Forza BOSS User manual

FORZA BOSS
OUTBOARD MOTOR

Table of Contents
1. Safety Information..………………………………………………......1
2. Product Features and Operation…................…………………………2
3. Technical Features and Specifications...…….………………………..
4. Overall Dimensions…………………..……………………………….8
5. Installation.........…………………....….……………………………...8
. Usage and Operational Warnings.…….………………………………8
7. Troubleshooting...........................……………………………………18
8. Safety precautions and accident handling……………………………20
9. Maintenance …………………………………………………………21
10. Delivery/Storage..…………………………………………………...22
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1. Safety Information
This outboard motor‘s engine is made of a single cylinder, four stroke, vertical shaft.
The machine has an advanced design, compact structure, light weight, reliable
performance, portable operating and maintenance. It is widely used in river, lake and
transport service.
●Before operating this outboard motor, please read entire manual and all warning
labels.
●Read all the manuals supplied by the boat manufacturer.
●Read all the labels both of outboard motor and boat. If these labels are broken,
illegible or get lost, please contact your dealer for a replacement.
●According to the danger level, the safety warning title in this manual uses the
following methods and warning marks.
Dangerous!
It means taking attention to high risk.
Warning!
It means taking attention to poor risk.
Attention!
It means taking attention to mild risk.
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2. Product Features and Operation
overall structure and main spare parts.①
1.Gasoline engine 2. Shifting
handle 3.Clamp bracket
4.Transmission shaft box
5.Gearbox . Propeller 7. Handle
8.Choke valve handle
9. Engine stop button
10. Operating handle
11. Starter handle
Figure 1 main spare parts
Operating handle assembly⑴
If you want to change the direction, you need to move the operating handle to
make it turn based on your intended direction. See Figure 1
Throttle handle⑵
Throttle handle is located on the end of operating handle assembly. Turn
counterclockwise to speed up, and clockwise rotation will slow down, see Figure
2 Figure 2
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Engine stop button⑶
If you want to stop the motor, please disconnect cable clamp. When you connect
the cable clamp, it can be restarted. See Figure 3.
Figure 3
Attention!
Boss outboard motor will not work when you remove the clamp.
Choke valve handle⑷
Before starting, you need to add fresh clean fuel. Then, you need to push the
choke valve handle to “Start”. Once started, you should push the choke valve handle
to “Operate” quickly. See Figure 4.
Figure 4
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(5)Starting handle
If you want to start the engine, first pull the handle gently until you feel resistance.
Then you may pull the handle quickly to start the engine. see Figure3.1.
( )Shifting handle
Move the handle down to the low position, Figure 5 , the outboard motor goes
forward, the propeller begins rotating and the boats goes Forward
Move the handle up to the high position,Figure 5, the outboard motor goes back,
and the propeller inverts, the boat goes in Reverse.
Move the handle to the middle,Figure 5, the outboard motor idles, and the
propeller stops, the boat loses driving force(Neutral).
Attention!
1. To ensure safety and easy starting, you need to start the engine on the null.
2. If you want to shift, motor must be at a stable idle and not at high speed.
Figure 5
(7)Handle
There are steel pipe handles on the head of cylinder on the Boss outboard motor.
You can use your hands to carry easily. See Figure .
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Figure
.Boss Outboard motor operating procedure②
See Figure 1, after starting the engine, transmission shaft turns with crankshaft by
the spline in the crankshaft. Turning the transmission shaft to Drive, the active
bevel gear turns, meshing with the passive bevel gear on the output shaft. There are
two passive bevel gears on the output shaft which can be paired with the active
bevel gear on the shaft. It can make the output shaft turn with different passive
bevel gears or don’t turn with them determined by shift handle position.
