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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

BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

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Page 1: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

PARTS MANUAL PN 9914920 and MICROFICHE PN 9915651 1/99

BIG BOSS 500 6x6Model #A99AE50AA

INT’L BIG BOSS 500 6X6 SLModel #A99AE50DA

Rev. 01

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Page 2: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

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Page 3: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

TABLE OF CONTENTSBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

Parts Manual

AA-ARM/STRUT MOUNTING B12. . . . . . . . . . . . . AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBUMPER/RACK MOUNTING A7. . . . . . . . . . . .

CCARBURETOR 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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH C8. . . . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH C9. . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT D3. . . . . . . . . . . . . . . ENGINE MOUNTING A11-12. . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM A13. . . . . . . . . . . . . . . . . . . .

FFOOT 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 TANK A14. . . . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D5-6. . . . . . . . . . . . . . . . . . . . . GEARCASE D7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . GEARCASE/BRAKE and

CHAIN COVER MOUNTING C13. . . . . . . . .

HHEADLIGHT B3. . . . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST D13. . . . . . . . . . . . . . . . .

MMAGNETO E8. . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE AXLE BRAKE C2. . . . . . . . . . . . . . . . . MIDDLE DRIVE C3. . . . . . . . . . . . . . . . . . . . . . . . MIDDLE WHEEL C5. . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER E5. . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP E4. . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PPART NUMBER INDEX E9-F3. . . . . . . . . . . . . . . . .

RREAR BED MOUNTING A8. . . . . . . . . . . . . . . . REAR BRAKE C11. . . . . . . . . . . . . . . . . . . . . . . . . REAR CAB A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR STRUT STABILIZER D1. . . . . . . . . . . . . REAR WHEEL DRIVE C14. . . . . . . . . . . . . . . . . . RECOIL STARTER E6. . . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR E7. . . . . . . . . . . . . . . . . . . . STEERING - HANDLEBAR B10. . . . . . . . . . . . . STEERING POST B11. . . . . . . . . . . . . . . . . . . . . . SWING ARM WELDMENT (REAR) D2. . . . . . . SWING ARM/GUARD MOUNTING C7. . . . . . . SWING ARM/SHOCK MOUNTING C6. . . . . . .

TTOOL KIT D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER 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.

Page 4: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Engine Oil (quarts) 10W30Engine Counter BalanceOil (quarts) InjectorRack, Front (pounds)Box, Rear (pounds)Tongue WeightTow HitchTow Weight

2.253.5

2N/AN/A

7580030

Standard850

DRIVE TRAINType PVT

DRIVE CLUTCHBearingsCenter Distance (inches)Clutch Offset (inches)Clutch Weight (grams)DiameterSpiderSpring Color

Garlock D.U.101/250

7.38Cast

Blue/Green

DRIVEN CLUTCHBearingsHelix AngleOutside Diameter (inches)Spring Position

Garlock D.U.Compound

9.52-2

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Box, Cargo BedBox, ToolBox Dimensions (inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

98Standard

N/A43.25x40.5x8.5

5.547

10336

8707546

GEARCASETrans. Number and TypeShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain TypeChain Adjustment

PRDSide Lever

6.64/15.13/13.29/1

11/22 68p12/42 88P11/24 72p

30/30 116P520 O-Ring

Eccentric

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - CenterWheel Bolt Pattern - FrontWheel Bolt Pattern - RearWheel Bolt Pattern - Center

GoodYear25x8x12

25x12x1025x12x10

555

4 Bolt, 6.15 Dia.4 Bolt, 4.0 Dia.4 Bolt, 4.0 Dia.

ENGINEEngine Model NumberEngine TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator Output (watts)Elec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EH50PLE064 Cycle, Single Cylinder

92x75498

10:1 Full StrokeLiquid

250Standard

1/BST34 (CV Type)14040

Q-6N/A

2 Turn5D78-3

CDI30@3500

.028NGKBKR5EUSFA Appr.

GRAPHICSDecal, Engine ColorBrake LeverBumpers, Front & Rear/SteelBumper Caps/Polyprop.Cargo Box or BedClutch Cover/NylonDecal, Demand-4-Drive ColorDecal, “Polaris” ColorDecal, MacPherson Strut LocationDecal, Model Name ColorFender, FrontFender, RearFootwellFrame/SteelGripsHandlebar/SteelHeadlight PodMud FlapsRack, FrontRack, RearRimsRadiator Structure ColorSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

White/BlackFire Red

Semi Flat BlackN/A

Eddie Bauer Green - BoxBlackSilver

White/BlackOn Front Bumper

White/BlkEddie Bauer GreenEddie Bauer Green

BlackBlackBlack

Semi Flat BlackSteel Gray

BlackEddie Bauer Green

N/AAluminum

BlackSteel Gray

Eddie Bauer GreenEddie Bauer GreenEddie Bauer GreenEddie Bauer Green

N/A

LIGHTS/BATTERYHeadlight (watts)Taillight (watts)Brake Light (watts)Other (Grill Mntd. Lights)Indicator BulbBattery

N/A12 V/8.26 W12 V/26.9 W

2, 12V/37.5 W12 V/1.25 W12 V 14 AH

SUSPENSIONFront Type -

Front Travel (inches)StrutAdjustment

Rear Type -Rear Travel (inches)ShockAdjustment

MacPherson Strut6.25

Gabriel–––––

Swing Arm w/Scissor Stabilizer7.5

25mm Bore Gas Bag StrutCam

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products withoutnotice.

Page 5: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

1999 BIG BOSS 500 6X6 PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Big Boss 500 6X6 A99AE50AA 9914919 9914920 9915651 9914922

Int’l Big Boss 500 6x6 SL A99AE50DA 9914919 9914920 9915651 9914922

Page 6: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A5

FRONT CABBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

2

3

4

5

6

78

1011

12

13

1

1410

15

1

9

1

16

16

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7670060 6 Nut, Speed2 ––––––– 1 Cover, Headlamp

(See Headlight Pg. B3, Ref. 10)3 7621460 2 Rivet, Pop4 2631812-195 1 Asm., Front Cab, Green

(Incl. Warning Decals)5 7555859 12 Washer, Flat6 7542122 17 Nut, Nylok7 5211131-067

5211020-06711

Bracket, Mudflap, LHBracket, Mudflap, RH

8 58501265850130

11

Mudflap, Front, LHMudflap, Front, RH

9 ––––––– 1 Footpad (See Bumper/Rack MntingPg. A7, Ref. 29)

10 7512282 17 Bolt11 5410012 2 Plug, Rubber Hole12 5211547-067 1 Strap, Fuel Pump Mounting13 7621432 2 Rivet, Pop14 5431197-195 1 Cover, Fuel Tank, Green15 5431675-195

5430971-19511

Cover, Side Panel, LH, GreenCover, Side Panel, RH, Green

16 7512232 6 Screw

1/99

Page 7: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A6

REAR CABBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

3

6

7

8

9

1314

15

129

1122

20

24

25

4

22

1

23

2

16

4

21

4

19

17

18

45

10

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5020663 2 Pin, Seat Latch2 7073761 1 Decal - Carb Information3 7512232 2 Screw4 7555859 17 Washer, Flat5 7515180 2 Screw6 2631839-195 1 Asm., Cab, Rear, Green

(Incl. Warning Decals)7 2681729-132

2681730-13211

Asm., Seat, Gray (Incl. 7-9)Covering, Seat, Gray

8 5410774 2 Grommet, Rubber9 5410414 6 Bumper, Rubber

10 7558212 2 Washer11 5222837-067 1 Bracket, Support, Seat Base12 7621403 2 Rivet, Pop13 5432798 2 Plug, Nylon14 7042032 1 Spring, Latch Return

15 7077446 1 Decal - Filter Element16 1012778-067

1012982-06711

Frame, Main (US)Frame, Main (Int’l)

17 3110064 1 Mount, Torque Stop18 7555925 1 Washer19 7542439 1 Nut, Nylok20 7512282 17 Bolt21 7558301 2 Washer, Flat22 7542122 17 Nut, Nylok23 5810957

581099111

Foil, Rear Cab Foil, Rear Cab, Small

24 585010958501045850103

111

Mudflap, Rear Lower, RH (US)Mudflap, Rear Lower, RH (Int’l)Mudflap, Rear Lower, LH

25 5211131-0675211020-067

11

Bracket, Mudflap, LHBracket, Mudflap, RH

1/99

Page 8: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A7

BUMPER/RACK MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

23 1

6

78

4

13

12

910

1114

15

7

16

1819

20

17

26 25

27

28

29

3 1

30

5

22

5

12

16

16

12

12

212324

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5410012 2 Plug2 5410414 3 Bumper, Rubber3 7512130 2 Screw4 5222860-067 1 Guard, Clutch Outer5 7661638 16 Rivet6 1040291-195 1 Lever, Box7 7558301 4 Washer, Flat8 7542122 2 Nut, Nylok9 5810455 2 Pad, Rack Mount

10 7515355 2 Screw11 2670134 2 Reflector, Amber12 7542324 8 Nut, Nylok13 2670137-067 1 Rack, Front14 2431017

403005921

Asm., 27W, Headlight, Bottom MountBulb, 27W, Headlamp

15 7512329 2 Bolt

16 7558402 6 Washer17 5810467 1 Plug, Frame18 7552801 2 Washer, Spring Lock19 7512126 2 Bolt20 2631989-067 1 Bumper, Front21 5241224-067 1 Hitch, U-Bolt22 7515399 2 Screw23 5211633-067 1 Plate, Back Mount24 7515547 2 Screw25 5242016-067 1 Guard, Rock26 7512232 7 Screw27 7661825 8 Rivet, Semi-Tubular28 5431484 2 Trim, Footrest29 1040274-067

1040351-06711

Footpad, LHFootpad, RH

30 1040293-067 1 Mount, Rear Strut

1/99

Page 9: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A8

REAR BED MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

18

810

11 12

14

15

16

17

21

1920

4

13

31

4

13

21

30

29

2324

2827

32

4

14

3534

3621

3738

39

33

1

2 3 5

4

4

22

6

25

7

9

13

21

2613

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7512282 2 Bolt2 7080496 2 Cable, Tailgate3 7517377 2 Screw4 7542122 24 Nut, Nylok5 1040283-195 1 Tailgate, Green6 7555824 4 Washer, Belleville Spring7 5020839 2 Rod, Pivot, Tapered8 5431524 2 Handle, Tailgate9 7041302 4 Spring, Tailgate Latch

10 5810455 2 Pad, Rack Mount11 1040455-195 1 Panel, Side, LH12 7512111 10 Bolt13 7558301 31 Washer, Flat14 7512208 4 Screw15 2682346-132

2681664-13211

Asm., Backrest, Gray (Incl. Cover)Cover, Backrest, Gray

16 7030011-195 2 Handle, Grab, Green17 7512284 8 Screw18 7515341 4 Bolt19 1040192-195 1 Latch, Box, Green20 ––––––– 1 Decal - Rider Warning

(See Decal Pg. A9. Ref.11)

21 7542324 15 Nut, Nylok22 2670133 2 Reflector, Red23 7542101 8 Nut24 7515314 4 Bolt, Flat Head25 5020662 2 Rod, Pivot26 7517242 2 Screw27 5240244-067 1 Bracket, Taillight Mount28 1040280-195 1 Bed, Green29 7542105 8 Nut30 7515137 4 U-Bolt31 7512103 3 Bolt32 7512113 2 Bolt33 1040456-195 1 Panel, Side, RH34 5333170 2 Spacer35 7512392 1 Screw36 7041301 1 Shock, Dump Box37 7515306 1 Screw38 7542449 6 Nut39 7512492 6 Screw

