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Boss kit won't fit correctly
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Author:  Decide [ Wed Nov 28, 2012 9:40 am ]
Post subject:  Boss kit won't fit correctly
Guys,
I recently purchased a boss kit for my 1997 Vitara SWB, the guy originally purchased it for his 93? vitara.
I tried to fit the boss last night but found that the boss won't slide down the spline far enough. It will slide down enough for me to get ~4 revolutions of the locking nut but not enough for the horn spring to touch the boss.
Does this sound right for the boss? Are they supposed to slide down like the stock wheel?

Any help is appreciated,
Thanks
Author:  oohsam [ Wed Nov 28, 2012 10:06 am ]
Post subject:  Re: Boss kit won't fit correctly
This does not sound right. I think you have the wrong boss kit.

My boss kit on my 96 slides all the way down.
Cheers

Chuck up a pic...

Have you checked if the splines are dirty, do the splines expand? If it fits on the stem of the spline, it should go all the way down....maybe u have some crud in there, spray some wd, or grease it or something.
Author:  Decide [ Wed Nov 28, 2012 10:25 am ]
Post subject:  Re: Boss kit won't fit correctly
No, splines are spotless.
Behind the teeth of the spline, the shaft tapers out. My boss kit does not taper, therefore it is just getting stuck at the start of the taper.
I think I have the wrong boss kit
Author:  Decide [ Wed Nov 28, 2012 10:26 am ]
Post subject:  Re: Boss kit won't fit correctly
Do you think this kit would fit?
http://www.ebay.com.au/itm/170909634024 ... 279wt_1029
Will fit up to 1997 MK1 vitara
Author:  atari4x4 [ Wed Nov 28, 2012 10:47 am ]
Post subject:  Re: Boss kit won't fit correctly
got a part number/brand on the boss kit you have?

post a pic of the back of the boss kit & a pic of the spline/indicator pins on the steering column.

this is what i did to get a saas boss kit to fit my 97 SV420

atari4x4 wrote:
The splines are the same for various Suzuki's, I'm running SAAS BK139BL boss kit to suit 97~on Vitara, with the indicator pins.
Image

fired up the Dremell & modded it to suit the female set up on the SV420's.
Image

Image
Author:  Decide [ Wed Nov 28, 2012 11:47 am ]
Post subject:  Re: Boss kit won't fit correctly
^Ah, i can see from the above photo that your boss kit is tapered after the spline. Mine is the same diameter as the spline all the way through, hence it won't slide further on.
Thanks!
Author:  oohsam [ Thu Nov 29, 2012 9:10 am ]
Post subject:  Re: Boss kit won't fit correctly
This is where I got my 96 one from. Fit perfectly. Give him a call first though, sometimes he has no stock.

http://www.ebay.com.au/itm/SUZUKI-VITAR ... 850wt_1131
Author:  fordem [ Sat Dec 01, 2012 1:39 pm ]
Post subject:  Re: Boss kit won't fit correctly
Decide wrote:
^Ah, i can see from the above photo that your boss kit is tapered after the spline. Mine is the same diameter as the spline all the way through, hence it won't slide further on.
Thanks!


I don't think that's a taper - more like a recess.
Author:  emre [ Tue Sep 03, 2013 9:54 am ]
Post subject:  Re: Boss kit won't fit correctly
Reviving an old thread here, but fitting an aftermarket wheel to my 97 Vitara is becoming a very complicated task. Hopefully someone here can help.

As said, the vehicle is a 97 swb Vitara, bought the Saas wheel and BK169L boss kit to suit.
This is the manufacturers info suggesting the 169L will fit the Vitaras from 1988-98. When I received it, it looked exactly like the pictures posted by atari4x4. Those incicator cancel pins aren't needed, so I cut them off and made the notches wider like atari did... But this time it won't sit on the spline all the way down, the hole seems to be a touch too small.
Image

In their wisdom Saas recommended the BK170L, which happens to be from a Feroza... Received it yesterday and it's too big.

