BA-2020-XX – BIG AIR KIT (BAK) YAMAHA ROAD STAR
Contents
1. locknut and turning in the adjusting screw one turn We have found the accelerator pump s factory setting to be too rich on many Road Stars Refer to Yamaha s shop manual for this adjustment procedure Version 4 5 06 092. each of these bolts Now install the backing plate onto the air filter Again align the filter with the groove in the backing plate and tighten the mounting hardware Take the three 3 supplied mounting arms and attach them to Baron backing plate in the correct position as indicated by stamped numbers on the arms and corresponding numbers on the backing plate Use the supplied 5mm x 10mm screws to attach mounting arms to the backing plate and tighten firmly be sure to use blue Loctite on each screw NOTE mounting arm stamped 2 rests on top of lower button head screw in backing plate Remove rubber grommets and washer inserts from the plastic mounting arms of the stock Yamaha air box Install these parts in the chromed mounting arms in your Baron kit It is easier to install grommets if you remove washer inserts first Once the grommets are installed push washer inserts in from the rear so washer will be against the engine mount points continued on reverse 311 Industrial Way 1 e Fallbrook CA 92028 e 760 731 1200 Ph e 760 731 1284 Fax e www baronscustom com tech baronscustom com BA 2020 XX BIG AIR KIT BAK YAMAHA ROAD STAR CONTINUED Remove metal hose clamp from stock air box s rubber carb intake connector Slip clamp over BAK s rubber intake boot but do not tighten at this time Make sure to install clamp with screw head facing rear of the bike Take the BAK assembly with mounting arms attached and
3. movement Drain the fuel from the float bowl and remove the bowl cover Remove the OEM main jet and replace it with a Baron s genuine Mikuni main jet Install the correct main jet as indicated in the chart in the upper right corner of the page Thoroughly clean the inside of the float bowl prior to reinstalling it 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 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 11 12 13 14 15 16 Locate the fuel mixture screw it will either be a screw head or a brass plug If itis a screw head skip to step 11c If you see a brass plug with a small hole in the center proceed as follows a With the drill bit carefully and slowly drill through the fuel mixture plug b 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
4. BA 2020 XX BIG AIR KIT BAK YAMAHA ROAD STAR CAUTION We Strongly recommend that a qualified technician install this kit if you do not completely understand the instructions prior to the install INCLUDED IN THE KIT 3 M5 Chrome Washers 1 4 28 x 1 Stainless Button Head Screw 1 Baron Jet Kit BA 2420RD TOOLS REQUIRED 3 4 amp 5 mm Allen Wrenches 10 amp 12mm Sockets 10mm Open End Wrench Phillips amp Flat Screwdrivers Pliers Std amp Needle nose Factory Service Manual INSTRUCTIONS NOTE We recommend the use of blue Loctite on all fasteners and mounting hardware The following directions will provide the information necessary to properly install Baron s Big Air Kit provided our Jet Kit BA 2420 RD included has already been installed according to our instructions With your tank removed you can begin the installation process as outlined below 1 The Baron Big Air Kit BAK comes unassembled First attach the Power Cone to the inside of your BAK cover with supplied double stick adhesive tape Next place your Performance Air filter in the groove on the cover make sure the filter seats properly to make a complete seal Place the supplied 14 28 x 1 e Hex Bolt 1 4 lock washer amp 1 4 flat washer in the backing plate in the top center mounting hole closest to the carb opening The stainless button head screw is used in the bottom mounting hole Insert one aluminum filter soacer on
5. ite www baronscustom com E mail tech baronscustom com Jet Kit Installation Yamaha XV1600 1700 Road Star 99 07 Please read ALL of the instructions BEFORE installing beginning the installation CAUTION We strongly recommend that a qualified Yamaha technician install this kit since the carburetor must be removed from the motorcycle Always perform internal carburetor work in a clean area Included in this kit Main Jet Settings 4 Mikuni main jets 1 titanium needle 2 clips 993 Models 4 cap head Allen screws 1 drill bit 1 sheetmetal screw 167 5 Stock pipes 170 Pipes w baffles To install this jet and needle kit L 2 3 10 172 5 Pipes w o baffles gt 04 07 Models 170 Stock pipes 172 5 Pipes w baffles Remove the vacuum slide from the carburetor 175 Pipes w o baffles Remove the OEM needle spacer and washers noting 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 The top is the blunt end of the needle Reinstall the OEM spacer and washers as shown in the figure below BARON S B A K PARTS a om cam INA A i j i j i ad TOP af THROTTLE SLIDE STOCK YAMAHA CARB PARTS Reinstall the vacuum slide along with the diaphragm spring Reattach the diaphragm cover back and tighten its screws Note Verify that the slide maintains its full range of
6. place it into position between the cylinders Install crankcase vent hose on small male vent fitting located on rear of backing plate The carb vent hose that was Originally routed to a bracket on the rear of the stock airbox should be shortened slightly and allowed to vent to the atmosphere Route this hose in such a manner as to make it inconspicuous from view ensuring that it will not get pinched or blocked in any way Install BAK assembly onto carburetor and insert chrome bolts and washers into each mounting arm and tighten we recommend using blue Loctite Slide carb boot clamp up against carburetor and tighten Check all linkages for interference check all hoses for kinks check all bolts and hardware for tightness and then check throttle action for smooth operation You are ready to ride Perform final idle mixture screw adjustments per instructions supplied with your Baron Jet Kit Our install guides provide a basic outline on the proper installation of our products Further tuning and or fitment may be required Baron bears no responsibility on installation costs associated with this product 2009 Baron Custom Accessories Revision 4 2 5 27 2009 311 Industrial Way 1 e Fallbrook CA 92028 e 760 731 1200 Ph e 760 731 1284 Fax e www baronscustom com tech baronscustom com 311 1 Industrial Way Fallbrook CA 92028 USA ice YEN iil Mam HNW Phone 760 731 1200 Fax 760 731 1284 CHUS RaM ARRORA RE Webs
7. 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 Reinstall the carburetor We strongly suggest that you attach the throttle cables prior to mounting to intake manifold Reconnect the fuel line ensuring the clamp is firmly in place Reinstall all vent hoses and electrical connectors that were previously removed checking for any obstructions or blockage Reinstall the OEM air filter assembly or if you are installing our Big Air Kit BAK follow the instructions that accompany that kit and then continue with step 16 When a BAK is installed the vent hose that terminated on the rear of the OEM airbox can be located in any safe position that does not kink or pinch it Note It is important to verify proper throttle operation before starting the engine Verify that the air fuel adjustment screw has been set to a starting position as described in step 1 1c and that the clip has been installed as detailed in step 3 Check the engine at idle speed for any popping or back firing For best results we recommend that the engine be adjusted on an Exhaust Gas Analyzer EGA to a CO reading between 2 and 3 If your bike emits black smoke when revving the engine indicating an over rich condition Barons suggests adjusting the carburetor s accelerator pump to a leaner setting by loosening the pump s lower
Download Pdf Manuals
Related Search