5/98

Page 10: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A9

DECALSBig 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

7 105

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”, Domed2 7076202 1 Decal - CE Regulation3 7076273 1 Decal - Override Switch, AWD4 7074929 2 Decal - “POLARIS”5 7077902 1 Decal - Tank Side, LH6 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 Stripe11 7072766 1 Decal - Rider Warning12 7074109 1 Decal - Load Distribution13 7075719 1 Decal - Tire Pressure

14 7074946 1 Decal - Clutch Cover15 7077365 1 Decal - Fuel Lever16 7078355 1 Decal - Disc Warning17 7077904 1 Decal - Side Panel, LH18 7078254 1 Decal - Age Warning19 7074935 1 Decal - Warning, AWD Switch20 7077903 1 Decal - Tank Side, RH21 7074220 1 Decal - MacPherson Strut22 7077905 1 Decal - Side Panel, RH23 7075741 1 Decal - Drain Recoil24 7072715 1 Decal - Operator Warning25 7077909 1 Decal - “Polaris 6x6”, Box, RH26 7073862 1 Decal - “POLARIS”

1/99

Page 11: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A10

COOLING SYSTEMBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

3

34

2

4

53332

3130 6

7

9

19

20

8

13

26

21

22

2324

18

27

25

3

12

10

1

14

1716

11

Main Harness Wire

15

28

29

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5411108 1 Hose2 7080614 2 Clamp, Hose, Worm Gear3 4010202 1 Switch, Thermal4 2511189 1 Cap, Pressure5 1240015 1 Radiator, U-Flow6 7552605 2 Washer, Split Lock7 7512113 2 Bolt8 5410584 2 Bushing, Mount, Lower Radiator9 5431610 1 Cover, Radiator w/Mesh

10 4170013 1 Motor, Fan w/Connectors11 5241788-067 1 Bracket, Fan Mount12 5242550 1 Blade, Fan13 7517475 3 Screw14 7512232 4 Screw15 5432294 3 Spacer, Fan Bracket16 7558201 3 Washer17 7547004 3 Nut, Nylok

18 7670090 8 Clip, Dart, Plastic19 5410607 4 O-Ring20 5433141

543314211

Shield, Radiator Side, LHShield, Radiator Side, RH

21 5431673 1 Tank, Surge22 8450003-1525 1 Line, Fuel23 7052065 1 Fitting, Barbed 90 Degree24 7512084 2 Screw25 5431895 1 Plug, Cap26 5810279 1 Gasket, Overflow Cap27 5430743 1 Cap, Overflow/Bottle, Drilled28 7052181 1 Valve, Drain Cock29 5432593 1 Shroud, Fan30 5020937 2 Spacer, Mount, Radiator31 3110032 2 Mount, Rubber, Radiator32 7558301 2 Washer, Flat33 7542122 2 Nut, Nylok34 8450050-305 AR Hose, Water

1/99

Page 12: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A11

ENGINE MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

46

1 23

4

57 8

9

9

10

11

11

12

18

20

19

1949

2223

24

2526

2728

29

30

31

3237

41

4342

44 456

48

10

1019

19

2

1415

1617

13

47

23

22

1

3633

35

13

38

39

34

1

23

2140

Page 13: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A12

ENGINE MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542411 4 Nut, FLEXLOC2 7555801 2 Washer, Wrought3 4010132 1 Cable, Ground/Engine4 3110044 1 Mount, Rubber, Top5 5240328-067 1 Mount, Engine, Top6 7542403 1 Nut, FLEXLOC7 7552901 2 Washer, Spring Lock8 7512315 2 Bolt9 7080307 2 Clamp, Hose, Large, Green

10 8450040-6005811373

AR1

Line, Fuel Tape, Foil

11 8450003-1525 AR Line, Fuel12 7052075 1 Fitting, Tee13 ––––––– 2 Screw and Washer

(See Crankcase Pg. D11, Ref. 6)14 3110050 2 Mount, Carburetor15 5240609-067 1 Bracket, Carburetor Mount16 7552605 2 Washer, Split Lock17 7542105 2 Nut18 _______ 1 Asm., Carburetor

(See Carburetor Pg. E2, Ref. 47)19 7080003 4 Clamp, Hose, Red20 8360009-600 AR Line, Fuel21 8450080-65 AR Sheath, Foil Laminated22 7512490 3 Screw23 7552603 4 Washer, Spring Lock24 5241921-067 1 Mount, Rear Motor25 5410421 1 Boot, Clutch Intake26 7080511 1 Clamp, Narrow Band27 5430261 1 Bushing28 5210748 1 Washer

29 7575202 1 Washer, Interlock30 7512566 1 Bolt31 _______ 1 Asm., Drive Clutch (See Drive Clutch

Pg. C8 For Details)32 ––––––– 1 Bracket, Retainer, Seal (See Clutch

Cover Pg. C10, Ref. 19)33 1040534-067 1 Mount, Engine34 7555806 2 Washer35 7515321 2 Bolt36 7542303 2 Nut37 3110067 1 Mount, Motor38 7555832 1 Washer39 7515438 1 Screw40 7080696 1 Clamp, Hose41 ––––––– AR Hose, Upper Engine (See Cooling

System Pg. A10, Ref. 34)42 ––––––– 2 Nut (See Cylinder Pg. D10, Ref. 22)43 ––––––– 2 Washer

(See Cylinder Pg. D10, Ref. 23)44 1260832-029 1 Manifold45 ––––––– 1 Gasket

(See Cylinder Pg. D10, Ref. 20)46 3085556 1 Engine, EH50PLE06 Short Block

NOTE: The Short Block assemblycontains a crankcase assembly,cylinder and cylinder head assem-bly, and a piston & crankshaft as-sembly. Prior authorization re-quired for warranty consideration.

47 ––––––– AR Hose (See Cooling System Pg.A10, Ref. 1)

48 7080694 1 Clamp, Hose49 3110068 1 Mount, Rubber, Rear

5/98

Page 14: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A13

EXHAUST SYSTEMBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

21

20

18

8

9

17

12

8

19

14

15

13

22

7

12345

24

23

6

10

8

16

7

6

11

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542324 1 Nut, Nylok2 7555716 1 Washer3 5010192 1 Bushing4 5410436 1 Washer, Rubber5 7555781 1 Washer6 3110064 2 Mount, Torque Stop7 7542301 2 Nut8 7042031 5 Spring, Exhaust9 1260856-029 1 Pipe, Exhaust

10 5240898 1 Seal, Exhaust11 ––––––– 1 Manifold (See Engine Mounting Pg.

A12, Ref. 44)12 7042029 1 Spring, Exhaust

13 7670060 1 Nut, Speed14 5240179-067 1 Bracket, Heat Shield15 7621462 1 Rivet, Pop16 7558301 1 Washer17 7512282 1 Screw18 1260717 1 Shield, Heat (Incl. Foil)19 7515140 3 Screw20 7052083 1 Plug, Clean Out21 7512666 2 Screw22 1260742-029 1 Exhaust23 7515383 1 Bolt, Carriage24 5410241 1 Dampener, Vibration

5/98

Page 15: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

A14

FUEL TANKBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

4

5 6

9

16

17

2220

19

21

23

24

25

1

2

3

10

78

13

13

12

13

14

18

15

12

11

11

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 2511342 1 Asm., Tank, Fuel (Incl. 5,22-24)2 5810144 1 Gasket, Fuel Cap3 5430725 1 Cap, Gas Tank4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451 2 Screw7 7552801 2 Washer, Spring Lock8 7558301 2 Washer, Flat9 5222154-067

5222155-06711

Bracket, Cover Mount., Rear, LHBracket, Cover Mount., Rear, RH

10 5333206 2 Spacer11 8450080-65 AR Sheath, Foil Laminated12 8450040-600 1 Line, Fuel

13 7080003 4 Clamp, Hose, Red14 2530009 1 Filter15 7542143 4 Insert, Steel16 5431021 1 Lever, Fuel17 7511840 1 Screw18 5432291 1 Grommet19 7555726 1 Washer20 7041209 1 Spring, Lever Compression21 5431391 1 Extension, Fuel Lever22 7515136 2 Screw23 7052190 1 Valve, Fuel24 5810859 1 Gasket, Fuel Valve25 8360026 2 Tape, Foam

5/98

Page 16: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B1

OIL TANKBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

25

1

2

8

7

9

10

11

12

13

14

15

16

1921

2223

24

20

6

3

17

4

18

5

13

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 7080003 1 Clamp, Hose, Red6 5411321 AR Line, Breather, Special7 7517102 1 Bolt, Banjo8 7555896 2 Washer, Copper9 7052152 1 Tube, Banjo Return

10 5431677 1 Dipstick11 5410889 1 O-Ring12 5411036 AR Hose, Formed13 7080474 2 Clamp, Hose

14 7052106 1 Fitting, 1/4” to 3/8”15 2530014 1 Screen, Oil Filter16 5131785 1 Tank, Oil, LH17 5411042 1 Grommet18 5410828 2 Grommet, Mounting Reservoir19 5333204 2 Bushing20 7558301 2 Washer, Flat21 7512242 2 Bolt22 7051524 1 Plug23 5850135 1 Washer24 7515158 9 Bolt25 5131004 1 Tank, Oil, RH

1/99

Page 17: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B2

AIR BOXBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

2

3

3611

26

27

283031

32

5

425

35

34

37

19

8

7

9

33

15

25

13

14

29

1817

10

6

16

23

2022

21

12

24

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542127 3 Nut, Wing2 5240424 1 Cover, Air Box3 5810948 1 Gasket, Cover4 5240336 1 Cover, Filter5 1253118 1 Filter, Air6 5211804 1 Plate, Air Box7 5811012 1 Seal, Foam Air Box8 7515151 1 Stud9 5811141 1 Foil, Air Box

10 7052164 1 Fitting11 5432691 1 Silencer, Air12 7080476 1 Clamp, Hose13 7080483 1 Cable Tie14 8450051-600 AR Line, Fuel15 7080487 1 Plug, Cap16 5411321 1 Line, Breather, Special17 7555893 2 Washer18 5431863 2 Insulator19 7052163 1 Fitting

20 8450073-600 AR Line, Breather21 7080544 1 Clamp, Hose22 2530029 1 Filter, Breather, In Line23 7080699 1 Clamp, Spring24 5411362 1 Hose, Breather25 7511881 8 Screw26 5410831 1 Boot, Carb Intake27 5431698 2 Ventura, Intake28 5410829 1 Boot, Air Silencer29 7080656 1 Clamp, Narrow Band30 5810988 1 Foam, Seal31 5224553 1 Support, Wire Frame32 5810444 2 Filter, Foam33 7080598 1 Cable Tie34 7558301 2 Washer, Flat35 7515180 2 Screw36 5432607 1 Stand, Filter37 7515150 2 Stud

5/98

Page 18: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B3

HEADLIGHTBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

12

34

5

6

78

10

9

11

12

131415

1617

19

20

21

2223

2826

19

2724

25

18

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 ––––––– 1 Harness, Main Wire (See Electrical/Taillight Pg. D3, Ref. 1)

2 4032066 1 Cover, Headlamp Socket3 4030028 1 Bulb, Headlamp4 4032063 1 Retainer, Headlamp Bulb5 4032065 1 Headlamp w/Bulb Seal6 4032002 2 Spring, Adjust7 4032041 2 Spring, Adjust8 7512017 2 Screw9 4032003 2 Screw

10 5431861-132 1 Cover, Headlamp, Gray11 5431201-132 1 Door, Access, Gray12 7670064 1 Fastener, 1/4 Turn13 7670065 1 Retainer, Split Ring14 7670066 1 Receptacle, Clip On15 4032042 2 Screw, Adjust16 7080727

220018811

Cable, Choke w/AdjusterKit - Choke Control

17 7511862 2 Screw18 2460613 1 Harness, Indicator w/Connector19 4110209

41101414110148

111

Switch, Ignition w/Conn. (Incl. Key) Key, BlankKey, Blank NOTE: Order Key byusing the four digit number on thekey.

