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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

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HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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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 V-Star 1100 Carburetor Bowl Screw Repair and Removal After Stripping and Pilot Cap Removal

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Filed Under (Yamaha) by admin on 19-01-2012

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When I first started working on bike many years ago, I learned the danger of stripping the heads of Philips screws when removing or installing them on motorcycles. I remember the two worst screws were the casing side-cover aluminum screws and carburetor bowl screws. I think I tried every method of screw removal after they were stripped. Vice grips, better tipped screwdriver, hammer, drill, and other tools were used. One way I learned to remove stripped screws is to re-make the Philips head into a flathead screw. Cutting a slot in the top of the screw and then use a flat-head screwdriver to remove the screw. On some parts this technique can work, other parts and screws it may not. The Philips screws on the bottom of the V-Star carburetor bowls are VERY prone to stripping. In fact, I will not start a carburetor cleaning without new hex head screws to replace the original Philips bowl screws. Replace the bowl screws for yourself if you keep the bike, or for the next rider that will appreciate the hex-head screws when they clean the carburetors. Not many other parts on a V-Star have screws that are prone to stripping. This documentation is to help riders with motorcycle maintenance. Some riders will find themselves with the problem of removing stripped screws. A carburetor cleaning can quickly double in time when you realize the hardest part of the job is removing bowl screws after they strip. And then realizing you do not have the replacement hex-head screws available and must now go to the hardware store.

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HSR Carburetor Total Kits Installation And Tuning Manual

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Filed Under (Tips and Review) by admin on 31-10-2010

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1. Disconnect the battery ground wire from the battery. 2. Turn the fuel petcock to the “OFF” position. 3. Elevate the rear of the fuel tank for better access to the carburetor area. 4. Remove the coil, horn or other devices on the left hand side of the engine to allow free access to the intake manifold bolts. 5. Remove the complete air cleaner assembly, including the backing plate. 6. Disconnect any vacuum hoses and the fuel hose from the stock carburetor. 7. Disconnect the choke cable from the frame. 8. Remove the stock carburetor. 9. Evo: remove the stock manifold. 10. Twin Cam: unplug MAP sensor, remove manifold and then remove the MAP sensor from the manifold. Installation: Intake Manifold: Twin Cam only: Install MAP sensor in Mikuni manifold. 1. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 2. Attach the rubber flange to the Mikuni manifold with the 5/16″x3/4″ bolts and washers. To ease installation, use liqiud detergent to lubricate the manifold seals. Choke: Evo: We recommend that you use the Mikuni choke cable that is furnished with the carburetor. However, you can use the stock Harley cable (’90-’99 models only) if you follow the Twin Cam choke cable instructions. Twin Cam: 1. Remove the Harley choke cable from the stock carb. 2. Remove the Harley spring and plunger from the Harley choke cable. 3. Remove the Mikuni spring and plunger from the Mikuni carburetor. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut. 6. Install the new assembly into the Mikuni. Be careful to only gently tighten the plastic nut.

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2001-2003 XV16 Fuel Pump and Carburetor Removal

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Filed Under (Yamaha) by admin on 31-12-2011

