CHAPTER 4 FUEL SYSTEM CARBURETION Jetting Guidelines 4 1 Main Jet Selection 4 1 Fuel Tank Asm Exploded View 4 2 Fuel Flow Diagram 4 3 Main Jet Pilot Jet Part Numbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 6 4 8 Exploded View Mikuni B
CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications 7 1 AWD Operation Overview 7 2 AWD Front Hub Disassembly 7 3 AWD Hub Bearing Installation 7 4 AWD Front Hub Bearing Adjustment 7 5 AWD Front Hub Exploded View 7 6 AWD Hub Seal Replacement 7 7 AWD Magnetic Coil Service 7 8 AWD Hilliard Clutch Disassembly Inspection
CHAPTER 6 PVT SYSTEM Service Tools and Supplies 6 1 PVT System Operation 6 2 PVT Maintenance Inspection 6 3 6 4 PVT Disassembly 6 5 6 6 PASS mb ceirios See AA 6 7 PVT Sealing and Ducting Components 6 8 Clutch System Operation Overview 6 9 Drive Clutch Spring Specifications 6 10 Shift Weights 6 11 Drive Clu
CHAPTER 9 BRAKES Specifications Torques 9 1 Brake System Service Notes 9 2 Brake Pad Kits u 2 een eek 9 2 Brake Noise Troubleshooting 9 3 Hydraulic Brake System Operation 9 4 Fluid Replacement Bleeding Procedure 9 5 9 6 Master Cylinder Disassembly 9 7 9 8 Master Cylinder Inspection 9 9 Master Cylinder Assembly
CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools 5 1 Body Assembly Exploded View 5 2 Dump Box Exploded View 02 0005 5 3 Cover Panel Removal eee ee ee eens 5 4 Steering Assembly Exploded View 5 5 A Arm Replacement cece eee ees 5 6 Standard Swing Arm Rear Suspension 5 7 Rear Strut Stabilizer Exploded View 5 8 Rear Swing Arm Weldment
CHAPTER 3 ENGINE Torgue Specifications 3 1 Torque Patterns asasan 3 2 Piston Identification 3 3 EH5OPL Service Data 3 4 3 5 Cooling System Pressure Test 3 6 Cooling System Specifications 3 7 EngineRemoval ssaanaawananuna 3 8 3 9 Engine Installation Notes 3 10 Cylinder Honing
CHAPTER 10 ELECTRICAL Special TOO Acs stele Ret Lut eQ amuyu Ds 10 1 Headlamp Service 1998 99 10 2 10 3 Indicator Lamp Service 10 4 Timing Check Procedure 10 5 Typical Ignition Timing Curve 10 6 Flywheel Identification 10 7 250 Watt Alternator Exploded View 10 8 Ignition System Testing 10 9 10 10 Ignition Syst
CHAPTER 2 MAINTENANCE Periodic Maintenance Chart 2 1 2 2 Pre Ride Inspection 2 2 Recommended Lubricants and Capacities 2 3 Lubricant and Maintenance Product Numbers 2 4 Lubrication Charts O cw dees YW 2 5 2 7 Transmission Lubrication 2 8 Transmission LInkage Adjustment 2 9 2 10 Carburetor Adjustments 2 11 2 14 F el System ee y twits Y Y Oy 2 15 2 16 C
ELECTRICAL WIRING DIAGRAM 1998 BIG BOSS 6X6 AWD SWITCH ETC SWITCH BUTTON GRY W CON BEAM LOW BEAN FAN ai FAULT 4 1 ES ARE REPRESENTED BY LOCATED IN FRONT OF RADIATOR OTOR a ID OR DASHED LINES Za 2 CAPACITOR GRN BLK R 446 0 PLIFY TRACING IN DIAGRAM VOLTAGE REGULATOR ETER 160 GROUND NO CONNEC D
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 Cha