1999 Polaris Big Boss 500 6x6 Parts Manual
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PARTS MANUAL PN 9914920 and MICROFICHE PN 9915651 1/99
BIG BOSS 500 6x6
Model #A99AE50AA
INT’L BIG BOSS 500 6X6 SL
Model #A99AE50DA
Rev. 01
1999
This page intentionally left blank.
TABLE OF CONTENTS
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
Parts Manual
A
A-ARM/STRUT MOUNTING B12 . . . . . . . . . . . . .
AIR BOX B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B
BUMPER/RACK MOUNTING A7 . . . . . . . . . . . .
C
CARBURETOR E1-2 . . . . . . . . . . . . . . . . . . . . . . . .
CENTER TIGHTENER C4 . . . . . . . . . . . . . . . . . .
CLUTCH COVER C10 . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - MASTER CYLINDER/
BRAKE LINE B13 . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - RH MASTER CYLINDER/
BRAKE LINE B14 . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - THROTTLE ASM./CABLE C1 . .
COOLING SYSTEM A10 . . . . . . . . . . . . . . . . . . . .
CRANKCASE D11 . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON D12 . . . . . . . . . . . .
CV JOINT - BTB B6 . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER D9-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D
DECALS A9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH C8 . . . . . . . . . . . . . . . . . . . . . . .
DRIVEN CLUTCH C9 . . . . . . . . . . . . . . . . . . . . . .
E
ELECTRICAL/TAILLIGHT D3 . . . . . . . . . . . . . . .
ENGINE MOUNTING A11-12 . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM A13 . . . . . . . . . . . . . . . . . . . .
F
FOOT PEDAL and PARKING BRAKE C12 . . . .
FRONT BRAKE B9 . . . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB A5 . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE B4 . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT STRUT B7 . . . . . . . . . . . . . . . . . . . . . . . .
FRONT TIGHTENER B5 . . . . . . . . . . . . . . . . . . .
FRONT WHEEL B8 . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP E3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL T ANK A14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
G
GEAR SELECTOR D5-6 . . . . . . . . . . . . . . . . . . . . .
GEARCASE D7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARCASE/BRAKE and
CHAIN COVER MOUNTING C13 . . . . . . . . .
H
HEADLIGHT B3 . . . . . . . . . . . . . . . . . . . . . . . . . .
I
INTAKE and EXHAUST D13 . . . . . . . . . . . . . . . . .
M
MAGNETO E8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIDDLE AXLE BRAKE C2 . . . . . . . . . . . . . . . . .
MIDDLE DRIVE C3 . . . . . . . . . . . . . . . . . . . . . . . .
MIDDLE WHEEL C5 . . . . . . . . . . . . . . . . . . . . . . .
O
OIL FIL TER E5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP E4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL T ANK B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P
PART NUMBER INDEX E9-F3 . . . . . . . . . . . . . . . . .
R
REAR BED MOUNTING A8 . . . . . . . . . . . . . . . .
REAR BRAKE C11 . . . . . . . . . . . . . . . . . . . . . . . . .
REAR CAB A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR STRUT STABILIZER D1 . . . . . . . . . . . . .
REAR WHEEL DRIVE C14 . . . . . . . . . . . . . . . . . .
RECOIL STARTER E6 . . . . . . . . . . . . . . . . . . . . .
S
STARTING MOTOR E7 . . . . . . . . . . . . . . . . . . . .
STEERING - HANDLEBAR B10 . . . . . . . . . . . . .
STEERING POST B11 . . . . . . . . . . . . . . . . . . . . . .
SWING ARM WELDMENT (REAR) D2 . . . . . . .
SWING ARM/GUARD MOUNTING C7 . . . . . . .
SWING ARM/SHOCK MOUNTING C6 . . . . . . .
T
TOOL KIT D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W
WATER PUMP D14 . . . . . . . . . . . . . . . . . . . . . . . . .
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly .
1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS
BRAKES
Type - Front
Type - Rear
Type - Auxiliary
Type - Parking
Hydraulic Disc
Hydraulic Disc
Hydraulic Disc
Hydraulic Lock, All Wheel
CAPACITIES
Coolant Capacity (quarts)
Fuel T ank (gallon)
Engine Oil (quarts) 10W30
Engine Counter Balance
Oil (quarts) Injector
Rack, Front (pounds)
Box, Rear (pounds)
T ongue Weight
T ow Hitch
T ow Weight
2.25
3.5
2
N/A
N/A
75
800
30
Standard
850
DRIVE TRAIN
Type PVT
DRIVE CLUTCH
Bearings
Center Distance (inches)
Clutch Offset (inches)
Clutch Weight (grams)
Diameter
Spider
Spring Color
Garlock D.U.