3 Boss outboard motor electrical schematic diagram.
Figure 7
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3. Technical Features and Specifications
Model 1P70
Gasoline
Engine
Technology
parameter
Performance index Specifications
stroke Cylinder, air-cooling, four stroke
Cylinder bore*stroke(mm) 70*45
Displacement(cm³) 173
Ma output power/rotate speed (kw/r/min) 4.4/3 00
Max torque/rotate speed N.m/r/min 8/3000
Highest stable rotate speed( r/min) 3500±100
Lowest no-load stable rotate speed (r/min) 1700±50
Lowest fuel consumption g/kw.h 420
Normal temperature start performance(s) ≤30
Heat engine start performance(s) ≤30
Spark model F RTC
Spark gap 0.7~0.8
Ignition system TCI
Start system Recoil start
Start with strong way Choke valve
Valve gap(cold)(mm) Intake/exhaust0.05~0.1
Wet weight 14KG
Size(mm) 430*380*410
Model Forza Boss Outboard Motor
Performance index Specification
Standard power&speed kw/r/min 3.75/2000

Gasoline
Engine
Technology
parameter
full throttle rotate speed r/min 2400±100
Size(mm) 480*400*1180
Weight(kg) 28.5kg
Hook height(mm) 47.5
Applicative tail- board vertical
height(mm)
503-530
Operating method Steering handle
Transmission method Gear
Gear ratio 1:1.5(1 /24)
Cooling method Forced cooling
Exhaust silence way Muffler keep in straight
Lifted method Manual
Propeller size 3-7 1/2’*5
Fuel 90# unleaded gas
Fuel tank capacity 1.2L
Engine oil 4 stroke engine oil SAE15-40
Lubricating system Splash lubrication
Max fuel consumption kg/h 1.25
Engine lubricant 0. L
Gear oil type Hypoid gear oil SAE#90
Gear oil 0.1L
grease General purpose lithium lubricating
grease(GB7324-1994)
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4. Overall Dimensions
Figure 8
5. Installation
(1)Choose matched outboard motor and boat
Before using the outboard motor, you should make sure that the power of the
outboard motor is compatible with the boat and the engines, it is usually subject to
when it’s fully loaded, the outboard motor runs full throttle and the maximum
speed range that the engine reaches.
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Warning!
When the boat doesn’t match outboard motor or the power is exceeded, it will lead
to a boat that can’t move stably, and it may put boat and people in danger, or cause
premature damage to engine.
(2) Installation of the outboard motor should let the boat get a good balance.
Otherwise, the boat will be angled wrong and can’t move easily. Always install the
outboard motor on the center line of the boat. See Figure 9
Figure 9
(3)You can install the outboard motor permanently to the boat transom. It should
only be done by experienced repair personnel. Please refer to your Dealer.
(4)Install outboard motor correctly by positioning the eddy plate between the hull
bottom and 25mm(1 inch) under the hull bottom, see Figure 9.
(5)When installing the outboard motor on the transom, you should tighten both
clamp screws equally and safely. Since the clamp screw may get loose due to the
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vibration of outboard motor, you should take attention to ensure the clamp screws
are tight during operation. Clamping system Figure 9
Warning!
1 Incorrect installation will cause the risk of instability and loss of control.
2 Installation by experienced personnel is recommended.
3 Clamp screw becoming loose will make the outboard motor dangerous and
lead to loss of control or serious damage, You should make sure that clamp
screws are tight during operation.
(5)Outboard motor trim
The trim angle of the outboard motor influences the bow’s location in the water.
Correct trim angle ensures maneuverability and fuel economy, correct trim angle
depends on the boat model and boat load. Boss outboard motor clamp bracket trims
5°，you can adjust the angle of the outboard motor by moving the handle on the
clamp bracket down. When the index plate aligns at the hole of swivel mount,
loosen the handle, make the handle shaft into index plate and the hole of swivel
mount. If you want to fine tune the angle, remove lock, reinsert in the appropriate
hole aligning with the metal plate grooves. There are grooves, the turning angle
between each groove is 4°. Adjustment subject to level angle of boat of 3~5° ，See
Figure 10
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Figure 10
Warning!
