Boss Hoss Cycles Year 2005 User 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.
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 2
Service Charts 3-5
Checking & Changing Oil 6-7
Vehicle Identification Number 8
Warranty 9-12
Reporting Safety Defects 13
SECTION TWO: FRAME
Frame & Cast Neck 15
Crash bars, Driver pegs 16
Engine Mounts 17
Kickstand and Water Pump 18
Inverted Front End 19
SECTION THREE: CHASSIS
Bike Specifications 21
Wheels 22-30
Brakes 31-32
Parking Brake 33
Drive Belt Tension 34-36
Front Forks 37
Shocks 37-38
Handlebar Controls 39-40
2004 Body Parts (Fenders, Rad. Shroud, Side Panels, 41-44
Seat Panel, Seat, Storage Compartment)
SECTION FOUR: ENGINE
GMmotors 46
Ignition System 46-47
Exhaust 48-49
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. iv
SECTION FIVE: FUEL
Carburetor 51
Fuel Pump 52
Throttle Linkage 53
Fuel Tank 54
Fuel Petcock 55
SECTION SIX: COOLING SYSTEM
Water Manifold 57
WaterPump 57
Radiator & Fan 58
Fan Controller 59
SECTION SEVEN: DRIVE SYSTEM
2-SPEED Transmission 61-65
Rear & Front Pulley 66
SECTION EIGHT: ELECTRICAL
Wiring Harness 68-69
Solenoid 69
Battery 70
Starter Relay 71
Alternator 72
Starter 73
Gauge Panel 74
Bulb Chart 75
Wiring Schematic in back pocket
SECTION NINE: TRIKES
Specifications 77
Chassis 78-80
Electronic Speedometer 80
BrakeSystem 81
Fuse Panel 82
Detent Cable 82
Fuel System 83-84
Shifting 85-86
Exhaust 87
Taillight Wiring 88-89
SECTION TEN: TROUBLESHOOTING
Engine 91-92
Lubrication System 92
Electrical System 92
Carburetor 92-93
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. v
Transmission 93
Brake 93
SECTION ELEVEN: ACCESSORIES
Mustang Seats 95-96
Windshields 97-98
Other Accessories 99-100
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 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 12-
MONTH 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 BH Part # Industry Part #
Engine Oil SB & BB 2280000 20W-50 Castrol
Oil Filter SB & BB 2280300 PF-454 AC Delco
Transmission Oil Bike 3370001 MX4T Mobil 1 Synthetic
Transmission Filter Bike 3370162 N/A (Clean & Reuse Filter)
Chart 1.1
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 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
First
300
miles
First
500
miles
Every
2500
miles
Every
5000
miles
Every
7500
miles
Every
10000
miles
Every
spring
or fall
Change engine oil X X X
Check condition of spark plugs
& replace if necessary X
Replace oil filter X X X
Inspect air cleaner & service as required X X X X X X X
Replace spark plugs Every 15,000 miles
Check & adjust belts X X X X X X
Check rear brake
pedal adjustment X X X X X X
Inspect brake fluid
level & condition X X X X X X
Check brake pad lining & discs for wear X X X X X X
Check antifreeze level & protection
strength X (1gal.
coolant)
Clean transmission filter &
change transmission oil X (bike
only)
X (bike
only)
Replace Magnetic Inline Transmission
Filter (Bikes Only) Replace at initial 5,000 miles, then every 20,000 miles
Check fuel valve, lines & fittings for leaks X X X X X X
Check oil lines and brake system for
leaks X X X X X X
Lubricate the front brake hand lever 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 First 500
miles Every 2500
miles Every 5000
miles Every 7500
miles Every 10,000
miles Every Fall or
Spring
Lubricate the throttle
cable x x x x
Check tightness of all
fasteners x x x x x x
Check tire pressure &
inspect tread x x x x x
Check engine speed
adjustment x x x x x
Check operation of
throttle controls x x x x x xx
Check operation of all
electrical equipment &
switches
x x x x x
Check auto. Transmission
fluid x (Fluid needs to be hot when checked- engine off & in upright level position)
Check battery and
clean/check connections x x
Check rear shock rubber
bushing adjustment x x
Check front fork bearing
adjustment x x x
Check front and rear
sealed wheel bearings. X
Check front and rear
sealed wheel bearings Every 20,000 miles replace if necessary
Change front fork oil x
Road test x x x x x xx
Date completed
Chart 1.2 continued
ADDITIONAL SERVICE INTERVAL CHART for TRIKES
Service to be performed Every 300
miles First 500
miles Every 2500
miles Every 5000
miles Every 7500
miles Every 10,000
miles Every Fall or
Spring
Lubricate drive u-joint,
transmission shifter
linkage, and all other rear
suspension components
x
x
Check rear axle lubricant
level x
Check tightness of all rear
suspension fasteners xx
Change rear axle lubricant x
Check transmission fluid
level x x
Change transmission fluid
and filter x
Adjust rear drum brakes xx
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 FRT REAR
GVWR……….1675 LBS. TIRE MT90B16 230/60-15
GAWRF………827 LBS. RIM 16” X 3 ½” 15” X 7”
GAWRR.……...848 LBS. 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 3 4
WORLD
MANUFACTURER
IDENTIFIER
(WMI)
VEHICLE
DESCRIPTOR
SECTION
CHECK
DIGIT MODEL
YEAR PLANT Manufacturer
Identifier if
<500
units/TR or
Sequential
Production
Number if
>500 units
/TR
Sequential
Production
Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 B 9 T B V C 3 2 N D 2 8 5 0 0 0
Chart 1.4
© Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved. 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
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 1-800-424-
9393 (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
This manual suits for next models
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