Boss Hoss Cycles Year 2005 Owner`s manual

BOSS HOSS CYCLES, Inc.
OWNER’S MANUAL
This owner’s manual contains important
safety, operational, and warranty information.
Please read it carefully.
BOSS HOSS MOTORCYCLES AND TRIKES ARE TO BE OPERATED ONLY BY
MATURE, EXPERIENCED MOTORCYCLE RIDERS THAT HAVE BEEN PROPERLY
TRAINED IN THE VEHICALS OPERATIONS.
Model Year 2005
9-2004
WARNINGS AND CAUTIONS
Statements in this manual preceded by the words WARNING or CAUTION are
very important.
WARNING
Means there is the possibility of personal injury to you or others.
CAUTION
Means there is the possibility of damage to the vehicle.
WARNING
READ OWNER’S MANUAL AND CLEARLY UNDERSTAND ALL OPERATING
INSTRUCTIONS BEFORE OPERATING VEHICLE.
WARNING
Proper service and repair is important for the safe reliable operation of all mechanical
products. The service procedures recommended and described in this manual are
effective methods for performing service operations.
It is important to note that some warnings are stated in this Owner’s Manual. However,
please remember that these warnings are not all inclusive, since Boss Hoss cannot
possibly know or advise of all possible ways assembly or service might be done or of the
possible consequences of each method. Accordingly, anyone who uses a service or
installation not recommended by Boss Hoss must thoroughly satisfy himself that neither
his nor the operator’s safety will be jeopardized by the service methods used.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
ii
Safe Operating Rules
Before operating your new Boss Hoss bike or trike be sure to read and follow the
owner’s manual. The owner’s manual includes maintenance schedules, safety tips,
and describes many of the parts that make up the bike or trike.
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Be sure to read and follow the MOTORCYCLE HANDBOOK for the state or
states that you will be traveling in.
Let only Boss Hoss Cycles, Inc. authorized dealers or service centers work on
your bike or trike and use only Boss Hoss Cycles, Inc. parts and accessories,
not doing this will void your warranty.
Do not inhale exhaust gases. Exhaust gases are poisonous so never run engine
in a confined area.
Follow maintenance schedule to make sure your bike or trike remains in safe
condition to ride.
You should operate your bike or trike at moderate speeds and out of traffic
until you have become familiar with all controls and you are comfortable
riding.
When riding remember to be a defensive driver do not depend on the other
drivers on the road to see you. Most accidents involving motorcycles are
caused when the driver of another vehicle fails to see the motorcyclist.
Operating at all times with your headlamp on will help other drivers see you.
Dress appropriately when riding. Wear an approved helmet and gear when
operating your bike or trike; this will help you to stay safe and comfortable.
Do not under any circumstances let anyone operate your bike or trike unless
you are certain that they are experienced, licensed riders and understand the
controls of your bike or trike.
Do not operate your bike or trike if you are fatigued, under the influence of
drugs or alcohol, or if you are not confident with road conditions. Operating
your bike or trike under any of the conditions listed puts you, your passenger,
and anyone else on the road at greater risk.
Be sure not to over load your bike or trike. Follow all weight guidelines listed
in the manual.
Do not use your bike or trike to tow a trailer or any other vehicle.
Keep all hazardous substances such as brake and battery fluids away from
eyes, skin, and out of mouth.
Consult your dealer regarding any question you may have about your bike or
trike. Should you have any kind of failure or problem with the operation of
your bike or trike DO NOT CONTINUE TO RIDE contact your dealer
IMMEDIATELY. The continued operation of a bike or trike that is not
performing properly will probably aggravate an initial problem, cause repairs
to be more costly, and may endanger the safety of the rider.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
iii
TABLE OF CONTENTS
Page No.
FOREWARD
i
WARNINGS AND CAUTIONS
ii
SAFE OPERATING RULES
iii
SECTION ONE: PRODUCT
Safe Operating Maintenance
Service Charts
Checking & Changing Oil
Vehicle Identification Number
Warranty
Reporting Safety Defects
2
3-5
6-7
8
9-12
13
SECTION TWO: FRAME
Frame & Cast Neck
Crash bars, Driver pegs
Engine Mounts
Kickstand and Water Pump
Inverted Front End
15
16
17
18
19
SECTION THREE: CHASSIS
Bike Specifications
Wheels
Brakes
Parking Brake
Drive Belt Tension
Front Forks
Shocks
Handlebar Controls
2004 Body Parts (Fenders, Rad. Shroud, Side Panels,
Seat Panel, Seat, Storage Compartment)
21
22-30
31-32
33
34-36
37
37-38
39-40
41-44
SECTION FOUR: ENGINE
GM motors
Ignition System
Exhaust
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
46
46-47
48-49
iv
SECTION FIVE: FUEL
Carburetor
Fuel Pump
Throttle Linkage
Fuel Tank
Fuel Petcock
51
52
53
54
55
SECTION SIX: COOLING SYSTEM
Water Manifold
Water Pump
Radiator & Fan
Fan Controller
57
57
58
59
SECTION SEVEN: DRIVE SYSTEM
2-SPEED Transmission
Rear & Front Pulley
61-65
66
SECTION EIGHT: ELECTRICAL
Wiring Harness
Solenoid
Battery
Starter Relay
Alternator
Starter
Gauge Panel
Bulb Chart
Wiring Schematic in back pocket
68-69
69
70
71
72
73
74
75
SECTION NINE: TRIKES
Specifications
Chassis
Electronic Speedometer
Brake System
Fuse Panel
Detent Cable
Fuel System
Shifting
Exhaust
Taillight Wiring
77
78-80
80
81
82
82
83-84
85-86
87
88-89
SECTION TEN: TROUBLESHOOTING
Engine
Lubrication System
Electrical System
Carburetor
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
91-92
92
92
92-93
v
Transmission
Brake
93
93
SECTION ELEVEN: ACCESSORIES
Mustang Seats
Windshields
Other Accessories
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
95-96
97-98
99-100
vi
SECTION ONE:
Product
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
1
GENERAL
The Boss Hoss is an American –made custom fabricated, two-wheeled motorcycle
powered by a General Motors V-8 engine. The specially designed frame and drive system
combined with a low center of gravity and balanced weight distribution results in a
stable, smooth motorcycle. Boss Hoss also produces a 3-wheel trike with the same
specially designed frame.
SAFETY and SERVICE
SAFE OPERATING MAINTENANCE
Good maintenance means a safe machine. A careful check of certain equipment must be
made after periods of storage and frequently between the regular service intervals to
determine if additional maintenance is necessary.
The following items should be checked as a routine pre-ride procedure:
1. Tires for correct pressure, abrasions, or cuts.
2. Belt for proper tension and adjustment.
3. Brakes, steering and throttle for responsiveness.
4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check
brake pads ands discs for wear.
5. Cables for fraying or crimping and free operation.
6. Engine oil and transmission fluid level.
7. Wheel nut tightness.
WARNING: Re-torque wheel nuts after first 25 miles and at 100-mile
intervals until torque is maintained at 80 ft.-lbs.
8. Headlight, taillight and directional light operation.
SERVICING A NEW MOTORCYCLE
WARNING
Failure by the owner to have the service and maintenance procedures
performed on each of the mileage intervals prescribed in this manual may
adversely affect the motorcycle operation and performance, causing injury to
the operator and/or passenger.
THE PRESCRIBED SERVICE AND MAINTENANCE PROCEDURES
OUTLINED IN THIS MANUAL ARE THE OWNER’S RESPONSIBILITY TO
HAVE PERFORMED. FAILURE TO PERFORM ALL OF THE SPECIFIED
MAINTENANCE SERVICES WILL VOID THE BOSS HOSS LIMITED 12MONTH WARRANTY.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
2
WARNING
• Carefully read all the appropriate sections of this manual before
performing any work on your motorcycle. Improper repair and /or
maintenance may result in personal injury.
• Adjustment and alignment of many serviceable components is critical.
Improperly adjusting and/or aligning components will adversely affect
motorcycle handling and stability, possibly leading to personal injury.
We recommend that an authorized Boss Hoss dealer perform all
adjustments and alignments to your motorcycle.
After a new motorcycle has been driven its first 500 miles and again at 2500 miles, the
following initial service operations must be performed.
CHECK AT FIRST 500 MILES and 2500 MILES:
1. Drain engine oil pan through drain plug and refill with fresh oil.
2. Replace engine oil filter.
3. Change transmission fluid and clean transmission filter.
4. Check and adjust belt drive.
5. Check battery for any signs of damage.
6. Check rear brake pedal adjustment.
7. Inspect brake fluid level and condition.
8. Check brake lines and fittings for leaks.
9. Inspect brake pad linings and brake discs for wear.
10. Check fuel valves, lines, and fittings for leaks.
11. Grease or oil all points indicated for 2500 miles attention in the “REGULAR
MAINTENANCE INTERVAL CHART”
12. Check front fork (steering head) bearing adjustment.
13. Check tightness of rear swing arm pivot bolts
14. Check tightness of all fasteners.
15. Check tire pressure and inspect tread.
16. Check engine idle speed adjustment.
17. Check throttle adjustment.
18. Check operation of all electrical equipment and switches.
19. Check and adjust alternator belt.
20. Road test.
SERVICE NOTES
Description
Application
Engine Oil
SB & BB
Oil Filter
SB & BB
Transmission Oil
Bike
Transmission Filter Bike
Chart 1.1
BH Part #
2280000
2280300
3370001
3370162
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Industry Part #
20W-50 Castrol
PF-454 AC Delco
MX4T Mobil 1 Synthetic
N/A (Clean & Reuse Filter)
3
Description
Application
BH Part #
Industry Part #
Transmission Oil
Trike
3670000
Dexron 3 / Mercon
Transmission Filter Trike
3620160
1-9702 Napa
Brake Fluid
All
1580000
DOT 5 Silicone
Antifreeze/Coolant All
4460000
Dex-Cool or equivalent
Spark Plugs
SB
2320200
FR5LS AC Delco (gap 0.045”)
Spark Plugs
BB
2320401
R45XLS AC Delco (gap 0.045”)
Fork Oil
All
1280000
10W
Air Filter*
SB & BB
2620201
735-4906 Napa
*You must remove the 2 rear bolts (closest to the rider seat) of fuel tank to service the air filter.
Chart 1 continued
CAUTION
Raising the rear section of the fuel tank will decrease the clearance between the front of
the tank and the handle bar assembly. Be careful not to damage the paint by impacting
the fuel tank to the handle bar assembly.
REGULAR SERVICE INTERVALS
The following chart outlines recommended Maintenance and Lubrication intervals after
performance of service on a new motorcycle and the initial break-in period. Refer to the
following charts to plan a service schedule.
