BOS Exhaust fitting, with pictures.

[Grizz]

Not sure if this will be of any value to anyone here, but I fitted a complete BOS Carbon and Stainless system to my 2006 1200GS tonight.
Took some pics of the process, will post basic instructions, or process.

This is by no means a professional account of how to do it, just a typical white collar worker saving a few pennies.

Full system, also fitting a K&N Filter in the morning.

Firstly, park on centre stand, remove original exhaust tailpiece.

Disconnect Lambda sensors, and unscrew, clip indicated by screwdriver point.

Remove bashplate. (Why would there be 3 different types of nut/bolt, in 12 and 13mm ? )

Unscrew header pipe nuts

They will come unstuck if the tear clamp on the catalytic converter is undone.

Catalytic converter clamp needs to be undone.

Also pry loose the cat clamp hanger with long screwdriver or similar.

Wiggle , and whole lot drops out.

At this point it is time to start adding the BOS system and its bits.... DO NOT TIGHTEN ANYTHING YET.

New hanger bracket slipped over hanger pin.

Headers in place.

Connecting pipe in place.

At this point hang end can from hanger using original hanger bolt. Adjust so as to maximise slip on effect. Springs in place too.

Springs tightened, and all allen head, Torx, and other nuts and bolts tightened.

Start up bike and grin madly

I really hope this helps anyone who does a thread search later on.

Oh, and Happy New Year.

 

[Gundog]

Very nice me ol fruit....

 

[ts2]

Cool! What did you do with the lambda sensors? There seemed to be holes in the BOS headers for them. Do they refit, or were they not needed? Just wondering, as I thought they'd control how rich/lean the engine runs?

Don't quote me on that though, I'm a biochemist not a mechanic.

TobyS

 

[Deleted account 211025001]

Cool! What did you do with the lambda sensors? There seemed to be holes in the BOS headers for them. Do they refit, or were they not needed? Just wondering, as I thought they'd control how rich/lean the engine runs?

Don't quote me on that though, I'm a biochemist not a mechanic.

TobyS

Yeah, they go back onto the BOS down pipes

Can't wait to see what you think of the pipe and filter when you get it out on the road Grizz

Andres

 

[GibGSA]

Nice pipe, let us know if theres a diference in performance.

Rgds
GibGSA

 

[claw]

Excellent photo's

 

[Grizz]

Hope to take the bike out for a ride tomorow, to go buy a large bench vice.
May shoot over to Mavericks place too.

Will surely report on my findings.

 

[Wanderer]

Love mechanical posts with 'how to' pictures. Thanks Grizz.

Bike is a real credit to you, very clean indeed ...

... until your pictures reveal the state of the underside of your gearbox and rear of the bottom of the engine. Bloody disgrace

 

[Grizz]

Love mechanical posts with 'how to' pictures. Thanks Grizz.

Bike is a real credit to you, very clean indeed ...

... until your pictures reveal the state of the underside of your gearbox and rear of the bottom of the engine. Bloody disgrace

Well spotted.

My 1150GS used to be laid on it's side in SA, next to the pool, and washed and paint brush cleaned underneath.... these days, pahhhh.

 

[Dee Tee]

Glad to see that the job was so simple . Like the others,i'll be interested to see what difference there is.

 

[bustupbiker]

Crissy pressy to self Griss! nice pics and report. Keep us informed of your thoughts on the system.
BTW. Happy new year/exhaust.
Lyn.

 

[Grizz]

Crissy pressy to self Griss! nice pics and report. Keep us informed of your thoughts on the system.
BTW. Happy new year/exhaust.
Lyn.

Hi Lyn, Thanks for the wishes, and same to you and your gang.

I should be out tomorrow, as I need to shoot over to Maidstone to Machine Mart
I need a large 100 - 150mm bench vice, so need to go there or one or two other places.
Then I may shoot out to Tilbury in Essex to see Maverick and mrs Maverick, if their perfect bundle of joy does not arrive between now and then.

Yep, this exhaust has been a long time in the planning, and when the right one at the right price came up, I was ready.

 

[Grizz]

Yeah, they go back onto the BOS down pipes

Can't wait to see what you think of the pipe and filter when you get it out on the road Grizz

Andres

Is it my imagination ?


I hate story tellers when it comes to performance.... louder is not always faster.

I really do not know what the truth is today

However, it is winter, roads are wet, salted, slippery, and generally not conducive to riding like a twat (Not that I do that, or condone that sort of riding)

I did only 20 miles, went to Maidstone , Machine Mart to buy a 6 inch bench Vice for the garage, and then back .
There are a few roundabouts on the way, some curvy bits and some straights.
My riding style is probably best described as "Brisk" but I have no points yet as testament to that.
Going there, I rode sensibly, traffic etc.
Comming back at one point I rolled on the throttle in 2nd or 3rd, and the front end became light and must have lifted an inch or so off the road, now I have never wheelied intentionally in my life, at least not since flipping a TS125 when I was 14 years old, and had to explain to my dad
Over the years I have had bikes raise front wheels, but then only when accelerating hard to beat traffic etc, and clearly the usual offroad type air, but never intentional or skilled wheelies.

Now to the point of that longwinded explanation......

The bike on not even brisk acceleration today on the way back, in 1st, or roll on in 2nd and 3rd gears kept on heading for the sky, again, I say inches, not feet.

I would like to say that the sound is good, and not at all intrusive (Decibell killer in place) so cancelling out "sounding faster" I would say there is deffo more to this bike now with the BOS full system, I have not added the K&N filter yet either , as I needed to get mobile this morning.

End result: Chuffed to bits, and I will have to be aware that there is a bit more go to this bike now than the more than ample before.



What was anyone elses experience with the changes ??


.

 

[Grizz]

Bounced up for those who are asking questions.

Have now done some distance, and the pipe is both nice to have , quiet enough.

Most importantly, it passed MOT with no hassle.

 

[Wapping]

Good write up, thanks

Glad to see you didn't gas yourself when running the bike up, with the garage door shut.

 

[Boz]

Good write up Grizz...

Does anyone know if there is a difference on the exhausts for 05/06 bikes compared to 08/09 bikes?

I have had a full bos system before on my 05 and was chuffed with it, but now have a 08 ADV (new version) and see that there are a few second hand ones around but dont know if these will fit and there seems to be some confusion (probably mine) if altered centre stand gets in the way?

Cheers

nik

 

[Big Lee]

I`ve just fitted a set of Remus headers onto my 54 plate 12 that came off a GSA and theres no problem with the older stand as far as I can see

I`ve also read on here about people snapping the exhaust studs taking them off. Mine were a little tight too so I cracked them off a little and used some plusgas then turned them back and forward a little to work it down the threads then loosened a little and repeated Reading this might stop someone snapping theirs off

 

[judge]

Sorry to see you didn't gas yourself when running the bike up, with the garage door shut, doos!

fixed, no charge

 

[Grizz]

fixed, no charge

Why not change and be nice for a change Andy ? (Or come join me ?)

 

[GSA Ghost]

I personally love my BOS system, I on the other hand have Titanium header from BOS and the only difference is weight. The sound is not much louder than stock but just perfect ( with baffle). I did find the need to replace the K&N filter back to the OEM as off roading is 40% of my riding and K&N its not made for that. The biggest difference I immediately noticed was the weight reduction (14 Lbs lighter ) and as far as performance, TOP END is where you say bye bye to the rest of the pack, you slowly start pulling away until you find yourself all alone