20 5220965-067 1 Bracket, Ignition Panel21 4032037 1 Strip, Socket22 4030042 5 Bulb23 5430995 1 Panel, Ignition24 5431964 1 Cover, Key25 5432090 1 Nut, Ignition Switch26 7072528 1 Decal - Panel27 7080229 1 Nut, Choke Slide28 2652049 1 Asm., Pilot Light Lens (Incl. 26)

1/99

Page 19: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B4

FRONT DRIVEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1814

21

20

1

15

10

45

9

76

2

19

22

12

11

8

17

6

3

14

1613

10

1

2

2

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542503 3 Nut, FLEXLOC2 7555883 5 Washer3 7670101 1 Clip, Christmas Tree4 5811502 1 Foil, Chain Guard5 5432572 1 Guard, Front Chain6 7512252 3 Screw7 ––––––– 1 Asm., Center Tightener(See Center

Tightener Pg. C4 For Details)8 3224043 1 Asm., Chain & Link, 72P (Incl. 12)9 7074956 1 Decal - Front Chain Tension

10 7517303 2 Screw11 3224041 1 Asm., Drive Chain, 64P (Incl. 12)

12 3225024 1 Link, Connector13 7555832 1 Washer14 7542449 2 Nut, Flange15 7512564 1 Screw16 7555806 2 Washer17 7515522 2 Screw18 7552603 2 Washer, Spring Lock19 5131379 1 Clamp, Front Eccentric20 ––––––– 1 Asm., Front Tightener (See Front

Tightener Pg. B5 For Details)21 7512583 2 Screw22 5811519 1 Spacer, Front Eccentric

5/98

Page 20: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B5

FRONT TIGHTENERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1 2

3

45 6

7 8

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1380024 1 Asm., Front Tightener (Incl. 2-8)1 3222044 1 Sprocket, 22T2 5130701 1 Eccentric, Front3 7080306 1 Fitting, Lubrication w/Ball4 5020527 1 Shaft, Output

5 3514402 2 Bearing, Open6 3610017 2 Seal, Tightener7 5410463 2 O-Ring8 5020474 2 Spacer, Front Tightener, Outer

5/98

Page 21: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B6

CV JOINT - BTBBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

BTB

101

2 3 4 56

7

8 9

13

14

12

11

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, Large, CV Joint4 7670091 1 Circlip, Drive Shaft5 5411106 1 Boot, CV Joint6 1380094 1 Shaft, Replacement (Incl. 4)7 1380092 1 Cardan, Replacement (Incl. 4,6,8,9)8 2200771 1 Kit - Cross and Bearing

9 3260130 1 Yoke, Splined10 7661913 2 Pin, Spring11 7571605 2 Washer,12 7080627 1 Clamp, Band, Small13 2200773 1 Kit - Replacement Boot, CV Joint

(Incl. 3,5,12)14 2200961 2 Kit - Drive Shaft w/Sleeve

5/98

Page 22: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B7

FRONT STRUTBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

5

6

78

910

11

13

15

1619

20

12

14

24

25

27

26

23

22

21

4321

18

9

171718

9

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5430806 2 Pivot, Ball, Top5 5411608 2 Bumper6 7041761 2 Strut, Front7 5211115 2 Washer8 7080573 2 Clamp, Rubber Coated9 7558402 12 Washer

10 7542303 4 Nut, FLEXLOC11 7512365 4 Screw12 7552901 4 Washer, Spring Lock13 5810439 2 Retainer, Strut Casting Wire14 7080306 2 Fitting, Lubrication w/Ball15 –––––––– 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B9)

16 5222193 2 Sleeve, Hubstrut Seal17 3554507 4 Bearing, Tapered Roller Cup18 3554509 4 Bearing, Tapered Roller19 4170010 2 Coil, Magnetic20 1843073

1843074

1

1

Asm., Hubstrut, Service, LH (Incl. 13,14,17,19,21)Asm., Hubstrut, Service, RH (Incl. 13,14,17,19,21)

21 3610028 2 Seal, Hubstrut22 ––––––– 1 Asm., Drive Shaft w/Sleeve

(See CV Joint Pg. B6, Ref. 14)23 7515339 4 Screw24 7041450-067 2 Spring, Coil25 5243364 2 Retainer, Spring26 5132062 2 Spacer27 5430807 2 Pivot, Ball, Bottom

1/99

Page 23: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B8

FRONT WHEELBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

10

11

1214

12

34

5

7

9

8

15

1625

24 7

2021

23

DETAIL A

A

136

6

22

17

19

18

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7512325 8 Screw2 5211326 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub w/Bearing Race

(Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter

13 1321814 2 Spacer14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5410947 2 Tire (25x8-12), Tracker17 7556004 2 Washer18 7542810 2 Nut19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520179-117 2 Rim, Front25 1525017 2 Valve, Rim

1/99

Page 24: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B9

FRONT BRAKEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

23

9

10

12

11

131415

6

4 5 78

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1910234 1 Caliper, Front Brake, LH1910235 1 Caliper, Front Brake, RH1930642 1 Kit - Front Brake Boot

1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

4 5410779 1 Ring, Square Molded (.094”)5 5410780 1 Ring, Square Molded (.103”)6 1930665 1 Kit - Piston and Insulator Seal

(Incl. 4,5,7,8)7 5020506 1 Piston, Caliper

8 5910026 1 Insulator, Caliper9 2200465

22011492200901

1

11

Kit - Brake Pad, Front(Complete set of 4 pads)Kit - Front Brake Pad, SoftKit - Front Brake Pad, Severe

10 1910056 2 Mount, Caliper11 5410495 1 Boot, Bushing12 5410494 1 Boot, Pin Seal13 7558402 4 Washer14 7552901 4 Washer, Spring Lock15 7512365 4 Screw

5/98

Page 25: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B10

STEERING – HANDLEBARBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

3

6

7

13

810 11

12

14

7

16171819

20

23

24

2526

30

31

1 2

15

2221

21

2728

29

54

9

32

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 ––––––– 1 Asm., Throttle Control(See Controls-Throttle Asm./CablePg. C1, Ref. 5)

2 7515189 4 Screw3 5810379 1 Pad, Handlebar4 7556033 2 Washer5 7517395 2 Screw6 5220946 1 Mount, Handlebar Pad7 5630616-067

220077421

Block, Handlebar RetainerKit - Handlebar Block(Incl. 2,7,16)

8 ––––––– 1 Asm., Master Cyl. (See Controls-Master Cylinder Brake Line Pg. B13for Details)

9 5433198 1 Spacer, LH10 4110205 1 Switch, Handlebar Hi/Low/Off w/

Connector, LH11 5431030 2 Grip, Handlebar12 2010055 2 Screw13 5243138-067 1 Tube, Handlebar14 5222269-067 1 Bracket, Speedometer

15 7080631 1 Clip, Cable Retaining16 7542122 4 Nut, Nylok17 7660701 2 Pin, Cotter18 5211189 2 Plate, Speedometer Mounting19 5810442 2 Spacer, Speedometer Mounting20 3280216 1 Cable, Speedometer21 7555725 3 Washer, Wrought22 7515378 2 Screw23 3280220 1 Adaptor, Drive24 7542324 1 Nut, Nylok25 3280217 1 Key26 3280164 1 Seal, Angle Drive27 5020741 1 Bushing, Speedometer28 ––––––– 1 Shaft, Output

(See Gear Case Pg. D8, Ref. 55)29 4030015 1 Bulb, Taillight30 5410546 1 Mount, Speedometer31 3280129

328013511

Speedometer, Faria (US)Speedometer, Kilometer (Int’l)

32 5433199 1 Spacer, RH

1/99

Page 26: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B11

STEERING POSTBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

5

67

89

4

32

1

14

18

1617

12

16

15

11

17

13

10

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7515321 2 Screw2 5220965-067 1 Bracket, Ignition Panel3 7080510 1 Fitting, 90 Degree4 5431573 1 Bushing, Steering Console5 1843051-067 1 Asm., Steering Post (Incl. 10,18)6 7542324 2 Nut, Nylok7 7558402 2 Washer8 5222999-067 1 Bracket, Upper Steering Bushing9 5431572 1 Bushing, Steering Console

10 7080433 1 Fitting, Lubrication11 7661632 2 Rivet12 5431570 1 Bushing, Steering, Lower13 5431571 1 Spacer, Steering Post14 7661633 1 Pin, Cotter15 7543203 1 Nut16 7555878 3 Washer17 5410772 2 O-Ring18 5431574 1 Plug, Grease, Steering

5/98

Page 27: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B12

A–ARM/STRUT MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

2

13

45

6

78

9

10

11

12

14

15

17

16

18

19

24

25

2322

21

2627

27 26

2221

28

20

29

12

13

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 5411291 2 Seal, Boot4 7061034 2 Rod End, RH5 7542711 2 Nut6 5020926 2 Tie Rod7 7547028 2 Nut, LH8 7061033 2 Rod End,LH9 1820567 2 Asm., Tie Rod(Incl. 3-8)

10 7555806 4 Washer11 7546904 2 Nut12 7661203 4 Pin, Cotter13 ––––––– 1 Asm., Hubstrut

(See Front Strut Pg.B7, Ref. 20)14 7080673 2 Joint, Ball, High Angle15 5211121 2 Bracket, Ball Joint16 7512284 4 Screw

17 5410548 2 Boot, Rubber18 7542438 2 Nut19 7512084 4 Screw20 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

21 5431596 2 Bushing, Long22 5020677 4 Bushing23 5020681 2 Shaft, A-Arm24 2200627

2200628

1

1

Kit - A-Frame, LH(Incl. 12,22-27)Kit - A-Frame, RH(Incl. 12,22-27)

25 7080433 2 Fitting, Lubrication26 7512492 4 Screw27 7552603 4 Washer, Spring Lock28 7517527 1 Screw29 7515415 1 Screw

5/98

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B13

CONTROLS – MASTER CYLINDER/BRAKE LINEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

4

5

11

12

25

10

1

2

3

22

24

1615

18

19

2023

17

14 136

7

9

8

26

21

27

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

2050073

2200809

1

1

Asm., Master Cylinder(Incl. 1-12,25)Kit - Master Cylinder Reservoir (Incl. 1-3,25)

1 1930797 2 Screw, Cap, Master Cylinder2 1930796 1 Cap, Reservoir, Master Cylinder3 1930795 1 Diaphragm, Master Cylinder4 2200808 1 Kit - Clamp, Master Cylinder5 1930799 1 Asm., Piston, Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever, w/Parking. Brake

Latch (Incl. 6-9)8 ––––––– 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8,9)

10 1930806 2 Nut11 1930792 1 Screw12 1930805 1 Screw

13 7621462 2 Rivet, Pop14 7080539 2 Clamp, Cable, Nylon15 1930752 1 Line, Brake, Left Front w/Fittings16 8360031-30 1 Conduit17 7512024 2 Screw18 8360031-38 1 Conduit19 1930753 1 Line, Brake, Front, RH w/Fittings20 7052103 1 Fitting, Inverted Flare Cross21 5411297 1 Boot, Brake Line, Rubber22 1930891

541129711

Line, Brake, LH w/BootBoot

23 4110164 1 Switch24 1930751 1 Line, Brake, Rear25 ––––––– 1 Reservoir26 5410988 2 Seal27 1930674 1 Bolt, Banjo

6/98

Page 29: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

B14

CONTROLS – RH MASTER CYLINDER/BRAKE LINEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

4

5

6

7

12

10

14

15

16

13

17

18

8

3

98

11

1

23

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

2050075

2200809

1

1

Asm., Master Cylinder(Incl. 4-7,10-18)Kit - Reservoir (Incl. 4-7,12)

