Baron Air & Fuel_FUEL PUMP RELOCATION KIT Yamaha Road Star - Manual

Page: 1 BA-2620RD
Road Star Fuel Pump Relocation Kit
NOTE: WE RECOMMEND INSTALLATION OF THIS KIT TO BE
PERFORMED BY A QUALIFIED MOTORCYCLE TECHNICIAN
CAUTION: WE RECOMMEND YOU RUN MOTORCYCLE WITH FUEL
PETCOCK IN THE OFF" POSITION TILL IT STALLS TO PURGE FUEL
FROM THE FUEL PUMP SYSTEM. LET MOTORCYCLE COOL BEFORE
ATTEMPTING INSTALLATION OF THIS KIT!
Revision: 1.4 - 04/02/2010
INCLUDED IN THE KIT:
(1) - Two-sided Tape Pad
(3) - Hose Clamps
(4) - Electrical Butt Connectors
(1) - Extended Wire Harness
(1) Pre-cut Length Braided Stainless Fuel Hose
(2) - Pre-cut Lengths Std. Fuel Hose
(2) - Zip Ties
(1) - Choke Bracket
(1) - Fuel Pump Bracket
INSTRUCTIONS:
1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and
remove air box from carburetor (all per Yamaha standard shop manual procedures).
2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket.
Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector.
3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide
fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and
fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and
remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp
knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A.
Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation
from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied
electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and
Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness
extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs
along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube
off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is
facing up (clockwise approx 1/4 turn).
4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line
from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder
head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut.
New choke bracket will mount to rear fuel tank mounting location (Photo C).
5. 99~03 models - Remove electrical relay bracket (found under the right side cover) from the bike and slide
each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the
same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for
proper installation.
6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut
rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket.
The second relay will be placed to the right of the tool bag under the seat and secured with the provided
two-sided tape pad. Reconnect plugs to the relays. (Photo F)
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]