9916575 1998-1999 Big Boss 6x6 Service Manual Chapter
Contents
1. 160 Valve Seat 1 5 Fuel Octane R4 M 2 87 Non Oxygenated or 89 Oxygenated CLUTCH AAA es tee PVT Bel Ar aa 3211077 Belt Width Projected 1 188 30 18mm Side Angle Overall 26 Outside Circumference 40 86 12 Center Distance Clutch Offset 10 12 254 5mm 0 5 12 7mm Secondary Spring Red Driven Helix Compound Spring Position Helix 2 Spring Position Sheave 2 ENGINE TYPE nka Aa ra 4 Cycle Single Cyl Displacement 498 cc BOIG ol D pes 3 625 92mm Stroke cr tore ts 2 955 75mm Valve Clearance In Ex Compression Ratio Cooling ssssssse Liquid Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure 1 6 JETTING CHART AMBIENT TEMPERATURE Below 0 F 0 to 40 F 40 to 80 F Above 80 F Below 18 C 18 to 5 C 5 to 26 C Above 26 C 0 900 Altitude Meters Feet 900 1800 1800 2700 2700 3700 Pilot screw in 1 2 turn CLUTCH CHART Clutch Spring Driven Shift Altitude Weight Helix Meters 0 900 Feet 0 3000 900 1800 10MH Blue Green 10BH Blue Green 3000 6000 1800 2700 6000 9000 10WH Blue Green 2700 3700 9000 12000 10RH Blue Green 0 006 0 006 TDC on compression GD POLARIS 1999 MODEL2. 70 97 716 a 35 48 55 76 80 110 12 E ARR SRN ORRNE PEN 50 69 urtica 75 104 IA 110 152 12 AO ae a ea 55 16 c puces idem SO COA atu ccce 120 166 Metric 6x1 0 72 78 In Ibs 8x 1 25 14 18 ft Ibs 10x1 25 26 30 ft Ibs To convert ft lbs to Nm multiply foot pounds by 1 382 To convert Nm to ft lbs multiply Nm by 7376 SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch lb ft Ib in Ib ft 0 74 8 65 36 14 1 48 17 30 36 88 2 21 25 95 37 62 2 95 34 60 38 36 3 69 43 26 39 09 4 43 51 91 39 83 5 16 60 56 40 57 5 90 69 21 41 31 6 64 77 86 42 04 7 38 86 51 42 18 8 11 95 16 43 52 8 85 103 81 44 26 9 59 112 46 44 99 10 33 121 11 45 73 11 06 46 47 11 80 47 21 12 54 47 94 13 28 48 68 14 01 49 42 14 75 50 16 15 49 50 89 16 23 51 63 16 96 52 37 17 70 53 11 18 44 53 84 19 18 54 58 19 92 55 32 20 65 56 06 21 39 56 80 22 13 57 53 22 87 58 27 23 60 59 01 24 34 59 75 25 08 60 48 25 82 61 22 26 55 61 96 27 29 62 70 28 03 63 43 28 77 64 17 29 50 64 91 30 24 65 65 30 98 66 38 31 72 67 12 32 45 67 86 33 19 68 60 33 93 69 33 34 67 70 07 35 40 70 81 z 3 OO COIN O H A O N io SS GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch Ib ft Nm Ib ft Nm 106 95 190 140 14 235 107 69 19
3. 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 7 8 9 7 8 14 1 8 1 12 1 1 8 7 1 1 8 12 1 1 4 7 1 1 4 12 1 1 2 6 1 1 2 12 1 3 4 5 1 3 4 12 2 4 1 2 2 12 2 1 4 4 1 2 2 1 2 4 2 3 4 4 3 4 27 64 29 64 31 64 33 64 17 32 37 64 21 32 11 16 49 64 13 16 7 8 59 64 63 64 1 3 64 1 7 64 1 11 64 1 11 32 1 27 64 1 9 16 1 43 64 1 25 32 1 59 64 2 1 32 21 4 21 2 2 3 4 DrillSize Decimal Equivalent Nearest Fraction GD POLARIS GENERAL INFORMATION GLOSSARY OF TERMS ABDC After bottom dead center ACV Alternating current voltage Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches Cl Cubic inches Clutch Buttons Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close Condenser Capacitor A
