Yamaha VSTAR 1100 Carb Install & Bike Reassembly after General Maintenance

In this video, having completed several maintenance procedure including the Carb rebuild, valve adjustment and tank and cable repairs, the reassembly of everything is now underway. This process is the exact reverse as the first video in this series.

The first being the carb, situating it between the frame and ultimately into the manifold. This is followed by the 90 degree rubber hoses for the intake. The fuel lines can then be safely connected as well as the electrical connections.

This brings the project to the enrichener cable re-connection, followed by the two throttle cables.

Normally an airbox would follow this but I have a Maxair podkit. Regardless, this is a good time to purge the residual fuel in the system before reconnecting everything back to the carbs by way of the electric pump and a small gas tank.. The option to replace the fuel filter is also shown here.

Then the hoses are reconnected to the carbs and the bowls are filled. This is the time to check for leaks, both under the carbs and in the 90 degree tubes to see if the carbs overflowed.

The airbox then goes back on followed by the gas tank which has a main harness reconnected. followed by the fuel line to the gas tank.

Yarn is added to the timing chain tensioner to confirm a leak suspicion.

Firing up the bike for the first time points towards an immediate electrical problem requiring repair. This is the second time these connectors failed. This time 3 sealed unions were made to solve the problem.

The bike is restarted and synced to confirm everything is working good. With that the rest of the assembly is conducted, plastichrome and all.