, along with their washers, and tighten securely. Tighten all other nuts and bolts securely. 9. Remove the protection on the front fender and you’re ready to ride. CAUTION!!! You must re-tighten all four of the engine guard mounting bolts after 100 miles of riding! Care & Cleaning: Engine guards take the full brunt of the worst of what the weather in your area has to offer, making it critical that proper and complete cleaning take place on a weekly basis, or corrosion will occur which is not covered by warranty! Proper cleaning procedure would be to use a product like Simple Green, LOC, Salt-Away or similar. Mix a strong batch and apply it liberally with a soft towel or soft nylon brush to the entire

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Yamaha V-Star 650 Engine Guard REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 03-01-2012

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Protect the rear portion of the front fender with a towel or other thick, soft cloth. Remove the OEM engine guards if they have been installed on the motorcycle. Your new Barons engine guard will fasten to the frame at the same points as the OEM guard and will use the same hardware. 2. Or, if OEM engine guards are not present, remove the 14mm bolts from the underside of the drivers footpeg mounts. 3. Remove the 12mm upper engine mount bolts located on both sides of the frame. Replacement bolts are included with your new engine guard. 4. Position the engine guard so that the lower brackets point towards the rear of the motorcycle, and slide the engine guard into the space between the front wheel and the frame. 5. Raise the guard until the holes in the lower mounting brackets align with the vacated bolt holes beneath the drivers footpegs. Due to production line tolerances in both the motorcycle and the engine guard, the mounting brackets may be too wide or too narrow for the frame. If this is the case, remove the guard from the motorcycle. Place the guard on a flat, firm surface. Insert a towel or other protective material between the guard and the surface. Using a rubber mallet or a block of wood and a hammer, tap the lower brackets until they are correctly spaced. 6. Insert the large washers (supplied with the guard) between the rear face of the lower bracket and the frame. The washer fills the space between the lower mounting bracket and the footpeg mount. Reinsert the 14mm bolts and finger tighten. 7. Rotate the guard until the holes in the upper mounting brackets align with the empty holes on each side of the frame. 8. Insert the replacement 13mm bolts, along with their washers, and tighten securely. Tighten all other nuts and bolts securely. 9. Remove the protection on the front fender and you’re ready to ride. CAUTION!!! You must re-tighten all four of the engine guard mounting bolts after 100 miles of riding! Care & Cleaning: Engine guards take the full brunt of the worst of what the weather in your area has to offer, making it critical that proper and complete cleaning take place on a weekly basis, or corrosion will occur which is not covered by warranty! Proper cleaning procedure would be to use a product like Simple Green, LOC, Salt-Away or similar. Mix a strong batch and apply it liberally with a soft towel or soft nylon brush to the entire

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YAMAHA V-Star 650 BIG AIR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 21-01-2012

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Remove fuel tank and air filter assembly per Yamaha service manual procedures. 2. Remove the air silencer box under the tank. 3. Install supplied BA-2410-00 Needle/Jet kit according to the instructions in the jet kit package being sure to use the Jets and Needle Slot setting called out for the external BAK filter assemble. 4. Reinstall the air silencer box under the tank. 5. Remove the rubber boot from the stock air box. It is glued-in from the factory, but will come loose if gently persuaded. See photo #1 Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Barons bears no responsibility on installation costs associated with this product. © 2010 Barons Custom Accessories 7401 Slater Ave. Huntington Beach, CA 92647 (714)274-4065 – Ph. (714)848-0718 – Faxwww.baronscustom.comtech@baronscustom.com Page: 2 BA-2011-00/03/06/07/13/13B BIG AIR KIT – YAMAHA V-Star 650 6. Install the stock rubber boot into your new Baron air filter backing plate with the supplied glue. Squeeze glue liberally into sealing groove in stock rubber boot. See photo #2 Allow glue to set up and dry prior to mounting onto bike