REGULAR SERVICE INTERVAL CHART
Service to be performed
Change engine oil
Check condition of spark plugs
& replace if necessary
Replace oil filter
Inspect air cleaner & service as required
Replace spark plugs
Check & adjust belts
Check rear brake
pedal adjustment
Inspect brake fluid
level & condition
Check brake pad lining & discs for wear
Check antifreeze level & protection
strength
Clean transmission filter &
change transmission oil
Replace Magnetic Inline Transmission
Filter (Bikes Only)
Check fuel valve, lines & fittings for leaks
Check oil lines and brake system for
leaks
Lubricate the front brake hand lever
First
300
miles
First
500
miles
X
Every
2500
miles
X
X
X
X
X
X
X
Every
5000
miles
Every
7500
miles
Every
10000
miles
X
X
X
X
Every 15,000 miles
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Every
spring
or fall
X
X
X
X
X
X (1gal.
coolant)
X (bike
only)
X
X
X
X (bike
only)
Replace at initial 5,000 miles, then every 20,000 miles
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Chart 1.2
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
4
REGULAR SERVICE INTERVAL CHART (CONTINUED)
Service to be performed
Every 300
miles
Lubricate the throttle
cable
Check tightness of all
fasteners
Check tire pressure &
inspect tread
Check engine speed
adjustment
Check operation of
throttle controls
Check operation of all
electrical equipment &
switches
Check auto. Transmission
fluid
Check battery and
clean/check connections
Check rear shock rubber
bushing adjustment
Check front fork bearing
adjustment
Check front and rear
sealed wheel bearings.
Check front and rear
sealed wheel bearings
Change front fork oil
Road test
Date completed
First 500
miles
Every 2500
miles
Every 5000
miles
Every 7500
miles
Every 10,000
miles
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Every Fall or
Spring
x
x
x
(Fluid needs to be hot when checked- engine off & in upright level position)
x
x
x
x
x
x
x
X
Every 20,000 miles replace if necessary
x
x
x
x
x
x
x
x
Chart 1.2 continued
ADDITIONAL SERVICE INTERVAL CHART for TRIKES
Service to be performed
Every 300
miles
First 500
miles
Lubricate drive u-joint,
transmission shifter
linkage, and all other rear
suspension components
Check rear axle lubricant
level
Check tightness of all rear
suspension fasteners
Change rear axle lubricant
Every 2500
miles
Every 5000
miles
Every 7500
miles
Every 10,000
miles
x
Every Fall or
Spring
x
x
x
x
x
Check transmission fluid
level
Change transmission fluid
and filter
Adjust rear drum brakes
x
x
x
x
x
Date completed
WARNING
Chart 1.3
VEHICLES RIDDEN UNDER ADVERSE CONDITIONS (HEAVY LOADS, CORROSIVE ENVIRONMENTS,
EXTREME TEMPERATURES, ETC.) MAY REQUIRE A MORE FREQUENT MAINTENANCE SCHEDULE.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
5
Checking Engine Oil
The dipstick is located on the right side of the motor for both the BB and SB. The dipstick for the BB is above
the center of the exhaust shield as seen in figure below. The dipstick for the SB is above the back of the exhaust
shield as seen in the figure below.
Figure 1.1 Big Block 502 dipstick location.
Figure 1.2 Small Block 350 dipstick location.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
6
Changing Engine Oil
CAUTION
Always change oil on level ground with the engine cooled.
Put something under the drain plug that will hold at least 5 quarts of oil. The drain plug is located on the left
side of the engine. It is not necessary to remove the skid plate. Unscrew the drain plug from the oil pan. Let
the oil drain into container. While oil is draining from oil pan the oil filter can be changed. The oil filter is also
on the back left side of the engine. Remove the oil filter and get the new oil filter out. Put oil around the seal
of the new filter and screw onto the engine. Now the oil should be done draining out of the oil pan. Screw the
plug back into the oil pan and remove container of the old oil. Add five quarts of oil to the engine.
Refer to Service Notes on page 3 for the type of oil filter, oil, and other maintenance needs.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
7
VIN TAG
GENERAL
THE TAG IS LOCATED ON THE RIGHT SIDE OF THE FRAME ON THE FORK
NECK.
MFD BY BOSS HOSS CYCLES, INC
MM/YY
TYPE: MC
GVWR……….1675 LBS.
GAWRF………827 LBS.
GAWRR.……...848 LBS.
FRT
REAR
TIRE MT90B16 230/60-15
RIM 16” X 3 ½” 15” X 7”
PSI
49
42
(COLD)
THE VEHICLE CONFORMS TO ALL APPLICABLE
FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN
EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
VIN NO.
1B9TBVC32ND285000
THE VEHICLE IDENTIFICATION NUMBER (VIN) IS DECODED USING THE
FOLLOWING BREAKDOWN:
1
2
VEHICLE
WORLD
MANUFACTURER DESCRIPTOR
SECTION
IDENTIFIER
(WMI)
1
2
1
B
Chart 1.4
3
9
3
4
CHECK MODEL PLANT Manufacturer
DIGIT
YEAR
Identifier if
<500
units/TR or
Sequential
Production
Number if
>500 units
/TR
4 5 6 7 8
9
10
11
12 13 14
T B V C 3
2
N
D
2
8
5
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Sequential
Production
Number
15 16 17
0 0 0
8
BOSS HOSS LIMITED 12-MONTH WARRANTY
Boss Hoss Cycles, Inc. warrants to the first retail purchaser and authorized
transferees of our new 2005 motorcycles/trikes that any authorized Boss Hoss dealer
will repair or replace any parts (except tires, maintenance items and battery under
certain conditions) found under normal use in the U.S.A. to be defective in factory
materials or workmanship, and upon the following terms and conditions:
Standard billing of parts will apply until the part in question is returned and
inspected by Boss Hoss Cycles, Inc. Credit will then be issued.
DURATION & TRANSFER
1. The duration of this limited warranty is twelve months, measured from the
date of initial purchase from an authorized Boss Hoss Dealer.
2. Any unexpired portion of this limited warranty may be transferred, with
written authorization, upon the resale of the motorcycle /trike during the
warranty period. To obtain authorization, a transfer application must be
filed with Boss Hoss Cycles, 790 S. Main, Dyersburg, TN 38024.
OWNER OBLIGATIONS
1. To qualify for warranty protection, you and the selling Dealer must complete
the Warranty Registration Form and return it to the Factory within 10 days
after delivery.
2. To obtain warranty service, return your motorcycle /trike at your expense
within the warranty period to any authorized Dealer. The Dealer will be able
to provide warranty service during normal business hours and as soon as
possible, depending upon the workload of the Dealer’s service department
and the availability of necessary parts.
EXCLUSIONS
This warranty will not apply to any motorcycle/trike as follows:
1. Which has NOT been operated or maintained as specified in the Owner’s
Manual.
2. WHICH HAS BEEN ABUSED, ALTERED OUTSIDE OF ORIGINAL
FACTORY SPECIFICATIONS, IMPROPERLY STORED OR USED “OFF
THE HIGHWAY”, FOR RACING OR COMPETITION OF ANY KIND.
3. Which has had the odometer removed or tampered with.
4. 502 BIG BLOCK BIKE AND TRIKE ENGINES AND DRIVETRAINS ARE
EXCLUDED FROM THE 12-MONTH WARRANTY.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
9
OTHER LIMITATIONS
THIS WARRANTY DOES NOT COVER:
1. Parts and labor for normal maintenance as recommended in the Owner’s
Manual, including such items as the following: lubrication, oil and filter
change, battery maintenance, engine tune-up, spark plugs, light bulbs, brake
and belt adjustment.
2. Seats, saddlebags, paint, chrome, or trim deterioration caused by ordinary
wear and tear, exposure or improper maintenance.
IMPORTANT / READ CAREFULLY
1. Boss Hoss dealerships are independently owned and operated and may sell
other products. Because of this, BOSS HOSS CYCLES, INC. IS NOT
RESPONSIBLE FOR THE SAFETY, QUALITY, OR SUITABILITY OF
ANY NON-BOSS HOSS PART, ACCESSORY OR DESIGN
MODIFICATION INCLUDING LABOR, WHICH MAY BE SOLD AND
/OR INSTALLED BY OUR DEALERS.
2. THERE IS NO OTHER EXPRESS WARRANTY (OTHER THAN
EMISSIONS AND NOISE WARRANTIES) ON THE
MOTORCYCLE/TRIKE. ANY IMPLIED WARRANTY OF THE
MERCHANTABILITY OR FITNESS IS LIMITED TO THE DURATION
OF THIS WARRANTY.
3. TO THE FULLEST EXTENT ALLOWED BY LAW, BOSS HOSS
CYCLES, INC. AND ITS DEALERS SHALL NOT BE LIABLE FOR LOSS
OF USE, INCONVENIENCE, LOST TIME, COMMERICIAL LOSS OR
OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
10
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
11
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
12
CONS
CONSUMER PRODUCT SATISFACTION
Boss Hoss Cycles designs, tests and constructs all its products of the highest quality
materials and components that meet or exceed industry standards. If at any time during
ownership of a Boss Hoss product, you feel that the quality or safety of your vehicle is
compromised please contact BOSS HOSS CYCLES immediately either by telephone at
731-286-4915, or e-mail to info@bosshoss.com , or mail to:
Boss Hoss Cycles, Inc.
790 South Main Street
Dyersburg, TN 38024
Attn.: Safety Management
Reporting Safety Defects
If you believe that your vehicle has a defect which could cause a crash or could cause
injury or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Boss Hoss Cycles, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a
safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in any individual problems between you,
your dealer, or Boss Hoss Cycles, Inc.
To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-4249393 (366-0123 in Washington, DC area) or write to:
NHTSA
U.S. DEPARTMENT OF TRANSPORTATION
400 7th Street SW, (NSA-11)
Washington, DC 20590
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
13
SECTION TWO:
FRAME ASSEMBLY
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
14
2005 BIKE FRAME
PATENTED BOSS HOSS FRAME
Cast Neck (Yoke)
(FIG. 2.1A)
(FIG. 2.1B)
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
15
1
2
3
4
Detachable crash bars
(FIG 2.1C)
To detach the crash bars remove the signal light screw (2), radiator shroud screw (3), and
the bolts that hold the crash bar to the frame (1) and (4).
Loosen before sliding
the pegs.
Slider Reinforcement
Clamp Screws
Adjustable driver pegs
(FIG. 2.1D)
To adjust the driver pegs loosen the two screws going through the slider reinforcement
clamps above. The screw on the shifter rod will also need to be loosened so that the
shifter rod will be able to slide in or out with the pegs. Once the pegs are in a
comfortable position tighten all the screws.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
16
Lower engine mounts
Upper Engine Mounting Brackets
(Fig. 2.1E)
(FIG. 2.1F)
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
17
Water Pump-
(FIG. 2.2)
Caution
DO NOT run pump dry. Operating the water pump without water and/or
antifreeze in the cooling system will reduce the operating life of the water pump.