1 1910126 1 Junction w/Bleeder2 1930743

708035221

Line, Brake w/FittingScrew, Bleeder

3 1930732 1 Line, Brake4 1930797 2 Screw5 1930796 1 Cap, Reservoir6 1930795 1 Diaphragm, Master Cylinder7 ––––––– 1 Reservoir8 5410469 2 Washer

9 1930674 1 Bolt10 1930687 1 Screw11 ––––––– 1 Seal, Reservoir12 1930807 2 Screw13 1930688 1 Nut14 5630362 1 Lever, Brake, RH15 2200805 1 Kit - Rebuild, Master Cylinder16 1930788 1 Nut17 1930786 1 Washer, Lock18 1930787 1 Screw

5/98

Page 30: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C1

CONTROLS – THROTTLE ASM./CABLEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1 2

3

4

5

8

9

10

11

13

12

5

7

6

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 2010079 3 Screw2 7072724 1 Decal - Throttle3 2010080 1 Cap4 2010081 1 Packing5 2010160 1 Asm., Throttle Control (Incl. 12)6 4110246 1 Switch, AWD w/Connector7 4030047 1 Bulb, Demand Drive Indicator

8 2010078 1 Holder9 2010077 2 Screw

10 2010076 1 Screw11 2010075 1 Plate12 4110245 1 Switch, ETC w/Connector13 7080649 1 Cable, Throttle Control

5/98

Page 31: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C2

MIDDLE AXLE BRAKEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1

23

4 5 67

910

11

12

131415

8

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1930663 1 Caliper, LH1930664 1 Caliper, RH

1 7080352 2 Screw, Bleeder (1 per Assembly)2 7515489 2 Screw, Socket Set (1 per Assembly)3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

4 5410779 1 Ring, Square, Molded5 5410780 1 Ring, Square, Molded6 5020506 1 Piston, Caliper7 5910026 1 Insulator, Caliper

8 1930665 1 Kit - Piston & Insulator Seal1930642 1 Kit - Front Brake Boot

9 2200465 1 Kit - Front Brake Pad (4 Pads)10 1910037 2 Mount, Caliper11 5410495 1 Boot, Bushing12 5410494 1 Boot, Pin Seal13 7558402 4 Washer14 7552901 4 Washer, Spring Lock15 7512365 4 Screw

5/98

Page 32: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C3

MIDDLE DRIVEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1 2 3 67

9 10

11

1617

18

15

19

145

13 12

2524

21

2223

26

28

1429

768

20

3 3031

8

4

4

4

4

20

5

527

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7710414 1 Ring, Retaining2 5020530 1 Spacer, Bearing, LH3 5410541 2 O-Ring4 3610013 4 Seal, Rear Axle5 7080306 3 Fitting, Lubrication w/Ball6 5130945 2 Housing, Swing Arm7 3514807 2 Bearing, Swing Arm Pivot8 3610024 2 Seal, Inner Swing Arm Pivot9 1910041-067 1 Brake, Hub

10 5211326 1 Disc, Brake11 7515488 6 Screw12 3225024 1 Link, Connector, Drive Chain13 5020803 1 Axle, Middle14 3515501 2 Bearing, Axle, Rear15 5410537 1 O-Ring16 1930663

193066411

Caliper, Brake, LHCaliper, Brake, RH

17 5130944 1 Mount, Brake Caliper18 3515502 1 Bearing, Brake Caliper Mount19 5020531 1 Spacer, Bearing Center20 5130663 1 Housing, Axle21 3224042 1 Chain, Drive, 88P22 5332935 6 Spacer23 3224055 1 Chain, Drive 116P24 3222047 1 Sprocket, 30T25 7542403 6 Nut, FLEXLOC26 3222070 1 Sprocket, 42T27 7515520 6 Stud, Sprocket Mount28 1520172 1 Hub, Sprocket29 5010204 1 Tube, Bearing Spacer30 5020532 1 Spacer, Bearing, RH31 7543601 2 Nut, Jam

5/98

Page 33: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C4

CENTER TIGHTENERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

15

16

109

7

8

2

34 5

6

1

11

12

1314

87

2

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1380143 1 Asm., Center Tightener (Less 3,13)1 5020934 1 Shaft, Center Tightener, Long2 3610017 2 Seal, Tightener, 4WD3 3221043 1 Sprocket, 11T, Splined4 7555815 1 Washer5 7571611 1 Washer, Dish Lock6 7512492 1 Screw7 3554506 2 Bearing, Tapered Roller Cone8 3554507 2 Bearing, Tapered Roller Cup

9 1380145 1 Asm. Center Eccentric w/Cups(Incl. 8,10)

10 7080306 1 Fitting, Lubrication w/Ball11 5410463 1 O-Ring12 5010450 1 Spacer, Tapered, Long13 3222051 1 Sprocket, 24T14 7555788 1 Washer15 7542810 1 Nut16 7661402 1 Pin, Cotter

6/98

Page 34: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C5

MIDDLE WHEELBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1

2

3

9

4

8

7

5

6

11

987

65

10

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 ––––––– 2 Nut, Jam (See Middle Drive Pg.C3, Ref. 31)

2 1520102-067 2 Hub, Wheel3 5410948 2 Tire (25x11-10)4 7542714 8 Nut, Wheel5 7661404 2 Pin, Cotter

6 5411164 2 Hub, Dust Cover7 7543005 2 Nut, Castle8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim

10 7512660 8 Screw11 1520183-117 2 Rim, Rear

5/98

Page 35: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C6

SWING ARM/SHOCK MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

2

3

4

1

5

6

7 8 910

11

20

109

87

13

12

15

19

14

15

12

13

18

1716

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7041305-067 1 Spring, Rear Compression2 7542439 2 Nut, Nylok3 7515415 1 Screw4 5220225 1 Retainer, Spring, Top5 7041220 1 Shock, Middle6 5210953 1 Retainer, Spring7 5240952 2 Bushing, Thrust, Steel8 5431977 2 Bushing, Thrust9 7555911 2 Washer

10 7542602 2 Nut, Nylok

11 ––––––– 2 Bushing, Pivot (See Gearcase Pg.D8, Ref. 4)

12 5020793 2 Bushing, Swing Arm Extended13 5220958 2 Plate, Screw Lock14 7512702 1 Screw, Shoulder15 5431972 4 Bushing16 7074177 1 Decal - Chain Tension17 1580091 1 Arm, Swing18 7515438 1 Screw19 7080438 2 Fitting, Lubrication, 45 Degree20 7512703 1 Screw, Shoulder

1/99

Page 36: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C7

SWING ARM/GUARD MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

3

1

4 5

67 11

12 13

1514

16

1718

1920

22

24

25

26

25

30

14

27

31

2

8

28

21

9

29

10

23

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5130945 2 Housing, Swing Arm2 7542522 4 Nut3 7512569 2 Screw4 1580067-067 2 Bracket, Swing Arm Extended5 7512520 2 Screw6 5130663 1 Housing, Axle7 7080306 3 Fitting, Lubrication w/Ball8 7512576 2 Screw9 5130712 1 Holder, Brake

10 5222220-067 1 Bracket, Front Chain Guard11 ––––––– 1 Arm, Swing (See Swing Arm Shock/

Mounting Pg. C6, Ref. 17)12 7621433 2 Rivet, Pop13 5431310 1 Guide, Chain14 7558402 3 Washer15 7542321 1 Nut, Flange

16 5430776 1 Guard, Chain17 5332828 1 Bushing18 7515304 1 Screw19 7512252 4 Screw, Tap20 7558301 4 Washer21 7074214 1 Decal - Lubrication22 5431102 1 Guard, Chain, Front23 7555904 2 Washer24 7661645 2 Rivet, T-Lock25 7512325 4 Screw26 1040522-067 1 Guard, Swing Arm27 7552901 2 Washer, Spring Lock28 7542503 2 Nut, FLEXLOC29 7555883 2 Washer30 5222221-067 1 Mount, Rock Guard Bracket31 7542324 2 Nut, Nylok

5/98

Page 37: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C8

DRIVE CLUTCHBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1 2

3 4

56

7

8

5

9

10

11

1213

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1321632 1 Asm., Clutch, Drive (Incl. 1-3,5-11,13)

1 7512176 6 Screw2 7552801 6 Washer, Spring Lock3 3576510 1 Bearing, Cover4 7041157 1 Spring, Clutch5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 5430945 6 Washer, Multilube

8 1321457 3 Roller and Bushing9 5210752

524298152107535210754

ARARARAR

Spacer (.020”)Spacer (.025”)Spacer (.032”)Spacer (.050”)

10 3576504 1 Bearing, Moveable, 1/2”11 7541906 3 Nut, FLEXLOC12 5630513 3 Weight, Shift, 10-MH13 7512266 3 Bolt, Shoulder

5/98

Page 38: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C9

DRIVEN CLUTCHBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

3

4

56

7

8

10

11

12

13

15

1617

4

12

9

14

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5010379 1 Spacer, Driven Clutch2 7556401 AR Bushing3 3211048 1 Belt, Drive4 1322180 1 Asm., Driven Clutch (Incl. 8-17)5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515327 1 Screw8 7555898 AR Washer9 7556804 AR Washer

10 7556076 1 Washer11 3514314 1 Bushing, Moveable, 1”12 7041198 1 Spring, Clutch, Red13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Screw17 5430766 3 Button, Ramp

1/99

Page 39: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C10

CLUTCH COVERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

34

5 67

9

10

11

12

8

14

15

16

17

18

1920

1

4

25

13

24

2321

5

2

22

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5432698 1 Duct, Inlet Down Tube2 5411180 2 Seal, Cover Case3 2200791 1 Kit - Cover, Clutch, Inner4 7555748 3 Washer5 7517219 3 Screw6 5521301 1 Seal, Clutch Cover7 5432849 1 Cover, Clutch, Outer8 7670051 1 Clip, Clutch Cover9 7512093 5 Screw

10 7074946 1 Decal - Clutch Cover11 7077377 1 Decal - Eng/Clutch Modification12 7074782 1 Decal - Automatic Trans.13 7512094 2 Screw

14 7080761 2 Cable Tie15 5411489 1 Boot, Intake16 7515180 1 Screw17 5432953 1 Duct, Clutch Outlet18 ––––––– 3 Screw and Washer

(See Crankcase Pg. D11, Ref. 6)19 5240409-067 1 Bracket, Retainer Seal20 5410575 1 Seal, Cover Case21 7512095 1 Screw22 7555935 1 Washer23 5241213-067 1 Bracket, Clutch Cover24 7661638 2 Rivet25 7080511 1 Clamp, Narrow Band

1/99

Page 40: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C11

REAR BRAKEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1

2

356

8

7

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 1910125

1910130

51311755130946

1

1

11

Asm., Brake Caliper, Rear (US)(Incl. 2,6,8)Asm., Brake Caliper (Int’l)(Incl. 2,6,8)Caliper, Brake, Rear (US)Caliper, Brake, Rear (Int’l)

2 7661820 2 Pin, Brake Caliper3 2200464

22011502200899

111

Kit - Brake Pad (Incl. 2)Kit - Rear Brake Pad, SoftKit - Rear Brake Pad, Severe

4 54107665410767

11

Ring, Square, Molded (.134 Sq.)Ring, Square, Molded (.099 Sq.)

