Baron FUEL PUMP RELOCATION KIT Yamaha Road Star User Manual

Road Star Fuel Pump Relocation Kit

Page: 1BA-2620RD

Revision: 1.4 - 04/02/2010

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!

INCLUDED IN THE KIT:
(1) - Two-sided Tape Pad
(3) - Hose Clamps
(4) - Electrical Butt Connectors
(1) - Extended Wire Harness

(2) - Pre-cut Lengths Std. Fuel Hose
(2) - Zip Ties
(1) - Choke Bracket
(1) - Fuel Pump Bracket

(1) Pre-cut Length Braided Stainless Fuel Hose

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

Page: 2BA-2620RD

Road Star Fuel Pump Relocation Kit

7. Mount fuel pump onto the new bracket so that hose nipples face the rear of the bike. Mount bracket to
frame.

8. Install, to the inlet side of the fuel pump, the stock short, curved hose with steel protector onto the filter.
Secure with stock gold-colored clamp. On to the filter attach the supplied 11" fuel hose. Secure with a stock
green clamp. To that hose, connect the stock steel fuel line with the wire tabs on it , noting the direction of the
bends so that the supplied stainless steel braided line, when attached to it, will point toward the fuel valve on the
tank per Photo G. Attach supplied stainless steel braided line and secure with one of the supplied clamps. This
hose is routed behind the rubber grommet that holds the side cover, and up the left side as the hard line crosses
the top of the rear cylinder.

9. Route fuel pumps wire harness up along the right frame. Continue to route pump harness along the fuel line
using the wire tabs to hold the wire in place. Plug pump harness back into main wire harness connector.

10. Attach the longer supplied hose to the fuel pump with a stock clamp. This hose should get covered with the
remaining piece of stock hose cover to prevent kinking. It routes up from the pump and along the right side of
the frame, then down to carb inlet. Secure with a supplied clamp. Secure hoses with supplied zip ties as needed.

11. Replace airbox and fuel tank, securing new choke bracket under left side of tank with rear tank mounting
bolt (Photo C). Route new braided stainless fuel line and install onto tanks petcock and secure with supplied
hose clamp. Turn petcock to the On" position, and switch on ignition to activate fuel pump. Check for any fuel
leaks at each fuel hose connection point. Start motorcycle and let run for a couple of minutes, continuing to
watch for any fuel leaks. Replace battery side covers and seat. Installation is now complete

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]