Mirage Kickstand
(FIG. 2.3)
The kickstand mounts on the left rear of frame close to swing arm pivot bolt.
Caution
Always park the motorcycle on a level, firm surface. Vehicle weight could
cause motorcycle to fall over. Cosmetic damage could occur. Use of parking
brake is recommended each time you park.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
18
Warning
Your motorcycle is equipped with a kickstand that locks when placed in the
full forward (down) position and the vehicle weight is rested on it. Without
vehicle weight resting on the kickstand, any movement of the motorcycle
could cause the kickstand to retract slightly from the full forward position. If
the kickstand is not n the full forward (lock) position when motorcycle weight
is rested on it, the motorcycle could fall over, possibly causing injury.
Inverted Front End
(FIG. 2.4)
The headlight (Fig. 2.5 on the right)
mounts on the headlight mounting bracket,
which is mounted to the front of the lower tree.
The only two models where the headlight does
not mount this way is the ‘57’ trike and the
truck trike. On these two models the mounting
bracket is mounted to the top of the lower tree.
Headlight
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
(FIG. 2.5)
19
SECTION THREE:
CHASSIS
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
20
BIKE SPECIFICATIONS
ZZ4 V8 DIMENSIONS
Wheel base……… ………80”
Saddle height……………. 28”
Dry Weight………………1100 lbs.
Engine…………… …….GM V8
Horsepower ………………355
ZZ502/502 V8 DIMENSIONS
Wheelbase……….………82”
Saddle height…………….28.5”
Dry Weight………………1300 lbs.
Engine…………………..GM V8
Horsepower……………..502
TORQUES
Front Axle …....…………....50 ft-lbs.
Rear Axle Nut…..………….15 ft-lbs.
Pulley mounting bolts……..45-50 ft-lbs.
Brake disc mounting (Frt.)....20 ft-lbs.
Brake disc mounting (Rear)...30 ft-lbs
Caliper mounting bolts…….. 30 ft-lbs.
Caliper bracket bolts……..…45 ft-lbs.
Fork brace pinch bolts…….. 40 ft-lbs.
Slider cap bolts………….….50 ft-lbs.
Riser bolts……………….….45 ft-lbs.
Riser cap bolts……………...15 ft-lbs.
Rear swing arm pivot bolts...100 ft-lbs
Rear wheel lug nuts .1/2-20…80 ft-lbs.
Steering stem bolt…………..55 ft-lbs.
VEHICLE WEIGHT RATINGS (LBS)
The Gross Vehicle Weight Ratings (GVWR)
and Gross Weight Ratings (GAWR) are
found on a label on the frame steering head.
S.B.
B.B.
V8 GVWR
1675 lbs. 1827 lbs.
V8 GAWR..(front) 827 lbs. 827 lbs.
V8 GAWR..(rear)
848 lbs
1000 lbs.
BRAKE DISC
Front……………………………12.5 in.
Minimum brake rotor thickness 4.5mm
Minimum brake pad thickness 0.050 in.
Rear…………………….………12.5 in.
Minimum brake rotor thickness 5.5mm
Minimum brake pad thickness 0.050 in.
CAPACITIES
Fuel tank (U.S. Gallons)
8.5
Cooling System (U.S. Quarts) SB 12 BB 14.5
Oil Pan (U.S. Quarts)
5
Auto Transmission (U.S. Quarts) Bike
2.5-3.5
Trike
8
TIRE DATA
Tire pressure
PSI (Cold)
FUEL: 92 OCTANE IS RECOMMENDED
Up to
Front Rear
GVWR* 50 42
Maximum
load
WHEEL
Front…16” x 3.5”
Rear…. 15” x 7”
TIRE
MT90B16 (Avon)
230/60R15(Avon)
WARNING
Maximum inflation pressure must not exceed specifications state in this manual.
Failure to follow this warning could cause tire failure possibly resulting in personal
injury.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
21
WHEELS
GENERAL
Maximum tire mileage and good handling qualities are directly related to care given to
wheels and tires. A tire kept in continuous service will wear irregularly and peaked and
may affect handling, especially if over-inflated. It is extremely important that correct tire
pressure be maintained at all times. Do not over-inflate tires.
Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., on weekly
bases. Check before going on trips, also.
WARNING
Riding with excessively worn tires is very hazardous and will adversely affect
traction, steering and handling. At regular intervals of 5000 miles, or at any time
handling irregularities are experienced, see the charts on pages 4-5.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
22
WHEEL SERVICE CHART
REMEDY:
CHECK FOR:
1. Tighten axle or axle nuts.
1. Loose axle or axle nuts.
2. Replace wheel hub bearings as
2. Excessive side-play or radial (updescribed in INSPECTING AND
and-down) play in wheel hubs.
REPAIRING WHEEL HUBS.
*See authorized Boss Hoss Technician.
*For Sealed Bearings
3. Check wheel alignment as
3. Alignment of rear wheel in frame.
described in Section Seven.
4. True wheels, replace rims.
4. Rims and tires out-of-true sideways,
(should not be more than 3/64 in.).
See Item 4, above.
5. Rims and tires out-of-round or
eccentric with hub (should not be
more than 3/32 in.)
6. Replace as described in
6. Irregular or peaked front tire wear.
REMOVING & INSTALLING
FRONT WHEEL.
7. Inflate tires to correct p.s.i., as
7. Correct tire inflation.
described in SPECIFICATIONS.
8. Static balance may be satisfactory if
8. Correct tire and wheel balance.
dynamic balancing facilities are not
available, however, dynamic
balancing is also recommended.
9. Correct adjustment and replace
pitted or worn bearings. See
9. Steering head bearings.
FORKS.
10. Check damping action and
mounting stud rubbers. See
10. Shock absorbers.
FORKS.
11. Check for looseness. See
11. Rear swing arm bushing.
SWINGARM
WARNING
When repairing a flat tire or installing a new tire, the procedures below should be
followed:
1. Always locate and eliminate the cause of the original tire failure.
2. Do not patch or vulcanize a tire casing because this weakens the casing and
may cause a blowout.
3. The use of tires other than those specified, may adversely affect handling.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
23
FRONT WHEEL (Figure 3-1)
1
5
13
12
7
4
16
1
9*
Right side of wheel
Figure 3-1A
* The axle pinch bolt is
not show in the picture,
but is located in the back
of the right side fork.
The arrow is pointing to
the location.
5
13
6
3
17
4
1
Left side of front wheel
Figure 3-1B
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
24
11555555
14
15
13
1
13
11
Front Wheel
2
10
2
18
1
8
Figure 3-2
Front Wheel Component Description & Part Numbers from
Figures 3-1 & 3-2.
Item #
Description
Part #
1
Side brake disc
Call for #
2
Wheel bearing
1630306
3
Left caliper mounting bracket
1550301C
4
Caliper mnt. Bolts & lock washers
5
Fender mounting brackets
1240350
6
Left lower brake line
1530352L
7
Right caliper mounting bracket
1550306C
8
Axle
1410302
9
Axle pinch bolt
10
Wheel assembly inner spacer
1630304
11
Left axle spacer
1420304
12
Right lower brake line
1530352R
13
Brake disc mounting bolts
14
Tire
1620003
15
Wheel
1610300B5
16
Right side brake caliper
1520300PA
17
Left side brake caliper
1520301PA
18
Right axle spacer
1420305
Chart 3.2
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
25
WARNING
Carefully read this section of the manual before performing any work. Your Boss
Hoss dealer has trained technicians who can complete the work using proper tools
and equipment. Improper repair and/or maintenance may result in personal injury.
CAUTION
Do not operate front brake lever when caliper is removed. The brake caliper pistons
may be forced out of the bore.
REMOVAL (FIGURE 3-1)
1. Apply rear brake lock.
2. Motorcycles proceed with steps 3 thru 9.
3. Begin by placing a jack stand (approximately 10” high) directly below the lower
engine mount, under the right side frame tube while the cycle is on the kickstand.
4. Place a floor jack under the frame just behind the lower engine mount. Lift cycle
by raising the jack. Place another jack stand (approximately 10” high) under the
left side frame tube, directly below the lower engine mount.
5. Lower the jack slowly until the cycle is supported by the jack stands. The front
tire should have approximately 6” of clearance above the ground.
NOTE: It may be necessary to remove the front fender for tire removal.
6. Remove the left and right caliper mounting bolts (4) using a 6mm hex bit tool and
slide calipers off the rotor. Secure away from wheel and fender to prevent contact.
7. Loosen axle pinch bolt (9) using a 5/16” hex bit tool.
8. Loosen the axle (8) by rotating counter clockwise using a 3/8” hex bit tool, then
pull axle free of fork assembly while supporting the wheel assembly.
9. Remove wheel assembly and axle spacers.
NOTE: Keep right and left axle spacers identified, they are not interchangeable.
They require different lengths for locating the wheel in the center and must
be reinstalled in the same location as removal.
Trike removal procedure. For the trike, proceed with step 10 and 11.
10. Begin by placing a floor jack under the center of the front cross member of the
frame. Lift the trike by raising the jack. Place a jack stand (approximately 10”
high) directly below engine mount, under each side frame tube.
11. Refer back to step 5 and proceed.
IMPORTANT NOTE: before removing front wheel assembly from the cycle, check
wheel-bearing condition. There are two steps in this procedure.
1. With the cycle supported off the ground, rotate the wheel listening for any
‘rough’ noise.
2. Check the endplay with a dial indicator; it should NOT be more than 0.002
inches. If any noise is heard or endplay is over 0.002 inches, bearings MUST be
replaced. Replace as a set.
3. Sealed wheel bearing removal requires a special tool and should be changed by
an authorized Boss Hoss service center.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
26
WARNING
After proper tightening of axle, wheel-bearing endplay should be less than 0.002
inches. Improper performance of this installation may result in personal injury.
DISASSEMBLY (FIGURE 3-2)
1. Remove brake disc mounting bolts (13) using a T40 Torx bit tool. Remove brake
discs (1).
2. Remove tire from wheel.
CLEANING, INSPECTION AND REPAIR
1. Clean all parts in solvent and inspect for damage or wear.
2. Replace brake disc if it is warped, scored or worn beyond specifications. See
SPECIFICATIONS.
ASSEMBLY (FIGURE 3-2)
1. Install tire (14) on wheel (15).
2. Install brake discs (1) with disc mounting bolts (13) using T40 Torx bit tool.
CAUTION Removable thread locker must be applied to disc mounting bolt (13)
threads. Tighten each bolt, in a criss-cross pattern, to 15ft-lbs. of torque.
INSTALLATION (FIG. 3-1)
1. Place front wheel assembly (Fig. 3-2) between fork legs.
2. Apply anti seize over complete front axle then insert axle (8) from right side fork
through right side axle spacer (18) Fig.3-2, wheel assembly spacer (10), left side
axle spacer (11) Fig. 3-2 and thread into left fork leg.
