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Hello, great forum here!
I bought a non running 1998 Big Boss 500 6x6. The previous owners had done quite a bit of work to it. It has a new carburator, fuel pump, starter, adjusted the valves, new mid sprockets and chain. But they said it wouldn't run.
When I got it home I did get it to run, though not very well. It doesn't want to idle and there is a very loud knocking. I didn't run it very long. Hopefully it's just the clutch knocking. It has 4000 miles on the odometer. I popped off the valve cover and the cam looks ok, (it's not flat!) I haven't measured it yet. I still need to check compression.
There's no oil in the gearbox, found a crack in the case behind the output shaft. Looks like a mounting point?
I think I'll try and find a case half. I should probably tear apart the gear box first, it might be in bad shape inside. Who knows how long it was ran without oil. It does shift between all gears.
The rest of it is in fair condition, normal wear and tear for 4000 miles.
Sorry I don't have any pictures of it other than the cracks.
I should probably make sure the motor is good before I put money into the gearbox.
Any tips on things to look for would be appreciated!
picking up atv tomorrow, guys says motor is locked up. he thinks, anyway has been sitting for more than three years. Please understand i have not touched it yet but if his description is accurate im looking for suggestions on freeing it up before having to tear it down. I'm hoping to get some great info from the pros on Quadcrazy.
I am new to this forum and hope that someone out there can help me, I have an early Suzuki King Quad 300 (280cc) which starts intstantly every time but at about half revs or there abouts it starts spluttering and will not rev any higher, this fault is present whether choke is applied or not, some one suggested that silencer maybe be clogged so removed baffle but no improvement have removed carb and stripped 3 times but still no joy.
Any ideas would be most welcome.
By colin james
View File 1996-1998 Polaris Big Boss 6x6 Service Manual
This is the factory service manual for the Polaris big boss and other ATVs for the years 1996/1997/1998. You can download sections that you need or just download them all for the complete manual
Submitter colin james Submitted 05/02/2019 Category Polaris ATV
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