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Disconnect the carburetor fuel line hose at the fuel pump. •Disconnect the fuel pump wire coupler. •Remove the choke cable from fuel pump bracket. •Remove the upper engine mount, leaving the fuel pump attached to the mount. •Disconnect the TPS and carburetor wire couplers.       Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws. PAGE 3 of 12 HIDDEN 6mm SCREW 6mm BOLT UPPER ENGINE MOUNT/ FUEL PUMP CARBURETOR PAGE 4 of 12 Right-Hand Footrest Removal: •Disconnect and remove the brake light switch. •Remove the forward-most tie wrap around the brake hose and frame. •Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: •Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting. Air Injection System (AIS) Removal: •Remove the electric starter motor. •Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. •Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. •Remove the three Phillips head screws holding    the AIS assembly on the frame. •Remove the AIS assembly from the left side. FOOTREST ASSEMBLY UPPER BANJO BOLT AIS AIR FILTER AIS ASSEMBLY
PAGE 5 of 12 Transfer Case Removal: •Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. •Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. •Remove the drive pulley cover and remove the drive pulley nut. •Loosen the drive belt tension. •Remove the drive pulley, inner cover, collar, and O-ring. NOTE: The collar has a bevel on its inside diameter     for the O-ring facing inward and a bevel on the outside diameter facing the pulley. •Remove the drive and driven sprockets with chain as an assembly. •Remove the collar and O-ring. NOTE: Collar has a bevel on its inside diameter that faces inward for the O-ring. •Remove oil tank filler neck. •Remove the relay bracket on the right-hand side. NOTE: Leave the relays connected. Simply move them out of the way to allow room for transfer case removal. •Slide the transfer case out from the right side.

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Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. 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. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. 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 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

Suzuki GSX1400FE CHASSIS REMOVAL AND INSTALLATION

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

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REMOVAL SEAT Remove the seat with the ignition key. FRAM COVERS Remove the seat. (*Above) Remove the frame cover mounting secrews (left and right sides). Remove the frame covers by pulling on the hooked parts. PILLION RIDER HANDLE Remove the pillion rider handle by removing the pillion rider handle mounting bolts. SEAT TAIL COVER Remove the seat. (*Above) Remove the pillion rider handle. (*Above) Remove the seat tail cover mounting screws. : hooked part 6-4 CHASSIS Remove the fasteners.(*6-5) Disconnect the seat lock cable A. Disconnect the brake light/taillight lead wire coupler. Remove the seat tail cover. REMOUNTING Remount the seat, frame covers, pillion rider handle and seat tail cover in the reverse order of removal. www.GSX1400FE.co.uk
CHASSIS 6-5 FASTENER REMOVAL AND REINSTALLATION FASTENER REMOVAL Depress the head of fasteners center piece 1. Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls 2 close. Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. Push in the head of center piece until it becomes flush with the fastener outside face.

Suzuki B-King GSX1300 BK Suspension Removal and Installation

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Filed Under (Suzuki) by admin on 01-12-2010

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Front Fork Removal and Installation B823H12206002 NOTE The right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation in Section 2D (Page 2D-4)”. CAUTION ! •Make sure that the motorcycle is supported securely. •Do not operate the front brake lever with the front wheel removed. 2) Disconnect the brake hose clamp (1) from the front fender. 3) Disconnect the brake hose (2) from the brake hose clamp. 4) Remove the front fender by removing the bolts (3) , left and right. 5) Remove the reflex reflector for E-03, 24, 28, 33. 6) After removing of the headlight cover upper screws (4), move the headlight assembly forward. 7) Loose the front fork upper clamp bolt (5). NOTE •Slightly loosen the front fork cap bolt (6) to facilitate later disassembly. •Be sure to adjust the rebound damping force adjuster (7) to the softest position before removing the front fork. 8) Loosen the front fork lower clamp bolts (8) and remove the front fork. NOTE Hold the front fork by the hand to prevent sliding out of the steering stem. Installation 1) Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts (1) . 2) Tighten the front fork cap bolt (2) to the specified torque. Tightening torque Front fork cap bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) 3) Loosen the lower clamp bolts. 4) Set the front fork with the upper surface “T” of the outer tube positioned 3.0 mm (0.12 in) “a” from the upper surface of the steering stem upper bracket. 5) Tighten the front fork lower clamp bolts (1). Tightening torque Front fork lower clamp bolt (b): 23 N·m (2.3 kgf- m, 16.5 lb-ft) 6) Tighten the front fork upper clamp bolt (3). Tightening torque Front fork upper clamp bolt (c): 23 N·m (2.3 kgf- m, 16.5 lb-ft

42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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