4. OF TERMS m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings Mechanical energy is converted to electrical energy in the stator mi Mile miles mm Millimeter Unit of length in the metric system 1mm approximately 040 Nm Newton meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow oz Ounce ounces Piston Clearance Total distance between piston and cylinder wall psi Pounds per square inch PTO Power take off PVT Polaris Variable Transmission Drive Clutch System qt Quart quarts RPM Revolutions per minute Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Reservoir Tank The fill tank in the liquid cooling system Resistance Inthe mechanical sense friction or load Inthe electrical sense ohms Both result in energy conversion to heat Right Side Always referred to based on normal operating position of the driver RPM Revolutions per minute Secondary Clutch Driven clutch on chaincase or jackshaft Seized Piston Galling ofthe sides of a piston Usually there is atransfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywhee
5. SPECIFICATIONS MODEL BIG BOSS 500 6X6 MODEL NUMBER A99AE50AA ENGINE MODEL EH50PLE06 ELECTRICAL Flywheel I D FF97 CDI Marking CU2557 Alternator Output 250 Watts Ignition Timing 30 BTDC 3500RPM 1 5 Spark Plug Gap NGK BKR5E 0 028 0 7mm Lights Head 12V 60W Grill 2 12V 27W Tail 8 26 watts Brake 26 9 watts Voltage Regulator LR39 Electric Start Standard SUSPENSION CHASSIS Body Style Gen Il Front Suspension MacPherson Strut Tow Capacity 1225 lbs 556 2kg Turning Radius 98 248 9cm Toe Out 1 8 1 4 3 6 35mm Ground Clearance 5 5 13 97cm Front Vertical Travel 6 25 15 88cm Rear Suspension Swing Arm w Scissor Stabilizer Rear Travel 7 25 18 42cm Rear Shock 25mm Bore Gas Bag Shock Adjustment Cam Center Suspension Progressive Rate Swing Arm Center Travel 5 12 7cm Center Shock 1 Bore Shock Adjustment Cam TIRES Tire Size Front 25x8 12 Tire Size Rear 25x 11 10 Tire Size Center 25x 11 10 Tire Pressure F R 5 5 5 lbs Total Width 46 116 84cm Total Length 103 261 62cm Total Height 47 119 38cm Wheel Base 75 190 5cm Weight Dry 870 lbs 395kg OPTIONAL SUSPENSION SPRINGS SOFT GENERAL INFORMATION FLUID Capacity
6. storage reservoir for DC voltage Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO DCV Direct current voltage Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt ft Foot feet Foot Pound Ft Ib A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon HP Horsepower ID Inside diameter in Inch inches Inch Pound In Ib 12 in lbs 1 ft Ib 2 kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or Itr Liter Ibs in i Pounds per square inch Left Side Always referred to based on normal operating position of the driver GENERAL INFORMATION GLOSSARY
7. 1 ira 4688 SOM dida 4844 Uli 5 33 04 viet ee teste pe EI O 5156 17 82 La 5313 Bcc 5469 9 16 5625 ST OA iine turbare bancs 5781 1932 n nos 5938 39 94 0 ioter eee 6094 O t 625 41 04 dada 6406 21 32 2 6563 43 64 obesse E oes 6719 11 16 6875 AO maa carl elena lune manele dare 7031 293 927 tidad 7188 AU ic 7344 MARA 75 49 64 cc 7656 26 32 A A 7813 51 64 7969 AA 8125 DU PO 8281 UI A stesso eae 8438 DOBA e AG 8594 Y O desee xen 875 BLOF zda nd ard to 8906 29 32 esses 9063 59 64 e 9219 15 16 9375 A A O 9531 31 32 cc 9688 A PPO PETE TA PU 9844 ednet 1 0 1 12 10 mm 0394 0787 1181 1575 1969 2362 2756 3150 3543 3937 4331 4724 5118 5512 5906 6299 6693 7087 1480 7874 8268 8661 9055 9449 9843 GD POLARIS GENERAL INFORMATION CONVERSION TABLE eem ce hg hoa EC Imperial pints Imp pt x 0 568 Liters l Imperia pints mp P Imperial quarts Imp qt x 1 137 Liters l l l TETO x RRM Mann C to F 9 C 40 5 40 F F to C 5 F 40 9 40 C Imperial quars mp 9 CC inch GENERAL INFORMATION SAE TAP DRILL SIZES 5 44 6 32 6 40 8 32 8 36 10 24 10 32 12 24 12 28 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 3 x 50 1 14 1
