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Old 09-14-2008, 10:14 PM   #1
]I)Money OP
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BMW F800 GS- Acerbis handguard install

Pissed off by the fact that everything for this bike is on backorder, I decided to take matters into my own hands. Gateway had a set of Acerbis Rally pros laying there that had been ordered for a customer, but didn't work. I took them home, and:


Drilled and tapped the end of the bar-end weight bolt to fit the M8 1.25 mounting bolt for the guards, and cut the bolts down to like 1.5" or so (I used the highly technical calibrated thumb measurement method).
Here's the finished product, from the end. The inside was a pretty direct bolt-in, except that I had to bend the left guard a little for it to fit.
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Yes, but everything you've ever posted in the basement indicates that you're certifiably crazy, so you don't count.

"Another road remains, but it provides no more. It can only take us away"
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Old 09-15-2008, 05:18 AM   #2
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Quote:
Originally Posted by ]I)Money
Pissed off by the fact that everything for this bike is on backorder, I decided to take matters into my own hands. Gateway had a set of Acerbis Rally pros laying there that had been ordered for a customer, but didn't work. I took them home, and:


Drilled and tapped the end of the bar-end weight bolt to fit the M8 1.25 mounting bolt for the guards, and cut the bolts down to like 1.5" or so (I used the highly technical calibrated thumb measurement method).
Here's the finished product, from the end. The inside was a pretty direct bolt-in, except that I had to bend the left guard a little for it to fit.
Did you have any problems with the handlebar clamps? They looked to me to be too small radius to fit the "fat bars".

Cowboy
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Old 09-15-2008, 07:55 AM   #3
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Handguards

Could you post a pic. of the inner handlebar mount? Is there plenty of room on the handlebar for this or is it a tight fit?
TIA, Wendell
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Old 09-15-2008, 08:26 AM   #4
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Quote:
Originally Posted by Cowboy2
Did you have any problems with the handlebar clamps? They looked to me to be too small radius to fit the "fat bars".

Cowboy
You have to get the ones designed for the protaper bars, then they fit.
I'll snap a picture later of the inside mounts. It is pretty tight.
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Yes, but everything you've ever posted in the basement indicates that you're certifiably crazy, so you don't count.

"Another road remains, but it provides no more. It can only take us away"
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Old 09-29-2008, 08:22 AM   #5
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If You Do This, Shorten Your Levers!

If you do this mod, shorten your levers. Had a getoff two days ago, caused when a friend dropped the bike in a parking lot. It apparently bent the right guard in just enough to put a slight amount of pressure on the brake lever (Note, I did not get an ABS fault!). Front brake pumped itself full, and locked up on me.
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Originally Posted by wxwax
Yes, but everything you've ever posted in the basement indicates that you're certifiably crazy, so you don't count.

"Another road remains, but it provides no more. It can only take us away"
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Old 09-29-2008, 06:52 PM   #6
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Quote:
Originally Posted by ]I)Money
If you do this mod, shorten your levers. Had a getoff two days ago, caused when a friend dropped the bike in a parking lot. It apparently bent the right guard in just enough to put a slight amount of pressure on the brake lever (Note, I did not get an ABS fault!). Front brake pumped itself full, and locked up on me.
Good to know! I'll definitely be careful of that -- my Acerbis Rally Pro's arrive tomorrow.

I don't know what sort of hardware is included, but I assume there is no way to modify the guards or braces or anything to use the original bolt or otherwise avoid tapping the bar ends? The existing bolt LOOKS (from the outside) a bit bigger than M8 1.25...
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Old 09-29-2008, 07:31 PM   #7
]I)Money OP
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the stock bar end bolt is about a 20mm or so. The machine work would be super cheap to have a local shop do. If you were around here, I'd just do it for you...
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Originally Posted by wxwax
Yes, but everything you've ever posted in the basement indicates that you're certifiably crazy, so you don't count.

"Another road remains, but it provides no more. It can only take us away"
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Old 10-03-2008, 02:15 PM   #8
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More Pics

here's a couple from the top that show how the inner bracket is placed. Clearance pictures don't show the newly shortened levers...


BTW, that cheap-ass wal-mart pannier bag saved me a ton of damage






They're not quite in the same spot on either side, but you have to be looking hard to tell.


Hope that helps.
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Originally Posted by wxwax
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"Another road remains, but it provides no more. It can only take us away"
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Old 10-04-2008, 06:50 PM   #9
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Make sure you check your lever freeplay on a regular basis, especially after any biff. Had these guards on my KTM 620, and the lever fitment was similar (until I cut the levers down). I find these guards bend without too much (IMO) provocation, and at one point, it was putting enough pressure on the brake lever to heat things up before I noticed it.


I also found that if you positioned the guard to protect the levers, they were rotated down and didn't really cover your hands all that well (and vice versa).
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Old 10-14-2008, 08:40 PM   #10
Keystone
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Finally I get around to posting to the thread...

I installed the Rally Pro's on my bike as well. They look good, they feel very solid, and I'm confident they saved me from having to buy a new clutch lever after this weekend.


The hardest part I needed to deal with was the brake hardware interfering with both the amount the inner mount could come out to the end of the bar AND the brake light switch interfering with the bar itself.

I ended up cutting some of the plastic away to allow the switch to clear and bent the bar to make it a little wider from inside to out. This enabled me to nestle the lever inside the hand guard, but still give me clearance to push the lever out and tap the guard. I'm developing the habit of tapping the guard with the lever while stopped, so I'll notice if that clearance goes away.

I also had to rotate the clutch lever down under the handguard. I don't know HOW you bent it to fit, but at first glance there is NO WAY I can get the lever inside the cup. It didn't seem to matter this weekend though as I had two falls at speed in the sand and the lever wasn't bothered at all, though I do have abrasions on the guards.

I had no problem getting the bar end bolts drilled and tapped for the 8mm acerbis bolts and it all went together really well.

Overall I'm really pleased. I wasn't sure if I'd get them at first, but when I priced out a new lever (some $80 or so I think!) it only made sense to protect them as much as possible.

More pictures of placement, clearance, etc in this album:
http://picasaweb.google.com/Hyperiat...84965150839730

These were before the bolts were tapped, so it's all just press fit together in the pictures. I didn't change the placement of the inner mounts at all in final form though.
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'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
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Old 10-14-2008, 09:08 PM   #11
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tom ,
how did you damage your radiator?
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Old 10-14-2008, 09:12 PM   #12
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Quote:
Originally Posted by jessehere
tom ,
how did you damage your radiator?
Hi Jesse,

See this thread for that write up:
http://www.advrider.com/forums/showthread.php?t=395717
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'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
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