3. Tighten front axle (8) to 50 ft-lbs. of torque.
4. Tighten pinch bolt (9) to 25 ft-lbs. of torque.
5. Reinstall brake calipers (16, 17). Align calipers with center of the brake disc.
Reinstall mounting bolts and lock washers (4). Tighten to 25 ft-lbs. of torque.
WARNING
After proper tightening of axle, wheel-bearing endplay should be below .004 inches.
Improper performance of this installation may result in personal injury.
WARNING
Lock washers may be damaged after initial use. Use new lock washers when
reinstalling brake calipers.
LOWERING CYCLE
When maintenance is complete, lower the cycle by reversing the REMOVAL steps 3
through 9 for a motorcycle or 10 and 11 for trikes.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
27
REAR WHEEL
2
1
2
3
Rear Wheel
3
FIGURE 3-3
REMOVAL OF BIKE WHEEL ASSEMBLY (FIG. 3-3)
IMPORTANT NOTE: before removing rear wheel assembly from the cycle, check
wheel-bearing condition. There are two steps in this procedure.
1. With the cycle supported off the ground, rotate the wheel listening for any
‘rough’ noise.
2. Check the endplay with a dial indicator; it should NOT be more than 0.002
inches. If any noise is heard or endplay is over 0.002 inches, bearings MUST be
replaced. Replace as a set.
3. Sealed wheel bearing removal requires a special tool and should be changed by
an authorized Boss Hoss service center.
WARNING
After proper tightening of axle, wheel-bearing endplay should be less than 0.002
inches. Improper performance of this installation may result in personal injury.
1. Begin by placing a jack stand (approximately 10” high) directly below the lower
engine mount, under the right side frame tube while the cycle is on the kickstand.
2. Place a floor jack under the frame just behind the lower engine mount. Lift cycle
by raising the jack. Place another jack stand (approximately 10” high) under the
left side frame tube, directly below the lower engine mount.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
28
3. Lower the jack slowly until the cycle is supported by the jack stands. The front
tire should have 10” (approximate) clearance above the ground.
4. Move jack to rear of frame, centered directly below the rear cross member. Lift
cycle until the rear tire is clear of the ground. Utilize jack stand for secure
support.
5. Remove the seat pan and rear fender by removing the body bolts using a 5/32”
hex bit tool. Be sure to unplug tail light harness. The connector is located at the
right front edge of the fender. This allows the taillight to remain mounted.
6. Remove the upper belt guard (Fig.3-3 (1)).
7. Remove four adjuster block bolts (Fig.3-3 (2)) from the top of the swing arm
using a 3/8” hex bit tool. This allows covers and spacer blocks to be removed.
8. Remove brake caliper mount (Fig. 3-4 (8)) by removing mounting bolts (Figure 34(6)) with a 6mm hex bit tool and slide calipers off the rotor. Secure away from
wheel and other components to prevent contact.
CAUTION: Do not push brake pedal with caliper off rotor! Caliper damage
could result.
9. Remove two adjuster end cap bolts (Fig.3-3 (3)) from back of swing arm using a
3/8” hex bit tool. This will release tension from the drive belt.
10. Remove cotter key (Fig. 3-4 (9)) and axle nut (Fig. 3-4 (10)) from right end of
axle. Using a rubber hammer, drive the axle out of housing and remove it by
pulling from the left side.
CAUTION: Do not pull cycle from secure jack stand location.
12. Slip belt over rear pulley and remove the wheel assembly by rolling straight
backwards. Remove axle spacers (Fig. 3-4 (2,7)) from each side of housing.
Note: Keep right (7) and left (2) axle spacers identified, they are not
interchangeable. They require different lengths for locating wheel center and
must be reinstalled in the same location.
15
14
12
13
11
10
9
1
2
3
4
5
REAR AXLE COMPONENTS
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
3
8
6
7
FIGURE 3-4
29
Rear Axle Component Description & Part Numbers from FIGURE 3-4
Item #
Description
1
Rear Pulley Mounting Bolts
2
Left Axle Spacer
3
Bearings
4
Bearing Spacer
5
Rear Caliper
6
Rear Caliper Mounting bolts
7
Right Axle Spacer
8
Brake Caliper Mount
9
Cotter Pin
10
Axle Nut and Washer
11
Rotor Bolts
12
Rear Rotor
13
Axle
14
Axle Housing
15
Rear Pulley
Chart 3.3
DISASSEMBLY OF REAR WHEEL FIG. (3-4)
Part #
8000620
6430226-1
6310218
6310219
6520300PA
818025
6430205-1
6570302C
8500616
6410210 & 11
8110408
6510300B5CA
6410201
6310203
3730103
1. With wheel assembly removed, place cardboard or equivalent for protection down
on the floor. Rotate the wheel assembly over placing the pulley flat on top of the
cardboard, this allows easy removal of the brake rotor and wheel.
2. Remove the rear brake disc mounting bolts (11) using a T45 Torx bit tool. Remove
brake disc (12).
3. Remove rear wheel lug nuts using a ¾” socket. Remove wheel.
4. Remove dust seals from outside of housing and remove bearings for inspection.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
30
BRAKES
GENERAL
The front and rear brakes are fully hydraulic disc brake systems utilizing full floating
rotors and four piston calipers. Every 2500 miles check master cylinders for proper fluid
levels and check brake pads and discs for wear. If brake pad material is worn to 0.050”
or less from backing they should be replaced. Replace in pairs. The minimum brake disc
thickness is 4.5 mm on the front rotors and 5.5 mm on the rear. The floating rotor
assembly should be visually inspected for any cracks or flaws every 2500 miles. A
complete brake system inspection should be performed at least twice a year (for instance,
each spring and fall). You should let your Boss Hoss dealer’s service department or other
qualified Boss Hoss service center do this inspection. The complete inspection should
include: inspecting brake lines and hoses for proper hook-up, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect
other brake parts, including calipers, parking brake, etc. You may need to have your
brakes inspected more often if your driving habits or conditions result in frequent
braking. Make sure any necessary repairs are completed at once.
The brake pedal controls the rear wheel brake and is located on the motorcycle’s right
side. It is operated by the right foot. The brake hand lever controls the front wheel
brakes and is located on the right handlebar control. It is operated by the fingers of the
right hand.
Brakes should be applied uniformly and evenly to prevent wheels from locking up. A
balance between rear and front braking is generally best.
Warning
• Do not apply either brake strongly enough to lock the wheel. This
may cause loss of control of the motorcycle.
• Brake pads must be inspected for wear every 2500 miles. However, if
you ride under adverse conditions, steep hills, heavy traffic, etc., more
frequent inspection, 1000 miles or less, will be necessary.
• Because brake performance is a critical safety item, brake system
serving requires special tools, correct replacement parts and
procedures. We recommend that you see your Boss Hoss dealer for
these services.
Note
•
Operating the motorcycle with right foot resting on rear brake pedal may cause
excessive heating of the rear brake components that can lead to brake fade and/or
loss of braking function.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
31
The rear brake master cylinder is located on the right side of the motorcycle near the
brake pedal. It utilizes a remote reservoir mounted behind the right side panel on the bike.
A visual check of the fluid level can be performed by looking in from the rear of the side
panel at the reservoir. Access for filling or maintenance would require the removal of the
side panel. The reservoir on the trike is mounted under the body near the battery. This
application is accessible from the battery access opening in the body that is located under
the seat; the seat must be removed from the body.
NOTE
No replacement parts are available for the master cylinder. If there is a problem, the
complete master cylinder must be replaced.
Figure3.5 Rear master cylinder Reservoir
(Bike)
Figure 3.6 Rear master cylinder reservoir
(Trike)
Both the reservoirs are on the right side of the bike or trike. The trike reservoir is
mounted behind the motor at the front of the trike body. The bike’s reservoir is mounted
towards the back of the motorcycle behind the right side panel.
The front reservoir is on the right side of the handlebars. It is shaped like a rectangle and
has a Boss Hoss emblem on the cap, which is held on by two screws.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
32
PARKING BRAKE
The parking brake is located on the right side of the motorcycle, under the right side
panel. The parking brake is applied by pressing and holding the rear brake, then pressing
the ‘Jamar’ Park-lok line lock to hold the rear brake pressure to the rear caliper. To
release the Park Brake you press on the rear brake pedal to apply a force equal to or
greater than the pressure that you used to set the brake. When servicing parking brake,
spray lubricant onto ‘Jamar’ Park-lok at the return spring on the plunger actuator shaft.
Parking Brake Fig. 3.7
WARNING
DO NOT pump up or apply excessive force to the rear brakes when setting
the Park Brake. The force needed to overcome the setting force when trying
to release the park brake can cause damage to the master cylinder and/or
caliper seals, causing brake system failure.
CAUTION
The Jamar Park-lok is a hydraulic lock that uses the line pressure of the system to hold
your brakes locked. The Park-lok will release automatically when the pressure in the
lines drops. Check your brake system carefully for leaks or damage that could cause an
unexpected release.
NOTE
If excessive force was used setting the park brake, it may be necessary to loosen a caliper
bleeder valve to allow the release of the Jamer Park-loc. Open the bleeder by turning
counter-clockwise just enough to allow a small portion of fluid to drain and then close by
tightening the valve clockwise, this releases the pressure from the Jamer Park-loc. TEST
BRAKES BEFORE OPERATING THE BIKE. Bleeding of the rear system may be
required after opening the bleeder valve.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
33
BELT ADJUSTING PROCEDURES
1
1
2
2
Figure 3.8
To adjust belt tension, loosen the adjuster block bolts (1) on top of the swing arm.
Adjust belt tension and or wheel alignment by turning the adjuster end cap (2) bolts at
rear of swing arm clockwise (TIGHTEN)….. Counterclockwise (LOOSEN)
MAINTENANCE NOTE:
Before alignment of belt…….Be sure rear axle torque is 15 ft lb. and axle nut cotter
key (Fig.3-4(10)) is in place. Rear pulley should remain in swing arm and line up
with front pulley. Belt should float in center of rear pulley and not contact sides.
CAUTION
PRELOAD AXLE NUT TO 15 FT-LBS. BEFORE BELT IS TIGHTENED.
Tightening the belt before the axle is properly secured can cause damage to the
rear pulley and drive belt.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
34
FIGURE 3.9
Pulley Alignment
1. Align belt by rolling tire forward and watching belt location on the pulley. If it is
to the inside of pulley, tighten the right side adjuster end cap bolt (Fig. 3-8(3)). If
it is located to the outside of the pulley, tighten the left side adjuster end cap bolt
(Fig. 3-8(3)). Keep rolling the tire forward and adjusted until the belt is centered
in the pulley. Now tighten bolts equally to achieve correct belt tension. After
completion of this process, DOUBLE CHECK that the belt is still aligned in the
center of the pulley after rotating tire forward approximately three revolutions.
