Target User:
Polaris Big Boss owners, mechanics, and enthusiasts seeking to perform maintenance, repairs, and restoration.
Value Proposition:
Essential tool for saving money on repairs, understanding vehicle systems, and maintaining peak performance.
Competitor Manuals:
Competes with other OEM service manuals and aftermarket repair guides, offering comprehensive OEM-level detail.
Completeness:
Covers a wide range of Polaris models and years beyond the primary Big Boss focus, increasing its versatility.
Information Quality:
Official workshop manual content ensures accuracy and adherence to manufacturer specifications.
Additional Services:
Includes offer for free manual replacement if lost, adding significant customer value.
Primary Coverage:
1989-1992 Polaris Big Boss 4x6 and 6x6
Secondary Coverage:
1985-1995 Polaris ATVs including Scrambler, Trail Boss, Cyclone, Trail Blazer, Sportsman, Sport, Xplorer, Magnum
Specific Model Examples:
Covers 1989-1992 Big Boss 4x6, 1991-1992 Big Boss 6x6, and a wide array of other Polaris models from 1985-1995.
Estimated Page Count:
Highly comprehensive; exact count not specified but typical for full workshop manuals (likely 500+ pages)
Type:
Complete Official Workshop Service and Repair Manual
Format:
Digital Download (PDF)
Engine:
Complete engine overhaul, diagnostics, repair procedures, specifications, and troubleshooting.
Fuel System:
Carburetor(s) tuning and overhaul, fuel pump, fuel lines, fuel tank service.
Transmission:
PVT (Polaris Variable Transmission) system service, belt replacement, clutch adjustments, gearcase lubrication.
Drivetrain:
Front and rear drive systems, differentials, driveshafts, CV joints, 4x6 and 6x6 driveline components.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, bushings, adjustments.
Brakes:
Hydraulic brake system service, caliper rebuild, master cylinder, brake lines, parking brake.
Electrical:
Wiring diagrams, lighting system, ignition system, charging system, starter motor, battery service, troubleshooting.
Body And Frame:
Body panel removal and installation, chassis, handlebars, seat, fenders.
Maintenance:
Scheduled maintenance, lubrication points, fluid changes, filter replacements, general upkeep.
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides.
Rebuilds:
Complete engine, transmission, differential, and brake component rebuild instructions.
Assembly Disassembly:
Detailed step-by-step instructions for disassembling and reassembling all major vehicle components.
Torque Specifications:
Includes critical torque values for engine, chassis, and suspension fasteners to ensure proper assembly and prevent component failure.
Depth:
Comprehensive, covering everything from basic maintenance to full mechanical overhauls and advanced diagnostics.
Detail Level:
Includes detailed illustrations, exploded diagrams, torque specifications, and wiring schematics.
Wiring Schematics Detail:
Provides comprehensive wiring diagrams essential for diagnosing and repairing electrical system faults.
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing quick navigation to specific topics.
Printability:
All pages are printable, allowing for creation of a physical reference copy.
Digital Format Advantage:
No physical binding, accessible on multiple devices. Print-on-demand capability.
N/A:
N/A (Digital format)
Engine Type Big Boss:
2-stroke, liquid-cooled, Twin-cylinder (common for Big Boss models of this era)
Engine Displacement Big Boss Variations:
Likely 250cc to 350cc range for Big Boss models, with specific variants covered in the manual.
Ignition System:
CDI (Capacitor Discharge Ignition), details on timing and troubleshooting included.
Horsepower Range:
Estimated 15-25 HP depending on specific engine and model, detailed specifications in manual.
Carburetion:
Dual carburetors (typical for twin-cylinder engines), with detailed tuning and overhaul procedures.
Fuel Type:
Unleaded gasoline, specific octane recommendations in manual.
Oil Mixture:
Oil injection system or pre-mix, detailed specifications for oil type and ratio in manual.
Cooling Type:
Liquid-cooled, including radiator, coolant, and fan operation.
Transmission Type:
Polaris Variable Transmission (PVT) Automatic with High/Low Range and Reverse.
N/A:
N/A (PVT was standard on Big Boss models).
Clutch System:
Centrifugal clutch and drive/driven clutch service, belt inspection, and replacement procedures.
Gear Reduction:
High and Low range gearing for varied terrain and towing.
Gearcase Oil:
Specific gear oil type and viscosity grade (e.g., SAE 80W-90 GL-4 or GL-5) detailed in manual.
Belt Inspection Interval:
Recommended interval for PVT belt inspection and replacement (e.g., every 1000 miles or 1 year).
Wheelbase:
Varies by model (e.g., 1989 Big Boss 4x6 ~52 inches, 6x6 longer), specific figures in manual.
Ground Clearance:
Typically around 5-8 inches depending on model and suspension setup, detailed specs in manual.
Dry Weight:
Approximately 550-650 lbs for Big Boss models, specific weights listed in manual.
Towing Capacity:
Typically rated for around 1500 lbs, specific capacity detailed in manual.
Rack Capacity:
Front and rear racks with specified weight limits (e.g., 50 lbs front, 100 lbs rear).
Atv Safety Standards:
Adherence to ANSI/SVIA safety standards for ATVs of the period; manual provides safe operation guidelines.
Braking System:
Hydraulic disc brakes (front and/or rear), detailed specifications on fluid and maintenance.
Lighting:
Headlights, taillight, brake light; wiring diagrams for troubleshooting.
Rollover Protection:
No specific ROPS (Roll-Over Protective Structure) fitted as standard; manual emphasizes safe riding practices.
N/A:
Basic instrumentation (speedometer, indicator lights). No advanced infotainment systems present.
N/A:
No electronic driver assistance features (ABS, traction control, etc.) typical for the era.
N/A:
No electronic connectivity features.
Oil Change Engine:
Specific interval for oil change/check (e.g., every 50-100 hours or annually, details in manual).
Spark Plug Service:
Recommended interval for spark plug inspection and replacement.
Air Filter Maintenance:
Regular cleaning or replacement of air filter, especially in dusty conditions.
Coolant Type:
Ethylene glycol based antifreeze, specific mixture ratio (e.g., 50/50) detailed in manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, specified in manual.
Pv T Belt Wear:
PVT belt wear is common; regular inspection and timely replacement are crucial for performance and to prevent secondary damage.
Carburetor Cleaning:
Carburetors can become gummed up with fuel varnish if the ATV sits for extended periods, requiring cleaning and potentially rebuilding.
Suspension Bushings:
Worn suspension bushings can lead to sloppy handling and premature wear on other components.
Polaris Atv Origins:
Polaris has a long history in snowmobiles and transitioned into ATVs, developing pioneering models like the Trail Boss and Big Boss.
Big Boss Development:
The Big Boss series was Polaris's foray into larger utility and multi-passenger ATVs, often featuring 6x6 configurations and enhanced hauling capabilities.
Extended Coverage Significance:
The extensive model coverage highlights shared components and systems across Polaris's ATV lineup during the late 1980s and 1990s, making the manual broadly applicable.
Manufacturing Era:
Late 1980s to Mid-1990s, a period of significant growth and innovation for Polaris in the ATV market.