When the outboard motor is running over trim,(up or down) both will lead to
instability and difficult handling, increasing risk of accident. If the boat is unstable
or hard to handle, you should lower the running speed or adjust the trim angle
again.
( )Check before running.
.1 Check ☆engine stop switch
●Make sure engine stop switch is normal.
●Make sure the switch is on “open” (clamp installed), then start the outboard
motor. Otherwise, you cannot start the motor. See Figure 3
Attention!
1. Removing the clamp from switch will prevent starting the engine.
2. Install the clamp to the switch, so you can start the outboard motor. Operator
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must fasten the stay rope on clothes, arm or leg for safety. If operator trips or falls
or leaves the tiller when operating, the stay rope will pull out the clamp, and the
engine will shut off preventing the operator from losing control.
.2 Check the fasteners and power train☆
●Check connection and fasteners are not loose or damaged.
●Check if propeller and clamp nut is loose or damaged. Make sure the end of
cotter in the hole is bent, see Figure 11
●Check if power train is normal with no damage or defects.
●Check if connection with the boat is dependable or not.
Figure 11
(7) Running Outboard Motor
7.1 Outboard Motor Break-in
New outboard motor needs 10 hours of breaking in so that the engine parts’
surfaces are sealed and seated properly .
Warning!
Before starting outboard motor, make sure it is in good repair, there are no
problems to operate, and there is no barrier in the nearby water area and all safety
measures are taken.
7.2 start outboard motor
●Boss Outboard Motor Stop Button clamp installed.
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●turn the throttle handle to increase engine speed.
●pull the choke valve handle to “start”, see Figure 4
●pull the handle slowly until you feel resistance, then pull strongly and rapidly,
starting the engine. If you fail to start, wait 5~10seconds, repeat procedure until
engine starts normally.
●After the outboard motor starts, let go of the start handle quickly.
7.3 Warming Up Outboard Motor
When outboard motor starts, you should operate it 5minutes at idle to warm up the
engine. After warm up, open the choke valve to allow it to continue running.
. Usage/Operational Warnings
1. Safe operation
●Every time before starting outboard motor, you must inspect motor to prevent
injury and machine damage.
●Children and pets must keep away from operation area due to risk of injury by
outboard motor.
●Be familiar with stopping machine quickly and all the controls and operations.
Persons who are not trained should not use outboard motor.
●Don’t put flammable goods like gas or matches close to the working outboard
motor.
●When the outboard motor works, the muffler is hot, and it will last some time
after stop working. Don’t touch it when it’s hot.
●The exhaust gas from the outboard motor includes carbon monoxide, keep head
and face away from exhaust port.
●Don’t put anything on the gasoline engine.
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2.Check lubrication oil
Warning!
Outboard motor will get serious damage if you operate it without proper lubrication oil.
2.1 Check lubrication oil
When you check the lubrication oil, you should stop engine, and let the engine be
in the vertical position, see Figure 12
Figure 12
●Remove the oil level gauge in the oil filler hole.
●Wipe oil level gauge dry and put into oil filler hole, but don’t rotate.
●If oil level is low, add recommended lubricant to make the oil level between
the high level and low level.
●Recommended engine oil
When the temperature is high than -15℃，SAE10W-30 four stroke gasoline
engine oil. When the temperature is lower than -15℃，SAE5W-30 four stroke
gasoline engine oil.
Warning!
1. Use lubrication oil without cleaning agents or two stroke lubrication oil, it will
shorten the life of engine.
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2. The engine is without oil when it leaves factory.
2.2 Check Gear Oil
●Owner needs to add hypoid gear oil(SAE#90) before first startup, The oil
capacity is 0.1L.
●Methods of filling and changing gear oil
(1)Put the outboard motor vertically, remove the oil filling port screw and air hole
screw, use oil bottle to fill gear oil slowly, then tighten the filling port screw and
air hole screw, Figure13.