CAUTION
•
If belt alignment is not centered on pulley, belt and pulley life could be
decreased or failure could occur.
•
BELT TENSION IS VERY SENSITIVE. TIGHTEN IN ¼ TURN
INCREMENTS ONLY. Over tightening may cause premature belt and
pulley wear, and or wheel or transmission bearing failure. Be sure belt is
properly aligned and all bolts are tight.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
35
FIGURE 3.10
DIRECT READINGS!
Operation:
With the indicator arm down, place the tension tester longitudinally with the belt span
and depress the blue pressure pad. When you feel and hear the distinct “click”, do not
press further. Remove the gauge and read the correct belt tension by observing the point
where the top side of the indicator arm crosses the numbered scale on the gauge body.
The engine should run at least five minutes and the belts retensioned to the tension lbs.
shown in the pretension column. This procedure insures that the belt will seat in the
pulleys properly and that desired belt life will be achieved.
OVERTENSIONING DURING THE INITIAL INSTALLATION TO OFFSET
THE OMISSION OF BELT RUN-IN IS NOT RECOMMENDED.
TENSION-TENSION-TENSION. The importance of belt tension cannot be emphasized
enough. Improper tensioning of belts is the greatest contributor to premature belt failures,
more than all other belt problems. Correct tension is a must for satisfactory belt life. Be
sure to read and know the required installation procedure and tensions.
BELT TENSION RANGE: 400-500 FT-LBS.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
36
Front Fork Lock
The front fork lock is located below and to the right of the right side steering stock on
the top tree of the inverted front end. To use the lock turn the handlebars to the left. By
turning the handlebars to the left that aligns the holes. Then push the lock down.
REAR SHOCK ABSORBER
GENERAL
The Boss Hoss uses two shocks with external coil springs. The shocks are preset for
50/50 extension compression.
ADJUSTMENT
To increase spring pressure for passenger or heavy loads use spanner tool or equivalent
and turn the spring seat clockwise to compress, tighten the spring. To reduce the springs
rate for a softer, lighter ride turn the spring seat counter clockwise to reduce the
compression preload on the spring.
Note
Lifting the weight of the bike will allow easier adjustment of the spring seat. Be sure
the bike is stabilized securely before attempting adjustment.
Warning
• Reducing the spring rate from the factory settings may allow the rear
fender to make contact with the rear tire potentially causing tire
failure, which may result in personal injury.
• Changing spring rate, length or mounting position from the factory
specifications may adversely affect the handling and operation of the
bike.
REMOVAL
Raise motorcycle as described in Rear Wheel removal section. Remove the bottom and
top mounting bolts. Then remove the shock assembly.
ASSEMBLY is reverse of REMOVAL.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
37
Rear Shock Adjustment
Fig.3.11
Shock Absorber Adjustable Dampening
Figure 3.12
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
38
HANDLEBAR CONTROLS
THROTTLE CONTROL
The throttle control must operate freely without binding and the carburetor throttle must
return to the closed position.
Warning
Check for free operation of the throttle grip allowing full range of carburetor
linkage movement before operating vehicle.
LEFT HANDLEBAR CONTROLS
Left Turn Signal
Horn
High Beam
FIGURE 3.13
Reverse Button
(Bike Only)
The left handlebar control assembly contains a push button switch for headlamp hi-lo
beam, horn and left turn signal, and a push button reverse located just to the left of the
high beam button switch, this button engages the transmission to reverse from the neutral
position. You shift up with your toes on the front shifter level to put the transmission into
reverse and then hold the reverse button to engage reverse. Reverse is powered by the
engine and is specially designed to engage smoothly at engine idle.
NOTE: SEE TRANSMISSION SECTION FOR FULL EXPLANATION.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
39
RIGHT HANDLEBAR CONTROLS
Electric
Start
Kill Switch
Indicator
Light
Figure 3.14
Throttle
Grip
Kill Switch
Right Turn Signal
The right handlebar control has the throttle grip, front brake lever, and a push button
switch for the electric start, right turn signal, and the kill switch. The engine kill switch
shuts off the engine immediately. The primary purpose of the kill switch is for
emergency situation. The kill switch maybe pushed on accident, which will cause the
motorcycle not to start. The RED kill switch indicator light will illuminate when the
ignition key is on and the kill switch is in the Run/On position. When the kill switch
indicator light is not illuminated the switch is in the Kill/Off position. The throttle is
worked by the right hand grip. Gas is given by twisting the grip counter clockwise. The
front brake is controlled by the lever in front of the grip.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
40
BODY PARTS
(FENDERS, SIDE PANELS, RADIATOR SHROUD, ETC.)
Left side panel
Seat pan
Right side panel
Front Fender
Rear Fender
Radiator Shroud
Figure 3.15
Storage lid
Seat
SIDE PANELS
2005 Vacuum Molded Side Panels
Fig. 3.16
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
41
RADIATOR SHROUD
The radiator shroud is vacuum molded and mounts on the front of the frame. To secure,
mount on crash bar tabs.
Radiator Shroud
Fig. 3.17
REAR FENDER
The rear fender is vacuum molded and has two mounting locations.
Rear Fender
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 3.18
42
STORAGE COMPARTMENT & LID
These two pieces are vacuum molded.
Lockable storage compartment & lid
Fig. 3.19
The storage compartment is mounted to the battery tray before installing the seat
pan. The storage compartment lid hinges from the seat pan.
SEAT PAN
The seat pan is vacuum molded and it covers the distributor, around the frame, under the
seat and holds the storage compartment lid.
Seat Pan shown with the storage lid w/latch
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 3.20
43
SEAT
Boss Hoss motorcycles use Mustang Seats. The standard seat has a driver seat and a
passenger seat that could also be used as a three-position driver backrest.
Standard Mustang Seat configuration
Fig. 3.21
CAUTION
• If the passenger seat is used as a backrest, DO NOT apply excess force against the
backrest. The three-position tab can be bent if excessive force is applied.
Improper operation can cause paint damage.
• When re-installing the passenger seat into the driver seat, be certain that the
tongue is inserted into the seat groove properly. It can mistakenly be slid into the
foam only and have no support from the driver seat. This may allow the top edge
of the tongue to contact the seat pan and storage compartment lid. PAINT
DAMAGE COULD OCCUR.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
44
SECTION FOUR:
ENGINE
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
45
Factory new General Motors (GM) engines power all
Boss Hoss motorcycles and trikes.
We offer the GM ZZ4 V8 Small Block (SB) crate engines and GM ZZ502/502 V8 Big
Block (BB) crate engines in our bikes and trikes.
Initial Engine Break-in
General Motor’s and Boss Hoss Cycles recommends that for proper engine break-in you
drive the first 500 miles normally, without high RPMs (below 5,000 RPM), hard use, or
extended periods of high loading. After the initial 500 miles change the engine oil and
filter. With the proper initial care your engine should be ready for many miles of
cruising.
Caution
Subjecting your engine to high RPMs (above 5,000 RPM) can damage your engine,
causing reduced performance and shorten engine life.
Ignition Timing
Ignition timing is preset at the factory. Spark timing is set to increase when engine speed
increases and to decrease when engine speed decreases.
Timing Indicator & Pulley Markings
Fig.4-1
Time stock ZZ4 engine using the indicator/pointer located on left front of engine. Start
engine. Disconnect vacuum advance tube and plug vacuum to carburetor at 800RPM.
Time engine to 10-degree mark (TDC mark for ZZ4/CAM & 502) located on the back of
crank pulley. Lock distributor in place. Reconnect vacuum advance.
Additional Timing Settings: (with vacuum advance connected)
ZZ4 engine with Cam: TDC at 36 degree at 2400 RPM
502 engine: TDC at 42 degree at 2400 RPM
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
46
Ignition Switch
The ignitions switch on the bike and the trike are both mounted in the same location the
bike ignition switch which is shown in figure 4.2 and trike switch which is shown in
figure 4.3 are both on the Left side of the vehicle behind the valve cover. The difference
between these two is that the trike has a red fuel selector switch mounted next to the
ignition switch. The switch allows the operator to select between the main fuel tank and
the reserve tank (see page 83).
Figure 4.2 Ignition switch on bike.
Figure 4.3 Ignition switch on trike.
The ignition key is also the key that operates the front fork lock (both bike & trike) and
the storage compartment lock (bike only). The trunk lock on the trike requires a different
key from the ignition.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
47
Exhaust System
GENERAL
The BOSS uses a D.O.T. Legal Standard exhaust system with block hugger headers,
custom exhaust pipes and 2-inch clamp on mufflers as shown in Figure 4-4.
D.O.T. Legal Standard Exhaust System
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 4-4
48
EXHAUST SHIELD
Fig. 4-5
The exhaust shields are custom fabricated and attach to the headers with two spring clips.
(Fig. 4-5)
WARNING
• This or any exhaust component can be extremely hot during or after engine
operation. Avoid contact with these components. Contact with these components
could cause personal injury.
• KEEP ANYTHING FLAMMABLE AWAY FROM THE EXAUST SYSTEM.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
49
SECTION FIVE:
FUEL SYSTEM
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
50
FUEL SYSTEM
GENERAL
The BOSS HOSS fuel system is composed of an 8.5-gallon main fuel tank and an electric
fuel pump. The carburetor for the ZZ4 engine is an Edelbrock 795 cfm Quadra jet with
an electric choke model #1904. The ZZ502 models utilize an Edelbrock 850 cfm Quadra
jet model #1910. The electric choke has to be removed from the carburetor for the 502
BB engine so that it will clear the frame.
CARBURETOR (FIG. 5-1)
Electric Choke
CARBURETOR
Fig 5-1
The picture above is an Edelbrock 795 with an electric choke. Electric choke is
the ZZ502 BB models.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
51
FUEL PUMP
The fuel pump, a Carter P4070 (4-6 psi, 72 gph) is mounted on the frame tube just above
the transmission bell housing on both the bike and trike. The wiring connects to the
main harness connector. A wire safety clip included, should be installed securing the
pump terminal connectors to the pump.
Fuel Pump for bike and Trike Fig.5-2
THROTTLE LINKAGE
The throttle bracket is bolted to the intake manifold. The throttle return spring is attached
to a tab mounted on the top front left side frame splice bolt.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
52
Throttle Linkage Connection at Carburetor
Fig. 5-3
WARNING
Throttle return spring must have appropriate tension to fully close carburetor linkage.
Failure to maintain this tension may cause component damage or personal injury.
CAUTION
• Use extreme caution when tightening the 12-24 lock nut onto cable end during
mounting. Over tightening may twist off the end of the cable or crack it causing failure.