5 –––––––– 1 Piston, Brake6 2200463 1 Kit - Piston & Seal (Incl. 4,5)7 5240993 1 Spring, Anti Rattle8 7080352 1 Screw, Bleeder

1/99

Page 41: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C12

FOOT PEDAL and P ARKING BRAKEInt’l Big Boss 500 6X6 SL A99AE50DA

15

1

2

3

4

8

5

16

15

9

11

10

12

132

14

19

8

1820

6

7

17

21

8

21

2

2

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1910154 1 Asm., Brake Lock w/Foot Brake(Incl. 2-5,8,13,14)

1 7670063 1 Pushnut2 7558201 8 Washer3 7041365 1 Spring, Brake Lock4 5224548 1 Rod, Brake Lock5 5240525 1 Stand-Off6 5431107 2 Bushing, Pedal Pivot7 7555919 2 Washer8 7661010 3 Pin, Cotter9 7542124 2 Nut

10 7555843 2 Washer, Flat

11 5240526 1 Catch12 7515101 2 Bolt13 5240524 1 Flipper14 7661640 1 Pin, Clevis15 7555806 2 Washer16 7512024 2 Screw17 7661401 1 Pin, Cotter18 7042029 1 Spring, Exhaust19 1910144-067 1 Brake, Foot20 5224531 1 Rod, Brake21 7661203 2 Pin, Cotter

1/99

Page 42: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C13

GEARCASE/BRAKE and CHAIN COVER MOUNTINGBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

12 3

56

9 8

10

7

33323111

2928

34

35

3637

8 938

4

11

414240

3939

2726

1213

214

1615

21

2324

30

21

253

17

18

20

19

22

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7515345 2 Screw2 7552901 3 Washer, Spring Lock3 7558402 3 Washer4 7075339 1 Decal - Brake Shield5 5241018-067 1 Shield, Caliper, Rear6 1910125 1 Caliper, Brake, Rear7 ––––––– 1 Plate, Screw Lock

(See Swing Arm/Shock MountingPg. C6, Ref. 13)

8 7552603 2 Washer, Spring Lock9 7515522 2 Screw

10 ––––––– 1 Screw, Shoulder(See Swing Arm/Shock MountingPg. C6, Ref. 14)

11 1590265 1 Asm., Output Shaft, Needle Bearing(Incl. 39-42)

12 7555701 1 Washer13 7515321 1 Screw14 5432254 1 Guard, Center Chain NOTE:

17-20,22 Inside Chain Guard15 7552606 1 Washer, Split16 7515384 1 Screw17 5811760 1 Foil, Chain Guard18 5811757 1 Foil, Chain Guard19 5811759 1 Foil, Chain Guard

20 5811758 1 Foil, Chain Guard21 7512269 2 Screw22 5811054 1 Foil, Tape23 7552605 1 Washer, Lock24 7555843 1 Washer, Flat25 5333254 1 Spacer26 3221058 1 Sprocket, 11T27 7710433 1 Ring, Retaining28 1910177 1 Asm., Disc, Brake29 7542449 2 Nut30 7670060 1 Nut, Speed31 7515484 2 Bolt, Carriage32 7710434 1 Ring, Retaining33 3221044 1 Sprocket, 12T, Splined34 7542403 1 Nut, FLEXLOC35 7515472 1 Screw36 7542404 1 Nut37 7515485 1 Screw38 7555806 1 Washer39 3610062 2 Seal, Brake40 3554202 1 Bearing, Needle41 7080433 1 Fitting, Lubrication42 5131643 1 Housing, Bearing, Output Shaft

1/99

Page 43: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

C14

REAR WHEEL DRIVEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 6X6 SL A99AE50DA

1 2

34

5

6

7

11

8

12

9

13

14

10

15

16

1718

1920

21

22

23

26

2425

27

28

2120

19

54

3

8129

14

13

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7555764 1 Washer2 5020468 2 Nut, Jam, Rear Axle3 7512673 8 Screw4 2200341 1 Kit - Service, Rear Hub (Incl. 12)5 7670081 8 Retainer, Screw, Pushnut6 5410948 2 Tire (25x11-10)7 1525017 2 Valve, Rim8 7555745 2 Washer, Flat9 7543005 2 Nut, Castle

10 3225024 1 Link, Connector, Drive Chain11 7542714 8 Nut, Wheel12 7555796 2 Washer, Cone13 7661404 2 Pin, Cotter14 5411164 2 Hub, Dust Cover

15 3224055 1 Asm., Drive Chain, 116P16 7515488 6 Screw17 3222047 1 Sprocket, 30T18 1380026-067 1 Sprocket, Hub, Extended19 5410415 2 O-Ring20 3610013 2 Seal, Rear Axle21 3515501 2 Bearing, Rear Axle22 5010204 1 Tube, Bearing Spacer23 5130663 1 Housing, Axle24 5010206 1 Spacer, Bearing25 7710405 1 Ring, Retaining26 7080306 1 Fitting, Lubrication w/Ball27 5020789 1 Axle, Rear, Wide28 1520183-117 2 Rim, Rear

5/98

Page 44: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D1

REAR STRUT STABILIZERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

8

11

5

9

4

13

126

32

1

7

10

6

6

321

32

1

4

5

5

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7555832 6 Washer2 7552603 6 Washer, Spring Lock3 7512492 6 Screw4 5431596 2 Bushing, A-Arm, Long5 5020677 6 Bushing6 7080433 3 Fitting, Lubrication7 5020764 1 Shaft, A-Arm, Upper

8 15800811580082-067

11

Stabilizer, Strut, RearStabilizer, Upper

9 5020765 1 Shaft, A-Arm, Middle10 5020766 1 Shaft, A-Arm, Lower11 1580083-067 1 Stabilizer, Lower12 5432091 2 Bushing, A-Arm, Short13 5431845 2 Bushing, Stabilizer, Long

5/98

Page 45: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D2

SWING ARM WELDMENT (REAR)Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

91011

8

12

13

14

15

7

16

17

19

23 21

22

20

28

26

1825

32

31 30

29

12

6

3

4

5

2627

27

202524

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5130663 1 Housing, Axle2 7517433 1 Bolt3 5630351 1 Adaptor, Spring Seat4 1580078

1580053-06711

Asm., Strut, Rear (Incl. 3,5)Strut, Rear

5 1580070 1 Cap, Striker6 5333172 1 Tube7 7041303-067 1 Spring, Compression8 5410535 1 Bumper, Shock9 7542507 1 Nut, FLEXLOC, Thin

10 7555749 1 Washer11 5810291 1 Spacer, Rubber12 5430806 1 Ball, Pivot, Top13 5130631 1 Spacer, Threaded14 5430807 1 Ball, Pivot, Bottom15 7555740 1 Washer, Flat16 1580055-067 1 Extension, Swing Arm

17 7512252 3 Screw, Tap18 7558301 1 Washer19 5521279 1 Guide, Chain, Rear20 7515321 3 Bolt21 7515117 1 Screw22 1040287-067 1 Extension, Chain Guard , Lower23 7541925 1 Nut, Nylok24 7558402 1 Washer25 7542324 3 Nut, Nylok26 7542503 3 Nut, FLEXLOC27 7555883 2 Washer28 5431556 1 Guard, Chain Extension, Top29 7080306 1 Fitting, Lubrication w/Ball30 7512576 2 Bolt31 2200472 1 Kit - Hitch32 7078261 1 Decal - Hitch

1/99

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D3

ELECTRICAL/TAILLIGHTBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

9

30

24

27

1

23

3334

2829

31

25

32

23

36

20

39

41

111310

38

35

24

26

40

14

7

6

8

5

12

4

19

1817

16

15

23

42

202221

37

14

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 2460606 1 Harness, Main Wire Connector2 2434012 1 Breaker, Circuit, 20 Amp3 7080138 12 Cable Tie4 7670054 2 Nut, Speed5 7555916 2 Washer, Nylon6 5211391-067 1 Isolator, Taillight7 ––––––– 1 Bracket, Taillight Mount (See Rear

Bed Mounting Pg. A8, Ref. 27)8 7621470 2 Rivet, Pop9 7621336 1 Rivet

10 2410023 1 Plug, Power, 12V11 7080524 1 Clamp, Plastic12 2432034 1 Taillight w/Brakelight13 2460442 1 Power, Pigtail14 7512027 4 Screw15 4032029 2 Screw, Taillight16 4032046 1 Lens, Taillight17 4030043 1 Bulb, Taillight18 4032045 1 Gasket, Taillight19 4032064 1 Backing, Tail/Brakelight20 5210650 1 Sink, Heat21 8360012-13 1 Trim, Edge

22 4010248 1 Limiter, Speed, 650 HZ (Int’l)23 7541925 4 Nut, Nylok24 7571602 4 Washer25 5810290 3 Pad, Battery26 5431769 1 Cover, Battery27 2200361 2 Kit - Battery Bolt, Short28 4010095 1 Cable, Battery/Engine29 7010032 2 Hook, Battery Strap30 5410424 1 Strap, Battery Holddown31 5432077 1 Tube, Battery Vent32 4140006 1 Battery33 4010094 1 Cable, Battery/Solenoid34 4010093 1 Cable, Solenoid/Starter35 7512018 4 Screw36 7512007 2 Bolt37 2460637 1 Adaptor, Harness Jumper (Int’l)38 5131036 1 Sink, Heat39 4060173 1 Rectifier, LR-3940 5240428 1 Bracket, CDI41 4060204 1 Limiter, RPM LR44-242 8360011-15 1 Tubing, Convoluted

1/99

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D4

TOOL KITBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

2

3

4

5

6

7

9

8

1

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

2871265 1 Asm., Tool Kit (Incl. 1-7)1 2870725 1 Gauge, Tire Pressure2 3085001 1 Wrench, Open 8-10mm3 3085002 1 Wrench, Open 12-14mm4 3085567 1 Wrench, Box5 3085569 1 Handle, Wrench

6 3082657 1 Screw Driver, Phillips7 2690016 1 Pouch, Tool Kit8 2460442 1 Pigtail, Power9 9914919 1 Manual, Owner’s, 99 Big Boss 500

6X6

5/98

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D5

GEAR SELECTORBig Boss 500 6X6 A99AE50AA

15

22

20

21

1819

24

23

12

3

4

5

6

7

8

9

28

10

11

12

13

14

16

17

25

29

30

2726

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1341219 1 Asm., Gear Selector (US)(Incl. 1-17,25-30)

1 3233195 1 Knob, High/Low/Reverse2 7512024 1 Screw3 3233131 1 Strap, Wire4 3233132 1 Clamp5 3233368 1 Boot, Gear Selector6 3233213 1 Cover, Gear Selector7 3233158 1 Spring, Holding8 3233227 1 Subasm., Handle9 3233063 1 Cup, Bearing

10 3233083 1 Spring, Centering11 3233062 1 Pin, Stop12 3233069 2 Spring, Detent13 3233060 2 Bullet, Detent14 3233455 1 Switch, Gear Selector

15 3233090 1 Strap, Wire16 3233216 1 Body, Gear Selector17 3233217 1 Slide, High/Reverse18 7061014 2 Rod End, RH19 7546702 2 Nut, LH20 5020703 1 Rod, Shift Linkage, High Range21 7061013 2 Rod End, LH22 5020702 1 Rod, Shift Linkage, Low Range23 7546701 2 Nut, RH24 7546707 4 Nut, FLEXLOC25 3233218 1 Slide, Low26 7558301 1 Washer27 7515181 3 Screw28 3233084 1 Butterfly, Interlock29 3233070 1 Pin, Interlock30 3233085 5 Screw

1/99

Page 49: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D6

GEAR SELECTORInt’l Big Boss 500 6X6 SL A99AE50DA

12

3

4

5

6

7

8

910

11

12

13

1415

16

17

18

1920

2122

23

24

26

2728

29

30

31

25

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1341303 1 Asm., Gear Selector (Int’l)1 3233196 1 Knob, High/Low/Reverse2 7512024 1 Screw3 3233131 1 Strap, Wire4 3233132 1 Clamp5 3233368 1 Boot, Gear Selector6 3233213 1 Cover, Gear Selector7 3233158 1 Spring, Holding8 3233227 1 Subasm., Handle9 3233063 1 Cup, Bearing

