Baron Air & Fuel_AIR INJECTION SYSTEM KIT Yamaha Road Star_V-Star1100 - Manual (Page 3)

Page: 3 BA-2521-00
AIR INJECTION REMOVAL KIT - Yamaha - Road Star (99-03)
& V-Star 1100 (All) Models
fitting and continue driving out the fitting. Sometimes fittings can be removed with vice-grip type pliers (Fig.
F).
3a. IMPORTANT: On V-Star 1100 applications, you must remove right side frame tube by loosening the foot
rest and brake master cylinder bolts so they can drop down out of the way. Then remove the two bolts on rear
of the right frame piece and the upper two bolts near frame neck under plastic cover. There is no need to
disconnect any hoses or wires, as the frame only needs to be moved aside to allow access to the cylinder head so
the supplied hole plug may be driven in correctly.
NOTE: SKIPPING THIS STEP CAN RESULT IN CRACKING OF THE CYLINDER HEAD WHERE PLUG
IS INSTALLED! YOU CANNOT INSTALL THE PLUG IN STRAIGHT IF YOU SKIP THIS STEP.
INSTALLATION TIP: At this point we recommend you start the motorcycle and allow the cylinders to get
warm/hot so the metal in the heads will expand, this makes installing the AIS plugs easier.
NOTE: Doing this will not cause any damage to the engine but will make the install much easier to do. BE
SURE YOUR BIKE IS OUT OF GEAR AND STABLIZED BEFORE STARTING.
4. Once air fittings are removed from cylinder heads (Fig. G) and the engine has been warmed and the frame
section is clear on V-Star 1100 models, you should remove the AIS pligs from the freezer one plug at a time.
Insert frozen plugs into the vacated fitting holes pushing them in by hand as far as possible. Then using a mallet
along with the supplied Baron aluminum drift, gentle drive these plugs into cylinder head/s (FIG. H) below.
NOTE: It is not necessary to drive the plugs in until they are fully seated. You should only drive these plugs in
with mild force. The cylinders AIS holes have been found to have varying tolerance, which allows some plugs to
drive only partially in while others may drive in fully. There is very little pressure in this area and as long as the
plugs are in firmly they will remain in place (Figs. H & I).
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.
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