8. 1 140 88 236 108 43 192 141 62 237 109 16 193 142 36 238 109 90 194 143 09 239 110 64 195 143 83 240 111 38 196 144 57 241 112 12 197 145 31 242 112 85 198 146 04 243 113 59 199 146 78 244 114 33 200 147 52 115 07 201 148 26 115 80 202 149 00 116 54 203 149 73 117 28 204 150 47 118 02 205 151 21 118 75 206 151 95 119 49 207 152 68 120 23 208 153 42 120 97 209 154 16 121 70 210 154 90 122 44 211 155 63 123 18 212 156 37 123 92 213 157 11 124 65 214 157 85 125 39 215 158 58 126 13 216 159 32 126 87 217 160 06 127 60 218 160 80 128 34 219 161 53 129 08 220 162 27 129 82 221 163 01 130 56 222 163 75 131 29 223 164 48 132 03 224 165 22 132 77 225 165 96 133 51 226 166 70 134 24 227 167 44 134 98 228 168 17 135 72 229 168 91 136 46 230 169 65 137 19 231 170 39 137 93 232 171 12 138 67 233 171 86 139 41 234 172 60 GENERAL INFORMATION DECIMAL EQUIVALENTS A PAA Le 0156 EA an ne 0312 3 64 0469 1 16 Lees 0625 DIDA ao tatiana cts 0781 3 82 2 0938 74 57 Ac 1094 1 8 uo otros 1250 a ked aaa Ades 1406 O82 Foo LM eet te eS 1563 nla OA A PUNAN INANG 1719 16 1875 13 64 sss 2031 7 32 lll cee 2188 15 64 acess cesta 2344 14 25 A AA Aa 2656 ETE XA 2813 A brod ohon oe obe 2969 SO xis 3125 21 04 2 3 aN eerte Ooh EET 3281 11 82 aaa 3438 23 64 cc 3594 3 8 375 25 64 3906 19 92 eritis 4063 27 04 intu RARAS 4219 TING 1 eee 4375 pcr 453
9. A Engine Oil 2 qts 1 9L PP4 Brake Hand sse Dot 3 Brake Foot aaa Dot 3 Front Hubs AWD N A Shift Selector Box Lubricant Key PP6 Polaris Premium 60 40 Antifreeze Coolant PPS Polaris Premium Synthetic Gear Case Oil PP4 Polaris OW 40 Synthetic Engine Lubricant DRIVE TRAIN Chain Type 520 O Ring 6 64 1 5 13 1 Gear Reduction Low Gear Reduction Rev Gear Reduction High 3 29 1 Front Drive Ratio 11 22 68P Center Drive Ratio 11 24 72P Final Drive Ratio 12 42 88P Axle to Axle 30 30 116P Brake Hand Single Lever Hyd Disc Brake Auxiliary Foot Hydraulic LOAD CAPACITY Front Rack 75 Ibs Rear Box 800 Ibs Tongue Weight 35 Ibs Tow Hitch Std STANDARD FIRM Rear Compression Spring 7041204 067 7041303 067 N A Option 190 Ib in Standard 250 Ib in Mid Compression Spring N A 7041305 067 Standard 60 Ib in Front Strut Spring 7041375 067 7041450 067 Option 64 113 Ib in Standard 101 Ib in GD POLARIS 1 5 GENERAL INFORMATION 1999 MODEL SPECIFICATIONS MODEL BIG BOSS 500 6X6 MODEL NUMBER A99AE50AA ENGINE MODEL EH50PLE06 CARBURETION TYP dna mba BST 34 Mikuni Main Jet 140 Pilot Jet 40 Jet Needle 4D33 3 Needle Jet Q 6 Throttle Valve 100 Pilot Screw 2 Pilot Air Jet