10
1/2
50
7.38
Cast
Blue/Green
DRIVEN CLUTCH
Bearings
Helix Angle
Outside Diameter (inches)
Spring Position
Garlock D.U.
Compound
9.5
2-2
DIMENSIONAL FEATURES
Approx. Turning Radius (inches)
Box, Cargo Bed
Box, T ool
Box Dimensions (inches)
Ground Clearance (inches)
Height (inches)
Length (inches)
Seat Height (inches)
Weight (dry)
Wheel Base (inches)
Width (inches)
98
Standard
N/A
43.25x40.5x8.5
5.5
47
103
36
870
75
46
GEARCASE
Trans. Number and Type
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Front Drive (ratio)
Final Drive (ratio)
Center Drive (ratio)
Axle to Axle
Chain Type
Chain Adjustment
PRD
Side Lever
6.64/1
5.13/1
3.29/1
1 1/22 68p
12/42 88P
1 1/24 72p
30/30 1 16P
520 O-Ring
Eccentric
TIRES & WHEELS
Tire Manufacturer
Tire Size - Front
Tire Size - Rear
Tire Size - Center
Tire Pressure - Front
Tire Pressure - Rear
Tire Pressure - Center
Wheel Bolt Pattern - Front
Wheel Bolt Pattern - Rear
Wheel Bolt Pattern - Center
GoodYear
25x8x12
25x12x10
25x12x10
5
5
5
4 Bolt, 6.15 Dia.
4 Bolt, 4.0 Dia.
4 Bolt, 4.0 Dia.
ENGINE
Engine Model Number
Engine Type
Bore & Stroke (mm)
Displacement (cc’s)
Compression Ratio
Cooling
Alternator Output (watts)
Elec. Start w/Recoil Back Up
Carburetors (no. of/size)
Main Jet
Pilot Jet
Needle Jet
Cut Away
Air Screw
Jet Needle
Ignition
Ignition (Type & Deg. BTDC)
Spark Plug Gap (inches)
Spark Plug (Type)
Exhaust
EH50PLE06
4 Cycle, Single Cylinder
92x75
498
10:1 Full Stroke
Liquid
250
Standard
1/BST34 (CV Type)
140
40
Q-6
N/A
2 Turn
5D78-3
CDI
30@3500
.028
NGKBKR5E
USFA Appr .
GRAPHICS
Decal, Engine Color
Brake Lever
Bumpers, Front & Rear/Steel
Bumper Caps/Polyprop.
Cargo Box or Bed
Clutch Cover/Nylon
Decal, Demand-4-Drive Color
Decal, “Polaris” Color
Decal, MacPherson Strut Location
Decal, Model Name Color
Fender , Front
Fender , Rear
Footwell
Frame/Steel
Grips
Handlebar/Steel
Headlight Pod
Mud Flaps
Rack, Front
Rack, Rear
Rims
Radiator Structure Color
Seat Vinyl
Side Panel
Spring, Front
Spring, Rear
T ank Cover
T ool Box Cover
w/lettering Color
White/Black
Fire Red
Semi Flat Black
N/A
Eddie Bauer Green - Box
Black
Silver
White/Black
On Front Bumper
White/Blk
Eddie Bauer Green
Eddie Bauer Green
Black
Black
Black
Semi Flat Black
Steel Gray
Black
Eddie Bauer Green
N/A
Aluminum
Black
Steel Gray
Eddie Bauer Green
Eddie Bauer Green
Eddie Bauer Green
Eddie Bauer Green
N/A
LIGHTS/BATTERY
Headlight (watts)
T aillight (watts)
Brake Light (watts)
Other (Grill Mntd. Lights)
Indicator Bulb
Battery
N/A
12 V/8.26 W
12 V/26.9 W
2, 12V/37.5 W
12 V/1.25 W
12 V 14 AH
SUSPENSION
Front Type -
Front Travel (inches)
Strut
Adjustment
Rear Type -
Rear Travel (inches)
Shock
Adjustment
MacPherson Strut
6.25
Gabriel
–––––
Swing Arm w/Scissor Stabilizer
7.5
25mm Bore Gas Bag Strut
Cam
Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without
notice.
