Baron BIG AIR KIT STEALTH Road Stratoliner Raider User Manual

Page: 1BA-2021-00
STEALTH BIG AIR KIT - Yamaha Roadliner/Stratoliner and
Raider

Revision: 8.4 - 03/30/2010
Install Time: 2 to 3 hours

INCLUDED IN THE KIT:
(2) Billet Topped Reusable High Flow Filter
(2) Oval Velocity Intake Funnel Base Mount
(1) Coil Mount Plate
(1) Black Fuel Pressure Regulator Mount
(1) Formed Steel Fuel Line
(2) Small Hose Clamp SS
(1) 2" Crankcase Vent Filter w/3/8" Male Fitting
(1) 2" Idle Speed Air Filter w/1/2" Male Fitting
(1) Crankcase Vent Hose 3/8"i.d. x 8"
(2) M10 x 1.25 x 35mm Cap Head Allen Bolt

TOOLS REQUIRED:

If you question your abilities it may be best for an experienced service

technician perform this installation. A Yamaha Service Manual would be

helpful to have on hand for reference.

(2) M10 Flat Washer
(1) M10 x 1.25 Flange Nut
(8) Black Zip Tie
(4) M5 x .80 x 16mm SS Cap Head Bolt
(4) M5 x.80 Flange Nut
(14) M6 x 1.0 x 20mm SS Cap Head Bolt
(14) M6 x 1.0 Flange Nut
(14) M6 x Flat Washer
(2) O-Ring for Intake Funnel Base Mount

8mm-10mm-12mm-14mm Wrenches & Sockets
4, 5, 6, & 8 Metric Allen Wrenches

T-30 TORX Head Allen
Phillips and Standard Screwdrivers

3mm 4" Extended Allen Wrench

INSTRUCTIONS:

NOTE: This kit can be installed on Yamaha Stratoliners/Roadliners & Raiders. There are subtle differences in the models.

STAGE I

1. Remove your seat and the left side cover (you will need a specialty T-30 Torx socket to remove the rear side cover bolt and a 4mm allen to remove the
front inner bolt.

2. Remove the 8mm hex bolts from the seat lock on the backside of the cover and set the cover aside.

3. Remove the 12mm hex bolts from the battery brace and we recommend you disconnect the positive battery cable for safety.

4. Remove the rubber caps from each of the fuel control valves, then use a flat-tip screwdriver to close the valves by gentle turning the brass screw
heads clockwise until they seat.

5. Each fuel control valve has a retaining clip that secures it to the battery brace. Leave the clips closed on each fuel control valve but release the small
barbed insert that attaches them to the battery brace. Then move the brace out of the way.

CAUTION: Moving forward from here you will be removing fuel lines. In each case please use caution as a small amount of fuel may be released. We
suggest having a shop towel ready for cleanup.

NOTE: Beneath each fuel control valve is a "T" junction attached to a rubber fuel hose, follow each hose from the "T" down to the white 90 degree
elbow coming out of the secondary fuel tank. Release each retaining clamp securing the hose to each fitting. Leave the center hose where it lies but take
the left hose and pull it forward from under the frame rail and out to the side of frame so the tank can be removed.

6. Remove the (2) m10 crown nuts from the rear fuel tank mount.

7. Remove the 5mm allen bolts from the rear and front of the chrome dash mount. Raise the dash up and disconnect the electrical connections attached
the wiring harness. Then set the dash aside.

NOTE: It is a good idea to cover the tank with a soft towel to prevent any scratches from occurring while disconnecting the dash plugs.

8. Disconnect the small white electrical connection on the left front side of the tank and remove the small rubber hose at the top front right of the tank.

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-2021-00
STEALTH BIG AIR KIT - Yamaha Roadliner/Stratoliner and
Raider

FRONT FUEL TANK MOUNT REMOVAL:

RAIDER FRONT TANK MOUNT: Remove the (2) 4mm allen bolts from the triangle shaped aluminum cover at the front of the fuel tank and set it
aside. Then remove two 6mm cap head allen bolts sitting beneath the cover. Lift the tank up and off the bike.

ROADLINER/STRATOLINER FRONT TANK MOUNT: Remove the (2) decorative fins at the front of the fuel tank by removing the (2) #4 allen bolts
from each side of the tank. Remove the allen bolts from the fuel tank mount at the front of the tank. Lift the tank straight up and off the bike.

AIR BOX REMOVAL:

1. Remove the (2) m10 bolts from the rear of the air box attaching the air pressure sensor to the air box. Remove the (1) m10 bolt from the front sensor
bracket located about three inches from the front right side of the air box. Remove the electrical leads and air hose to each sensor and disconnect them
from their mount brackets. Set these sensors aside we will remount them later. See photo 1:

2. Remove the 5mm allen bolt attaching the air box mount tab bracket to the frame at the front of the air box.

3. RAIDER ONLY: Disconnect the (7) electrical wiring leads connected to the wiring mount bracket on the top of the air box. Do not panic! These
connectors are mated male and female connectors and can only connect to their appropriate mate. Open the reusable zip ties holding the wiring
bundles to the mount plate.

