Baron Air & Fuel_BIG AIR KIT PINSTRIPE, BLACK Yamaha Road Star - Manual

Page: 1 BA-2020-00/02/03/04/06/07/08/13/13B/15
BIG AIR KIT (BAK) - Yamaha Road Star (99-07)
We recommend 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.
Revision: 6.2 - 02/23/2011
Install Time: 1.5 Hours
INCLUDED IN THE KIT:
(1) Baron Jet Kit BA-2420-00
(1) Billet BAK Cover
(1) Black BAK Backing Plate
(1) Black Dual Point Mounting Arm
(1) Black 5/8x7/16 Alum. Spacer
(1) Black 5/8x1 Alum. Spacer
(1) Re-usable Performance Air Filter
(1) BAK Filter Raincoat
(1) Power Cone
(1) Rubber Boot
(1)Black Zip Tie
(1) Nylon Nipple Pre-installed
(2) M6x18 fender washers
(2) 1/4" Lock Washer
(2) 1/4" -28 x 1 13/16" Zinc Hex Bolt
(2) 1/4" Aluminum Filter Spacer
(1) M6x1.0x45 Sockethead Allen Bolt
(1) M6x1.0x30 Sockethead Allen Bolt
(2) 1/4x20x1/2 Button HeadBolt
TOOLS REQUIRED:
7/16 Combination Wrench
3/16 Allen Wrench
3, 4 & 5 mm Allen Wrenches
10mm Open-End Wrench
Pliers (Std. & Needle-nose)
10 & 12mm Sockets
Phillips & Flat Screwdrivers
Factory Service Manual
INSTRUCTIONS:
1. Take the front BAK cover and clean the rear side with glass cleaner or rubbing alcohol. Remove the power cone from the box and
attach it to the rear of the cover plate using the double faced tape pad supplied in the kit. You will see an engraved circle on the rear
of the cover, place the power cone adhesive pad inside this circle and press/hold firmly for 30 seconds. Attach the power cone to this.
Be sure to press firmly and hold pressure for 30 seconds.
2. Set the cover down on a clean surface, being sure nothing will scratch the front of the cover. Take the 1/4-28 bolts and check to be
sure they thread into the upper and lower threaded holes in the cover, then remove and set them aside. Take the performance air
filter and insert it into the filter groove, carefully seating and sealing it in place. Set aside for the moment.
3. Place the supplied 1/4-28 x 1 13/16" hex bolt, 1/4" lock washer & 1/4" flat washer through the rear of the backing plate in the top
center mounting hole (closest to the carb. opening). Insert the stainless button head screw in the bottom mounting hole (No flat or lock
washers will be used). Put blue Locktite® on the last 1/4" of threads. Insert one aluminum filter spacer on each of these bolts. You
may find it easier to place masking tape over the heads of the two bolts to hold them in the backing plate. Bring the cover/filter and
backing plate together as you now align the filter seal with the groove in the plate being sure it and the cover are fully seated in the
seal. Now carefully get the threads of the 1/4"-28 bolts started and then tighten them firmly.
4. Lay the assembly on the table so the backing plate is facing up. Take the Black Dual Point Mounting Arm and using the two 1/4-20
x 1/2" SS Socket Cap Screws, attach the black motor mount to the rear of the backing plate. Be sure the use Blue Loctite® and torque
these screws to 8 to 10 ft.lbs. NOTE: The notches on the mount should be on your left when you install the plate. (Which means the
notches will be on the side of the rear cylinder when installed)
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.
© 2013 Barons Custom Accessories
5221 Oceanus Drive Huntington Beach, CA 92649 (925)583-2499 - Ph. (714)901-0520 - Fax www.baronscustom.com [email protected]