Boss Hoss Cycles Year 2005 Owner's Manual

2005 motorcycles/trikes

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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

Table of Contents

Summary of Contents for Boss Hoss Cycles Year 2005

Page 1 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.
Page 2: Warnings And Cautions
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.
Page 3: Safe Operating Rules
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.
Page 4: Table Of Contents
Front Forks 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 GM motors Ignition System 46-47 Exhaust 48-49 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 5 Chassis 78-80 Electronic Speedometer Brake System Fuse Panel Detent Cable Fuel System 83-84 Shifting 85-86 Exhaust Taillight Wiring 88-89 SECTION TEN: TROUBLESHOOTING Engine 91-92 Lubrication System Electrical System Carburetor 92-93 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 8: Safe Operating 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.
Page 9: Service Charts
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.
Page 10 Replace at initial 5,000 miles, then every 20,000 miles Check fuel valve, lines & fittings for leaks Check oil lines and brake system for leaks Lubricate the front brake hand lever Chart 1.2 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 11 Adjust rear drum brakes 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.
Page 12: Checking & Changing Oil
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.
Page 13 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.
Page 14: Vehicle Identification Number
DIGIT YEAR Identifier if Production IDENTIFIER SECTION <500 Number (WMI) units/TR or Sequential Production Number if >500 units 12 13 15 16 17 T B V C 3 Chart 1.4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 15: Warranty
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.
Page 16 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.
Page 19: Reporting Safety Defects
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:...
Page 22: Crash Bars, Driver Pegs
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.
Page 24: Kickstand And Water Pump
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.
Page 25: Inverted Front End
‘57’ trike and the truck trike. On these two models the mounting bracket is mounted to the top of the lower tree. Headlight (FIG. 2.5) © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 27: Bike Specifications
Rear…. 15” x 7” 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.
Page 28: Wheels
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.
Page 29 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.
Page 31 1420304 Right lower brake line 1530352R Brake disc mounting bolts Tire 1620003 Wheel 1610300B5 Right side brake caliper 1520300PA Left side brake caliper 1520301PA Right axle spacer 1420305 Chart 3.2 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 32 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.
Page 33 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.
Page 34: Rear Wheel
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.
Page 35 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. REAR AXLE COMPONENTS FIGURE 3-4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 36: Wheels
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.
Page 37: Brakes
• 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.
Page 38 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.
Page 39: Parking Brake
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.
Page 40: Drive Belt Tension
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.
Page 41 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.
Page 42 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.
Page 43: Front Forks
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.
Page 45: Handlebar Controls
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.
Page 46 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.
Page 47: 2004 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.
Page 48 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 Fig. 3.18 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 49 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 Fig. 3.20 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 52: Ignition System
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.
Page 53: Ignition Switch
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.
Page 54: Exhaust
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 Fig. 4-4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 55: Exhaust
• 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.
Page 57: Carburetor
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.
Page 58: Fuel Pump
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.
Page 59: Throttle Linkage
• 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.
Page 60: Fuel Tank
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 FIG. 5-4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 61: Fuel Petcock
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.
Page 64: Radiator & Fan
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 Fig. 6.3 Top radiator clamp Fig.6.4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 65: Fan Controller
The fans will come on at 180 degrees and will go off when a certain deviation to the bi- metal 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.
Page 67: Speed Transmission
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.
Page 68 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.
Page 69 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.
Page 70 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.
Page 71 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.
Page 72: Rear & Front Pulley
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 FIG 7-4 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 74: Wiring Harness
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 Fig. 9-2 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 76: Battery
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.
Page 77: Starter Relay
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.
Page 78: Alternator
• 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.
Page 79: Starter
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.
Page 80: Gauge Panel
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.
Page 81: Bulb Chart
57 – Taillight 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.
Page 83: Specifications
DO NOT EXCEED LOAD LIMITS. Exceeding the designed Gross Vehicle Weight Axle Rating (GVWR) and/or Gross 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.
Page 84: Chassis
350 Hydromatic transmission. The fiberglass trike body is also secured to the trike sub- frame by six bolts on the tail section of the frame (Fig. 8-1(3)). BOSS HOSS TRIKE CHASSIS Trike Sub-frame Fig. 8-1 Rod End Joint Alignment Fig. 8-2 © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 85 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.
Page 86: Electronic Speedometer
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.
Page 87: Brake System
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.
Page 88: 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.
Page 89: Fuel System
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.
Page 90 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) © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 91: Shifting
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. © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 92 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. © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 93: Exhaust
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. © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 97: Engine
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.
Page 98: Lubrication System
Engine ground wire loose or broken. Loose or broken wires in charging circuit. Alternator Charge Rate is Below Normal Weak battery. Excessive use of add-on accessories. Loose or corroded connections. CARBURETOR Carburetor Floods © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.
Page 99: Transmission
Brake pads badly worn (check owner’s manual under Brake Disc). Brake disc badly worn or warped. Brake fades because of heat build up. Excessive braking or brake pads dragging. Brake drags. Insufficient hand lever free play. © Copyright Boss Hoss Cycles, Inc. 2004. All Rights Reserved.

This manual is also suitable for:

2005 zz4 v8 2005 zz502 2005 zz502 v8

Boss Hoss Cycles Year 2005 Owner's Manual

Section One: Product

Section Two: Frame

Section Three: Chassis

Section Four: Engine

Section Five: Fuel

Section Six: Cooling System

Section Seven: Drive System

Section Eight: Electrical

Section Nine: Trikes

Section Ten: Troubleshooting

Section Eleven: Accessories

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Summary of Contents for Boss Hoss Cycles Year 2005

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