1998-1999 Polaris Big Boss 500 6x6 Repair Manual Clymer M362-2 Service Shop

Clymer manuals are the ultimate do-it-yourself guide for motorcycle, ATV, snowmobile, and personal watercraft maintenance and repair. Each manual is based on a complete teardown and detailed rebuilding of the specific model it documents. This book covers all major vehicle systems and shows you exactly how to carry out routine maintenance, restoration and servicing using easy to follow pictures, instructions, and diagrams, allowing you to save time and money by doing the work yourself.

This manual contains the following sections:

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals / Maintenance schedule / Battery / Tires and wheels / Periodic lubrication / Engine oil and filter change / Engine oil pressure test / Transmission oil change / Rear axle housing eccentric bearings / front hub wheel bearings / Front hub / Control cable lubrication / Periodic maintenance / Drive belt inspection / drive chain and sprocket lubrication and inspection / Rear drive chain adjustment 2 x 4 and 4 x 4 models / Center and front chain adjustment 94 x 4 models / Rear axle chain and axle-to-axle drive chain 6 x 6 models / Brake fluid check and fill / Auxiliary brake testing / Electronic throttle control adjustment / Air filter / Engine breather filter / Coolant change / Fuel filter / Front wheel toe out / rear axle housing / Unscheduled inspection and maintenance / drive axle sprockets / recoil starter / Engine tune-up / Valve clearance adjustment / Spark plugs

CHAPTER FOUR / ENGINE
Cylinder head and cover / Camshaft, cam chain sprocket and tensioner / Decompressor / Valves and components / Piston and rings / Cam chain, sprocket and guides / Crankcase / Crankshaft / Balancer shaft / Shaft end play measurement and shim selection / Oil pump / Oil system one-way check valve

CHAPTER FIVE / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor / Carb inspection, repair and adjustment / Throttle control and cable / Exhaust pipe and muffler / Fuel valve / Starting enrichment cable (choke) / Fuel tank

CHAPTER SIX / COOLING SYSTEM
Polaris variable transmission ( PVT ) cooling system / Engine cooling system / Hoses and clamps / Coolant pump / Engine gaskets and seals / Thermostat / Temperature sensors

CHAPTER SEVEN / CLUTCHAND DRIVE BELT SYSTEM
Drive unit / Drive pulley / Driven pulley / Drive belt / Clutch inner cover

CHAPTER EIGHT / TRANSMISSION
Mainshaft / Countershaft / Shift selector / Shift selector and linkage

CHAPTER NINE / FRONT DRIVE SYSTEM
Front hub and Hillard clutch / Front drive axle, boots and constant velocity CV joints / Center chain and sprockets / Front chain and sprockets / Front and center eccentric shafts

CHAPTER TEN / ELECTRICAL SYSTEM
Charging system / Alternator stator / Voltage regulator rectifier / Capacity discharge ignition CDI / Igntion coil / Ignition stator coils / Electric driving system / Starter drive gears / Starter solenoid / Lighting / Switches

CHAPTER ELEVEN/ FRONT SUSPENSION AND STEERING
Front wheel and hub / Strut / Control Arm / Tie rods / Handlebar / Steering shaft

CHAPTER TWELVE / REAR SUSPENSION
Wheels and hub /Rear axle / Center axle / Center eccentric / Drive chain / Driven sprocket / Shock absorber / Swing arm

CHAPTER THIRTEEN / BRAKES
Front middle and rear brake pads / front middle rear brake caliper / Output shaft caliper / Master cylinder / Brake discs / Fluid / Bleeding

CHAPTER FOURTEEN / BODY
Seat / Fuel tanks cover and side cover / Headlight cover / Fenders / Rack / Bumper / Cargo Box

INDEX

WIRING DIAGRAMS

Contact Sixity

• If you have any questions you may reach us via our eBay Contact Form.
• Our U.S.-based customer service agents are available Monday through Friday, 9am-5pm PT.

Checkout & Payments

• Sixity accepts payments from Visa, MasterCard, American Express, Discover, and PayPal.
• All orders delivered to California (CA) are charged the applicable sales tax.

Shipping

• This product features FREE SHIPPING.
• ORDERS PLACED BY 5PM ET WILL SHIP SAME DAY.
• All orders placed after 5pm ET will ship next business day (Monday - Friday) after payment is received. We will email you a tracking number when your order ships.
• Standard shipping via USPS First Class Mail / USPS Parcel Post / UPS Ground with Delivery Confirmation is $0.
• Expedited shipping via USPS Priority Mail with Delivery Confirmation is $2.99.
• Sorry, no local pickups available.
• We participate in the eBay global shipping program. Please see the 'Shipping and payments' eBay tab above for details on countries outside of the U.S. which we ship to.

Customer Satisfaction

• Sixity stands for value, selection and quality. If you are not satisfied with your purchase please contact us and we'll make it right!
• Our goal is to provide a 5-star experience with our detailed descriptions, clear communications, fast shipping times and low shipping charges.
• We give all our paying customers positive eBay feedback. Please work with us if you have a problem before leaving negative feedback.

Returns and Exchanges

Many of the parts we sell at Sixity only work with specific vehicles. Please double-check the accuracy of your order before purchasing. Check that the reference number, size, and placement are correct. Feel free to contact us with any product or fitment questions.

• If you receive an item other than the item you purchased, or an item that does not fit a vehicle as advertised, contact us within 30 days and we will ship out the correct item, and send you a prepaid mailing label to ship the original product back to us.
• If you receive the item you ordered, but decide you no longer want it, and the item is unopened, ship it back to us within 30 days and we will exchange it or issue a full refund, less the original shipping costs.
• If the item is opened, and has not been used or installed, ship it back to us and we will exchange it or issue a full refund, less the original shipping costs and a 15% re-stocking fee.
• If the item has been installed and/or used, we are unable to accept a return due to safety concerns with used parts.
• Please refer to our contact page for details on how and where to send a return.

About Sixity

Sixity, Inc. launched in 2006 and is based outside of Sacramento, California. We have a dedicated team of product engineers, technicians, and sales staff to bring you the best possible products for your ATV, motorcycle, snowmobile, car, or truck.

• Proud member of the Better Business Bureau, with an A+ Rating.
• Sixity is American-owned and operated.
• Please contact us with any questions about our business or products. All questions are handled locally by personnel in our California offices.