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 re

Description Application BH Part # Industry Part # Transmission Oil Trike 3670000

SECTION ELEVEN Accessories © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 94

Mustang Seats TRIKE Mustang Touring Seat with Driver Backrest Touring Passenger Backrest © Copyright Boss Hoss Cycles, Inc. 2004. All Rig

BIKE Mustang Touring Seat Mustang Rider Backrest and Wide Passenger Seat © Copyright Boss Hoss Cycles, Inc. 2004. All Right

Windshields Front View of Fairing Back View of Fairing © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 97

Front View of the Quick Release Windshield Back Left View of Quick Release Windshield © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Rese

Other Accessories Gas Cap Covers “Boss” “Hoss” V-8 Taillight Grill 2” Pull Back Risers Assembly © Copyright Boss Hoss Cycles, Inc. 2004. A

Highway Pegs with ‘Kuryakin’ Mounts Mustang Sissy Bar Assembly Rear Fender Luggage Rack (Sissy Bar Required) Hard Saddlebags © Copyright Boss

REGULAR SERVICE INTERVAL CHART (CONTINUED) Service to be performed Every 300 miles First 500 miles Every 2500 miles Every 5000 miles Every 7500 mile

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 th

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

VIN TAG GENERAL THE TAG IS LOCATED ON THE RIGHT SIDE OF THE FRAME ON THE FORK NECK. MFD BY BOSS HOSS CYCLES, INC

BOSS HOSS LIMITED 12-MONTH WARRANTY Boss Hoss Cycles, Inc. warrants to the first retail purchaser and authorized transferees of our new 2005 motorcyc

OTHER LIMITATIONS THIS WARRANTY DOES NOT COVER: 1. Parts and labor for normal maintenance as recommended in the Owner’s Manual, including such item

© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 11

© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 12CONS

CONSUMER PRODUCT SATISFACTION Boss Hoss Cycles designs, tests and constructs all its products of the highest quality materials and components that me

WARNINGS AND CAUTIONS Statements in this manual preceded by the words WARNING or CAUTION are very important. WARNING Means there is the possibility

SECTION TWO: FRAME ASSEMBLY © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 14

2005 BIKE FRAME PATENTED BOSS HOSS FRAME (FIG. 2.1A) Cast Neck (Yoke) (FIG. 2.1B) © Copyright Boss Hoss Cycles, Inc. 2004.

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)

Lower engine mounts (Fig. 2.1E) Upper Engine Mounting Brackets (FIG. 2.1F) © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Res

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 redu

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

SECTION THREE: CHASSIS © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 20

BIKE SPECIFICATIONS ZZ4 V8 DIMENSIONS TORQUES Front Axle …...…………...50 ft-lbs. Wheel base……… ………80” Rear Axle Nut…..………….15 ft-lbs. Saddle hei

WHEELS GENERAL Maximum tire mileage and good handling qualities are directly related to care given to wheels and tires. A tire kept in continuous ser

WARNING WHEEL SERVICE CHART CHECK FOR: 1. Loose axle or axle nuts. 2. Excessive side-play or radial (up-and-down) play in wheel hubs. *For Sealed B

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 ma

FRONT WHEEL (Figure 3-1) 1 5 13 16 7 4 12 1 9* Right side of wheel Figure 3-1A * The axle pinch bolt is not show in the picture, but is located

11555555 15 1 11 13 2 8 2 10 18 14 13 1 Front Wheel Figure 3-2 Front Wheel Component Description & Part Numbers from Figures 3-1 &

WARNING Carefully read this section of the manual before performing any work. Your Boss Hoss dealer has trained technicians who can complete the wor

WARNING After proper tightening of axle, wheel-bearing endplay should be less than 0.002 inches. Improper performance of this installation may resul

REAR WHEEL 2 3 3 2 1 Rear Wheel FIGURE 3-3 REMOVAL OF BIKE WHEEL ASSEMBLY (FIG. 3-3) IMPORTANT NOTE: befo

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.