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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 V-STAR 650 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 28-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. This Exhaust system is specifically designed for California models, before continuing be sure it is the correct system for your application. 2. Loosen clamp that connects muffler to front head pipe. 3. Remove cylinder exhaust bolts from rear head pipe that connects rear head pipe to cylinder (save for re- use). 4. Remove bolts that connect mufflers to mounting bracket. Remove complete system. Note: Assistance may be required. Page 1of 4 Y411IN Rev. 1.0 YAMAHA V-STAR 650 CRUZER EXHAUST SYSTEM, CA Model Part #31505 Tools required for installation: 1/2”, 12mm & 10mm wrenches 5mm, 6mm Allen wrenches 5/16″ nutdriver / flat blade screwdriver VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. 2. Install mounting bracket (stamped 370-P) in the original muffler mounting position, using two 8mm bolts (supplied)(Figure 1). 3. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside (Figure 2). Place each heat shield on a non abrasive surface such as a blanket or carpet. Lay each head pipe/muffler onto its respective heat shield (Figure 3). 4. Loosely install each hose clamp by feeding tail end of clamp into heat shield clip (Figure 4). Take note of clamp screw head direction (Figure 3). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Note: Do not tighten yet. 5. Install T-bolt clamp onto front muffler. Slide muffler onto front head pipe. Slide dog bone shaped nut plate (supplied) inside bracket welded to backside of front muffler. Attach muffler to mounting bracket 370-P using two 5/16″ flange bolts (supplied) engaging dog bone nut plate. Leave head pipe/muffler assembly loose at this time (Figure 4). 6. Using stock Allen bolts, carefully install rear head pipe/muffler assembly into exhaust port. (Assistance may be required). Note: Do not tighten yet. 7. Slide dog bone shaped nut plate (supplied) inside bracket welded to backside of rear muffler

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Yamaha V-Star 650 Rear Lowering Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 18-10-2010

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INSTALLATION PROCEDURE 1. Secure motorcycle to a bike lift and raise the motorcycle. 2. Remove stock rear shock from the motorcycle per standard Yamaha shop manual instructions. 3. Place the shaft of the shock in V” blocks and secure this in a vice or press, applying firm pressure to the V” blocks to trap the shaft so it will not turn. Unscrew the upper shock mount eyelet from the shaft. NOTE: The upper mount is a standard thread so you will rotate the mount counter-clockwise to unscrew it. 4. Next, screw the New LA Choppers Shock Mount onto shock shaft using Loctite. 5. Re-install shock spring, making sure it is locked in place with the retaining ring prior to slowly releasing the spring compressor. Allow shock spring to expand against the retaining ring and machined washer. 6. Reinstall shock onto the motorcycle per standard Yamaha shop manual instructions. WARNING: Installing a lowering kit will decrease initial ground clearance. The motorcycle will be lower to the ground and care should be taken to avoid bottoming, especially over bumps or in turns. To maintain proper balanced geometry, the front and rear of the motorcycle should be lowered equally. Failure to properly install the lowering kit and operate the motorcycle after installation may result in serious injury or death to the rider. LIMITED GUARANTY: Because we cannot control the application of our products, buyer assumes risks for any and all damage caused to him or herself or any third party by virtue of any failure of these parts. Guaranty for such parts is limited to our replacement costs thereof. This guaranty is in lieu of all other guaranties or warranties express or implied, and all other such guaranties or warranties are hereby expressly disclaimed. By installation of these parts, buyer irrevocably agrees to the foregoing

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HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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Yamaha V-Star 650 Outlaw Part Installation Instructions

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Filed Under (Yamaha) by admin on 09-11-2010

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Remove both Allen bolts that hold the muffler together (Fig. 1) . Also Loosen clamp from the front muffler to front head pipe (Fig. 2) , and remove allen bolts from rear head pipe and remove in one peace carefully (Fig. 3) . Figure 1 Figure Figure 3 2. Once the two mufflers are removed with the rear head pipe, remove bracket by removing two 8mm bolts as shown and remove bracket. (Fig 4) Figure 4 3. Remove spring from brake light switch to the brake rod located on the right side footrest. (Fig 5) Figure 5 4. Remove two bolts holding the footrest, and brake pedal (Fig. 6) . Carefully rest right side footrest on the floor or you can use a two by four to rest the footrest onto. Figure 6 5. Remove front head pipe by removing two nuts on the head pipe flange as shown in figure (Fig 7). Now your stock exhaust should be fully remove as shown in (Fig.8) Figure 7 Figure 8 6. Remove right side exhaust stud with a stud remover or double nut two 8mm nuts and remove stud. (Fig. 9 & 10) Note: We supply two 8mm x 1.25 flange nuts in the hardware kit so you can remove the stud. Figure 9 Figure 10 Assembly 7. Tape off your frame and parts of the motor before installing the Roadhouse exhaust, this will prevent any scratches on your V-Star. (Fig. 11) Figure 11 8. Mount Roadhouse muffler bracket on bike with supplied two 8mm x 1.25 x 20mm flange bolts as shown in (Fig. 12). Figure 12 9. Slide front head flange onto Roadhouse front head pipe as shown in (Fig. 13) . Once head flange is mounted on head pipe mount head pipe into port as shown in (Fig. 14) and use from hardware kit (one) 8mm x 1.25 x 25mm flange bolts and one of the stock nuts to mount on the stud (Fig. 15) . Make collar is flush with the front port and tighten flange bolt and nut.

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

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