BA-2440VS Needle/Jet Kit Installation Yamaha V-Star 1100 - 1999-08
CAUTION! We Strongly recommend that a qualified Yamaha Technician install this kit since the carburetors must be removed from the motorcycle.
INCLUDED IN THE KIT: (4) Mikuni Main jets (107.5, 110, 112.5, 115) (2) Mikuni Pilot jets (2x22.5) (8) Cap-head Allen Screws TOOLS REQUIRED: 3, 4 & 5mm Allen Wrenches 10mm Open-end Wrench Pliers (Std. & Needle-nose) INSTRUCTIONS: 1. 2. 3. 4. 5. Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. Work on one carb at a time! Remove the screws on the plastic cap of one carburetor, and pull the vacuum slide. Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to clip position, use these to fine tune the needle) Counting from the top to the bottom, install the new Baron Needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. Reinstall the OEM spacer and washers as shown in the figure below. 10 & 12mm Sockets Phillips & Flat Screwdrivers Drill & Shop Manual (2) Baron Adjustable Needles (2) Clips
Reinstall the vacuum slide along with the diaphragm spring and reattach the diaphragm cover. Verify the slides maintain their full range of movement and do not bind. soft and are prone to stripping.
7. Drain the fuel from the float bowls and remove the bowl covers. Take care as these screws are very 8. Remove the OEM jets and replace them with Barons supplied Mikuni jets as indicated below. Make
sure the front cylinders carburetor gets the larger main jet. 2006- up bikes come with the proper jets. They will flow more fuel with our needles and will require the included larger pilot jets. Important! Baron jet and clip recommendations best suit average riding. Differences in weather, altitude or modifications to your exhaust system may require jets other than those supplied.
Stock Air Filter/Pipes: 112.5 F 110 R Aftermarket Filter/Pipes: 115 F 112.5 R F=Front cylinder, R=Rear cylinder High altitude applications may require leaner jets
311 Industrial Way #1 Fallbrook, CA 92028 (760) 731-1200 Ph. (760) 731-1284 Fax www.baronscustom.com tech@baronscustom.com

CONTINUED:

Thoroughly clean the inside of the float bowls prior to reinstalling them.
10. Reassemble the carburetors by reversing the order of step #1 through step #9. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. 11. Locate the fuel mixture screws - they will either be a screw head or a brass plug. If it is 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 a 5/32 drill bit, carefully and slowly drill through the fuel mixture plugs. CAUTION! The fuel mixture screw is directly under this plug. Be prepared to stop the drill the INSTANT you break through the plug or you may destroy the screw. b) Insert a self-tapping sheet metal screw into the drilled hole and remove the plugs. c) With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it lightly seats, then carefully turn it counter-clockwise 4 turns. Refer to step #16 for assistance in fine-tuning the setting of the air/fuel adjustment screw. Do this to both carburetors.
12. Reinstall the carburetors. 13. Reconnect the fuel lines, ensuring the clamps are firmly in place. 14. Reinstall all vent hoses and electrical connectors that were previously removed, checking for any obstructions or blockage. 15. 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. 16. Verify proper throttle operation before starting the vehicle. Make sure the cables are not binding. 17. The adjusting procedure requires the use of carburetor sticks or a set of vacuum gauges. The carburetors must be synchronized in order to achieve optimum performance. This procedure should be performed by a qualified Yamaha repair technician. Verify that the air/fuel adjustment screw has been set to a starting position as described in step #11c, and that the clip has been installed as detailed in step #4. Check the engine at idle speed for any popping or back firing. For best results, we recommend the air/fuel mixtures be adjusted with an Exhaust Gas Analyzer (EGA) to a CO reading between 2% and 3%.

Revision 6.0 (05/08)