Disassembly, Cut Supports, Remove Tank & Handlebar, Fender Bkt & Seat Pan Install

hello from blue collar bobbers uh thank you very much for purchasing our 1100 yamaha v-star bobber kit uh we get real excited about these bikes because uh we just think that the v-stars make the longest lowest most vintage looking bobbers of all of the bikes that we do so this 1100 is going to be a super one to to do for you so anyway let's go ahead and get started okay first a couple of words of safety here that's always really important because you don't want this bike to tip over and either hurt yourself or the bike so anyway what we do and it's a good practice is when you're going to work on your bike for a little bit go ahead and tie the kickstand to the foot peg like that that way if you're working on the bike and it rolls forward or something the kickstand won't fold and it'll fall over so do that and then the other thing to be really careful with is the gasoline doesn't hurt to shut the petcock off there when you're when you're working with the tank and stuff be careful because gasoline is you know it's just really flammable and it can really burn you up bad so anyway be careful there and then we'll get started taking this bad boy apart okay the first item we want to take off is the right side cover below the seat here it's real easy to do you just take this allen screw out here go ahead and loosen that all the way and then this side cover will just pop right off there can i do it with one hand here so go ahead and remove that side cover and then while we're on this side go ahead and take this rear foot peg off you won't need that anymore so these two bolts here you can take these these foot pegs off do it on both sides and the last item we want to do is we'll go ahead and take this little buddy seat off here go ahead and just remove this nut right here and then the buddy seat should slide off to the back so do that and then we'll continue on okay our next step is we want to move this seat from this bike this is a custom model so i hope the classic models are the same they should be pretty similar so the way you get the seat off you take these two allen screws out of this bracket this is the bracket that held the front of the buddy seat on remove those two screws and lift that little bracket off and then your seat should just pull off just go ahead and pull it kind of to the rear of the bike and it should come right off okay before we move or remove the rear fender we need to unplug this wire see this wire right here this is the wire that goes from your tail light and your signal lights and it goes down and hooks down inside here so we want to unhook this down inside this area before we take the fender off so now you'll notice these little clips right here these are really cool what you do is just take a little pointed object like a screwdriver or something just push on the center of that little button in the middle and that'll pop kind of make a pop and then you should be able just to lift the little little thingy out like it looks like that then to put these back in you just basically push the center like that slide them in and then push the little button and it locks it back in so these are cool little little keepers let's go ahead and do that on all three sides of this plastic thing there's one here one over here and then the one we just did you should be able to lift this plastic up now for some reason you can't the connector should be down in this area down here it's a white connector uh if you have a problem too you can always take this electronic gizmo here out you can undo that and then it might be a little easier to pry this up and see it down there so anyway go ahead and go ahead and find that white connector i'll show you what this one looks like i've disconnected this so that's what it looks like on the ends if it's a little tight you may have to apply a pry with some a screwdriver on the two sides to kind of pry it off because after they sit for a while they get kind of sticky so go ahead and unplug that and then we'll continue on okay the next step is to go ahead and remove these two screws on the sides here there's one there and one there you probably have some kind of a chrome strip on there on your bike this spike when we bought it it had a bar on there so they had taken that bar off but anyway go ahead and take those screws out of both sides and then you should be able to lift the fender up away from the uh like that it should it should just basically lift off that framework there let's go ahead and lift the back in there and then we'll disconnect the front and we'll have that fender off there okay on the custom model like this one we don't have to take these three uh little pop things out uh you may only on the classic model i don't know for sure but i'll go ahead and show you how this fender lifts off without taking those out so the fender just basically lifts off the bike kind of slides off underneath the plastic thing and off it comes so go ahead and remove your rear fender and then we'll be ready to start moving along here okay that's what it should look like when you get the rear fender off i want to just tell you right now anytime you want to jump ahead on this video and check other other things out go ahead and do that anytime would be a good time to send your paint or your fender and your tank or whatever you want to have painted out so you can jump ahead and see how all the things happen on that stuff so anyway we'll be right back okay our next step is to go ahead and remove the rear passenger seat bracket this big ugly bracket that sticks up this is going to be a big improvement on this bike to get that big old honker out there so what we want to do is we're going to cut it right here just right at that seam uh you can use a hack saw i'm kind of a lazy butt so i'm going to go ahead and use a sawzall but anyway basically we're going we're just going to cut that even with that seam right there so let's get started okay let's uh cut this bad boy off here i'm going to use a sawzall uh you could use a hacksaw probably take a little longer with a hacksaw but basically what we're going to do is we're going to just cut this off flush right here so we'll go ahead and get started with the sawzall what i do is i squirt a little oil wd or 40 or something on the blade once in a while it cuts a lot easier if you kind of keep