RAIDER & LINERS: At the front of the air box above the front cylinder disconnect the idle air hose from the front of the air box:

4. Remove the two small hoses from the left side of the air box.

5. Remove the crankcase vent hose from the rear of the air box. You may also remove the hose from the top of the rear cylinder, it will be replaced
later.

6. Under the air box loosen the retaining clamps securing the air box to the throttle bodies. It is best to reach these by going through, past and under
the left and right upper motor mounts. An extended 3mm ball allen wrench will be necessary. You can remove the motor mounts for easier access. A
flashlight or work light is very helpful in locating the clamp screws.

LINER NOTE: The forward mount tab of the air box attaches over the top of the front fuel tank mount. You must remove the two allen bolts at the
front of the tank mount and the one allen the goes through the bracket where the frame rails come together and then remove the air box with the tank
mount bracket attached. Once off the bike you must remove the smaller allen connecting the air box to the bracket and then remove the rubber
grommet you will expose when the air box bracket is removed, set the grommet aside do not reuse it. Then re-attach tank mount bracket using only the
two larger allen bolts to the frame. For now just set the single center bracket allen back in the hole and start the threads, you will attach the new coil
mount plate to this hole and use the stock bolt later in the installation.

7. After both clamps are loosened lift the air box straight up and off the bike. There will be two vacuum hoses that must be released for the front right
side of the air box before you can set the air box aside. You will not reuse the air box.

8. You should place a clean cloth inside each throttle body to keep any foreign material from entering your engine. Don't forget to remove cloth material

when you begin to install your new filter assembly.

9. RAIDER ONLY: Remove wiring mount bracket from the top of the air box by removing the (2) phillips head screws from the top of the air box.

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: 3BA-2021-00
STEALTH BIG AIR KIT - Yamaha Roadliner/Stratoliner and
Raider

INSTALLING NEW FILTER ASSEMBLY:

The left velocity filter base will sit with the oblong portion pointed to the 2:00 position being sure it is not touching the cylinder head and the right
velocity filter base will sit at the 12:00 position.

NOTE: These velocity filter bases are a tolerance fit so they require firm constant pressure to install. See photo series 2:

1. Take the velocity filter base and install the o-rings into the slots in the base of each unit if they are not already installed.

2. Place a velocity filter base down over the top of the throttle body until the o-ring contacts the top of the throttle body, now press down firmly on the
velocity base to get the o-ring to slide past the top and down the body until the top of the throttle body is evenly aligned with the lip on the inside of the
base above the o-ring. When the base is on correctly you will see an even seem around the entire circumference. If the seam is not even you must adjust
with pressure until it is. It may be necessary to use a soft blow mallet to attain a proper fit. Install on each throttle body.
DO NOT moisten or lubricate these o-rings or the metal around them. See photo series 2:

3. Loosen the screw clamp on the new high flow filter/s. Look inside each filter and you will see the point of the power cone, be sure the filter is installed
on the velocity filter base with the point directly over the center of the throttle body. Be sure the clamp screws are placed on the side and direction of
the filters that allows you to get your tool on them. Tighten the clamp being sure to not over-tighten it or the filter will be driven off the velocity filter
base. Repeat on both sides. See photo 3:

4. Check the left filter to be sure it is not touching the head. Rotate the base for clearance if necessary. Check to be sure the throttle linkage bracket is
not touching the filter. If it is touching, pull/tweak the bracket outward slightly as needed.

5. Install the UP-123 uni-filter on the hose you disconnected from the front of the air box earlier. Use the supplied screw clamp to secure it to the hose.
Take a zip tie and attach the filter to the vacuum lines or wiring harness to hold it high enough so it cannot be seen from the side of the bike.

6. Install the rubber hose supplied in the kit on to the crankcase vent spout on top of the rear cylinder, reuse the clamp that previously secured the
original crankcase vent hose in position. Install the UP-122 uni-filter on to the end of this hose and secure with supplied clamp.

TIME FOR A DECISION:

At this point, if you wish to leave your coils and stock engine side covers in place, move on to steps 7 thru 12. Re-install the fuel tank, seat and
side cover. You are now ready to visit the local tuning shop to maximize performance with the installation of a Power Commander®. However if
you wish to clean up the sides of your engine by removing these covers and all the related clutter contained under and around these covers then
proceed to STAGE II section bypassing steps 7 thru 12 at this time.

AIR SENSORS:

7. Take the black coil mount plate and attach the air sensors you removed from the stock air box earlier and attach them as follows. Using the
supplied m6-1.0 x 16mm cap head allen bolts and m6 flange nut attach one sensor to the very rear of the coil mount plate to the two holes located
in the bent tail section. The air nozzle/spout will point towards the engine. Attach the front air sensor to the foremost two parallel 6mm holes
just behind the center front 8mm mount hole. The electrical receiver points towards the engine and the nozzle/spout points towards the rear of
the bike. The bolts should go through the sensor and into the coil mount plate then thread and tighten the flange nuts. Connect the rear
electrical lead to sensor and insert the small vacuum line onto the nozzle/spout.
NOTE: It will be necessary to trim appox. 2" of the wiring sheath away from the wiring loom at the front of the bike in order to release the air
sensor electrical lead so it can properly connect to the sensor. See photo 4:

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]