Baron NEEDLE JET KIT V-Star 650 Classic Custom User Manual

NEEDLE/JET KIT - Yamaha XV650 V-Star 650 1998-2010

Page: 1BA-2410-00

Revision: 3.5 - 01/22/2010

Install Time: 90 Minutes

CAUTION: We strongly recommend that a qualified Yamaha technician

install this kit. Please read ALL of the instructions BEFORE installing

beginning the installation.

INCLUDED IN THE KIT:
(6) Assorted Mikuni Main Jets
(2) Mikuni Pilot Jets

(2) E-clips
(8) Cap head Allen screws

(2) Titanium Adjustable Needles

TOOLS REQUIRED:
10 & 12 MM Wrenches & Sockets
Assorted Allen Wrenches

Phillips and Flat Tip Screwdrivers
Factory Service Manual

INSTRUCTIONS:

JET/NEEDLE Size & Setting Chart

STOCK AIR BOX or K&N REPLACEMENT FILTER REQUIRES: 100 Main Jet, 22.5 Pilot Jet, Needle with "e" clip
in #3 slot

BARON CHROME EXTRENAL BAK REQUIRES: 112.5 Main Jet, 22.5 Pilot Jet, Needle with "e" clip in #4 slot

STEALTH BIG AIR KIT REQUIRES: 130 Main Jet, 22.5 Pilot Jet, Needle with "e" clip in #4 slot

You will need to remove and disassemble the following components:
Fuel Tank
Factory Airbox
Carburetors

1. Remove the vacuum slide from the carburetor per Yamaha shop manual procedures.

2. Remove the OEM needle and spacer, noting the order of assembly.

3. Counting from down from the top (The blunt end closest to the grooves) of the adjustable needle, install new "e"
Clip in the specified slot of new adjustable Baron Needle as specified in chart at the top of this box.

4. Reinstall the OEM spacer under the e" clip just as it was on the stock needle.

5. Reinstall the vacuum slide along with the diaphragm spring.

6. Be sure the spring base cap, small spring and its containment cap along with the larger slide spring are reinstalled in
the same order as removed. Reattach the diaphragm cover and tighten it's screws.
Note:Verify the slide and the throttle linkage have full range of motion!

7. Drain the fuel from float bowl and remove the bowl cover.

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-2410-00

NEEDLE/JET KIT - Yamaha XV650 V-Star 650 1998-2010

8. Remove the OEM Main Jet and Pilot Jet, and replace them with the appropriate Main and Pilot Jets as specified.
See Chart at top of box for proper jet sizes and needle slot/clip position.

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

10. Reassemble the carburetor by reversing the order of step #1 through step #9. Use the new cap head Allen screws in
place of the OEM Phillips head screws.

11. Repeat step #1 through step #10 for the other carburetor.

12. 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 #12c. 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.
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 step #15 for assistance in fine-tuning the setting of the air/fuel
adjustment screw.

13. FILTER INSTALLATION:
If you are maintaining the stock airbox reinstall the OEM air filter assembly now.
If you are installing a Baron external BAK, filter refer to their instructions.
If you are installing a STEALTH BIG AIR KIT refer to their instructions.

14. 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.

15. 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.

16. Check the engine at idle speed for any popping or back firing. If popping is occurring at idle: Verify the
air/fuel adjustment screw has been set to the recommended starting position as described in above step, then fine
tune + or from there until popping stops or improves.(See Tuning note)

TUNING NOTE: Proper carburetor adjusting would include balancing which does 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.

For best results, we recommend the engine be adjusted on an Exhaust Gas Analyzer (EGA) to a CO reading
between 3% and 4%. Please bear in mind this percentage depends on various factors including: Altitude,
Humidity, Temperature, Air Pressure, etc.
CAUTION: The adjusting procedure is critical. Correct carbon monoxide settings are key to maximum
performance. Do not overlook this step!

Contact us if you have any questions regarding this installation.

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]