(2)When you check gear oil, put the outboard motor vertically, loosen purge cock
until there is a little oil leakage. Observe the color of the gear oil to make sure
whether there is water included. Change gear oil as needed.
(3) When you check gear oil, put the outboard motor vertically, loosen purge cock
until gear oil is all flowing clean, use oil bottle to fill hypoid gear oil, then tighten
the filling port screw and air hole screw.
Attention!
1. We have added gear oil when outboard motor leaves factory.
2. Change gear oil regularly and also check the o ring, replace if broken.
Figure13
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3.Fuel
3.1Fill fuel
Check the fuel tank to ensure there is enough fuel. Take spare fuel and check
whether fuel path is open and no leakage.
(1) put the outboard motor vertically, open the fuel tank.
(2) Add fuel carefully to prevent spilling.
(3) After filling, close fuel tank cover and wipe dry any spilled fuel.
3.2 Recommended to use 87+ Octane unleaded gasoline.
Warning!
1. When you fill the fuel, outboard motor must be stopped, and should be done in
an open area.
2. No smoking or any other flame when filling fuel and in fuel storage.
3. Don’t fill too much fuel(no fuel in aperture. When finished, tighten down the
fuel tank cap.
4. Don’t spilled oil when filling, the petroleum may burn. You must make sure the
spilled oil has been cleaned thoroughly before starting.
5. Avoid contact or breathing in gasoline or oil, don’t let children contact gasoline
or oil.
. Don’t use engine oil, oil mixture or dirty gasoline.
7. Avoid getting dust, debris or water into fuel tank.
Dangerous!
The gasoline is flammable, in some cases, it can explode.
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4.Ship safety.
(1) people on the boat must wear life jacket.
(2) Forbid overload, it will have an effect on boat operation and cause accident.
(3) Operate carefully and keep safe speed, keep safe distance with people, things
and other boats in the water.
(4) Avoid entering water area which has barrier or shallow water area.. When
entering unfamiliar water area, the engine should run in medium-low speed.
5.Safe operation
(1) After outboard motor starts and preheats, you should turn the throttle handle
to speed up throttle slowly.
(2) You should shift when it runs idling, after shifting, turn the throttle handle to
speed up slowly.
Warning!
When outboard motor starts or runs, don’t touch ignition coil, spark plug or other
circuit components in case of electric shock.
.Boat backwards
take shift handle to extreme position,(Figure 5) make outboard motor in reverse
condition, then increases throttle to backward.
Warning!
When the boat backwards, the rotate speed of outboard motor can’t exceed 3/4
standard rotate speed.
7.Boat runs in shallow water
Warning!
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When boat runs in shallow water, you must make outboard motor in low speed,
maybe it’s necessary for you to adjust lifted device. When the water is shallow,
you have to stop running to lift to pass, or you may damage the outboard motor.
8.Run in other environment.
（1）After running in sea or in serious acid generation environment, in order to
reduce corrosion of outboard motor, you must use fresh water to wash
outboard motor surface.
（2）Try best to avoid run the machine in muddy water, meanwhile, in order to
reduce the damage of propeller or other spare parts in high speed rotating,
it’s better to run in low speed.
9.Stop machine
Before stopping the machine, you should firstly make it run some minutes in
idling or low speed, it mustn’t run in high speed and stop machine at once. Stop
machine process:
(1) turn the throttle handle back slowly, make the outboard motor in idling
condition for some minutes(put the gears in null)
(2) pull stop switch( pull clip) until outboard motor stopping running.
7.Troubleshooting
Fault phenomenon Reason analysis solution remark
Starter fault Replace spare part or
check
Take down button clip Put on button clip in”
open”
Cold start,choke valve not in
“start” position Push choke valve to
“start” position
No fuel in tank Fill fresh fuel
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