Filed Under (Yamaha) by admin on 11-02-2012
Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.
Filed Under (Yamaha) by admin on 08-01-2012
90 LOWER END REMOVAL & INSTALLATION TOOLS SHOP EQUIPMENT & TOOLS 35-8399 35-8513 35-8516 35-8508 35-8504 35-8507 YAMAHA CRANKSHAFT PROTECTORS Sold each. 35-8504 YM-4063-A, XV750/920 Virago, XT550, YFP350, YFM660R Raptor 35-8399 YM-1382, XT250/XT350, RZ350, YFP350, YFZ350 35-8507 YM-33282, XV500 Virago, XZ550 Vision, XVZ12/13 Venture & Venture Royale, VMX12 V-Max 35-8508 YM-38145, XV750/XV1000 Virago YAMAHA CRANKSHAFT INSTALLATION SET Sold as a set. Consists of the following: Qt1-Installing Pot, Qt1-Pot Spacer, Qt1-Bolt. 35-8509 YU-90050 Crankshaft Installation Set OPTIONAL POT SPACERS 35-8513 YU-90070-A, XV750/920 Virago, XT550, TT600 35-8515 YU-91044, YFM350, SRX600, XT550/600 35-8516 YU-1202, SR500, TT/XT500 CRANKCASE PRESSURE TESTER An accurate method for checking possible air leaks on two-stroke engines. Complete with air pressure gauge, pump-up bulb and all fittings and adapters for single and multi-cylinder two-cycle engines. 35-5962 Crankcase Pressure Tester CRANKSHAFT INSTALLING JIG TOOL Supports and centers crankshaft webs while assembling two-stroke engine cases and rebuilding crankshafts. Prevents rod misalignment. Adjustable tang ends. 35-9804 Crankshaft Installing Jig Tool CRANKCASE SEPARATOR TOOL This tool will work on most two and four stroke engines that have a vertically split crankcase. Moveable fingers allow a multitude of bolt patterns to be used so it will work on a variety of models. Includes 6mm and 8mm mounting bolts, center pulling bolt and a three leg frame that is appropriate for many applications. 35-9642 Crankcase Separator Tool 35-9637 Replacement 6mm and 8mm mounting bolts. Each
Filed Under (Yamaha) by admin on 27-12-2011
GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.
Filed Under (Yamaha) by admin on 26-12-2011
Remove any aftermarket accessories (saddle bags, back rests, etc) before hitch installation. After installation remount accessories. NOTE: Some aftermarket accessories may not be compatible with InstaTrike hitch. 1) Place motorcycle on a smooth level surface on center stand. 2) Attach Bracket A (left) to outside of rear passenger foot peg mount. Place spacers between Bracket A and foot peg mount. Use new bolts provided. 3) Attach Bracket B (right) to outside of rear passenger foot peg. Place spacers between Bracket B and foot peg mount. Use new bolts provided. Bracket will extend over top of mufflers. 4) Attach Brackets C (left) and D (right) to rear frame bolts on
motorcycle. Located near rear turn signals Use new bolts provided. (10M x 25mm long) It may be necessary to loosen or remove backrest covers or hardware in order to easily access rear frame bolts. After Bracket C and D installation, reattach and/or tighten backrest mounts. 5) Attach Bracket E(left) / F(right) to bottom of Brackets A & B and to the TOP of the forward hitch arms. Ensure hitch is square on motorcycle and snug bolts for Brackets A, B, and E,F at this time. 6) Raise rear of hitch so bottom of Brackets C & D are flush with top of rear hitch plate. Ensuring that hitch is square with motorcycle, carefully mark hole locations for bottom of Brackets C&D on rear hitch plate. Drill rear hitch plate holes with 3/8 inch drill. This step ensures proper alignment and spacing of hitch on the motorcycle. 7) Tighten all bolts ensuring that hitch is square on motorcycle. Periodically check bolts for tightness. Bracket Identification
INSTALLATION OF THE TOW-PAC HITCH CART.
1. Place your motorcycle on a smooth flat surface, like a garage floor, and rest it on its center stand. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bo
Filed Under (Yamaha) by admin on 17-01-2012
In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine
There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p