Baron xXx BIG AIR KIT Road Star (08+) User Manual

Page: 1LA-2322-00 & LA-2322-00B

xXx BIG AIR KIT (BAK) YAMAHA ROADSTAR (2008-2011)

Revision: 2.4 - 06/01/2011

Install Time: 45 Minutes

INCLUDED IN THE KIT:
(1) Chrome or Black xXx Cover
(1) Chrome Mesh Cover
(1) Black Intake Backplate
(1) Black Filter Cinch Plate
(3) Aluminum Stand-Offs
(1) 11" Black Zip Tie
(6) 1/4-20x3/4" Black Flat Head Allen Screws
(1) Performance Re-Usable Air Filter

TOOLS REQUIRED:
4, 5, 6mm & 5/32" Allen Wrenches
10 & 12mm Sockets

CAUTION! We Strongly recommend that a qualified technician install this kit

if you do not completely understand the instructions prior to the install.

(1) M6x1.0x30mm Stainless Socket Cap Screw
(1) M6x1.0x45mm Stainless Socket Cap Screw
(1) 3/8" White Plastic Hose Fitting
(1) Black Motor Mount
(2) Black Mount Spacers
(2) 1/4-20x1/2" Stainless Socket Cap Screw
(1) 1/4-20x1/2" Stainless Flat Head Screw
(1) 2-5/8" Dia. Neoprene Hose 1/8" Wall Thickness

Phillips & Flat Screwdrivers
Blue Loctite®

Pliers (Std. & Needle-nose)

Factory Service Manual

INSTRUCTIONS:

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 loosen the clamp on the back side of the filter assembly for the rubber
boot that attaches to the throttle body. Then 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. The xXx comes loosely assembled. Unwrap the protective bubble wrap and remove the exterior covers and
you should find the required hardware contained inside the filter. Remove the hardware kit and check the
contents against the list of included items above.

3. Using three 1/4-20x3/4" Black Flat Head Allen Screws, install the three aluminum stand-offs on to the
backing plate. Be sure to use Blue Loctite® and torque these screws to 8 to 10 ft. lbs.

4. Thread the plastic hose fitting into the rear of the BAK backing plate. Be careful as this fitting can be easily
cross-threaded or stripped.

5. Using the two 1/4-20x1/2" Stainless Socket Cap Screws, attach the black motor mount to the rear of the
backing plate. Be sure to use Blue Loctite® and torque these screws to 8 to 10 ft. lbs. 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)

6. Place the filter over the stand-offs and slip it into the groove on the backing plate. Place the black cinch plate
onto the filter and align the cinch plate to the stand-offs. Insert the three 1/4-20x3/4" Black Flat Head Allen
Screws through the cinch plate and into the aluminum standoffs on the backing plate. Be sure to use Blue

Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or

fitment may be required. LA Choppers bears no responsibility on installation costs associated with this product.

© 2013 LA Choppers

5221 Oceanus Drive Huntington Beach, CA 92649 [phone] - Ph. [phone] - Fax www.lachoppers.com [e-mail]

Page: 2LA-2322-00 & LA-2322-00B

xXx BIG AIR KIT (BAK) YAMAHA ROADSTAR (2008-2011)

Loctite® and torque these screws to 8 to 10 ft. lbs.

7. Using the 1/4-20x1/2" Polished Stainless Flat Head Allen Screw, attach the mesh and xXx cover and torque to
5 ft. lbs. Be sure to use Blue Loctite®.

8. Install the Neoprene hose onto the tubing protrusion on the rear of the backing plate and secure with the
supplied zip tie. Be sure not to over tighten the zip tie as you can tear the hose. There is a slight recess in the
protrusion to help secure it. Once secure, trim the excess zip tie.

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. 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 using
the M6x1.0x30mm Stainless Socket Cap Screw and short black spacer, secure the right arm of the BAK mount
arm to the engine at the upper right mount point near the top of the front push rod tube, 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 long black spacer and the M6x1.0x45mm Stainless Socket Cap Screw 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
being careful not to over tighten the clamp which may tear the tube. This clamp does not support the BAK, it is
there purely to seal against air leakage.

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 devise is necessary.

Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or

fitment may be required. LA Choppers bears no responsibility on installation costs associated with this product.

© 2013 LA Choppers

5221 Oceanus Drive Huntington Beach, CA 92649 [phone] - Ph. [phone] - Fax www.lachoppers.com [e-mail]