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1. YAMAHA Ss REL OS TAR ROAD STAR XV1600 STAGE Il COMPETITION KIT SPD 4WMO9 00 02 INSTALLATION MANUAL INSTALLER PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS COMPLETELY BEFORE INSTALLATION TO AVOID POSSIBLE INJURY TO YOURSELF OR DAMAGE TO THE PERFORMANCE KIT COMPONENTS OR MOTORCYCLE DEALER THIS MANUAL CONTAINS IMPORTANT INFORMATION FOR FUTURE REFERENCE AND MUST BE GIVEN TO THE CUSTOMER FEBRUARY 2002 PAK 42M09 00 02 Road Star Speedstar Competition Kit Stage II Installation Manual 2002 by Yamaha Motor Corporation U S A February 2002 Revised 5 02 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A INTRODUCTION Congratulations on your purchase of this genuine Yamaha Speedstar Competition product Speedstar components have been precision made to Yamaha s exacting standards so they fit right and give you a level of power and performance previously unavailable To enjoy your Speedstar products to the fullest be aware of any laws that might affect your use of these modifications as well as all requirements of the sanctioning organization for competition use Also remember that modified motorcycles may need a higher level of maintenance to perform to the fullest This Installation Manual does not contain all the information necessary to install the kit components These2. Clamp 7 Push the Drain Cap onto the Drain nipple next to the Air Intake 8 Install the K amp N Filter Element on the air filter case back Be sure the air filter case back is fully seated in the groove of the filter 9 Install the Air Cleaner Cover over the K amp N Filter Element with the Spacer between the Air Cleaner Cover and the Air Filter Case Back Insert the Hex Socket Head Screw through the Air Cleaner Cover and Spacer and tighten it securely 10 Reinstall the Air Filter Case being sure to reconnect the breather hoses to the nipples on the air filter case back AIR FILTER MAINTENANCE CAUTION e The air filter is an oiled element type which comes pre oiled from the factory After cleaning the filter element must be re oiled with K amp N Air Filter Oil e Use only K amp N Air Filter Oil If the filter is used without oil or with the wrong kind of oil it cannot offer the filtration it was designed to provide and severe engine damage can occur Never use other oils including foam air filter oil motor oil transmission fluid diesel fuel or WD 40 e Do not use compressed air to clean the filter it will blow holes in the element fabric e Use K amp N Air Filter Cleaner to clean the filter element Do not use gasoline solvents cleaning solutions steam or high pressure water which can damage the filter material and the rubber end caps e After cleaning allow the filter element to air dry
3. Do not use compressed air heat hair dryers or open flame to try to speed up the drying process The high performance air cleaner element is designed by the manufacturer to have a service interval of up to 50 000 miles or more before cleaning is required This maintenance interval will be reduced if operating in dusty or wet conditions When the filter looks too dirty use the following procedure Pre Cleaning 1 Remove the filter element Tap the element to dislodge dirt then gently use a soft bristle brush to remove surface dirt 2 Ifa thorough cleaning is not practicable re oil the element with K amp N Air Filter Oil available from your dealer or other K amp N retailer following package instructions Otherwise continue with Cleaning Cleaning 3 Spray K amp N Air Filter Cleaner available from your dealer or other K amp N retailer liberally onto the entire element Let it soak for 10 minutes 4 Rinse the element thoroughly with clean low pressure water Rinse from the inside out so the dirt is removed and not driven further into the filter 5 Shake off the filter element to remove excess water then let the filter element air dry naturally 6 Re oil the filter with K amp N Air Filter Oil Let the oil soak into the filter waiting for it to saturate the cotton material about 10 minutes for spray oil or 20 minutes for bottled oil Re oil any dry spots still showing 7 Reinstall the air filter element on the
4. e Manual and the following instructions 1 Remove the carburetor 2 Remove the vacuum chamber cover and remove the piston valve slide CAUTION Be careful not to damage the diaphragm 3 Remove the jet needle and replace it with the Jet Needle from the kit Use the original plastic ring spacer washers C clip in the 5th groove down from the top spring O ring and diaphragm spring seat DIAPHRAGM SPRING SEAT C CLIP IN 5th GROOVE SPRING CAUTION Do not put the clip in the 6th position on the Jet Needle to avoid damaging the jet needle holder in the slide NOTE The Jet Needle Washers plastic Ring Spacer and the Jet Needle C Clip are extra Keep them in case you lose or damage the original pieces 4 Double check that the Jet Needle is assembled correctly and reinstall it in the Piston Valve 5 Replace the original Pilot Jet in the Carburetor with the Pilot Jet 50 6 Remove the Float Bowl being careful not to damage the Float Bowl Gasket Replace the original Main Jet to work with the Long Drag Exhaust Pipes as follows Primary Operation Elevation Main Jet starting point Below 2000 ft below 607m Main Jet 165 2000 ft 607m or above Main Jet 160 7 Locate the pilot air screw plug in the bottom of the carburetor Using a 5 32 inch 4mm drill bit with a drill stop at 5 32 inch carefully drill through the plug Screw a sheet metal screw into the hole in the plug and then pull on the sc