Should I have a go at the 139L...? Only problem is, I don't think they would take back another boss kit after I modified it... And there is no way of knowing whether it'll fit on the spline or not without cutting those long pins.
Author:  atari4x4 [ Tue Sep 03, 2013 5:08 pm ]
Post subject:  Re: Boss kit won't fit correctly
what type of vitara do you have SE416 or SV420/SV620? mine (pictured above) swapped over from my SWB SV420 & straight onto my SV620.
Author:  DarkHorse [ Tue Sep 03, 2013 6:21 pm ]
Post subject:  Re: Boss kit won't fit correctly
I had the same problem with my SE, just lived with it (although the horn contacts were fine.)
Fit on my SV as it should... and then the horn didn't work! Still haven't figured out why yet.
Author:  emre [ Tue Sep 03, 2013 7:51 pm ]
Post subject:  Re: Boss kit won't fit correctly
atari4x4 wrote:
what type of vitara do you have SE416 or SV420/SV620?

I don't even know how to tell mate... :?
JX, 1.6lt, soft top, 5 speed... From the brief search I did on redbook (there are 18 different variants of Vitaras built in 97) I think it is SE416C.

DarkHorse wrote:
I had the same problem with my SE, just lived with it (although the horn contacts were fine.)

Horn spring is about 10mm off the the bottom of the boss kit contact.

Saas are absolutely clueless, they are suggesting I try the Autotecnica stuff.
Author:  emre [ Wed Sep 04, 2013 12:22 pm ]
Post subject:  Re: Boss kit won't fit correctly
Bought an Autotecnica one from ebay, BOSS328 seems to be the correct one from the photos...
$55 including postage... Fingers crossed till it arrives, will report back.

Image

Image
Author:  atari4x4 [ Wed Sep 04, 2013 1:27 pm ]
Post subject:  Re: Boss kit won't fit correctly
emre wrote:
atari4x4 wrote:
what type of vitara do you have SE416 or SV420/SV620?

I don't even know how to tell mate... :?
JX, 1.6lt, soft top, 5 speed... From the brief search I did on redbook (there are 18 different variants of Vitaras built in 97) I think it is SE416C.


1.6l vitara is a SE416... the part number i've posted was for the 2.0l SV series of vitara's, hence the drama's you're having... i had the same issues but the other way around when trying to find one that will work.
Author:  DarkHorse [ Thu Sep 05, 2013 12:37 am ]
Post subject:  Re: Boss kit won't fit correctly
This is the one I bought - fits my SV perfectly (except random horn fault...)
http://www.ebay.com.au/itm/Steering-whe ... 8a6&_uhb=1

Same seller lists this one for 88-92 Vits:
http://www.ebay.com.au/itm/Steering-whe ... a19&_uhb=1

and this one for 92-96:
http://www.ebay.com.au/itm/Steering-whe ... 213&_uhb=1


Check pics and part numbers. Seller was good with answering questions when I bought mine.
Author:  emre [ Thu Sep 05, 2013 8:19 am ]
Post subject:  Re: Boss kit won't fit correctly
atari4x4 wrote:
the part number i've posted was for the 2.0l SV series of vitara's, hence the drama's you're having...

I haven't tried your boss kit, 139BL yet, as according to Saas it's for Vitaras 98 onwards. I linked their selection chart in my first post.
I had a go at 169L and for the stupid recommendation by Saas, 170L.

DarkHorse wrote:
This is the one I bought - fits my SV perfectly (except random horn fault...)
http://www.ebay.com.au/itm/Steering-whe ... 8a6&_uhb=1

Oh crap !!!
Are you saying that one fits your SV perfect but didn't fit on your SE...? Cause that's the one I just bought from the same seller...
Author:  DarkHorse [ Thu Sep 05, 2013 8:36 pm ]
Post subject:  Re: Boss kit won't fit correctly
Not exactly... on the SE I had a genuine Momo boss. I bought that Autotechnica one when I changed cars and the horn didn't work, I thought the contact ring had worn too far down from being jammed on too tight.

On the SE I could only get the nut a few turns on, as you described. Horn worked fine, and I just periodically re-tightened the nut. I used a couple of pop-rivets as indicator pins. It also rubbed on the plastic cover of the steering column behind it quite badly, but after a few weeks it self-clearanced mostly. As far as physically fitting it was perfect on the SV (minus the rivets.)
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