10 3233083 1 Spring, Centering11 3233062 1 Pin, Stop12 3233069 2 Spring, Detent13 3233060 2 Bullet, Detent14 3233455 1 Switch, Gear Selector15 3233090 1 Strap, Wire

16 3233216 1 Body, Gear Selector17 3233570 1 Slide, High/Reverse18 7061014 2 Rod End, RH19 7546702 2 Nut, LH20 5020703 1 Rod, Shift Linkage, High Range21 7061013 2 Rod End, LH22 5020702 1 Rod, Shift Linkage, Low Range23 7546701 2 Nut, RH24 7546707 4 Nut, FLEXLOC25 3233076 2 O-Ring26 3233089 1 Slide, Low27 7558301 1 Washer28 7515181 3 Screw29 3233084 1 Butterfly, Interlock30 3233070 1 Pin, Interlock31 3233498 5 Screw

1/99

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D7

GEARCASEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

2

3 45

6

78

910

1112

131415

1514

1312

1110

16

17

18

20

21

17

19

22

2324 2526

2728

29

3031

3230

27 3334

37

19

19

38

439

40 414243 44

454647 3

4849

50

215152

5354

55

56

52

6

35 36

57

3

Page 51: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D8

GEARCASEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1341184 1 Asm., Gearcase (Incl. 1-38,47-57)

1 3233002 1 Case, LH2 3233026 10 Screw3 3233248 3 Seal4 3233024 2 Bushing, Pivot5 3233025 1 Stud6 3233021 2 Pipe, Knock7 3233022 1 Rail, Shift, Low8 3233023 1 Rail, Shift, High/Reverse9 3233151 1 Shaft, Low Shift

10 3233548 2 O-Ring11 3233040 2 Washer12 3233045 2 Ring, Retaining13 3233153 2 Bell Crank, High/Low/Reverse14 3233054 2 Washer15 3233055 2 Nut16 3233152 1 Shaft, High/Reverse Shift17 3233031 2 Pin18 3233030 1 Bracket19 3233018 3 Bearing20 3233032 1 Spring21 3233033 4 Screw22 3233361 1 Shaft, Input, 31T23 3233019 1 Bearing24 3233007 1 Washer25 3233125 1 Gear, 33T26 3233009 1 Bearing, Needle27 3233010 2 Washer28 3233126 1 Engagement Dog, Low29 3233362 1 Shaft, Reverse, 29T30 3233012 2 Washer31 3233036 1 Chain, Silent, 34P, 11W32 3233029 1 Ring, Retaining33 3233359 1 Gear, 30T34 3233017 1 Bearing, Needle

35 3233176 1 Washer, Thrust36 3233177 1 Ring, Retaining37 3233037 1 Vent38 3233478 1 Dipstick39 ––––––– 1 Disc, Brake

(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 28)

40 ––––––– 1 Ring, Retaining(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 32)

41 ––––––– 1 Sprocket, 11T(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 26)

42 ––––––– 1 Washer(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 12)

43 ––––––– 1 Washer(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 2)

44 ––––––– 1 Screw(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 13)

45 ––––––– 1 Ring, Retaining(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 27)

46 ––––––– 1 Sprocket, 12T(See Gearcase/Brake and ChainCover Mounting Pg. C13, Ref. 33)

47 3233448 1 Plug48 3233035 1 Washer49 3233003 1 Case, RH50 3233043 1 Deflector, Oil51 3233128 1 Engagement Dog, High/Reverse52 3233020 2 Bearing53 3233014 1 Bearing, Needle54 3233127 1 Sprocket, 24T55 3233150 1 Shaft, Output56 3233360 1 Gear, Output, 100T57 5020741 2 Bushing, Speedometer

1/99

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D9

CYLINDERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

2

20

38

2223

21

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

18

Page 53: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D10

CYLINDERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3083166 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 1 Adapter, Water Out9 3084877 10 Bolt, Flange

10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange20 3085075 1 Gasket, Exhaust

21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer, Lock24 3084880 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3085634 1 Cylinder (Incl. 32)32 3084130 1 Elbow Pipe 233 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3084869 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head

(Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3084879 1 Adapter

5/98

Page 54: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D11

CRANKCASEBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

2

4

10

11

2

19

20

1

22

7

5

16

3

1817

9

1514

1213

21

6

5

8

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3083669 1 Bushing, Starter2 3085633 1 Asm., Crankcase

(Incl. 1,4,5,7,8,10,11,16,19,20,22)3 3084838 2 Pin, Straight4 3080676 3 Ball Bearing5 3084840 2 Pin, Dowel6 3084205 5 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3084842 2 Union

10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, One Way Valve15 3084843 1 Valve, One Way16 3084841 10 Bolt, Flange17 3082956 1 Gasket18 3083453 1 Plug19 3084837 1 Seal, Mechanical20 3084836 1 Seal, Oil21 3084847 1 O-Ring22 3080103 2 Pin, Dowel

5/98

Page 55: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D12

CRANKSHAFT and PISTONBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

19

20

6

10

1412

5

8

18 13

9

17

7

2

11

1

15

21

16

3

4

1

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3085534 2 Clip2 3085533 1 Pin, Piston3 3085866

3085867

3085868

1

1

1

Asm., Piston and Pin (Standard) (Incl. 2,3) Asm., Piston and Pin (0.25 O/S) (Incl. 2,3)Asm., Piston and Pin(0.50 O/S) (Incl. 2,3)

4 308537930853803085381

111

Piston Ring Set (Std)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

5 3085374 1 Crankshaft 26 3085341 1 Pin, Crank7 3085376 1 Rod, Connecting8 3085400 1 Bearing, Large End9 3085024 1 Ball, Steel

10 30853993085373

11

Asm., Crankshaft (Incl. 5-11,19)Crankshaft 1

11 3085852 1 Balancer Gear 112 3085404 1 Asm., Balancer Shaft13 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

14 3240088308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3083904 1 Washer18 3083905 1 Nut, Lock19 3085346 1 Pin, Dowel20 3081447 1 Key21 3080130 1 Key, Woodruff

5/98

Page 56: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

D13

INTAKE and EXHAUSTBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

14

18

15

16

17

25

26

13 1211

10

6

98

22

7

20

8

21

24

4

3

21

5

19

27

23

89 6

9

1211

13

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3084919 1 Spring, Tensioner4 3084918 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Rocker Arm, Intake (Incl. 8,9)7 3084913 1 Asm., Rocker Arm, Exhaust

(Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting

10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3084907 4 Retainer, Spring13 3084906 4 Spring, Valve

14 3084898 1 Camshaft (Incl. 15-18)15 3080103 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3081657 3 Bolt and Washer20 3084914 1 Sprocket 221 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3084905 2 Valve, Exhaust27 3084874 2 Bolt, Flange

5/98

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D14

WATER PUMPBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

11

7

83

3

2

1

9

12

13

4

10

65

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084940 1 Thermostat2 3085352 1 Switch, Thermostat3 3084191 2 Clamp, Hose4 3085857 1 Hose, Main5 3085359 1 Bolt, Flange6 3082758 1 Gasket, Aluminum7 3085351 1 Cover, Water Pump

8 3084937 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock

10 3083138 1 Gasket11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

5/98

Page 58: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

E1

CARBURETORBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

47

37

34

9

50

5

49

12

4

6

4142

38

36

1235

13 1214

15

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

40

23

51

4445

87

46

39

33

32

31

28

17

48

43

Page 59: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

E2

CARBURETORBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3130507 1 Ring2 3130508 1 E-Ring3 3130900 1 Needle, Jet (4D33-3)4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3130899 1 Jet, Needle (Q-6)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Block, Jet

10 3130014 1 Washer, Needle Jet Setter11 3130527 1 Jet, Main (#140)12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Body, Float21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw24 3130668 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3130624 1 Jet, Pilot (#140)

27 3130522 1 O-Ring28 3130523 1 Washer29 3130525 1 Spring30 3130524 1 Adjuster31 3130546 1 Screw, Adjust32 3130545 1 Ring33 3130544 1 Spring34 3130502 1 Valve, Throttle (100)35 3130589 1 Spring36 3130514 1 Ring37 3130501 2 Screw38 3130513 1 Shaft, Throttle39 3130543 1 Guide, Cable40 3130535 4 Screw41 3130511 1 Cover42 3130512 1 O-Ring43 3130199 1 Holder, Guide44 3130538 1 Spring45 3130593 1 Asm., Plunger46 3130625 1 Jet, Air (#160)47 3130898 1 Asm., Carburetor

(Incl. 1-38,43-51)48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

5/98

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E3

FUEL PUMPBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

5

2

4 3

3

5

1

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3085275 1 Asm., Fuel Pump (Incl. 2-5)2 3084999 1 Screw and Washer3 3085356 2 Screw and Washer

4 3084591 4 Screw and Washer5 3084998 1 Diaphragm Gasket Set

5/98

Page 61: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

E4

OIL PUMPBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

4

1

10

32

11

12

15

87

6

13

14

5

1617

9

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084946 1 Oil Pump Case 22 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3084944

3084945

1

1

Asm., Oil Pump (Incl. 1-8,10-15)Oil Pump Case 1

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer

10 3084947 1 Pump, Oil Pump Case 311 3084950 1 Rotor, Inner (Scav)12 3084951 1 Rotor, Outer13 3084956 1 Oil Strainer Unit14 3084205 3 Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear, Pump 217 3084959

30849603084961

ARARAR

Spacer (0.8)Spacer (1.0)Spacer (1.2)

5/98

Page 62: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

E5

OIL FILTERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

4

5

3

3

3

2

2

2

2

2

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084963 1 Oil Filter2 3084846 8 Gasket, Aluminum3 3084966 4 Bolt, Banjo

4 3084964 1 Oil Delivery Pipe 15 3085638 1 Oil Delivery Pipe 2

5/98

Page 63: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

E6

RECOIL STARTERBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085856

308594311

Asm., Recoil (Incl. 1-6,9-11,14,15)Starter Case (Incl. 11)

15 3085083 1 Asm., Rope

5/98

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E7

STARTING MOTORBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

1

10

12

2

6

11

5

4

18

13

17

16

15

14

78

9

32

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084981 1 Asm., Starting Motor (Incl. 2-6,8-12)2 3084982 1 Washer Set3 3085353 1 Asm., Armature4 3084406 1 Brush, Carbon5 3083649 2 Nut, Flange6 3084408 3 O-Ring7 3082038 2 Bolt and Washer8 3085034 1 Asm., Rear Bracket9 3085033 1 Asm., Front Bracket (Incl. 10)

10 3240114 1 O-Ring11 3084983 2 Asm., Set Bolt (Incl. 6)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip18 3085394 1 Asm., Gear Shaft (Incl. 13-17)

5/98

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E8

MAGNETOBig Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

206

5

8

9

10

11

12

13 14

4

7

1

2

16

19

3

1517

18

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 30852273085228

11

Asm., Ignition Coil (Incl. 1,2)Ignition Coil

2 3084980 1 Cap, Spark Plug3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3085559

308556011

Asm., Plate (Incl. 5,6,8-12,14,15)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3085561 1 Stator (Incl. 13)

10 3085563 3 Screw and Washer11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3085639 1 CDI System17 3083073 2 Nut18 3080077 2 Washer, Spring19 3085521 1 Switch, Magnetic20 3085558 1 Flywheel w/Ring Gear

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Page 66: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E9

1012778-067 16 A6. . . . . 1012982-067 16 A6. . . . . 1040192-195 19 A8. . . . . 1040274-067 29 A7. . . . . 1040280-195 28 A8. . . . . 1040283-195 5 A8. . . . . . 1040287-067 22 D2. . . . . 1040291-195 6 A7. . . . . . 1040293-067 30 A7. . . . . 1040351-067 29 A7. . . . . 1040455-195 11 A8. . . . . 1040456-195 33 A8. . . . . 1040522-067 26 C7. . . . . 1040534-067 33 A12. . . . 1240015 5 A10. . . . . . . . . 1253118 5 B2. . . . . . . . . . 1260717 18 A13. . . . . . . . 1260742-029 22 A13. . . . 1260832-029 44 A12. . . . 1260856-029 9 A13. . . . . 1321457 8 C8. . . . . . . . . . 1321632 C8. . . . . . . . . . . . . 1321814 13 B8. . . . . . . . . 1322180 4 C9. . . . . . . . . . 1341184 D8. . . . . . . . . . . . . 1341219 D5. . . . . . . . . . . . . 1341303 D6. . . . . . . . . . . . . 1380024 B5. . . . . . . . . . . . . 1380026-067 18 C14. . . . 1380092 7 B6. . . . . . . . . . 1380094 6 B6. . . . . . . . . . 1380119 1 B6. . . . . . . . . . 1380143 C4. . . . . . . . . . . . . 1380145 9 C4. . . . . . . . . . 1520102-067 2 C5. . . . . . 1520172 28 C3. . . . . . . . . 1520179-117 24 B8. . . . . 1520183-117 11 C5. . . . . .