• 2 spacers lie underneath each bolt of the ZZ4 model throttle cable mount, and under
the front only of the 502 model throttle cable mount for best alignment of cable.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
53
FUEL TANK
The tank is a 5 piece stamped unit with a single filler opening on the right side. The left
filler is welded close. The fuel petcock (fig. 5-6 on the next page) (Pingel 6210 AH 3/8”
NPT) is on the left side. The tank utilizes a 3/8” crossover line for fuel transfer between
the two sides. The tank utilizes a ¼” medal vent tube that exits from the bottom right side
of the tank, directly under the filler cap location. A vent hose is routed from the tank to
the lower rear frame cross member. The tank has a recessed pocket for gauge clearance
and enabling a lower dash profile. This pocket is where the fuel indicator sender is
mounted, which is illustrated below. The tank is mounted to the frame with 4 bolts
through the mounting tabs in the front and rear of the tank.
8.5 GALLON TANK TOP
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
FIG. 5-4
54
Fuel Sender
Fuel Petcock
Fig. 5-5
(Fig. 5-6)
The fuel petcock is located underneath the left side of the gas tank. The petcock is the
fuel on/off valve. If the lever on the petcock is going towards the front the valve is open.
If the valve is going towards back the fuel is off.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
55
SECTION SIX:
COOLING SYSTEM
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
56
COOLING SYSTEM
GENERAL
The BOSS uses an aluminum radiator, electric water pump, electric fan, fan controller
and water manifold to cool the engine.
WATER MANIFOLD (FIG. 6-1)
The water manifold is installed on the engine in the same location as an automotive style
water pump with three o-rings and four 3/8” x 1” socket head cap screws. Make sure the
o-rings used to seal the manifold are in place. Torque bolts to 45 ft-lbs.
Water Manifold
Fig. 6-1
WATER PUMP
The electric water pump is mounted on the pump shelf located at the lower left front of
the frame using four ¼” x 1” bolts with flat washers on top and ¼” nylon locknuts on the
bottom (Fig. 6-2). The water manifold and pump are connected with 5” of ¾” hose and
two hose clamps.
CAUTION: If Chrome Cover is
placed on water pump, it must be
mounted flush with the back of the
pump motor. Wiring must be
routed outside of the cover and
secured to prevent the wire from
chafing.
Water Pump
Fig. 6-2
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
57
RADIATOR
The aluminum radiator is mounted on the front frame brackets on bottom and held in
place with one clamp on top center (Fig. 6.3). The fan is mounted on the radiator. The
lower radiator hose is approximately 4” long and connects the radiator and water pump.
The upper radiator hose connects from the radiator to intake manifold water neck. An
overflow tube is placed at the filler neck and extends down past bottom of frame.
Caution
Check fan periodically for secure fan mounting. Operation of vehicle with fan
mounting in loose condition could damage radiator and/or cause personal injury.
Radiator and Fan
Top radiator clamp
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 6.3
Fig.6.4
58
FAN CONTROLLER (FIG. 6-5)
The Boss Hoss uses a specially made thermostatic switch installed in the intake manifold.
The fans will come on at 180 degrees and will go off when a certain deviation to the bimetal disc is reached.
FAN CONTROLLER
Fig. 6-5
The thermostatic switch is a standard part. The part number is 5420301-1.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
59
SECTION SEVEN:
DRIVE SYSTEM
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
60
2-SPEED AUTOMATIC TRANSMISSION
GENERAL
The BOSS HOSS has a specially designed two speed automatic transmission with a
reverse gear. The transmission is shifted manually by a standard motorcycle style shifter
(Fig.7-1). The transmission is considered automatic because there is no manual clutch
system. First gear is used from a dead stop up till a desired speed or rpm is reached (See
FIRST on the next page). Once a desired speed or rpm is reached shift to second gear,
which is an OVERDRIVE ratio. The overdrive ratio allows the engine to turn a pleasant
2300-rpm at 70 miles per hour (See SECOND on next page). Reverse is a two step
process that is achieved from neutral with the engine at idle. Reverse is powered by the
engine and is specially designed to engage smoothly and be very controllable as a rider
friendly feature (See REVERSE on next page).
Front shifter lever
Rear shifter lever
Two Speed Shifter
Fig. 7-1
Proper Operation of the Two-Speed Transmission
Your Boss Hoss motorcycle has a two-speed transmission that is manual shifted from one
gear to the next without using a conventional manual clutch system. Proper operation of
this specially designed transmission will help insure that you enjoy many miles of trouble
free use of your motorcycle.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
61
Your motorcycle should only start while the transmission is in the NUETRAL position.
The illuminating of the GREEN light on your dash panel indicates this. After starting
your motorcycle you can select either reverse or first gear to move your motorcycle.
CAUTION
Shifting the transmission while under a load (accelerating or decelerating) or at high
RPM can damage the internal components of the transmission, causing the
operating life of the transmission to be reduced.
REVERSE: To select reverse from the neutral position either press down on the rear
shifter lever (Fig. 7-1) or use your toes to raise the front shifter lever (Fig. 7-1) with the
engine at idle, this put the transmission into Reverse gear. Once in Reverse gear, press
and hold the thumb button, located on the left handlebar controls below the turn signal
button. While holding the Reverse button IN carefully use the throttle to control your
reverse rate. Avoid repetitive pressing of the reverse button, especially while
applying throttle control, to reduce unnecessary loading of the reverse band.
FIRST: To select first gear from the neutral position press down on the front shifter lever
(Fig. 7-1). The Green neutral light should go out and our motorcycle is now engaged in
drive gear. Just carefully twist the throttle control to accelerate the motorcycle.
SECOND: To select second gear from first gear position you should hold the throttle
control at a steady speed (at or above fifty-five (55) miles per hour) and then press down
on the front shift lever (Fig. 7-1) to select second gear.
To return to first and/or neutral press on the rear shifter lever or use your toe to raise the
front shifter lever once for each gear position desired.
Additional Transmission Notes
Second gear is designed as an OVERDRIVE gear, and should only be utilized as such. It
is important that the bikes not be ridden in second gear at speeds below fifty-five
(55) miles per hour. As with most automatic transmissions it is important that the bike
is not operated under a heavy load in overdrive while at low engine rpm’s, such as
climbing a hill (an automobile automatic transmission will automatically down shift to a
lower gear when it is heavily loaded). Running at slow speeds under a load in second
gear reduces the fluid coupling efficiency of the torque converter and causes the
temperature of the transmission fluid to increase. Overheating of the transmission fluid
can lead to premature transmission failure.
All the transmissions that are produced for the Boss Hoss motorcycle are using Mobil 1,
MX4T synthetic oil. The Mobil 1 synthetic fluid will maintain its physical properties
better than organic fluids when subjected to the heat that the two-speed transmission can
produce. This helps to maintain proper fluid coupling through the torque converter, but
doesn’t protect the soft parts from the heat generated while loading the transmission in
second gear.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
62
Shifting of the transmission from first to second gear is another area were the operator
can reduce the life of the transmission. You should never shift the transmission while
accelerating. The best way to shift is to maintain a neutral throttle position at cruising
speed while the transmission shifts from one gear to the next. This allows one clutch
pack to release and the other to engage without subjecting the internal components of the
transmission to any needless high torque shock loads.
Another convenient and often misused feature of the two-speed transmission is the
reverse gear. When you press the thumb button to engage reverse you are actuating a
solenoid that feeds oil pressure to a band that clamps around the ring gear of the planetary
gear set inside the transmission. Each time you press the button the reverse band locks
down on the ring gear stopping its rotational motion, repetitious pressing of the reverse
button can cause premature wear of the reverse band and also, repetitious pressing of the
reverse button while accelerating can cause the reverse band to fail due to needless shock
loads. The proper way to use the reverse gear is to press and hold the button until
the reverse band has completely locked the ring gear, and then use gradual
acceleration to control the movement of the bike in reverse.
Vent/Filler Cap
TRANSMISSION FILLER VENT CAP
Fig. 7-2
The vent cap is located at the top right of the transmission housing and is accessed by
removing the right side panel from the motorcycle.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
63
OIL USED: Mobil 1 – MX4T Synthetic Oil
FILTER:
This is an internal filter that is removed, cleaned, and reinstalled. It is
located inside of the transmission just above the bottom plate.
SERVICING OF FILTER: Clean filter at 500 miles, 2500 miles and every 10,000
miles as directed. With the transmission warm, remove one (1)of the button head bolts
from the bottom of transmission to allow the fluid to drain. After the fluid has drained,
remove the second button head bolt and remove the pan bottom to expose the
transmission filter. Remove filter and clean with solvent. Blow particles, sludge, etc.
from filter and replace the filter to its original position. Replace pan bottom, resealing or
replacing the gasket and fill transmission housing with 2 QTS. MOBIL 1 – MX4T oil or
to the proper level. (CAUTION: DO NOT OVERFILL). The filler plug is located on the
right side, front corner of the transmission just below the fuse panel.
CAUTION
Pan bolt torque is 4 ft/lbs. Bolt over-torque could result in bolt failure and/or flexing
of transmission pan resulting in leaking.
NOTE
This service will drain oil in transmission only. The converter will hold
approximately 2.5 quarts that cannot be drained without removal. The transmission
housing should hold approximately 2 quarts.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
64
TO ALL OWNERS OF BOSS HOSS MODELS WITH 2- SPEED/REVERSE
TRANSMISSION:
THIS IS A MANDATORY SERVICE BULLETIN ISSUED TO PREVENT OIL
STARVATION TO PUMP AND CLUTCH PACKS DUE TO CLOGGED OR DIRTY
FILTERS.
1. AFTER 500 MILES (NOT EXCEEDING 800 MILES), PLACE BIKE ON JACK
STANDS.
2. RUN ENGINE APPROXIMATELY 5 MINUTES TO INSURE FLUID IS
WARM AND FLUID LEVEL IS STABILIZED.
3. REMOVE ONE (1) BOTTOM BOLT FROM TRANSMISSION PAN AND
DRAIN FLUID INTO CONTAINER.
4. AFTER FLUID HAS DRAINED REMOVE THE SECOND PAN BOLT TO
REMOVE THE TRANSMISSION PAN.
5. WITH BOTTOM PAN REMOVED, NOTE FILTER SCREEN LOCATED AT
BOTTOM OF TRANSMISSION. REMOVE; CLEAN WITH SOLVENT AND
AIR BLOW ALL PARTICLES FREE. CLEAN PAN BOTTOM TAKING CARE
NOT TO DAMAGE PAN GASKET.
6. REPLACE FILTER AND PAN BOTTOM.
CAUTION: DO NOT OVER TIGHTEN PAN BOLTS (4 FT.-LBS. MAX)
7. REFILL WITH APROXIMATELY 2.75 QUARTS OF MOBIL 1 – MX4T
THROUGH FILLER PLUG LOCATED ON UPPER RIGHT CORNER OF
TRANSMISSION.
