FORZA BOSS OUTBOARD MOTOR

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1 FORZA BOSS OUTBOARD MOTOR

2 Table of Contents 1. Safety Information Product Features and Operation Technical Features and Specifications Overall Dimensions Installation Usage and Operational Warnings Troubleshooting Safety precautions and accident handling Maintenance Delivery/Storage

3 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. 1

4 2. Product Features and Operation ①overall structure and main spare parts. 1.Gasoline engine 2. Shifting handle 3.Clamp bracket 4.Transmission shaft box 5.Gearbox 6. Propeller 7. Handle 8.Choke valve handle 9. Engine stop button 10. Operating handle 11. Starter handle Figure 1 main spare parts ⑴Operating handle assembly 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 ⑵Throttle handle 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 2

5 ⑶Engine stop button 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. ⑷Choke valve handle 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 3

6 (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. (6)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 6. 4

7 Figure 6 ②.Boss Outboard motor operating procedure 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 5

8 3. Technical Features and Specifications Model Gasoline Engine Technology parameter 1P70 Performance index Specifications stroke Cylinder, air-cooling, four stroke Cylinder bore*stroke(mm) 70*45 Displacement(cm³) 173 Max output power/rotate speed (kw/r/min) 4.4/3600 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 F6RTC 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 6

9 full throttle rotate speed r/min 2400±100 Size(mm) 480*400*1180 Weight(kg) 28.5kg Hook height(mm) Gasoline Applicative tail- board vertical Engine height(mm) Technology Operating method Steering handle parameter Transmission method Gear Gear ratio 1:1.5(16/24) 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 0.6L Gear oil type Hypoid gear oil SAE#90 Gear oil 0.1L grease General purpose lithium lubricating grease(gb ) 7

10 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. 8

11 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 9

12 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 6 grooves, the turning angle between each groove is 4. Adjustment subject to level angle of boat of 3~5 See Figure 10 10

13 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. (6)Check before running. 6.1 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 11

14 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. 6.2 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. 12

15 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. 6. 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. 13

16 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. 14

17 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 15

18 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. 6. 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. 16

19 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. 6.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! 17

20 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 Replace spare part or check Put on button clip in open Starter fault Take down button clip Cold start,choke valve not in Push choke valve to start position start position No fuel in tank Fill fresh fuel 18 remark

21 Fail to start Polluted fuel Fill fresh fuel Fuel filter block Clean or change filter Spark plug dirty Check it,clean or change Spark plug fix wrong Check and fix again Ignition line damage Check the line is damage or loosen Ignition parts fault Replace part or overhaul High idling speed, Rotate speed waves, Auto stop Internal part damage Replace parts Scale on spark plug Check it and clean or replace Oil way blocking Check oil tube is bend or not Polluted fuel Fill fresh fuel Fuel filter block Clean or change filter Ignition parts fault Replace part or overhaul Spark plug gap abnormal Check and adjust Ignition line damage Check the line is damage or loosen Use wrong oil Check and replace oil Carburetor abnormal Replace parts or overhaul Over screw down tank Loose tank cap and or air hole block clean air hole Choke valve shaft in start Choke valve shaft in run Regulating mechanism abnormal Replace parts or overhaul Propeller damage Repair or replace Propeller off-gauge Fix correct propeller 19

22 Shipping abnormal Trim angle abnormal Adjust trim angle Outboard motor fixed wrong on the deck Fix again Hull bottom dirty Clean it Gearbox matter Over shock winds foreign Clean it Propeller damage Repair or replace Output shaft damage Replace Propellerwinds matter Take down and clean foreign Installation screws too loose Screw down 8.Safety precautions and accident handling 1. When you start the engines, please make sure there is no any barrier behind you. 2. When outboard motor starts or runs, please don t touch ignition coil, spark plug wire, spark plug cap and other circuit element to prevent electric shock. 3. When the outboard motor starts or runs, don t touch propeller or any other high-speed rotating parts. 4. Emergency action in emergency. When outboard motor crashes into something in the water it will lead to damage, please execute following procedures. (1) Stop machine at once. (2) Check if the outboard motor and boat are ok? (3) Let boat pull in to the shore slowly, check for damaged parts. If it is damaged, please change it. (4) Before continue using outboard motor, please check up it carefully, if it is in necessity, you can ask dealer to check up. Warning! 20

23 During running or dragging, any crash at all will lead to bad damage, and it will be dangerous for outboard motor to run. 9.Maintenance Periodic maintenance: item operation Each use Gasoline engine Check lubrication 20 hours oil level change Air purifier Spark plug 100hours or 1 year check clean Check&c lean Valve clearance overhaul Fuel tank &filter clean Fuel line check Gear oil change Note 1 Lubrication Fill grease Propeller/screw/cotter Check Change clutch Check change anode Stop change button/choke Check 21

24 valve button Change Fuel tank Check clean Attention! Don t paint on anode, or the anode will lose effectiveness. Check anode regularly, clean if dirty. 10.Transporting/Storage Attention! 1. When transporting and storing the outboard motor, please clean the fuel. 2. To prevent the gas in the engine entering into cylinder, don t place face down when transporting and storing. When placing on the side, you should put the fuel tank down on a pad, and make outboard motor one side higher than other side in case of play and damage. 3. Use fresh water to clean outboard motor surface. The place storing outboard motor must be dry, airy and no direct sunlight. 22

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