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Starting the Project

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Written by Randy Fox   
Saturday, 03 November 2007

Beginning Disassembly, at Last

Remove the seat.

Take off the fuel tank and side covers. Store them.

Tip: Be sure you store the fuel tank in a dry (non-humid) place, to minimize the potential for rust build-up inside.

Disconnect or remove the battery, but keep a maintainer-charger on it if you can.

Remove and store the intake system, including the intake manifold, carb and fuel pump assemblies. Refer to the service manual. However, be sure to drain (or spill or shake) gasoline from all parts, and let them sit out for several days before storing indoors.

Drain the oil from the crankcase, oil tank, and transfer case. Tip: Put a strip of blue masking tape over the ignition switch area and/or the key. Write the word "oil" on it to remind yourself not to start the bike before putting oil back in.

Remove and discard the oil filter.

Remove, bag, label, and store the oil filter bracket and its four bolts.

 

Removing the Right-Side Floorboard

Unplug the rear brake light wire, and pull it free. This will help you avoid accidentally breaking the light switch plunger, and allow you to move the floorboard assembly further out of the way. To do this, trace the wire from the rear master cylinder--located near the right floorboard--up the frame, to a connector on the left side of the frame near the left coil. (See photo below). Now, disconnect the connector, pop open the several wire-retainers that route this wire, and pull the wire free of the bike--but still connected to the right-side floorboard assembly.

 

Brake light wiring, Yamaha Road Star

 

Cut any wire-ties from the rear brake hydraulic hose--along the right-side frame. Then open the hydraulic hose’s two, hose clamps. Remove the right-side floorboard assembly by removing the two button-head bolts under the floorboard that attach the assembly to the frame. As you unscrew the last bolt, hold the floorboard assembly. Then pull it out from the bike a ways, and set it on a shop cloth on the floor.

 
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