Rear Axle Component Description & Part Numbers from FIGURE 3-4 Item # Description Part # 1 Rear Pulley Mounting Bolts 8000620 2 Left Axle

BRAKES GENERAL The front and rear brakes are fully hydraulic disc brake systems utilizing full floating rotors and four piston calipers. Every 2500

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

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

TABLE OF CONTENTS Page No. FOREWARD i WARNINGS AND CAUTIONS ii SAFE OPERATING RULES iii SECTION ON

BELT ADJUSTING PROCEDURES 1 22 1 Figure 3.8 To adjust belt tension, loosen the adjuster block bolts (1) on top of the swing arm. Adjust belt ten

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, ti

FIGURE 3.10 DIRECT READINGS! Operation: With the indicator arm down, place the tension tester longitudinally with the belt span and depress the blu

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. T

Rear Shock Adjustment Fig.3.11 Shock Absorber Adjustable Dampening Figure 3.12 © Copyright Boss Hoss Cycles,

HANDLEBAR CONTROLS THROTTLE CONTROL The throttle control must operate freely without binding and the carburetor throttle must return to the closed p

RIGHT HANDLEBAR CONTROLS Electric Start Kill Switch Indicator Light Figure 3.14 Kill Switch Throttle Grip Right Turn Signal The right handleb

BODY PARTS (FENDERS, SIDE PANELS, RADIATOR SHROUD, ETC.) Left side panel Seat pan Right side panel Front Fender Rear Fender Radiator Shroud Figu

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

STORAGE COMPARTMENT & LID These two pieces are vacuum molded. Lockable storage compartment & lid Fig. 3.19 The storage compartment is

SECTION FIVE: FUEL Carburetor 51 Fuel Pump 52 Throttle Linkage 53 Fuel Tank 54 Fuel Petcock 55

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 d

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 ZZ5

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 figu

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 mu

EXHAUST SHIELD Fig. 4-5 The exhaust shields are custom fabricated and attach to the headers with two spring clips.

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 en

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

Throttle Linkage Connection at Carburetor Fig. 5-3 WARNING Throttle return spring must have appropriate tension to fully close carburetor li

Transmission 93 Brake 93 SECTION ELEVEN: ACCESSORIES Mustang Seats 95-96 Windshields 97-98 Other Acc

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

Fuel Sender Fig. 5-5 Fuel Petcock (Fig. 5-6) The fuel petcock is located underneath the left side of the gas tank. The petcock is the fuel on/

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.

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 i

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 de

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 transmissio

Your motorcycle should only start while the transmission is in the NUETRAL position. The illuminating of the GREEN light on your dash panel indicates

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 sh

SECTION ONE: Product © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 1

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 tra

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 A

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 bush

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 mad

Wiring Harness Fig. 9-3 Master Solenoid (Fig. 9-4) The master solenoid (Fig. 9-4) is controlled by

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

Neutral safety switch Fig. 9.7 Starter Relay Fig. 9.6 The female spaded wire off of the relay goes to neutral safety switch on s

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

STARTER Mini-Starter Fig.9-9 WARNING Make sure the S-terminal does not touch the battery lead. Note: Shims should n

GENERAL The Boss Hoss is an American –made custom fabricated, two-wheeled motorcycle powered by a General Motors V-8 engine. The specially designed f

GAUGE PANEL GENERAL The gauges are mounted on a separate stamped mounting panel and include water temperature, oil pressure, speedometer, tachomete

Bulb Chart Description Part Number Headlight Bulb H4 60/55W Front Light Signal Bulb 1007 Rear Light Signal Bulb 1007 Taillight Bulb1157 ZR-1 Kit T

SECTION NINE: TRIKES © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 76

TRIKE SPECIFICATIONS ZZ4 DIMENSIONS TORQUES Wheel base (front to rear)……………81.5” Front Axle …...…………...50 ft-lbs. Vehicle width……………...

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))

Rear Axle Assembly Attachment Fig. 8-3 The trike sub-frame and mainframe attach at the swing arm attachment location with a 1-3/4” spacer (on bot

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

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 B

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

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), whi

WARNING • Carefully read all the appropriate sections of this manual before performing any work on your motorcycle. Improper repair and /or maintena

TRIKE RESERVE TANK Fig. (8-11) On all trikes, the reserve tank mounts on the trike sub frame (Fig. 8-11). Reserve Fuel

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 moun

Shifter Connection Fig. 8-14 Cable Adjustment The cable attachment tab must be bolted to the outside surface of the shifter base. Move the t

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

(Any two taillight TRIKE system)TAILLIGHT WIRING DIAGRAM FOR '57 AND '32 MODEL TRIKE © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Re

(Any four taillight TRIKE system)PICKUP MODEL TRIKETAILLIGHT WIRING DIAGRAM FOR © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 89

SECTION TEN: Troubleshooting © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 90

TROUBLESHOOTING GENERAL Proper care of your bike or trike including following the regular service interval charts listed in the owner’s manual is a

3. Spark plug gap not right. 4. Battery does not have correct charge. 5. Battery has loose or corroded connection. 6. Short circuit in wires. 7.

1. Pumping of the throttle grip. TRANSMISSION Transmission Shifts Hard 1. Bent shifter rod. 2. Transmission shifting mechanism needs adjustment.