28 C14. . 1520243 9 B8. . . . . . . . . . 1520281 5 B8. . . . . . . . . . 1525017 25 B8. . . . . . . . . .

9 C5. . . 7 C14. .

1580053-067 4 D2. . . . . . 1580055-067 16 D2. . . . . 1580067-067 4 C7. . . . . . 1580070 5 D2. . . . . . . . . . 1580078 4 D2. . . . . . . . . . 1580081 8 D1. . . . . . . . . . 1580082-067 8 D1. . . . . . 1580083-067 11 D1. . . . . 1580091 17 C6. . . . . . . . . 1590265 11 C13. . . . . . . . 1820567 9 B12. . . . . . . . .

1843051-067 5 B11. . . . . 1843073 20 B7. . . . . . . . . 1843074 20 B7. . . . . . . . . 1910037 10 C2. . . . . . . . . 1910041-067 9 C3. . . . . . 1910056 10 B9. . . . . . . . . 1910125 1 C11. . . . . . . . . .

6 C13. . 1910126 1 B14. . . . . . . . . 1910130 1 C11. . . . . . . . . 1910144-067 19 C12. . . . 1910154 C12. . . . . . . . . . . . 1910177 28 C13. . . . . . . . 1910234 B9. . . . . . . . . . . . . 1910235 B9. . . . . . . . . . . . . 1930642 B9. . . . . . . . . . . . . 1930663 C2. . . . . . . . . . . . .

16 C3. . . 1930664 C2. . . . . . . . . . . . .

16 C3. . . 1930665 6 B9. . . . . . . . . . .

8 C2. . . 1930674 27 B13. . . . . . . . .

9 B14. . 1930687 10 B14. . . . . . . . 1930688 13 B14. . . . . . . . 1930732 3 B14. . . . . . . . . 1930743 2 B14. . . . . . . . . 1930751 24 B13. . . . . . . . 1930752 15 B13. . . . . . . . 1930753 19 B13. . . . . . . . 1930786 17 B14. . . . . . . . 1930787 18 B14. . . . . . . . 1930788 16 B14. . . . . . . . 1930792 11 B13. . . . . . . . 1930795 3 B13. . . . . . . . . .

6 B14. . 1930796 2 B13. . . . . . . . . .

5 B14. . 1930797 1 B13. . . . . . . . . .

4 B14. . 1930799 5 B13. . . . . . . . . 1930804 6 B13. . . . . . . . . 1930805 12 B13. . . . . . . . 1930806 10 B13. . . . . . . . 1930807 12 B14. . . . . . . . 1930891 22 B13. . . . . . . . 2010055 12 B10. . . . . . . . 2010075 11 C1. . . . . . . . . 2010076 10 C1. . . . . . . . . 2010077 9 C1. . . . . . . . . . 2010078 8 C1. . . . . . . . . . 2010079 1 C1. . . . . . . . . . 2010080 3 C1. . . . . . . . . .

2010081 4 C1. . . . . . . . . . 2010160 5 C1. . . . . . . . . . 2050073 B13. . . . . . . . . . . . 2050075 B14. . . . . . . . . . . . 2200188 16 B3. . . . . . . . . 2200341 4 C14. . . . . . . . . 2200361 27 D3. . . . . . . . . 2200463 6 C11. . . . . . . . . 2200464 3 C11. . . . . . . . . 2200465 9 B9. . . . . . . . . .

9 C2. . . 2200472 31 D2. . . . . . . . . 2200627 24 B12. . . . . . . . 2200628 24 B12. . . . . . . . 2200771 8 B6. . . . . . . . . . 2200773 13 B6. . . . . . . . . 2200774 7 B10. . . . . . . . . 2200791 3 C10. . . . . . . . . 2200805 15 B14. . . . . . . . 2200808 4 B13. . . . . . . . . 2200809 B13. . . . . . . . . . . .

B14. . . . . . . . . . . . . . . . . . . . . 2200899 3 C11. . . . . . . . . 2200901 9 B9. . . . . . . . . . 2200961 14 B6. . . . . . . . . 2201034 7 B13. . . . . . . . . 2201090 9 B13. . . . . . . . . 2201149 9 B9. . . . . . . . . . 2201150 3 C11. . . . . . . . . 2410023 10 D3. . . . . . . . . 2431017 14 A7. . . . . . . . . 2432034 12 D3. . . . . . . . . 2434012 2 D3. . . . . . . . . . 2460442 13 D3. . . . . . . . . .

8 D4. . . 2460606 1 D3. . . . . . . . . . 2460613 18 B3. . . . . . . . . 2460637 37 D3. . . . . . . . . 2511189 4 A10. . . . . . . . . . 2511342 1 A14. . . . . . . . . 2530009 14 A14. . . . . . . . 2530014 15 B1. . . . . . . . . 2530029 22 B2. . . . . . . . . 2631812-195 4 A5. . . . . . 2631839-195 6 A6. . . . . . 2631989-067 20 A7. . . . . 2652049 28 B3. . . . . . . . . 2670133 22 A8. . . . . . . . . 2670134 11 A7. . . . . . . . . 2670137-067 13 A7. . . . . 2681664-132 15 A8. . . . . 2681729-132 7 A6. . . . . . 2681730-132 7 A6. . . . . . 2682346-132 15 A8. . . . . 2690016 7 D4. . . . . . . . . .

Page 67: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E10

2870725 1 D4. . . . . . . . . . 2871265 D4. . . . . . . . . . . . . 3070175 3 E8. . . . . . . . . . 3080077 18 E8. . . . . . . . . 3080103 22 D11. . . . . . . . .

15 D13. . 3080130 21 D12. . . . . . . . 3080285 22 D10. . . . . . . . 3080530 23 D10. . . . . . . . 3080676 4 D11. . . . . . . . . 3081256 15 E8. . . . . . . . . 3081330 3 D10. . . . . . . . . 3081447 20 D12. . . . . . . . 3081497 2 D10. . . . . . . . . 3081657 19 D13. . . . . . . . .

7 E8. . . 3082038 7 E7. . . . . . . . . . 3082657 6 D4. . . . . . . . . . 3082758 6 D14. . . . . . . . . 3082956 17 D11. . . . . . . . .

8 E6. . . 3083073 17 E8. . . . . . . . . 3083138 10 D14. . . . . . . . 3083166 1 D10. . . . . . . . . 3083185 10 E6. . . . . . . . . 3083378 3 E6. . . . . . . . . . 3083379 4 E6. . . . . . . . . . 3083453 18 D11. . . . . . . . .

7 E6. . . 3083463 2 E6. . . . . . . . . . 3083649 5 E7. . . . . . . . . . 3083669 1 D11. . . . . . . . . .

9 E6. . . 3083737 13 E7. . . . . . . . . 3083904 17 D12. . . . . . . . 3083905 18 D12. . . . . . . . 3084130 32 D10. . . . . . . . 3084191 3 D14. . . . . . . . . 3084205 6 D11. . . . . . . . . .

48 E2. . . 14 E4. . .

3084215 19 D10. . . . . . . . 3084405 12 E7. . . . . . . . . 3084406 4 E7. . . . . . . . . . 3084408 6 E7. . . . . . . . . . 3084409 17 E7. . . . . . . . . 3084410 16 E7. . . . . . . . . 3084411 15 E7. . . . . . . . . 3084412 14 E7. . . . . . . . . 3084591 4 E3. . . . . . . . . . 3084744 5 E6. . . . . . . . . . 3084750 11 E6. . . . . . . . . 3084822 1 E6. . . . . . . . . . 3084834 10 D11. . . . . . . . 3084835 11 D11. . . . . . . .

3084836 20 D11. . . . . . . . 3084837 19 D11. . . . . . . . 3084838 28 D10. . . . . . . . .

3 D11. . 3084839 7 D11. . . . . . . . . 3084840 5 D11. . . . . . . . . 3084841 16 D11. . . . . . . . 3084842 9 D11. . . . . . . . . 3084843 15 D11. . . . . . . . 3084844 14 D11. . . . . . . . 3084845 12 D11. . . . . . . . .

1 D13. . 3084846 13 D11. . . . . . . . .

2 E5. . . 3084847 21 D11. . . . . . . . 3084849 29 D10. . . . . . . . 3084857 4 D10. . . . . . . . . 3084858 6 D10. . . . . . . . . 3084859 14 D10. . . . . . . . 3084860 16 D10. . . . . . . . 3084861 17 D10. . . . . . . . 3084862 18 D10. . . . . . . . 3084863 27 D10. . . . . . . . 3084864 26 D10. . . . . . . . 3084866 10 D10. . . . . . . . 3084867 7 D10. . . . . . . . . 3084868 34 D10. . . . . . . . 3084869 35 D10. . . . . . . . 3084873 30 D10. . . . . . . . 3084874 13 D10. . . . . . . . .

27 D13. . 3084875 15 D10. . . . . . . . 3084876 25 D10. . . . . . . . 3084877 9 D10. . . . . . . . . .

13 D14. . 13 E6. . .

3084879 38 D10. . . . . . . . 3084880 24 D10. . . . . . . . 3084882 15 D12. . . . . . . . 3084892 14 D12. . . . . . . . 3084893 14 D12. . . . . . . . 3084894 14 D12. . . . . . . . 3084895 13 D12. . . . . . . . 3084896 13 D12. . . . . . . . 3084897 13 D12. . . . . . . . 3084898 14 D13. . . . . . . . 3084899 18 D13. . . . . . . . 3084905 26 D13. . . . . . . . 3084906 13 D13. . . . . . . . 3084907 12 D13. . . . . . . . 3084908 11 D13. . . . . . . . 3084909 10 D13. . . . . . . . 3084910 6 D13. . . . . . . . . 3084911 9 D13. . . . . . . . . 3084912 8 D13. . . . . . . . .