8. RUN BIKE 5 MINUTES, SHIFT THROUGH THE GEARS TO FULL ALL
FLUID PASSAGES.
9. TURN ENGINE OFF AND LET SET FOR 30 TO 60 SECONDS TO
STABILIZE FLUID LEVEL.
10. WITH BIKE STANDING LEVEL; CHECK THE FLUID LEVEL IN SIGHT
TUBE AT LOWER RIGHT FRONT OF TRANSMISSION (FLUID LEVEL
SHOULD BE IN THE MIDDLE OF TUBE). ADD FLUID AS NEEDED.
CAUTION
• May require two persons to safely check the fluid level in the transmission.
• Overfill of fluid may cause excess fluid to discharge from breather/fill plug.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
65
FINAL DRIVE
Front Pulley
The front pulley is installed on the transmission output shaft using a 5/16” x 1-7/8” key,
set screw, SKX1.5 taper lock bushing and three 5/16” x 1-¼” grade 8 bolts and washers.
Front Pulley
Fig. 7-3
Rear Pulley
The rear pulley is mounted on the axle spool with four ½” x 2 1/2” socket head bolts
and washers. There are two keyway slots in the pulley that match the keyways in the
axle spool that assist in stabilizing the rear pulley.
AXLE PULLEY and HOUSING ASSEMBLY
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
FIG 7-4
66
SECTION EIGHT:
ELECTRICAL
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
67
ELECTRICAL SYSTEM
WIRING
GENERAL
The BOSS uses a main wiring harness, tank gauge harness, and fuse block as its main
components. Provisions are made to connect to the alternator, fan controller, starter,
water temp sensor, water pump, key switch, handlebar controls and lights.
Wiring Harness
Fig. 9-1
Wiring Harness with Fuse Block
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 9-2
68
Wiring Harness
Fig. 9-3
Master Solenoid
(Fig. 9-4)
The master solenoid (Fig. 9-4) is controlled by the ignition switch.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
69
BATTERY
The 680 Odyssey batteries are used on both the bikes and trikes. Odyssey batteries are
dry cell batteries which take away the chance of acid spilling. The battery is located
under the seat (as seen in figure below).
Model No.
Figure 9-5
PC 680 MJT
680 Odyssey Battery
WARNING: Battery must have mounting bracket securing it in proper location before
operating bike/trike.
WARNING: Use extreme caution with correct cable mounting. The (HOT) positive
cable is routed to the master solenoid. The (GROUND) negative cable is routed to the
bell housing mounting bolt.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
70
Starter Relay
Fig. 9.6
Neutral safety switch
Fig. 9.7
The female spaded wire off of the relay goes to neutral safety switch on shifter for a trike
(neutral safety switch shown in figure 9.6, located below left floorboard on trike).
Note: Other terminal on neutral switch goes to engine ground it does not matter which
wire goes to each terminal.
On a bike the spaded wire goes to the green wire coming from the center, rear fitting on
the transmission.
Note: The black wire coming out of the back of the transmission is a ground.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
71
ALTERNATOR
BOSS HOSS recommends using a one-wire alternator rather than the stock GM unit. The
wiring harness will accommodate either the one-wire or the standard GM three-wire
alternator.
On the Small Block ZZ4 model, a Gates 5330212 belt is used.
On the Big Block ZZ502 model, a Gates 5330216 belt is used.
Alternator
Fig. 9.8
CAUTION
• If proper alternator belt tension is not maintained, the alternator may not supply
sufficient voltage to the battery.
• Riding in wet conditions may magnify the effects of a loose belt. Keep belt
TIGHT.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
72
STARTER
Mini-Starter
Fig.9-9
WARNING
Make sure the S-terminal does not touch the battery lead.
Note: Shims should not be needed on most applications. In some instances, shimming
may be necessary for optimum engagement with the flex plate.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
73
GAUGE PANEL
GENERAL
The gauges are mounted on a separate stamped mounting panel and include water
temperature, oil pressure, speedometer, tachometer, voltmeter, and a separate indicator
panel.
ASSEMBLY
Starting from left to right the water temperature, oil pressure, speedometer, tach, and
voltmeter are mounted to the panel. The indicator panel is mounted under the
speedometer. The gauges are secured in the panel using gauge brackets.
7
1
8
9
2
10
11
12
3
4
5
6
Gauge Panel
1. Oil Pressure
4. Right/Left Signal Lights
7. Tachometer (RPM Gauge)
10. Fuel Gauge
Fig.9-10
2. Water Temperature
5. Neutral Light
8. Voltmeter
11. Fan Indicator Light
3. Fan On/Off Button
6. Check Engine Light
9. Low Fuel Indicator
12. High Beam Indicator
Note: The fan ON/OFF Button can be used to turn fan on manually (overriding the fan
controller) if desired.
Note: The check engine light is only operational on the fuel injected models.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
74
Bulb Chart
Description
Headlight
Front Light Signal
Rear Light Signal
Taillight
ZR-1 Kit Truck Trike Light
’39 Ford Lo-Boy Trike Light
Lens LED
License Lamp/Trike, Coupe, Truck
57 – Taillight
Part Number
Bulb H4 60/55W
Bulb 1007
Bulb 1007
Bulb1157
5720200-1
5720220
5720221-1
Bulb 168
LED Board 5220123
Chart 9.1
Note:
The wiring schematic for the main harness and for the dash harness is located in the
pocket of owner manual folder.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
75
SECTION NINE:
TRIKES
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
76
TRIKE SPECIFICATIONS
ZZ4 DIMENSIONS
Wheel base (front to rear)……………81.5”
Vehicle width……………..................60”
Saddle height……………..........……28.5”
Dry Weight…………………….…...1500 lbs
Engine…………………………..….GM V8
Horsepower ……………………...…355
ZZ502/502 V8 DIMENSIONS
Wheel base (front to rear)………..…83.5
Vehicle width……………..................60”
Saddle height…………………….....28.5”
Dry Weight…………………………1700 lbs.
Engine……………………………....GM V8
Horsepower…………………..……..502
VEHICLE WEIGHT RATINGS (LBS)
The Gross Vehicle Weight Ratings (GVWR)
and Gross Axle Weight Ratings (GAWR) are
found on a label on the frame steering head.
S.B.
B.B.
V8 GVWR
2093 lbs. 2293 lbs.
V8 GAWR (front)
665 lbs.
729 lbs.
V8 GAWR(rear)
1428 lbs. 1564 lbs.
CAPACITIES
Fuel tank (U.S. Gallons)
8.5
Cooling System (U.S. Quarts) SB 12; BB 14.5
Oil Pan (U.S. Quarts)
5
Auto Transmission (U.S. Quarts) Trike 8
Reserve Tank (U.S. Quarts)
3.5
CARGO (TRUNK) LOADING CAPACITY
Maximum Load* *
150 lbs.
* *DO NOT EXEED GVWR and/or GAWR
TORQUES
Front Axle …....………….............50 ft-lbs.
Brake disc mounting (Frt.)….........20 ft-lbs.
Caliper mounting bolts……..........30 ft-lbs.
Caliper bracket bolts………......…45 ft-lbs.
Fork brace pinch bolts……….......40 ft-lbs.
Slider cap bolts……………..…....50 ft-lbs.
Riser bolts………………...…..….45 ft-lbs.
Riser cap bolts………..……….....15 ft-lbs.
Steering stem bolt………..…..…..55 ft-lbs.
Rear Sub frame mount bolts…....100 ft-lbs.
Rear Shock mounting bolts……....60 ft-lbs.
Rear wheel lug nuts .1/2-20.……..80 ft-lbs.
BRAKES
Front
Rotor Diameter……………………12.5 in
Minimum Rotor thickness. 0.177 in.(4.5mm)
Rear
Drum…………..…………………..9.0 in.
Maximum drum diameter……...9.060 in.
TIRE DATA
Tire pressure
PSI (Cold)
Front
40
30
Rear
* * DO NOT EXEED GVWR * *
WHEEL
TIRE
Front…16” x 3.5”
MT90B16 (Avon)
Rear…. 15” x 10”*
275/60R15
* Rear wheel has a 6” offset from back
FUEL: 92 OCTANE IS RECOMMENDED
WARNING
DO NOT EXCEED LOAD LIMITS. Exceeding the designed Gross Vehicle Weight
Rating (GVWR) and/or Gross Axle Weight Ratings (GAWR) may cause fatigue
and/or structural failure to your vehicle, which could result in personal injury.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
77
General
The Boss Hoss trikes consist of a rear sub-frame that connects to the motorcycle frame at
the motorcycle swing arm pivot point (Fig. 8-1(1)) and upper shock mounting points
(Fig. 8-1(2)). This sub-frame allows for the REMANUFACTURED narrowed Ford 7.5
inch rear axle assembly to be mounted and connected to the REMANUFACTURED GM
350 Hydromatic transmission. The fiberglass trike body is also secured to the trike subframe by six bolts on the tail section of the frame (Fig. 8-1(3)).
BOSS HOSS TRIKE CHASSIS:
2
1
3
Trike Sub-frame
Fig. 8-1
Rod End Joint Alignment
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Fig. 8-2
78
Rear Axle Assembly Attachment
Fig. 8-3
The trike sub-frame and mainframe attach at the swing arm attachment location with a 13/4” spacer (on both sides) Fig. 8-3. The high strength alloy rod ends that are used to
secure the rear axle assembly to the trike sub-frame must be properly aligned with the
transmission to insure that the drive shaft yoke assemble will pivot properly.
WARNING
Improper alignment of the rear axle assembly can damage the drive train of the trike,
which may result in serious personal injury. IT IS RECOMMENDED THAT ALL
DRIVETRAIN SERVICE AND ALIGNMENT PROCEEDURES ARE CONDUCTED
BY YOUR AUTHERIZED BOSS HOSS DEALER.
Trike Sub-frame and Rear Axle Assembly Fig. 8-4
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
79
Mounting of the fiberglass bodies requires mounting bolts through the floor of the trunk
into the sub-frame and through the upright back of the trunk wall into the sub-frame (Fig.
8-1 (3)) and one on each side of the front through the front body mounting plates.
WARNING
Operation of Trike with any bolts missing may damage sub-frame and/or Trike
body, which could result in personal injury.
Trike Electronic Speedometer
Drive Yoke
Electronic
Speedometer
Sensor
Drive yoke and Electronic Speedometer Sensor
Fig. 8-5
The electronic speedometer pickup sensor is mounted from the rear axle housing and is
positioned to read pulse produced by a sprocket attached to the pinion flange of the rear
axle drive system.
Note: Clearance between sensor and sprocket is .004.
