Polaris Big Boss 6x6 Problems

The Polaris Big Boss 6x6. A beast of a machine, promising unparalleled traction and hauling power. But like any complex piece of engineering, it's not without its quirks and potential pitfalls. Understanding these common issues can save you time, money, and a whole lot of frustration, whether you're a seasoned Big Boss owner or considering adding one to your fleet.

So, You're Having Big Boss Blues? Let's Talk

Owning a Polaris Big Boss 6x6 can be an incredibly rewarding experience. These machines are workhorses, capable of tackling terrain and loads that would leave lesser ATVs spinning their wheels. However, some recurring problems can sour the experience. We're going to delve into the most common issues, offering insights into why they happen and, more importantly, how to address them.

Transmission Troubles: More Common Than You Think

One of the most frequently reported problems with the Polaris Big Boss 6x6 revolves around the transmission. These issues can range from minor annoyances to complete failures, leaving you stranded.

• Shifting Difficulties: Many owners report difficulty shifting gears, especially between forward and reverse. This can be caused by several factors, including:
  • Worn Clutch: The clutch is responsible for engaging and disengaging the engine from the transmission. Over time, the clutch plates can wear down, leading to slippage and difficult shifting.
  • Stretched or Damaged Shift Cable: The shift cable connects the shift lever to the transmission. A stretched or damaged cable can prevent the transmission from fully engaging the selected gear.
  • Low Transmission Fluid: Low fluid levels can starve the transmission of lubrication, leading to increased friction and difficult shifting.
  • Incorrect Clutch Adjustment: If the clutch isn't adjusted properly, it can cause the engagement point to be off, resulting in hard shifting.
• Transmission Slippage: Slippage occurs when the transmission fails to properly transfer power from the engine to the wheels. This can manifest as a loss of power, especially when climbing hills or carrying heavy loads. Common causes include:
  • Worn Clutch: Again, a worn clutch is a prime suspect.
  • Damaged or Worn Transmission Gears: Internal damage to the transmission gears can cause slippage. This often results from excessive wear and tear or improper maintenance.
  • Incorrect Belt Tension: (If equipped with a CVT transmission) A loose or worn belt can cause slippage.
• Transmission Noise: Unusual noises coming from the transmission, such as whining, grinding, or clunking, are often a sign of internal damage. This could be caused by:
  • Worn Bearings: Bearings within the transmission can wear out over time, leading to excessive noise.
  • Damaged Gears: Broken or chipped gear teeth can cause significant noise and eventual transmission failure.
  • Low Transmission Fluid: Insufficient lubrication can exacerbate wear and tear, leading to noisy operation.

What to do about it: For shifting difficulties, start by checking the shift cable for proper adjustment and lubrication. Inspect the clutch for wear and tear. For slippage or noise, check the transmission fluid level and condition. If the fluid is low or contaminated, change it immediately. If the problem persists, a more thorough inspection of the transmission's internal components may be necessary.

The Dreaded 6x6 Drive System: A Complex Beast

The 6x6 drive system, the heart of the Big Boss's impressive traction, is also a potential source of problems. The more complex the system, the more points of failure exist.

• Chain Issues: The Big Boss utilizes chains to transfer power to the rear axles. These chains are subject to wear and tear, and if not properly maintained, they can break.
  • Stretched or Broken Chains: Over time, chains can stretch due to constant use and heavy loads. A stretched chain can skip on the sprockets, causing a jerky ride and potential damage. If neglected, the chain can eventually break, leaving you stranded.
  • Worn Sprockets: The sprockets that the chains run on can also wear down over time. Worn sprockets can cause the chain to skip and accelerate chain wear.
  • Lack of Lubrication: Proper chain lubrication is essential to prevent wear and tear. A dry chain will quickly wear out and is more likely to break.
• Axle Problems: The Big Boss has six axles, increasing the likelihood of axle-related issues.
  • Damaged CV Joints: CV (constant velocity) joints allow the axles to articulate as the suspension moves. These joints are protected by rubber boots, which can tear, allowing dirt and debris to enter, leading to premature wear and failure.
  • Bent Axles: Impact from rocks, stumps, or other obstacles can bend an axle, causing vibrations and potential damage to other components.
  • Worn Wheel Bearings: Worn wheel bearings can cause excessive play in the wheels and can eventually lead to axle failure.
• Differential Issues: The differentials distribute power to the wheels. Problems with the differentials can lead to poor traction and difficulty steering.
  • Worn or Damaged Gears: Internal damage to the differential gears can cause slippage and noise.
  • Low Differential Fluid: Low fluid levels can lead to increased friction and wear, eventually causing differential failure.

