Baron BIG AIR KIT PINSTRIPE, Suzuki C-50 User Manual

BIG AIR KIT - Suzuki C50/M50 Boulevard

Page: 1BA-2080-00/03/06/07/13/13B

Revision: 4.1 - 04/05/2010

Install Time: 1 Hour

INCLUDED IN THE KIT:
(2) Mounting Arm
(2) 20mm Diameter x .76" Aluminum Stepped Spacer
(2) M6 x 1.0 x 35 Chrome Socket Cap Head Screw
(2) M6 Chrome Lock Washer
(2) M6 Chrome Fender Washer
(3) M5 x 10mm Button Head Allen Screw SS
(2) M6 x 1.0 x 16mm Button Head Screw Chrome
(2) M6 Serrated Flange Nut
(1) M5 x 12 Socket Cap Head Screw SS
(1) Spacer Tube 2.42L x .25 I.D. x .50 O.D.

INSTRUCTIONS:

We highly recommend the use of Blue Loctite® on all fasteners and mounting

hardware. Our installation guide provides a basic outline on the installation of
our products. Further tuning and/or fitment may be required and we suggest

a professional technician be utilized. Barons bears no responsibility on

installation costs associated with this product. 2009 Barons Custom

Accessories

(1) M6 x 80mm x 1.0 Socket Head Cap Screw SS
(1) Aluminum Manifold
(2) 1/4 28 x 1 13/16" Hex Bolt
(2) Aluminum Filter Spacer
(2) 1/4" Lock Washer
(1) Nylon Nipple Pre-installed
(1) Slimline Air Filter
(1) Raincoat Filter
(1) Billet BAK Cover

READ COMPLETE INSTRUCTIONS BEFORE STARTING INSTALLATION

NOTES: We highly recommend the use of the Blue Loctite® on all fasteners and mounting hardware. It will
not be necessary to remove your seat or your fuel tank for this installation.

1. Remove the (2) Bolts at the top of the stock air cleaner to the left and right of the oval rubber hose coming
from under the fuel tank.

2. Loosen the hose clamp at the base of the oval rubber hose on the top of the air cleaner.

3. A male barb protrudes from the rear of the air cleaner that inserts into a rubber grommet mounted to the
cylinders. Pull the air cleaner away from the cylinders firmly and you will feel the barb release. Now pull the
upper section of the air cleaner downward to remove it from the oval snorkel tube from under the fuel tank.

4. Now you can reach to the rear of the box and unplug the electrical lead for the Air Sensor" which sits just
about in the middle of the rear of the air cleaner. Now remove the breather hose at bottom of the air cleaner.

5. Set the air cleaner aside and turn it over to access the back. Remove the single bolt that secures the Air
Sensor" (This sensor will be installed into the Aluminum Manifold of your new BAK assembly later)

6. Remove the lower mounting arm assembly from the cylinders. (You will not reuse this).

7. Using the (2) Dome head m6 x 15mm screws install the (2) #1 Arms to the rear (the side without the groove)
of the backing plate, the shiny/chrome side of the arms should face outward. The smaller of the two holes in
each arm is the one you place the screws through. Use the m6 Flange Nuts to secure the bolts at the rear of
backing plate. Snug these up but do not tighten fully.

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 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]

Page: 2BA-2080-00/03/06/07/13/13B

BIG AIR KIT - Suzuki C50/M50 Boulevard

8. Using the (3) Dome head m5 x 10mm screws attach the aluminum manifold the rear of the backing plate
aligning the radiusd intake hole of the backing plate with the manifolds intake hole. (Use Blue Loctite® on
these screws). Note: The oval opening should face upwards towards the fuel tank.

9. Thread the Barbed Nylon Nipple (supplied) into the rear of the aluminum manifold (supplied).

10. Install the "Air Sensor" (previously removed from the stock air box) using the supplied m5 into the
manifold, insert the sensor through the manifold and then thread the m5 screw and tighten from the rear.

11. Now mount the partially assembled backing plate to the cylinders and plug the electrical lead into the
sensor and you may attach the fresh air hose to the nipple or you may plug the hose and the nipple and not use
them. Either way tuning will not be effected. NEXT: Align the upper oval "Male" protrusion from the manifold
with the "Female" portion of the rubber snorkel insert then tighten the stock hose clamp. NEXT: Using the (2)
stepped black spacers insert the small step into each of the (2) #2 spacer arms then align these with the thread
hole at the tops of the cylinders then thread the (2) m6 x35mm Chrome Cap Head Screws (Use Blue Loctite®
on these screws). Do not tighten these screws until after step 12.

12. Take the 2.42" Spacer Tube and the M6 x 80mm SS Cap Head bolt and align the tube between the rear of
the backing plate and threaded hole in the front right cylinder. Insert the m6 x 80mm bolt (Use Blue Loctite®
on these screws) and tighten in place. Now tighten the two upper mount arm screws.

13. Now tighten the m6 x 15mm screws and the flange nuts at the base of the mount arms.

14. Take the slimline air filter and insert it into the filter groove on the backing plate, be sure the grooves in the
filter and the backing plate align and seal properly.

15. Install the 1/4" Lock Washers, then the 1/4" Flat Washers on the (2) 1/4-28 x 13/16" Hex Bolts, then insert
these through the rear of the backing plate. Install one of the 1 1/4" Aluminum Spacers on each bolt put a drop
of Blue Loctite® on the end of the threads. Being sure the filter remains seated/sealed against the filter groove
of the backing plate, place cover plate against the filter being sure it slides into the filter groove and seats/seals
on the filter groove. (Make sure the Aluminum Spacers stay on the bolts while you do this. (Use Blue Loctite®
on these screws) Now get the threads started on each bolt and then tighten them firmly in place.

16. Install the BAK RainCoat and your installation is now complete.

RECOMMENDATION: Our testing and evaluation of this kit on our test motorcycles produced a very
acceptable air/fuel curve between 12 and 14% and thus did not require any EFI modifier units when run with
our BAK and stock or after market exhaust. However, we strongly recommend you have your bikes air/fuel
mixture tested at a service facility equipped to do this work.

NOTE: Though we make no recommendation for any EFI modifying systems we do not recommend against
them and we do recommend proper testing to identify the need if present.

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 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]