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colin james

1996-1998 Polaris Big Boss 6x6 Service Manual

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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


 

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    • By kgrant
      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!
       
      Thank you
       
       
    • By colin james
      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
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