10. CHAPTER 1 GENERAL INFORMATION Model Identification o ooooooooo 1 1 Serial Number Location nnna 1 1 Machine Dimensions lt 1 2 1 3 Specifications 1998 Big Boss 500 6x6 1 4 1 5 Specifications 1999 Big Boss 500 6x6 1 6 1 7 Publication Numbers a 1 8 Paint CodeS ositos 1 8 Standard Torque Specifications 1 9 Torque Conversion Table 1 10 1 11 Decimal Equivalent Chart aa 1 12 Unit of Measure Conversion Table 1 13 Tap Drill Charts 3 SAA te Rat 1 14 Glossary of Terms a 1 15 1 16 GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service Machine Model Number Identification A 98 AE 50AA pa Ja Emissions amp Year Designation Basic Chassis Model Option Designation Engine Designation ENGINE DESIGNATION NUMBERS 50 EH50PLE06 Single L C SOHC 4 Stroke Electric Start VIN IDENTIFICATION Vehicle Identifier Body Style Emissions Model This could be either Engine Year Individual Serial No a number or a letter Powertrain Check Digit Plant No ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine be sure to refer to the engine model number and serial number This information can be found on the sticker applied to the recoil housing on the right s
11. TDC 3500RPM 1 5 Spark Plug Gap NGK BKR5E 0 028 0 7mm Lights Head 12V 60W Grill 2 12V 27W Tail 8 26 watts Brake 26 9 watts Voltage Regulator LR39 Electric Start Standard SUSPENSION CHASSIS Body Style Gen Il Front Suspension MacPherson Strut Tow Capacity 1225 lbs 556 2kg Turning Radius 98 248 9cm Toe Out 1 8 1 4 3 6 35mm Ground Clearance 5 5 13 97cm Front Vertical Travel 6 25 15 88cm Rear Suspension Swing Arm w Scissor Stabilizer Rear Travel 7 25 18 42cm Rear Shock 25mm Bore Gas Bag Shock Adjustment Cam Center Suspension Progressive Rate Swing Arm Center Travel 5 12 7cm Center Shock 1 Bore Shock Adjustment Cam TIRES Tire Size Front 25x8 12 Tire Size Rear 25x 11 10 Tire Size Center 25x 11 10 Tire Pressure F R 5 5 5 lbs Total Width 46 116 84cm Total Length 103 261 62cm Total Height 47 119 38cm Wheel Base 75 190 5cm Weight Dry 870 lbs 395kg OPTIONAL SUSPENSION SPRINGS SOFT GENERAL INFORMATION FLUID Capacity Type Fuel Tank 3 5 gals 13 2L Injector Oil N A aie Coolant 2 25 gts PP6 Transmission 20 oz PPS Gearcase Oil Front N A Gearcase Oil Center N A Gearcase Oil Rear N
12. Type Fuel Tank 3 5 gals 13 2L Injector Oil N A aie Coolant 2 25 gts PP6 Transmission 20 oz PPS Gearcase Oil Front N A Gearcase Oil Center N A Gearcase Oil Rear N A Engine Oil 2 qts 1 9L PP4 Brake Hand sse Dot 3 Brake Foot aaa Dot 3 Front Hubs AWD N A Shift Selector Box Lubricant Key PP6 Polaris Premium 60 40 Antifreeze Coolant PPS Polaris Premium Synthetic Gear Case Oil PP4 Polaris OW 40 Synthetic Engine Lubricant DRIVE TRAIN Chain Type 520 O Ring 6 64 1 5 13 1 Gear Reduction Low Gear Reduction Rev Gear Reduction High 3 29 1 Front Drive Ratio 11 22 68P Center Drive Ratio 11 24 72P Final Drive Ratio 12 42 88P Axle to Axle 30 30 116P Brake Hang Single Lever Hyd Disc Brake Auxiliary Foot Hydraulic LOAD CAPACITY Front Rack 75 Ibs Rear Box 800 Ibs Tongue Weight 35 Ibs Tow Hitch Std STANDARD FIRM Rear Compression Spring N A 7041303 067 N A Standard 250 Ib in N A Mid Compression Spring Front Strut Spring 7041375 067 7041450 067 7041696 067 Option 64 113 Ib in Standard 101 Ib in Option 140 190 Ib in GD POLARIS N A 7041305 067 Standard 60 Ib in 1 7 GENERAL INFORMATION PUBLICATION NUMBERS Model No Owner s Parts Parts Service Manual Manual Micro Fiche PN M