1999 BIG BOSS 500 6X6 PUBLICATION NUMBERS
MODEL MODEL NO. OWNER’S
MANUAL
PARTS
MANUAL
PARTS
MICROFICHE
ASSEMBLY
INSTRUCTIONS
Big Boss 500 6X6 A99AE50AA 9914919 9914920 9915651 9914922
Int’l Big Boss 500 6x6 SL A99AE50DA 9914919 9914920 9915651 9914922
A5
FRONT CAB
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
1
2
3
4
5
6
7
8
10
11
12
13
1
14
10
15
1
9
1
16
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7670060 6 Nut, Speed
2 ––––––– 1 Cover , Headlamp
(See Headlight Pg. B3, Ref. 10)
3 7621460 2 Rivet, Pop
4 2631812-195 1 Asm., Front Cab, Green
(Incl. Warning Decals)
5 7555859 12 Washer , Flat
6 7542122 17 Nut, Nylok
7 5211131-067
5211020-067
1
1
Bracket, Mudflap, LH
Bracket, Mudflap, RH
8 5850126
5850130
1
1
Mudflap, Front, LH
Mudflap, Front, RH
9 ––––––– 1 Footpad (See Bumper/Rack Mnting
Pg. A7, Ref. 29)
10 7512282 17 Bolt
11 5410012 2 Plug, Rubber Hole
12 5211547-067 1 Strap, Fuel Pump Mounting
13 7621432 2 Rivet, Pop
14 5431197-195 1 Cover , Fuel T ank, Green
15 5431675-195
5430971-195
1
1
Cover , Side Panel, LH, Green
Cover , Side Panel, RH, Green
16 7512232 6 Screw
1/99
A6
REAR CAB
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
3
6
7
8
9
13
14
15
12
9
11
22
20
24
25
4
22
1
23
2
16
4
21
4
19
17
18
4
5
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5020663 2 Pin, Seat Latch
2 7073761 1 Decal - Carb Information
3 7512232 2 Screw
4 7555859 17 Washer , Flat
5 7515180 2 Screw
6 2631839-195 1 Asm., Cab, Rear , Green
(Incl. Warning Decals)
7 2681729-132
2681730-132
1
1
Asm., Seat, Gray (Incl. 7-9)
Covering, Seat, Gray
8 5410774 2 Grommet, Rubber
9 5410414 6 Bumper , Rubber
10 7558212 2 Washer
11 5222837-067 1 Bracket, Support, Seat Base
12 7621403 2 Rivet, Pop
13 5432798 2 Plug, Nylon
14 7042032 1 Spring, Latch Return
15 7077446 1 Decal - Filter Element
16 1012778-067
1012982-067
1
1
Frame, Main (US)
Frame, Main (Int’l)
17 3110064 1 Mount, T orque Stop
18 7555925 1 Washer
19 7542439 1 Nut, Nylok
20 7512282 17 Bolt
21 7558301 2 Washer , Flat
22 7542122 17 Nut, Nylok
23 5810957
5810991
1
1
Foil, Rear Cab
Foil, Rear Cab, Small
24 5850109
5850104
5850103
1
1
1
Mudflap, Rear Lower , RH (US)
Mudflap, Rear Lower , RH (Int’l)
Mudflap, Rear Lower , LH
25 5211131-067
5211020-067
1
1
Bracket, Mudflap, LH
Bracket, Mudflap, RH
1/99
A7
BUMPER/RACK MOUNTING
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
2
3
1
6
7
8
4
13
12
9
10
11
14
15
7
16
18
19
20
17
26
25
27
28
29
3
1
30
5
22
5
12
16
16
12
12
21
23
24
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5410012 2 Plug
2 5410414 3 Bumper , Rubber
3 7512130 2 Screw
4 5222860-067 1 Guard, Clutch Outer
5 7661638 16 Rivet
6 1040291-195 1 Lever, Box
7 7558301 4 Washer , Flat
8 7542122 2 Nut, Nylok
9 5810455 2 Pad, Rack Mount
10 7515355 2 Screw
11 2670134 2 Reflector , Amber
12 7542324 8 Nut, Nylok
13 2670137-067 1 Rack, Front
14 2431017
4030059
2
1
Asm., 27W, Headlight, Bottom Mount
Bulb, 27W, Headlamp
15 7512329 2 Bolt
16 7558402 6 Washer
17 5810467 1 Plug, Frame
18 7552801 2 Washer , Spring Lock
19 7512126 2 Bolt
20 2631989-067 1 Bumper , Front
21 5241224-067 1 Hitch, U-Bolt
22 7515399 2 Screw
23 5211633-067 1 Plate, Back Mount
24 7515547 2 Screw
25 5242016-067 1 Guard, Rock
26 7512232 7 Screw
27 7661825 8 Rivet, Semi-Tubular
28 5431484 2 Trim, Footrest
29 1040274-067
1040351-067
1
1
Footpad, LH
Footpad, RH
30 1040293-067 1 Mount, Rear Strut
1/99
A8
REAR BED MOUNTING
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
18
8
10
11
12
14
15
16
17
21
19
20
4
13
31
4
13
21
30
29
23
24
28
27
32
4
14
35
34
36
21
37
38
39
33
1
2
3
5
4
4
22
6
25
7
9
13
21
26
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512282 2 Bolt
