YAMAHA ROADLINER / STRATOLINER REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 04-01-2012

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1. Cover the right frame tube in front of the exhaust with duct tape or any suitable material to protect frame during exhaust removal. 2. Remove the three capscrews holding the muffl er assembly to the support bar, loosen the muffl er clamp and carefully remove the muffl er from the motorcycle. 3. Remove and save the two 12mm bolts from the right side fl oorboard assembly (Figure 1) and carefully lower the fl oorboard out of the way. NOTE: Support the fl oorboard with a block of wood or other appropriate material, do not let it “hang” by the brake switch wire. 4. Remove the chrome cover over the power valve pulley. Using a 10mm wrench, remove both cables attached to the power valve pulley (Figure 2). 5. Remove and save the 5mm capscrew on the rear side cover to gain access to the O2 sensor harness plug and unplug O2 sensor from harness (Figure 3). 6. Remove the 4 nuts holding the exhaust system and carefully remove the exhaust system from the motorcycle (may require assistance). NOTE: It may be necessary to loosen the heatshield clamps to access the nuts on the front cylinder. 7. Trace the power valve cables to the drive motor (just under the rear fender on the right side). Remove the power valve cables and mounting clips from the motorcycle. 8. Using a 22mm wrench, carefully remove the O2 sensor from stock exhaust system and save for reuse with the new system. 9. Remove the plastic cover over the clutch banjo bolt (Figure 4). 10. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them

YAMAHA ROADLINER 1854cc exhaust system Installation Manual

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

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1. Loosen and move the right side floorboard out of the way to ease installation of the exhaust. 2. Perform the following to remove the stock exhaust system. NOTE : You must disconnect and remove the power valve cables as well as unplug the oxygen sensor connector first, then remove the exhaust system and mounting bracket, see Figure 1 for power valve. Loosening the jam nuts on each cable, and disengaging the cable barrels from the power valve pulley disconnect the power valve cables. The power valve, and cables are not needed with the new Cobra exhaust system, leave the solenoid box under the seat in place without the cables. To disconnect the O 2 sensor remove the right rear footpeg and remove the steel plate with hook securing O 2 sensor harness behind it, retain plate for later reinstallation. Remove the socket head screw securing the O 2 sensor harness and bracket to engine case on the right side of the motorcycle, see Figure 2 , unplug the stock male and female connectors, and remove entire exhaust system. Disengage the female O 2 connector from the small bracket, (which was unbolted from engine case), to gain extra harness length, upon reassembly of new Cobra exhaust, the small bracket, (from engine case), will not be reused, unless a closed loop Fi2000 ® (92-1773CL /92-1773CL-50), is to be used, then please refer to those specific instructions. Next remove the oxygen sensor from the stock exhaust and retain for later reinstallation. 3. Install new exhaust-mounting bracket using the stock M10 bolts; tighten to factory specifications, Figure 3. 4. Install the front and rear headpipes on to the motorcycle using the supplied flanges, stock bolts and nuts. NOTE: On the rear headpipe be sure to install the stock flange cover as shown in Figure 4. Make sure the pipes are parallel to each other. DO NOT TIGHTEN. 5. Remove the muffler assembly from the box and slide two supplied 27-61MSC clamps onto the muffler inlets, refer to Figure 5 for alignment. Do not install oxygen sensor at this time, as it will not clear the frame rail during installation of the muffler assembly. 6. Slide the muffler assembly on to the headpipes by tapping on the headpipes by hand as you push the muffler forward making sure the assembly slides as far forward as possible. Secure the muffler assembly to the mounting bracket using the supplied 5/16-18 bolts but DO NOT TIGHTEN. Install the oxygen sensor at this time, by inserting it between the right frame rail, and engine case, tighten securely once installed. 7. Reconnect the oxygen sensor connectors, then reposition behind the frame rail and reinstall the M6 x 50 mm bolt removed from engine case and tighten to proper factory torque specification.