What to do about it: Regularly inspect the chains for wear and tear and lubricate them frequently. Replace stretched or damaged chains immediately. Inspect the CV boots for tears and replace them as needed. Check the differential fluid level and condition and change it according to the manufacturer's recommendations.

Electrical Gremlins: When Things Just Don't Work

Like any modern ATV, the Polaris Big Boss 6x6 relies on a complex electrical system. Electrical problems can be frustrating to diagnose and repair.

• Battery Issues:
  • Dead Battery: A dead battery is a common problem, especially if the Big Boss is not used frequently.
  • Faulty Charging System: Problems with the alternator or voltage regulator can prevent the battery from charging properly.
  • Corroded Terminals: Corroded battery terminals can prevent a good electrical connection, leading to starting problems.
• Wiring Problems:
  • Damaged Wiring Harness: The wiring harness can be damaged by rodents, abrasion, or exposure to the elements.
  • Loose Connections: Loose electrical connections can cause intermittent problems.
  • Short Circuits: A short circuit can blow fuses and damage electrical components.
• Sensor Failures:
  • Faulty Sensors: Various sensors monitor engine performance and other parameters. A faulty sensor can cause the engine to run poorly or not start at all.

What to do about it: Start by checking the battery voltage and terminals. Clean any corrosion from the terminals. Inspect the wiring harness for damage and repair any damaged wires. Check the fuses and replace any blown fuses. If the problem persists, you may need to consult a qualified mechanic to diagnose and repair the electrical system.

Cooling System Concerns: Keeping Your Cool

Overheating can cause serious damage to the engine. It's crucial to maintain the cooling system properly.

• Radiator Issues:
  • Clogged Radiator: The radiator can become clogged with mud, debris, or insects, restricting airflow and reducing cooling efficiency.
  • Leaking Radiator: A leaking radiator can lead to low coolant levels and overheating.
• Coolant Leaks:
  • Leaking Hoses: Coolant hoses can crack or become loose, leading to leaks.
  • Leaking Water Pump: A leaking water pump can also cause coolant loss.
• Faulty Thermostat:
  • Stuck Thermostat: A stuck thermostat can prevent the engine from reaching its operating temperature or can cause it to overheat.

What to do about it: Regularly clean the radiator to remove any debris. Inspect the coolant hoses for cracks or leaks and replace them as needed. Check the coolant level and add coolant as needed. If the engine overheats, stop immediately and allow it to cool down before attempting to restart it.

Suspension Woes: A Rough Ride

The suspension system is responsible for providing a comfortable ride and maintaining traction.

• Worn Shocks: Over time, the shocks can wear out, leading to a bouncy ride and reduced handling.
• Broken Springs: Springs can break due to excessive stress or impact.
• Worn Bushings: Bushings in the suspension components can wear out, leading to play and sloppy handling.

What to do about it: Inspect the shocks for leaks or damage. Replace worn shocks as needed. Inspect the springs for cracks or breaks. Replace broken springs. Inspect the bushings for wear and tear and replace them as needed.

Frequently Asked Questions

• Why is my Big Boss hard to shift? The most common causes are a worn clutch, stretched shift cable, or low transmission fluid. Check and address each of these potential issues.
• How often should I lubricate the chains on my 6x6? Lubricate the chains every 25 hours of use, or more frequently in dusty or muddy conditions. Use a chain lubricant specifically designed for ATVs.
• What type of oil should I use in my Big Boss engine? Refer to your owner's manual for the recommended oil type and viscosity. Using the wrong oil can damage the engine.
• Why is my Big Boss overheating? Check the radiator for clogs, coolant level for leaks, and the thermostat for proper function. Addressing these can usually resolve overheating issues.
• My Big Boss battery keeps dying. What could be wrong? The battery may be old and need replacing, or there may be a problem with the charging system. Have the charging system tested to identify the cause.

The Bottom Line: Keeping Your Big Boss Bossing

The Polaris Big Boss 6x6 is a capable machine, but like all ATVs, it requires regular maintenance and attention to potential problems. By understanding the common issues and taking proactive steps to address them, you can keep your Big Boss running smoothly for years to come. Remember, preventative maintenance is always cheaper than major repairs.