5. instructions were designed to be used along with the Yamaha XV1600 Service Manual part number LIT 11616 12 56 available from your Yamaha dealer CAUTION e Speedstar engine related competition parts are intended for closed course racing applications only e An alteration of emission related components constitutes tampering under Federal and State laws and can lead to substantial fines and penalties if used other than in closed course competition e Installation of this PERFORMANCE KIT requires extensive mechanical and tuning knowledge of 4 stroke motorcycle engines A professionally trained motorcycle mechanic should install this kit and do any necessary tuning e For increased air intake this competition kit uses an exposed air cleaner element Do not operate the modified motorcycle in wet conditions Carefully cover the air filter element with a plastic bag before washing the motorcycle Driveability will be impaired if the air cleaner becomes wet e The components in this kit were designed to be used together as a complete system Use of some components without others may cause running problems and may reduce performance WARRANTY INFORMATION Genuine Yamaha Speedstar components are covered by a 90 day warranty against defects in material or workmanship Labor for replacement of defective components is not covered The Yamaha Limited Warranty provided with new Yamaha Star motorcycles has exclusions for certain failures including th
6. ket Head Bolts and Flange Nuts at the Exhaust Support Bracket to 22 ft lb 3 0 m kg Attach the stock Rear Brake Hose anchor to the new Exhaust Support Bracket using the original Hex Flange Bolt and tighten to 5 1 ft lb 0 7 m kg
7. motorcycle LONG DRAG PERFORMANCE EXHAUST SPD 4WM09 90 02 CONTENTS RAS edad Cee ee oe assembled with the Exhaust Pipes and i NOTE New exhaust gaskets 3EG 14613 00 00 qty 2 are recommended but not included with the exhaust pipe components INSTALLATION 1 Refer to the Road Star Service Manual as you remove the stock exhaust system and the muffler support bracket 2 Install the Exhaust Support Bracket on the frame using the stock M10 hex socket head bolts Tighten to 22 ft lb 3 0 m kg 3 Insert exhaust gaskets in the cylinder heads New gaskets are not included in the kit order part number 3EG 14613 00 00 4 Install the Rear Cylinder Exhaust Pipe using two Special Female Hex Nuts at the Cylinder Head Cylinder Head Finger tighten the nuts 5 Install the Front Cylinder Exhaust Pipe using two Special Female Hex Nuts at the Cylinder Head Finger tighten the nuts NOTE Sandwich the Rear Cylinder Exhaust Pipe Bracket between the Front Cylinder Exhaust git Pipe Bracket and the Exhaust Support RE aR ACKET Bracket as shown SUPPORT AND ACKET 6 Install the Hex Socket Head Bolts Plain Washers and Hex Flange Nuts at the Exhaust Support Bracket Finger tighten the nuts Tighten the Special Female Hex Nuts at the cylinder heads to 11 ft lb 1 5 m kg Tighten the M8 Hex Soc
8. ose caused by competition or racing use as well as by abnormal strain or abuse While installation of these Speedstar Competition components will not void your motorcycle s warranty specific failures adjudged by Yamaha to have resulted from the installation of kit components modifications or from competition use may not be covered by warranty or extended service coverage KIT CONTENTS COMPONENTS REPLACEMENT PART NUMBER PAGE PERFORMANCE IGNITION MODULE SPD 4WM09 50 00 Looe PERFORMANCE JET KIT SPD 4WM09 49 00 PERFORMANCE AIR CLEANER amp SPD 4WM09 47 05 BREATHER SET LONG DRAG PERFORMANCE EXHAUST SPD 4WM09 90 02 8 NOTE To avoid doing unnecessary duplicate work study the kit contents and installation procedures thoroughly and install the components in a logical order Yamaha suggests installing the components in the order that they appear in this manual PERFORMANCE IGNITION MODULE SPD 4WM09 50 00 This PERFORMANCE IGNITION MODULE is a direct replacement for the stock ignition module CONTENTS Item PartName ty PERFORMANCE IGNITION MODULE INSTALLATION Refer to the Road Star Service Manual and replace the stock ignition module with the PERFORMANCE IGNITION MODULE PERFORMANCE JET KIT SPD 4WM09 49 00 The Jets in this PERFORMANCE JET KIT are a direct replacement for the stock jets in the carburetor CONTENTS Part Name 9 lt 61 Ea Ca INSTALLATION Refer to the Road Star Servic
9. rew with pliers to remove the plug CAUTION Be careful not to drill to deeply Otherwise the pilot air screw or carburetor can be damaged 8 Carefully turn the pilot air screw in clockwise until it is lightly seated then turn it out counterclockwise 3 to 3 1 2 turns 9 Reinstall the carburetor WARNING After reinstalling the carburetor check for proper throttle operation being certain that the throttle works smoothly as the handlebars are moved from steering stop to steering stop PERFORMANCE AIR CLEANER amp BREATHER SET SPD 4WM09 47 05 This PERFORMANCE AIR CLEANER amp BREATHER SET is a direct replacement for the stock air filter assembly CONTENTS Part Name Qty AIR CLEANER COVER SPACER DRAIN CAP INLET PLUG _ _ oOo o o SoS O O INLET PLUG CLAMP K amp N FILTER ELEMENT ae HEX SOCKET HEAD SCREW M6 x 1 0px 70mmLg 1 INSTALLATION INLET PLUG 6 Refer to the Road Star Service Manual and the following instructions 1 Remove the air filter case 2 Remove the two Phillips screws from the back of the air filter case Remove the center screw from the front and remove the outer cover 3 Remove the screws holding the filter Remove the filter and breather hose 4 Reinstall the two filter screws in the threaded filter mounting holes and tighten them securely 5 Install the Inlet Plug Clamp on the air intake 6 Push the Inlet Plug into the Air Intake and tighten the Inlet Plug
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