it oiled okay that's how it looks i'm not just kind of cutting if you draw a line on the blade just draw a line straight across to the other brace you don't want to don't tip the blade too much to where you're scarring this paint right here just kind of cut it straight across that way you won't gouge into this area right here so go ahead and do that and you'll notice i put the sheet over here to catch all the filings and stuff so let's go ahead and cut that bad boy off and i'll be right back oh another thing uh and obviously you've probably noticed this but the tire is right here so be careful don't uh cut into the tire if you hear the big um a loud pop in your uh some air coming out you cut into your tire so be careful we're almost finished okay there you have it i'm glad this is uh finished here i hate cutting these motorcycles you're probably like me it's kind of makes you a little nervous when you start cutting away but once you get it finished it's really nice because uh it's a job well done there you'll notice here i kind of skin this just a little bit don't worry about that this is basically this is flush with the with the metal part so you may want to take a file now and just file these edges especially this back corner you don't want to leave a sharp edge there and cut yourself so anyway that's what it looks like let that baby cut off there it looks a lot cleaner but when you stand back you'll like the looks of the bike it looks better already there you have it we'll go to the next step okay before we go any further in case you haven't done it yet and you want to take your tank off to send it out to be painted or whatever let's go ahead and just show you how to remove the tank on these v-stars it's really simple on this bike first thing you do is you disconnect the fuel line and see it right there make sure that you have the fuel petcock in the off position there and then you may want to drain some of the gas out you know it's a little lighter weight to tank if you get some of the gas out of it but anyway that's an option so first thing disconnect the gas line and then excuse me for that moving the cam around here okay next step there's uh there's uh this cover right here now you want to disconnect that remember these little buttons you just push the center that pops and then you can go ahead and take that little button out of there a little plastic button oh before before you put the reinstall these what you do is you push the center back in so that the top sticks out like that and then you just simply push them back down in and push the button until it clicks so that's how they work so anyway let's go ahead and pull that out then you can go ahead and lift the cover back and then underneath the cover you'll see the connector for the this is the connector that connects the gauge on your gas tank so go ahead and disconnect that i've done this before so it's really easier it might be a little tight but whatever you do don't pull on the wires just pull on the connectors you push that little button right there and then it should pull out so go ahead and do that and then the next step we want to remove remove these two bolts right here remove these and then we'll go ahead and show you how to lift it off there so go ahead and remove these and then we'll be right back okay let's go ahead and remove this bad boy from this motorcycle here so it's really simple just make sure your handlebars are straight uh making sure they're not angled too much you might hit the tank when you take it off so anyway just go ahead and lift up the back side kind of rotate it a little bit and it should just come right off up and out like that watch your connector in the back there make sure it doesn't snag on something and there you have it okay go ahead and screw these back into their uh their holes there real quick and then it's good good practice also to go ahead and plug your fuel line just put something in there so no dirt or anything will get in it while you're working on the bike so go ahead and do that and then we'll continue on okay just a quick note on removing your gauge from your tank if you decide to paint the tank i remove these three screws there's two here and one here when you take these out make sure you don't lose the little plastic washers there are little plastic washers there on the bottom so make sure you don't use it lose those and then just lift the chrome bezel off and then you just unplug this plug right here and then basically just take these uh three bolts out here make sure you don't lose your little hardware and stuff and then the gauge should slip out and the wire should pull out with it so there you go so let's move on okay the next step i'm going to show you is how to change out the handlebars it depends on how you're doing this your bike you may not want to go in this sequence but let's go ahead and show you how to do this now you may want to do this while your tank's being painted or whatever okay so let's start with the tank is on this bike so what i've done is i put a like triple layers of towel on it do that because you want to protect your tank in case something falls off a wrench or the handlebar slip down make sure you protect your tank really well with like two or three layers of uh towel or whatever so do that first and then the next step we're going to go ahead and disconnect these wires from their little uh just pop these little covers open here these little cable ties pop those open to release your cables and then the next step we want to unplug the uh these wires that come out of your grips here this is the one that goes to the uh the brake on this side then the one on this side has let me lower this down here it has this connector on here that fastens in your clutch so that it won't start without the clutch in go ahead and disconnect that there's a little tab that you push on be when you slide that out so make sure you push on that tab and that should slide rail out real easily don't pull on the wires you might pull them out of the little connector so go ahead and disconnect that uh there again i've disconnected this cable here like this so go ahead and do that and then we'll continue on oh one other thing you want to do is i've popped the little chrome covers off these bolts right here there's a little chrome cover on there just put a little small screwdriver in there and they'll pop right out so do that