Baron NEEDLE JET KIT Royal Star User Manual

Jet Kit Installation for Yamaha Royal Star

Page: 1BA-2400RS

Revision: 1.0 - 02/19/2010

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:
(16) - Cap Head Carb-Plate Allen Screws
(16) - Cap Head Float-Bowl Allen Screws

(4) - Titanium Needles
(4) - Mikuni Main Jets

(4) - Clips

INSTRUCTIONS:

Remove the vacuum slide from one of the carburetors.
Remove the OEM needle and spacer, noting order of assembly.
Counting from the top to the bottom, install the new Baron needle clip on groove #3 of the replacement
Baron adjustable needle. Make certain that the OEM spacer is correctly reinstalled with its alignment
post.
Reinstall the vacuum slide. Note: Verify that the slide maintains a full range of movement before
reinstalling it.
Repeat above steps for each carburetor.
The carburetors must now be de-racked in order to install new main/pilot jets. To de-rack the
carburetors:

1. Remove the Phillips head screw and steel plate on the top and sides of each carburetor.

2. Remove the crossover hose from carburetor number two.

3. Remove the 2 Phillips head screws from the sides of carburetor three and four.

4. Drain the fuel from the float bowls and remove the bowls from each carburetor.

5. Replace the OEM main and pilot jets with Barons genuine Mikuni jets.

6. Thoroughly clean the inside of each float bowl prior to reinstalling it.

7. Reassemble the carburetors by reversing the order of above steps. Replace the Phillips head screws on the
carburetor bowls with the small Allen head screws provided in the kit, and replace the Phillips head screws
on the steel carburetor plates with new Allen head screws from the kit. The internal installation is now
complete.

Reinstall the carburetors on the engine, paying special attention to the routing and the correct connection
points of all vacuum hoses, vent hoses and fuel hoses.
Check all vent lines, fuel lines, and linkage for any obstructions or blockage. Note: It is important to
verify proper throttle operation before starting the engine.
Reinstall the OEM air box.
Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a
screw head, skip to step c. 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 plug for each carburetor.

CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and
remove the bit the instant you break through the plug.

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-2400RS

Jet Kit Installation for Yamaha Royal Star

b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug.

c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats,
then carefully turn it counter-clockwise 3 turns. Refer to final step below for assistance in fine-tuning the
setting of the air/fuel adjustment screw.

CAUTION: The adjusting procedure is critical. Correct carbon monoxide settings are key to maximum
performance. Do not overlook the next step!

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 above,
and that the clip has been installed as detailed previously. Check the engine at idle speed for any
popping or back firing. For best results, we recommend that the engine be adjusted on an Exhaust
Gas Analyzer (EGA) to a CO reading between 3% and 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]