Boss Hoss Cycles Year 2005 Owner's Manual page 32

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.
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