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I am in need of a owner's manual and a repair manual for a 1991 Polaris 250 Big Boss 6X6 quad

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Www.polaris.com/en-us/company/owners-manual.asp

Posted on May 15, 2014

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1999 polaris big boss 6x6. got a valve stuck open, don't know if it is bent or just stuck, is there a quick fix for this or do i have to pull the head ?


Yes, you need to remove the head. You also need to see if the piston crown is damaged, and the reason why the valve stuck.

Do the job right, do it only once.

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User manuel 1991 Polaris 250 Big Boss 6x6 quad


owners manual see this site. free and shows you everything
http://www.scribd.com/doc/93891348/Polaris-Atv-Service-Manual-Repair-1985-1995-All-Models

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hope this helps , it's a free download of a complete repair manual for the Polaris 2004 Trail Boss 330

http://www.gobookee.org/2004-polaris-trail-boss-330-service-manual/

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Engine wont start on my polaris big boss 500 6x6 after the piston and rings was replaced


First - Did you find ALL the pieces of the broken piston...if not...STOP and FIND them.. they are in the bottom of the crankcase...you engine WILL NOT live long if you have not gotten ALL the pieces--even the TINIEST ones out!! You mat have more damage than just a broken piston.. something caused it to break.. you may have cracked the crankcases...may have damaged the main bearing(YES) and/or damaged the crank bearing.. see if gas in leaking into the transmission oil.
There is an arrow on the piston that faces toward the EXHAUST port. If there are hole(s) in the piston, they go towards the INTAKE.
Do some more searching and repost the results for review!

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