and then we'll continue on okay our next step we want to go ahead and remove this counterweight on the end of the left-hand grip here they just screws in there like that you may have to get a big pair of pliers or something to get it started so anyway that just unscrews like that so go ahead and remove that okay our next step is uh to be really careful what i've done is i've actually removed the key from the motorcycle go ahead and take your key out because this has some electrical connections back there and you don't want to arc something on there and blow a fuse or something so anyway go ahead and take your key out then what i've done is i've just cut that old grip like that and i've pried it open it's glued on there and then you can take that little ring off like that then this switch there's two screws in the back just go ahead and remove those and take the back cut back cover of this switch off then that just simply just slides off like that and then just go ahead and let that hang down there i put the cover back on the on the back side just so we keep the screws and everything straight so go ahead and do that and then we'll show you the next step or one other thing too make sure you keep this little rubber uh gasket here let's keep that for future reference okay next we want to remove the clutch cable from the clutch lever here uh it's real simple you just unloosen the big flange lock nut here and then let's go ahead and run that the adjuster and the in the mechanism here all the way in as far as we can so that it'll leave the most slack in the k in the clutch cable as possible what you want to do is run them all the way in as close as you can to the lever here and make sure that the slot is facing forward there's a slot in both of them and then all you do is you just pull the clutch lever in let it go while you pull out on the cable like that and then just rotate that cable out like that and just pop it out of the bottom of the clutch lever and there you have it again this is all the way in as far as it'll go without with still that allowing the two slots to be forward okay the last thing on the left side of the handlebar is to remove the clutch lever uh just loosen this bolt here on the bottom of this uh slit area here and then get that nice and loose and then just go ahead and slide that off okay let's go ahead and do the right side now uh we're going to remove the brake lever and the brake master cylinder here so go ahead and just take these two screws out like that careful not let that fall then just go ahead and release that and just uh let it hang down out of the way there they want to make sure it doesn't leak uh brake fluid out it shouldn't because they're pretty much sealed up real nice so let's do that and we'll continue on okay let's go ahead and remove the end cap out of this side there again you may have to put some big pair of pliers on it to get it loosened up to start and then just go ahead and screw that make sure you don't drop that because it's real heavy on mine to hit your side case or something so make sure you unscrew it very carefully and set that aside okay i have a personality disorder and i don't have any friends so i'm gonna go ahead and show you how to do this uh just if you're by yourself so anyway what i've done is uh turn the handlebars all the way to the left side then what i did is i disconnected this clamp here then i loosened this one and i slid the handlebar over all the way to the left side like that and then what i do is i just go ahead and clamp that down temporarily close to the band there what that does is it allows you to get this the grip close enough to the to the center of the bike so you can get the grip off without uh totally taking the handlebars off so if you have a friend and you're not like me and you do have friends and have it you can have a friend hold that for you so anyway do that like say clamp this temporarily and then we'll continue on now that you've got your bars moved over go ahead and loosen this adjuster here this is in your cable here go ahead and loosen that all the way down toward this um this bend here what that does is that gives you the maximum amount of play in your throttle because you'll need to do that later on anyway so go ahead and adjust that all the way in as far as it'll go so that throttle is loose and then the next step you want to loosen the screw here and down to the bottom here by this cable what that does is that you don't need to take this housing completely apart right now you can just loosen it and so it'll pop off this little there's a little hole here that a tab on the back of the bracket fits into so if you loosen that enough that should pop off and slide on there like that then all you got to do is just hopefully the cables are long enough to where you can just pull that off the end yup let me move the camera here should be able to just pull that off the end there and that should pop off the end of the handlebar that way the whole thing kind of stays together for now so go ahead and do that and then we can go ahead and take our bars off go ahead and loosen the clamp on the center there and pop those old bars off and we'll get going on the new ones okay now would be a good time to send your tank and your fender out to be painted i like to put the straps the reinforcement straps in later after the fender is painted just because if you get a little bit of the silicone sealant on the outside of the fender then it's really hard to get the paint to stick so and then one other thing these new aluminum fenders we have are beautiful and if you didn't get a painted one or a polished one a painted color then the gray is just a powder coat primer so all you have to do basically is just sand it smooth with some real fine like or five hundred grit sandpaper and then it should be ready to paint so this gray is just a primer so i'm gonna go ahead and send those out and then we'll get started on the next brackets okay let's go ahead and grab this bracket uh this is the uh rear fender front brackets it's the one that holds the front of the rear fender on so go ahead and grab this bracket and then we'll get started okay this part of the bracket goes on the front side of the square tube that's down inside right here this is a square tube that fastens to the swing arm here uh anyway this this bracket basically will go down in in that area there and then