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Boss Hoss · Hydraulic-lifter four-stroke eight, wet sump, separate gearbox oil, belt drive

BHC-3 (6200 cc)

Library entry covers 2005-2017

28 factory 46 guideline

Published source

Boss Hoss Cycles Year 2005 Owner's Manual, Service Charts 1.1-1.2 pp.3-5

74 items for a 2005 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Hydraulic lifters (no routine clearance adjustment)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2005 Boss Hoss BHC-3 (6200 cc)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 300 mi

4 items

Check tightness of all fasteners

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 300 mi and in every mileage column
Road test

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every column
Check operation of throttle controls

Controls and cables

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 300 mi, in every mileage column and every fall or spring
Lubricate the throttle cable

Controls and cables

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 300 mi, first 500 mi, every 2,500 mi and every fall or spring

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,500 mi

13 items

Change engine oil

Engine

Factory

Factory: Initial service at 500 and 2,500 mi (Chart 1.1). Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X at first 500 mi, every 2,500 mi and every fall or spring. 20W-50 (Castrol)
Check & adjust belts

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Check engine speed adjustment

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Check operation of all electrical equipment & switches

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Replace oil filter

Engine

Factory

Factory: Initial service at 500 and 2,500 mi (Chart 1.1). Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X at first 500 mi, every 2,500 mi and every fall or spring. AC Delco PF-454
Check fuel valve, lines & fittings for leaks

Fuel and air

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Inspect air cleaner & service as required

Fuel and air

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column and every fall or spring
Check brake pad lining & discs for wear

Brakes

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Check oil lines and brake system for leaks

Brakes

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Check rear brake pedal adjustment

Brakes

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Inspect brake fluid level & condition

Brakes

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column. DOT 5 silicone
Lubricate the front brake hand lever

Brakes

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column
Check tire pressure & inspect tread

Wheels and tires

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X in every mileage column

Every 3,000 mi or 12 months

7 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 5,000 mi or 12 months

3 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline
Inspect drive belt, pulleys and tension

Final drive

Guideline

Every 5,000 mi

5 items

Check battery and clean/check connections

Ignition and electrics

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 5,000 and 10,000 mi
Clean transmission filter & change transmission oil (bike only)

Primary and gearbox

Factory

Factory: Initial service at 500 and 2,500 mi (Chart 1.1). Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X at first 500 mi and every 5,000 mi
Check front fork bearing adjustment

Front end

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X at first 500 mi, every 5,000 and 10,000 mi
Check rear shock rubber bushing adjustment

Rear suspension and frame

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 5,000 and 10,000 mi
Check front and rear sealed wheel bearings

Wheels and tires

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 5,000 mi; every 20,000 miles replace if necessary

Every 6,000 mi or 12 months

7 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 10,000 mi

1 item

Change front fork oil

Front end

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every 10,000 mi. 10W fork oil

Every 12,000 mi or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace spark plugs

Engine

Factory

Factory: Every 15,000 miles

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 20,000 mi

1 item

Replace magnetic inline transmission filter (bikes only)

Primary and gearbox

Factory

Factory: Replace at initial 5,000 miles, then every 20,000 miles

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 50,000 mi

1 item

Replace drive belt (wear or damage based)

Final drive

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

2 items

Check antifreeze level & protection strength

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every fall or spring (1 gal. coolant)
Check condition of spark plugs & replace if necessary

Engine

Factory

Factory: Regular Service Interval Chart columns: first 300 mi, first 500 mi, every 2,500, 5,000, 7,500 and 10,000 mi, every fall or spring. X every fall or spring

Every 2 years

4 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

1 item

Check and adjust alternator belt

Engine

Factory

Factory: Initial service at first 500 and 2,500 miles (Chart 1.1)

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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