2 7080496 2 Cable, T ailgate
3 7517377 2 Screw
4 7542122 24 Nut, Nylok
5 1040283-195 1 T ailgate, Green
6 7555824 4 Washer , Belleville Spring
7 5020839 2 Rod, Pivot, T apered
8 5431524 2 Handle, T ailgate
9 7041302 4 Spring, T ailgate Latch
10 5810455 2 Pad, Rack Mount
11 1040455-195 1 Panel, Side, LH
12 7512111 10 Bolt
13 7558301 31 Washer , Flat
14 7512208 4 Screw
15 2682346-132
2681664-132
1
1
Asm., Backrest, Gray (Incl. Cover)
Cover, Backrest, Gray
16 7030011-195 2 Handle, Grab, Green
17 7512284 8 Screw
18 7515341 4 Bolt
19 1040192-195 1 Latch, Box, Green
20 ––––––– 1 Decal - Rider Warning
(See Decal Pg. A9. Ref.1 1)
21 7542324 15 Nut, Nylok
22 2670133 2 Reflector , Red
23 7542101 8 Nut
24 7515314 4 Bolt, Flat Head
25 5020662 2 Rod, Pivot
26 7517242 2 Screw
27 5240244-067 1 Bracket, T aillight Mount
28 1040280-195 1 Bed, Green
29 7542105 8 Nut
30 7515137 4 U-Bolt
31 7512103 3 Bolt
32 7512113 2 Bolt
33 1040456-195 1 Panel, Side, RH
34 5333170 2 Spacer
35 7512392 1 Screw
36 7041301 1 Shock, Dump Box
37 7515306 1 Screw
38 7542449 6 Nut
39 7512492 6 Screw
5/98
A9
DECALS
Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA
15
3
21
20
1
19
17
23
24
13
11
22
25
LH
RH
7
10
5
16
12
9
4
6
8
18
7
4
10
26
2
14
6
8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7077765 1 Decal - “Polaris”, Domed
2 7076202 1 Decal - CE Regulation
3 7076273 1 Decal - Override Switch, AWD
4 7074929 2 Decal - “POLARIS”
5 7077902 1 Decal - T ank Side, LH
6 7077906 2 Decal - “Big Boss 6x6”
7 7075705 2 Decal - “Demand 6 Drive”
8 7077907 2 Decal - “500”
9 7077908 1 Decal - “Polaris 6x6”, Box, LH
10 7076558 2 Decal - Box Stripe
11 7072766 1 Decal - Rider Warning
12 7074109 1 Decal - Load Distribution
13 7075719 1 Decal - Tire Pressure
14 7074946 1 Decal - Clutch Cover
15 7077365 1 Decal - Fuel Lever
16 7078355 1 Decal - Disc Warning
17 7077904 1 Decal - Side Panel, LH
18 7078254 1 Decal - Age Warning
19 7074935 1 Decal - Warning, AWD Switch
20 7077903 1 Decal - T ank Side, RH
21 7074220 1 Decal - MacPherson Strut
22 7077905 1 Decal - Side Panel, RH
23 7075741 1 Decal - Drain Recoil
24 7072715 1 Decal - Operator Warning
25 7077909 1 Decal - “Polaris 6x6”, Box, RH
26 7073862 1 Decal - “POLARIS”
1/99
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Print one or all pages of your manual
$35.99
1999 Polaris Big Boss 500 6x6 Parts Manual is essential for both professional mechanics and DIY enthusiasts. ATVs are known for their reliable design, simple construction, and ease of repair, making them ideal for home maintenance. Regular maintenance, including oil changes, inspection of various systems, and part replacements, is crucial for ensuring the longevity of your ATV.
Having a quality parts manual specific to your ATV is invaluable for identifying and maintaining its components. It also proves beneficial in understanding the working of your ATV and can save costs compared to professional maintenance. The manual consists of 74 pages in English format, allowing you to print only the necessary sections.
The manual includes detailed topics such as specifications, front and rear cab, rack mounting, decals, cooling and exhaust systems, fuel and oil tanks, air box, drive components, brake systems, steering, electrical components, engine parts, and part number index. Each topic is accompanied by exploded diagrams and part number lists, aiding in easy identification and procurement of parts.
Whether for routine maintenance or periodic repairs, having access to this comprehensive parts manual will enhance your understanding of your ATV's mechanics and contribute to its prolonged service life.
