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BIG AIR KIT (BAK) - Yamaha Road Star (2008-2010)
Page: 1BA-2022-00/03/06/07/13/13B
Revision: 3.3 - 03/30/2010
Install Time: 30 minutes
INCLUDED IN THE KIT:
(1) Billet BAK Cover
(1) Black Intake Backing Plate
(1) Re-usable Performance Air Filter
(1) BAK Filter Raincoat
(1) Power Cone
(1) Black Dual Point Mount Arm
(1) 5/8" x 1" Black Spacer
(1) 5/8" x 7/16" Black Spacer
(1) M6 x 1.0 x 45mm Cap Head Chrome
TOOLS REQUIRED:
3, 4 & 5 mm Allen Wrenches
We recommend the use of a factory service manual for all installations. Our
We suggest when running the BAK with other than stock exhaust pipes you
should have your air/fuel mixture analyzed to determine if you need a fuel
instructions are for use a guide only.
injection modifier like a Dynojet, Cobra, TFI or similar.
(1) M6 x 1.0 x 30mm Cap Head Chrome
(2) M6 Chrome Washer
(2) 1/4-20 x 1/2" Cap Head
(1) Nylon Nipple Pre-installed
(2) 1/4-28 x 1 13/16" Hex Bolt
(2) 3/8" x 1.25 Aluminum Spacer
(2) 1/4" Lock Washer
(1) Neoprene Boot
(1) 14" Zip Tie
Needle-nose or standard pliers
10mm Open-End Wrench
7/16" Wrench
Phillips Screwdrivers
Factory Service Manual
INSTRUCTIONS:
NOTE: We recommend the use of the Blue Loctite® on all fasteners and mounting hardware.
Before you begin, be sure to check your BAK kit contents against the hardware list above.
If you are missing any contents, please contact us at 714-274-4065.
To help ensure your BAK cover does not get scratched or damaged during installation, we suggest you slice the
plastic covering around the base of the cover packaging so you can leave the plastic in place during the install.
1. Remove the stock air cleaner from the right side of your bike. You do not have to remove the chrome cover.
Using a Long Phillips Head Screwdriver first loosen the clamp on the back side of the filter assembly for the
rubber boot that attaches to the throttle body. Remove the three Socket Cap Screws at the top left, right and
bottom of the assembly. You can now remove the air cleaner from the bike.
2. Attach the Power Cone to the rear of the cover plate using the double faced tape pad supplied in the kit. On
the '08-'010 Road Star place adhesive pad about 5/16" above the round groove just below/inside the filter
groove. Clean the backing plate and the Power Cone with glass cleaner or similar then place the pad on the
back plate and press it firmly in place smoothing the pad forcefully with your thumbs. Press and hold the wide
base of the Power Cone firmly against the pad for 30 seconds.
3. Take the backing plate and place the air filter into the filter groove seating and sealing it in place.
4. 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
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 tech@baronscustom.com
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Page: 2BA-2022-00/03/06/07/13/13B
BIG AIR KIT (BAK) - Yamaha Road Star (2008-2010)
a drop of Blue Loctite® on the end of the threads.
5. 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. Now get the threads started on each bolt and then
tighten them firmly in place.
6. Lay the assembly on the table so the backing plate is facing up. Take the Black Dual Point Mounting Arm
and using the two 1/4-20 x 1/2" SS Socket Cap Screws, attach the black motor mount to the rear of the backing
plate. Be sure the use Blue Lockite® and torque these screws to 8 to 10 ft. lbs. NOTE: The notches on the mount
should be on your left when you install the plate. (Which means the notches will be on the side of the rear
cylinder when installed)
7. Thread the plastic hose fitting into the rear of the BAK backing plate. Be careful as these fittings can be
easily cross-threaded or stripped.
8. Install the Neoprene hose onto the tubing protrusion on the rear of the backing plate and secure with the
supplied Zip Tie. (It may be necessary to trim this hose in step 11 (The trimming can be rough. You are just
ensuring there is no bunching in the hose and that there is enough hose to protrude over the throttle body
allowing the hose clamp to seal on it.
9. Remove the metal hose clamp from the boot on the rear of the stock air box's rubber carb intake connector.
Slip this clamp over the BAK's Neoprene hose. Make sure you install the clamp so the screw head faces the rear
of the bike when installed.
10. Take the assembled BAK and place it into position between the cylinders. Install the crankcase vent hose on
the male hose fitting on the rear of the BAK backing plate, then slide the clamp in place. Route this hose so it is
inconspicuous from view, ensuring it will not get pinched or blocked in any way.
11. Align the boot from the BAK with the throttle body being sure it and the clamp slide on evenly. Then place
the 7/16" Black Spacer between the Forward Mounting Arm and the threaded upper mounting hole at the top
of the push rod on the front cylinder. Using the M6x1.0x30mm Chrome Cap Screw and the Large Chrome
Washer secure the right arm of the BAK mount arm to the engine leaving it loose at this time.
12. Align the left arm of the BAK mount with the upper left mount point at the top of the rear push rod tube.
Use the 1" Black Spacer and the M6x1.0x45mm Chrome Cap Head Screw and Large Chrome Washer to attach
the left side motor mount. Once all parts are in line, check the rubber boot for a proper seal and tighten the left
and right mounts securely. Be sure to use Blue Loctite®.
13. Tighten the hose clamp to the throttle body being sure the clamp sits evenly on the outer mouth of the body
and do not over tighten the clamp or you will tear the tube. This clamp does not support the BAK it is there
purely to seal against air leakage.
14. Remove the protective plastic from the cover. Clean if necessary with a soft towel and glass cleaner or
non-abrasive chrome polish.
NOTE: We recommend you have a qualified tuning center check the air/fuel mixture of your engine in order to
determine if a fuel injection modifying device is necessary.
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 tech@baronscustom.com
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