13. anual PN PN 1998 Big Boss 500 6x6 A98AE50AA 9914720 9914639 9915239 9916575 1999 Big Boss 500 6x6 A99AE50AA 9914919 9914920 9915651 9916575 When ordering service parts be sure to use the correct parts manual PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER 1998 99 Big Boss 500 6x6 Eddie Bauer Green 44931 P 195 Springs 1998 99 Big Boss 500 6x6 Aluminum N A N A Rims 1998 99 Big Boss 500 6x6 Eddie Bauer Green 44931 P 195 Rack A Box FRAME COLOR All P067 Medium Gloss Black 9440 8520147 Order direct from Midwest Industrial Coatings 952 942 1840 Mix as directed GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section for torque values of fasteners before using standard torque DUE Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in Ibs Nm 10 O BB AA 43 5 0 AG 60 6 9 10 BO Nka Baa ANA 3T FO eee ee SN 68 7 8 Torque ft Ibs Nm 114 Dr aane nones 517 SOS RE EL a AAA 12 16 14 A oe Oe ee EM GL omer Sim A EU 10 14 A 14 19 5 16 15 UMP PERMET 1115 econ doen imd ccd 210 A ARRA PA 25 35 5 16 OW 19 AG CRON 19 96 010 obras 29 40 38 jo PT AA BOAO z cene eech 45 62 38 7 RR e RENE RENE S548 secte 50 69 7A6 dd ues 30 40 2 50 69
14. ide of engine A An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification The machine serial number is stamped on the lower left side of the frame tube B TRANSMISSION I D NUMBER LOCATION The transmission I D number is located on top of the transmission right side of machine GENERAL INFORMATION MACHINE DIMENSIONS p j l 1 mes 46 NEN 116 8 103 261 6 7 cdam 13 3 4 P x PT Pa NE YEN 27 1 2 69 8 SIDE 75 190 5 1 2 GENERAL INFORMATION MACHINE DIMENSIONS 110 4 43 1 2 LC A POLARIS E 121 2 47 3 4 SEC e EE BE 106 41 3 4 fi TNT i a Ht ll m MODA 82 5 32 5 REAR 88 5 34 7 8 115 5 45 1 2 1 3 GENERAL INFORMATION 1998 MODEL SPECIFICATIONS MODEL BIG BOSS 500 6X6 MODEL NUMBER A98AE50AA ENGINE MODEL EH50PLE06 CARBURETION Types aan mba BST 34 Mikuni Main Jet 140 Pilot Jet 40 Jet Needle 4D33 3 Needle Jet Q 6 Throttle Valve 100 Pilot Screw 2 Pilot Air Jet 160 Valve Seat 1 5 Fuel Octane R4 M 2 87 Non Oxygenated or 89 Oxygenated CLUTCH AAA es tee PVT Bel Ar aa 3211077 Be
15. l supporting the battery charging coils TDC Top dead center Piston s most outward travel from crankshaft Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle 116 SE POLARIS
16. lt Width Projected 1 188 30 18mm Side Angle Overall 26 Outside Circumference 40 86 12 Center Distance Clutch Offset 10 12 254 5mm 0 5 12 7mm Secondary Spring Red Driven Helix Compound Spring Position Helix 2 Spring Position Sheave 2 ENGINE TP s ete Ere 4 Cycle Single Cyl Displacement 498 cc Boren cia abad ana 3 625 92mm SI CAR 2 955 75mm Valve Clearance In Ex Compression Ratio COOLING uz foe ce 4 een nag Liquid Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure 1 4 JETTING CHART AMBIENT TEMPERATURE Below 0 F 0 to 40 F 40 to 80 F Above 80 F Below 18 C 18 to 5 C 5 to 26 C Above 26 C Meters 0 900 Altitude 900 1800 1800 2700 2700 371 Pilot screw in 1 2 turn CLUTCH CHART Clutch Driven Altitude Spring Helix Meters 0 900 Feet 0 3000 Blue Green 200 1800 Blue Green 8000 6000 n Blue Green 2700 3700 9000 12000 Blue Green 0 006 0 006 TDC on compression GD POLARIS 1998 MODEL SPECIFICATIONS MODEL BIG BOSS 500 6X6 MODEL NUMBER A98AE50AA ENGINE MODEL EH50PLE06 ELECTRICAL Flywheel I D FF97 CDI Marking CU2557 Alternator Output 250 Watts Ignition Timing 30 B
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