Boss rad guard: how to install

LeFrog · Nov 26, 2005

How does one install the Boss rad guard? Mine are the slimmer one.

Of the two horizontal mounts which hold the louvers and the tank shrouds at the same time, one is longer by an inch. The diameter is too large for it to go all the way through the top holes of the guard. Am I supposed to drill the top hole ?

BendBerg · Nov 26, 2005

Lefrog, what year bike are you putting the gaurds on? If you have a 2000-2006 bike the gaurds are held on using the aluminum rods that hold the stock plastic louvers on. On my 02 model all four of these rods are the same length. Did Boss supply the rubber grommets that install on the radiator gaurds? If not, you will need four 1/2"o.d.x3/8i.d. rubber grommets, available at any auto parts store. Install the rods on the frame, install the rubber grommets on the gaurds, then slide the gaurds on to the rods, using the stock hardware, bolt on the gaurd and gas tank. You may just need to get the correct rods for your application. If you have any problems let me know.

LeFrog · Nov 26, 2005

They are not the Boss guards, but look a bit like them.

On my 01, the rods are not the same size. The top ones are longer by about 25mm or an inch.

I guess I will have to carefully drill the top exit holes to make sure it slides out properly and then slide some type of pipe with the same inside diameter as that of the rods' outside diameter.

BendBerg · Nov 26, 2005

Lefrog, yes after replying.I was checking your post on the fans, and figured it out from there. No offense to Berger, but he has his guards mounted on the wrong sides. If you look at the photos closely you will see the guard for the hose spigot pointing up!

husabutt · Nov 27, 2005

LeFrog said:
How does one install the Boss rad guard? Mine are the slimmer one.

Of the two horizontal mounts which hold the louvers and the tank shrouds at the same time, one is longer by an inch. The diameter is too large for it to go all the way through the top holes of the guard. Am I supposed to drill the top hole ?

With the "BOSS" guards and possibly others no drilling should be required . The upper and lower guard mount fits behind (under) the end of the guard. It does not slide through it. The shroud bolt fits through the guard and is drilled as supplied to fit that bolt.

To get the left bottom guard holder to line up better I added a regular size nut between the holder and frame to shim it out a tad bit. Also (and maybe why Berger installed them the way he did) the top of the guard contacted the triple clamps when the forks were at full turning lock. To correct this I just took a rubber mallet to the top of the guard bending it back a little more. The aluminum bends fairly easy and will move with a few good raps.

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Boss rad guard: how to install

LeFrog

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