fit around this square tube right here so i'm gonna go ahead and slide that down inside the best place to to try to fit it on the tube is down about where that tube takes the bend down in there that's the best place for it to kind of fit in there and and fit over that tube i've actually took it took a little the air out of this rear tire so that it would actually flex in a little bit enough to get this bracket on you may have to do that but all our newer brackets hopefully will be a little bit smaller so let's go ahead and i'll show you how to do that okay i'm on the left side of the bike here and i'll show you how this bracket goes down inside there uh basically i just reach my hand through the left side and slide it through that area that i told you where that to this the square tube takes a bend down inside there you should be able to just slide that through there and then slide it up toward the toward this round bar right here so this is the square tube here and this is the round bar it's the tire here and there it is it should just slide up and down there i painted these flanges white just you could see it down in there because it's so black so anyway that's go ahead and put that bracket like that and then we'll install the other piece oh okay this is how the other side of the bracket mounts uh down inside here uh if you look this is a this bracket that's unpainted that way you can see it i've gone ahead and left that screw sitting there this is the screw that one of the two that's down inside there but make sure you put the loctite that we gave you in your kit make sure you put the loctite on the threads before you screw these two screws in there because you don't want those vibrating loose and coming out later you kind of have to be a contortionist to hold that back the back side on there while you start these screws down inside there but if you hold up you know the bracket with your left hand and screw these in with your right you can get them started and what you want to do is you want to mount this so this fits nice and straight and flush in there uh do just a you know tighten a little bit at a time go back and forth and tighten a little bit of time make sure that the gap on the sides on both sides here this side and this side are about the same as you snug these up uh just go ahead and snug them until they uh you know get feel kind of tight but you don't have to get carried away because you'll just bend the metal there if you get too tight with it so and then also make sure that this the seats down flat against this round tube here as you snug that up and make sure that the weld clears this little window area so anyway that's how it should look when you get it all mounted in there and then we'll continue on okay next let's grab this big old seat pan bracket it looks like kind of like a bat if you'll notice we put the uh the front bracket here it's unpainted i'll leave those unpainted just so we can show you how they fasten it's just better because the the black paint's so dark so anyway grab that and then we'll get started okay go ahead and remove the bottom bracket off that seat pan it's look it's the one that looks like this and what we're going to do is we're going to mount that to the two gas tank bolts right here just like that uh so anyway i'm just showing you this with the gas tank uh on the bike and then uh from now on i'll remove the gas tank and show you how we do it without the gas tank on so i'll be right back let's go ahead and mount this bracket as you see it here these are the original bolts that the uh that held the gas tank on so go ahead and mount that on there but leave this loose for now just leave it so it slides back and forth and then we'll continue on or you'll notice these angle back like this okay next we want to mount this big old seat pan to the motorcycle uh first thing you can go and leave these screws in here you don't need to take those out because then they'll just get lost so leave those in there lay them up the pan on the motorcycle like that okay now what we want to do is we want to go ahead and put these four screws in here you don't need to put the top bracket on here for now just put these four screws in here and snug those up and then what we want to do is we want to align the back of the pan so that we have the same amount of gap uh on here and on here make sure that that it overhangs there just a little bit make sure that's the same on both sides and then also make sure that this is flush on this corner flush with the metal underneath it'll move back and forth a little bit so go ahead and align all that very carefully and then when you have it where you want it let's go ahead and tighten these two screws right down in here go ahead and snug those up uh double check make sure the back's still lined up properly the gap's the same and the points about the same there and then what we want to do once that's uh all snugged up there uh in your kit we give you the drill bit so we'll go ahead and pop that in there and we'll drill those holes these are already drilled i drilled these ahead of time so you can okay what you do is you drill the one first go ahead and use a little oil on the drill if you want to that'll help kind of lubricate it as you're drilling and once you drill that one it's most important you put the put the button head screw in the hole that'll help this side stay steady while you drill the other side so anyway go ahead and put that screw in there maybe you could even put the nut on the bottom first and then go ahead and drill the other side and then you should have her so go ahead and do that and we'll continue on once you remove the seat pan let's go ahead and just paint these uh cut areas here with some black paint or whatever color you want to use i guess on there as long as it won't show once you put the pan on so we'll put a little paint on there to keep them from rusting because water will be trapped into there so do that and then we'll continue on well you may want to deburr these holes too a little bit get rid of the burrs on the top and the bottom

Channel: Blue Collar Bobbers

Views: 185,840

Keywords: custom, motorcycle, Blue Collar Bobbers, blue, collar, bobbers, bobber, kit, bolt on, install, Yamaha, v-star, 1100, Yamaha V-Star 1100, Yamaha DragStar 1100, DragStar, disassembly

Id: 4U1uktMiCs8

Length: 24min 15sec (1455 seconds)

Published: Thu Sep 11 2014