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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 V-Star 1100 Motorcycle Enhancements Remote Oil Filter Installation Manual

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

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Removing Your Old Filter and Beauty Cover 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. The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter. Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover. “O” ring for bottom bolt. When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover.

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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 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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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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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

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2002 YAMAHA BT 1100 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 29-11-2010

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1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the “SPECIALTOOLS” section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EB101020 GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
GEN INFO IMPORTANT INFORMATION 1-3 EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1Oil seal Do not use compressed air to spin the bearings dry. This will damage the bearing sur- faces. 1Bearing CAUTION: EB101050 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2is positioned opposite the thrust 3 it receives. See sectional view

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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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