Note: Shield wire must be used for proper speedometer function.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
80
Trike Brake System
General
The trike brake system implements the same front brake system as bikes. The details of
this system are outlines in the Brake Section of this manual beginning on Page 31. The
Trike rear brake pedal and rear master cylinder are also the same as the bike (See Brake
section beginning on page 31).
Unlike the rear disc system on the bike, your trike utilizes a nine (9) inch drum brake
system, with a self adjusting brake system.
9” Rear Drum Brake Assembly
Fig. 8-6
Automatic Brake Adjusters
The rear brakes on your trike are self-adjusting, designed to eliminate periodic manual
brake adjustments. Drum brake adjustment is made automatically as the rear brakes are
applied while the car is moving backwards. If excess brake pedal travel develops, drive
alternately backward and forward several times and apply the rear brakes firmly in each
direction. If normal brake pedal travel and performance is not restored, or if there is a
rapid increase in pedal travel, which could be sign of other brake trouble, contact your
Boss Hoss Dealer IMMEDIATELY.
Warning
Operating your vehicle with improper braking functions can result in serious injury
personal injury or death.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
81
Trike Fuse Panel
Fig. 8-7
The electrical fuse panel for the trike is located in the center of the vehicle underneath the
rider’s seat. To access the fuse panel the seat must be removed. There is one 5/16”
button head bolt located at the center-rear section of the seat pan that holds the seat into
position. Extracting this bolt will allow you to remove the seat and access the fuse panel.
Detent cable mount (Kick-down cable)
Fig. 8-8
The detent cable is the device that automatically down shifts the transmission to a lower
gear during acceleration (i.e. passing a vehicle / climbing an incline).
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
82
Fuel System
Selector Valve
Fig.8-9
Selector Switch
Fig. 8-10
The fuel selector valve is mounted on the battery box (Fig. 8-9), which is located under
the rider’s seat.
The rocker switch that operates the fuel selector is located just above the ignition switch
(Fig.8-10).
The normal operating position of this switch would be pressed forward which allows use
of the main fuel tank. When pressed backward, the switch will illuminate as an indicator
that the reserve tank has been selected.
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
83
TRIKE RESERVE TANK
Fig. (8-11)
On all trikes, the reserve tank mounts on the trike sub frame (Fig. 8-11).
Reserve Fuel Tank Filler Cap
Fig. 8-12
On the truck, ‘57 and coupe trike, the fuel filler is permanently mounted externally on the
right side of the body. The filler hose assembly consists of a 3 inch piece of hose
attaching the tank to a 90 degree elbow. The elbow then is attached to a hose that
connects the second 90 degree elbow which is turned upward. The second elbow is then
connected to the cap by another 3 inch piece of hose. (See Fig. 8-12)
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Trike Shifter
The Boss Hoss uses the B&M Quicksilver Shifter, # 80683.
On all trikes, the shifter is mounted permanent on the left front body mount.
Trike Shifter-
Fig. 8-13
Operation of Shifter
The stick travels in a direct line forward and backwards from Park, Reverse, Neutral,
Drive, Second, and Low. The shifter stick must be raised to clear the stop gates when
going through the gear positions.
Park: To put in park, put the shifter stick into the Drive location and then lift the stick all
the way and push the stick all the way forward to the Park location. Release the stick and
the shifter is locked in Park. To put in any other gear position you must raise the stick to
clear the stop gates.
Reverse: Raise the stick to clear the stop and move the stick to the Reverse location.
Neutral: Move the stick to Neutral. You do not have to raise the stick unless you are in
Park.
Drive: Move the stick to Drive. You do not have to raise the stick unless you are in Park.
Second and Low: These gears should never be selected. If the Trike is operated in these
gears, the desired RPM range will be exceeded and it will overheat the fluid and
discharge it from the vent tube.
CAUTION
Manually operating the vehicle in Second or Low gear could damage the engine
and/or transmission.
Mount cable bracket in the center two bolts of transmission pan on left side (Refer to
figure 8-14). Loop cable under the battery tray and mount cable from the rear pointing
forward. When installing left exhaust pipe, maintain maximum clearance between pipe
and shift arm.
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Shifter Connection
Fig. 8-14
Cable Adjustment
The cable attachment tab must be bolted to the outside surface of the shifter base. Move
the transmission selector lever by hand to the full rear position (Low). Shift the shifter
mechanism to the Low gear position (ratcheted all the way back). Adjust the large nuts on
the cable so that the swivel will slide into the hole on the selector lever. Tighten the large
nuts completely. Be sure that the swivel will slide freely in and out of the hole in the
selector lever. Leave the swivel out of the hole and move the transmission selector lever
to Park, all the way forward. Also move the shifter to Park position. Reinsert the swivel
into the hole in the selector lever. Check to see that the swivel will slide freely in and out
of the hole in the selector lever in this position. If it does not slip in freely, adjust the
swivel slightly until it will slip into the hole in the lever. Move the shifter back to Low
gear position and check that the swivel will still slide easily in and out of the hole in the
selector lever. (If you do not use the hole in the lever, it will be impossible to correctly
adjust the cable.) Operate the shifter through all the gear positions. Check to make sure
the swivel will slide in and out of the selector hole in each gear position. The shift cable
is now correctly adjusted. Install the cotter key into the swivel and spread the key ends.
CAUTION
If you have a problem, DO NOT FORCE THE SHIFTER, this will damage the
cable, the shifter or he transmission. Simply start at the beginning and carefully
check all your steps.
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Warning
If you don’t adjust the cable correctly, you will destroy the cable, shifter and/or
transmission in as little as one shift.
Warning
Route the cable avoiding exhaust pipes and sharp bends that will kink and damage
the cable. If the cable is close to the exhaust it will melt or become brittle. Do not
wrap the cable this retains heat. Heat will destroy the cable. Cable should be kept
straight for two inches on each end where it leaves the brass.
Neutral Safety Switch
The neutral safety switch (the lower switch) on the shifter should operate ONLY in
Neutral and Park. It is located on the rear, outside of the shifter base. Check the switch
operation by sitting on the Trike, locating the On/Off switch to OFF and applying both
front and rear brakes. With switch in the OFF position and both brakes applied, attempt
to start the engine in each shifter position. The starter must engage only when the shifter
is in the Park or Neutral position.
Trike Exhaust
Exhaust Mount
Fig. 8-15
This is the rear exhaust pipe clamp. It bolts through a welded on pipe bracket onto the
sub-frame. Shim attachment (with washers) as needed to allow tailpipe to retain
appropriate clearances and align with body.
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TAILLIGHT WIRING DIAGRAM FOR '57 AND '32 MODEL TRIKE
(Any two taillight TRIKE system)
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TAILLIGHT WIRING DIAGRAM FOR
PICKUP MODEL TRIKE
(Any four taillight TRIKE system)
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SECTION TEN:
Troubleshooting
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TROUBLESHOOTING
GENERAL
Proper care of your bike or trike including following the regular service interval charts
listed in the owner’s manual is a must for keeping the bike in a good running condition.
WARNING
The troubleshooting section of this Owner’s Manual is intended solely as a guide to
diagnosing problems. Repairs and maintenance operations for your bike or trike should
be performed only by a Boss Hoss Cycles, Inc. dealer.
ENGINE
Starter Does Not Turn Engine Over
1. The kill button has been engaged check light on the right handlebar control.
2. Ignition key not “ON.”
3. Battery maybe discharged, loose, or have corroded connections.
Engine Will Turn Over But Does Not Start
1. Check fuel.
2. Fuel valve maybe in “Off” position.
3. A fuel line disconnected.
4. Fuel valve or filter clogged.
5. Have a bad battery connection or a discharged battery.
6. Fouled spark plugs.
7. Spark plug cables have bad connection.
8. Loose or corroded wire or cable connection at battery.
9. Fuel pump inoperative.
10. Engine maybe flood.
Hard to Start
1. Spark plugs in bad condition or are fouled.
2. Spark plug cables in bad condition.
3. Battery not properly charged.
4. Check connections to battery and coil.
5. Carburetor not adjusted correctly.
6. Fuel tank vent maybe plugged or closed off.
7. Water or dirt in fuel system (bad gas).
8. Ignition timing off.
Run Irregularly
1. Check condition of spark plugs.
2. Spark plug cables in bad condition.
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3.
4.
5.
6.
7.
8.
9.
Spark plug gap not right.
Battery does not have correct charge.
Battery has loose or corroded connection.
Short circuit in wires.
Water or dirt in fuel system (bad gas).
Fuel vent system plugged.
Injectors fouled.
Overheats
1. Heavy carbon deposit from “lugging” engine.
2. Water pump not working properly.
3. Stat switch not working properly.
4. Fan switch not working properly.
5. Timing, ignition off.
Excessive Vibration
1. Engine mounts loose.
2. Engine to transmission mounting bolts loose.
3. Wheels or tires damaged or not balanced.
4. Vehicle not properly aligned.
LUBRICATION SYSTEM
Oil Does Not Return to Oil Tank
1. Restricted oil lines or fittings.
2. Restricted oil filter.
Engine Leaks Oil
1. Loose parts.
2. Imperfect seal at gaskets, washers, etc.
ELECTRICAL SYSTEM
Alternator Does Not Charge
1. Engine ground wire loose or broken.
2. Loose or broken wires in charging circuit.
Alternator Charge Rate is Below Normal
1. Weak battery.
2. Excessive use of add-on accessories.
3. Loose or corroded connections.
CARBURETOR
Carburetor Floods
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1.
Pumping of the throttle grip.
TRANSMISSION
Transmission Shifts Hard
1. Bent shifter rod.
2. Transmission shifting mechanism needs adjustment.
Transmission not Down Shifting (Trike)
1. Detent cable broke or not adjusted properly.
BRAKE
Brakes Do Not Hold Normal
1.
Master cylinder low on fluid.
2.
Brake line contains air bubbles.
3.
Master of wheel cylinder piston worn.
4.
Brake pads contaminated with grease or oil.
5.
Brake pads badly worn (check owner’s manual under Brake Disc).
6.
Brake disc badly worn or warped.
7.
Brake fades because of heat build up. Excessive braking or brake pads dragging.
8.
Brake drags. Insufficient hand lever free play.
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SECTION ELEVEN
Accessories
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Mustang Seats
TRIKE
Mustang Touring Seat
with Driver Backrest
Touring Passenger
Backrest
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BIKE
Mustang Touring Seat
Mustang Rider Backrest and
Wide Passenger Seat
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Windshields
Front View of Fairing
Back View of Fairing
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97
Front View of the Quick Release Windshield
Back Left View of Quick Release Windshield
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Other Accessories
Gas Cap Covers
“Boss” “Hoss”
V-8 Taillight Grill
2” Pull Back Risers
Assembly
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Highway Pegs with
‘Kuryakin’ Mounts
Mustang Sissy Bar
Assembly
Rear Fender Luggage Rack
(Sissy Bar Required)
Hard Saddlebags
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