3084913 7 D13. . . . . . . . . 3084914 20 D13. . . . . . . . 3084915 22 D13. . . . . . . . 3084916 21 D13. . . . . . . . 3084917 24 D13. . . . . . . . 3084918 4 D13. . . . . . . . . 3084919 3 D13. . . . . . . . . 3084920 2 D13. . . . . . . . . 3084922 5 D13. . . . . . . . . 3084924 23 D13. . . . . . . . 3084933 12 E6. . . . . . . . . 3084935 11 D14. . . . . . . . 3084937 8 D14. . . . . . . . . 3084940 1 D14. . . . . . . . . 3084942 12 D14. . . . . . . . 3084944 4 E4. . . . . . . . . . 3084945 4 E4. . . . . . . . . . 3084946 1 E4. . . . . . . . . . 3084947 10 E4. . . . . . . . . 3084948 3 E4. . . . . . . . . . 3084949 2 E4. . . . . . . . . . 3084950 11 E4. . . . . . . . . 3084951 12 E4. . . . . . . . . 3084952 15 E4. . . . . . . . . 3084953 8 E4. . . . . . . . . . 3084954 7 E4. . . . . . . . . . 3084955 6 E4. . . . . . . . . . 3084956 13 E4. . . . . . . . . 3084958 16 E4. . . . . . . . . 3084959 17 E4. . . . . . . . . 3084960 17 E4. . . . . . . . . 3084961 17 E4. . . . . . . . . 3084962 9 E4. . . . . . . . . . 3084963 1 E5. . . . . . . . . . 3084964 4 E5. . . . . . . . . . 3084966 3 E5. . . . . . . . . . 3084972 5 E8. . . . . . . . . . 3084973 8 E8. . . . . . . . . . 3084976 12 E8. . . . . . . . . 3084977 14 E8. . . . . . . . . 3084978 4 E8. . . . . . . . . . 3084980 2 E8. . . . . . . . . . 3084981 1 E7. . . . . . . . . . 3084982 2 E7. . . . . . . . . . 3084983 11 E7. . . . . . . . . 3084994 5 D10. . . . . . . . . 3084998 5 E3. . . . . . . . . . 3084999 2 E3. . . . . . . . . . 3085001 2 D4. . . . . . . . . . 3085002 3 D4. . . . . . . . . . 3085024 9 D12. . . . . . . . . 3085033 9 E7. . . . . . . . . . 3085034 8 E7. . . . . . . . . . 3085072 8 D10. . . . . . . . . 3085073 12 D10. . . . . . . .

Page 68: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E11

3085074 11 D10. . . . . . . . 3085075 20 D10. . . . . . . . 3085076 17 D13. . . . . . . . 3085077 9 D14. . . . . . . . . 3085083 15 E6. . . . . . . . . 3085227 1 E8. . . . . . . . . . 3085228 1 E8. . . . . . . . . . 3085266 6 E6. . . . . . . . . . 3085275 1 E3. . . . . . . . . . 3085326 21 D10. . . . . . . . 3085341 6 D12. . . . . . . . . 3085346 19 D12. . . . . . . . 3085348 16 D13. . . . . . . . 3085349 25 D13. . . . . . . . 3085351 7 D14. . . . . . . . . 3085352 2 D14. . . . . . . . . 3085353 3 E7. . . . . . . . . . 3085356 3 E3. . . . . . . . . . 3085359 5 D14. . . . . . . . . 3085360 13 E8. . . . . . . . . 3085370 33 D10. . . . . . . . 3085371 37 D10. . . . . . . . 3085373 10 D12. . . . . . . . 3085374 5 D12. . . . . . . . . 3085376 7 D12. . . . . . . . . 3085379 4 D12. . . . . . . . . 3085380 4 D12. . . . . . . . . 3085381 4 D12. . . . . . . . . 3085394 18 E7. . . . . . . . . 3085399 10 D12. . . . . . . . 3085400 8 D12. . . . . . . . . 3085404 12 D12. . . . . . . . 3085521 19 E8. . . . . . . . . 3085525 8 D11. . . . . . . . . 3085527 36 D10. . . . . . . . 3085528 16 D12. . . . . . . . 3085533 2 D12. . . . . . . . . 3085534 1 D12. . . . . . . . . 3085535 5 E4. . . . . . . . . . 3085554 11 E8. . . . . . . . . 3085556 46 A12. . . . . . . . 3085558 20 E8. . . . . . . . . 3085559 6 E8. . . . . . . . . . 3085560 6 E8. . . . . . . . . . 3085561 9 E8. . . . . . . . . . 3085563 10 E8. . . . . . . . . 3085567 4 D4. . . . . . . . . . 3085569 5 D4. . . . . . . . . . 3085633 2 D11. . . . . . . . . 3085634 31 D10. . . . . . . . 3085638 5 E5. . . . . . . . . . 3085639 16 E8. . . . . . . . . 3085852 11 D12. . . . . . . . 3085856 14 E6. . . . . . . . . 3085857 4 D14. . . . . . . . .

3085866 3 D12. . . . . . . . . 3085867 3 D12. . . . . . . . . 3085868 3 D12. . . . . . . . . 3085943 14 E6. . . . . . . . . 3110032 31 A10. . . . . . . . 3110044 4 A12. . . . . . . . . 3110050 14 A12. . . . . . . . 3110064 17 A6. . . . . . . . . .

6 A13. . 3110067 37 A12. . . . . . . . 3110068 49 A12. . . . . . . . 3130014 10 E2. . . . . . . . . 3130199 43 E2. . . . . . . . . 3130361 16 E2. . . . . . . . . 3130501 37 E2. . . . . . . . . 3130502 34 E2. . . . . . . . . 3130503 50 E2. . . . . . . . . 3130504 9 E2. . . . . . . . . . 3130505 49 E2. . . . . . . . . 3130507 1 E2. . . . . . . . . . 3130508 2 E2. . . . . . . . . . 3130511 41 E2. . . . . . . . . 3130512 42 E2. . . . . . . . . 3130513 38 E2. . . . . . . . . 3130514 36 E2. . . . . . . . . 3130515 12 E2. . . . . . . . . 3130517 13 E2. . . . . . . . . 3130518 14 E2. . . . . . . . . 3130519 15 E2. . . . . . . . . 3130520 19 E2. . . . . . . . . 3130521 21 E2. . . . . . . . . 3130522 27 E2. . . . . . . . . 3130523 28 E2. . . . . . . . . 3130524 30 E2. . . . . . . . . 3130525 29 E2. . . . . . . . . 3130527 11 E2. . . . . . . . . 3130529 22 E2. . . . . . . . . 3130532 18 E2. . . . . . . . . 3130533 25 E2. . . . . . . . . 3130535 40 E2. . . . . . . . . 3130538 44 E2. . . . . . . . . 3130540 8 E2. . . . . . . . . . 3130541 7 E2. . . . . . . . . . 3130543 39 E2. . . . . . . . . 3130544 33 E2. . . . . . . . . 3130545 32 E2. . . . . . . . . 3130546 31 E2. . . . . . . . . 3130589 35 E2. . . . . . . . . 3130590 20 E2. . . . . . . . . 3130591 23 E2. . . . . . . . . 3130592 51 E2. . . . . . . . . 3130593 45 E2. . . . . . . . . 3130594 17 E2. . . . . . . . . 3130624 26 E2. . . . . . . . . 3130625 46 E2. . . . . . . . .

3130668 24 E2. . . . . . . . . 3130732 5 E2. . . . . . . . . . 3130752 4 E2. . . . . . . . . . 3130898 47 E2. . . . . . . . . 3130899 6 E2. . . . . . . . . . 3130900 3 E2. . . . . . . . . . 3211048 3 C9. . . . . . . . . . 3221043 3 C4. . . . . . . . . . 3221044 33 C13. . . . . . . . 3221058 26 C13. . . . . . . . 3222044 1 B5. . . . . . . . . . 3222047 24 C3. . . . . . . . . .

17 C14. . 3222051 13 C4. . . . . . . . . 3222070 26 C3. . . . . . . . . 3224041 11 B4. . . . . . . . . 3224042 21 C3. . . . . . . . . 3224043 8 B4. . . . . . . . . . 3224055 23 C3. . . . . . . . . .

15 C14. . 3225024 12 B4. . . . . . . . . .

12 C3. . . 10 C14. .

3233002 1 D8. . . . . . . . . . 3233003 49 D8. . . . . . . . . 3233007 24 D8. . . . . . . . . 3233009 26 D8. . . . . . . . . 3233010 27 D8. . . . . . . . . 3233012 30 D8. . . . . . . . . 3233014 53 D8. . . . . . . . . 3233017 34 D8. . . . . . . . . 3233018 19 D8. . . . . . . . . 3233019 23 D8. . . . . . . . . 3233020 52 D8. . . . . . . . . 3233021 6 D8. . . . . . . . . . 3233022 7 D8. . . . . . . . . . 3233023 8 D8. . . . . . . . . . 3233024 4 D8. . . . . . . . . . 3233025 5 D8. . . . . . . . . . 3233026 2 D8. . . . . . . . . . 3233029 32 D8. . . . . . . . . 3233030 18 D8. . . . . . . . . 3233031 17 D8. . . . . . . . . 3233032 20 D8. . . . . . . . . 3233033 21 D8. . . . . . . . . 3233035 48 D8. . . . . . . . . 3233036 31 D8. . . . . . . . . 3233037 37 D8. . . . . . . . . 3233040 11 D8. . . . . . . . . 3233043 50 D8. . . . . . . . . 3233045 12 D8. . . . . . . . . 3233054 14 D8. . . . . . . . . 3233055 15 D8. . . . . . . . . 3233060 13 D5. . . . . . . . .

13 D6. . .

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PART NUMBER INDEX

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Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E12

3233062 11 D5. . . . . . . . . 11 D6. . .

3233063 9 D5. . . . . . . . . . 9 D6. . .

3233069 12 D5. . . . . . . . . 12 D6. . .

3233070 29 D5. . . . . . . . . . 30 D6. . .

3233076 25 D6. . . . . . . . . 3233083 10 D5. . . . . . . . .

10 D6. . . 3233084

28 D5. . . 29 D6. . .

3233085 30 D5. . . . . . . . . 3233089 26 D6. . . . . . . . . 3233090 15 D5. . . . . . . . .

15 D6. . . 3233125 25 D8. . . . . . . . . 3233126 28 D8. . . . . . . . . 3233127 54 D8. . . . . . . . . 3233128 51 D8. . . . . . . . . 3233131 3 D5. . . . . . . . . .

3 D6. . . 3233132 4 D5. . . . . . . . . .

4 D6. . . 3233150 55 D8. . . . . . . . . 3233151 9 D8. . . . . . . . . . 3233152 16 D8. . . . . . . . . 3233153 13 D8. . . . . . . . . 3233158 7 D5. . . . . . . . . .

7 D6. . . 3233176 35 D8. . . . . . . . . 3233177 36 D8. . . . . . . . . 3233195 1 D5. . . . . . . . . . 3233196 1 D6. . . . . . . . . . 3233213 6 D5. . . . . . . . . .

6 D6. . . 3233216 16 D5. . . . . . . . .

16 D6. . . 3233217 17 D5. . . . . . . . . 3233218 25 D5. . . . . . . . . 3233227 8 D5. . . . . . . . . .

8 D6. . . 3233248 3 D8. . . . . . . . . . 3233359 33 D8. . . . . . . . . 3233360 56 D8. . . . . . . . . 3233361 22 D8. . . . . . . . . 3233362 29 D8. . . . . . . . . 3233368 5 D5. . . . . . . . . .

5 D6. . . 3233448 47 D8. . . . . . . . . 3233455 14 D5. . . . . . . . .

14 D6. . .

3233478 38 D8. . . . . . . . . 3233498 31 D6. . . . . . . . . 3233548 10 D8. . . . . . . . . 3233570 17 D6. . . . . . . . . 3240088 14 D12. . . . . . . . 3240114 10 E7. . . . . . . . . 3250010 11 B8. . . . . . . . . 3250028 10 B8. . . . . . . . . 3250030 14 B8. . . . . . . . . 3250032 12 B8. . . . . . . . . 3260115 3 B6. . . . . . . . . . 3260130 9 B6. . . . . . . . . . 3280129 31 B10. . . . . . . . 3280135 31 B10. . . . . . . . 3280164 26 B10. . . . . . . . 3280216 20 B10. . . . . . . . 3280217 25 B10. . . . . . . . 3280220 23 B10. . . . . . . . 3514314 11 C9. . . . . . . . . 3514402 5 B5. . . . . . . . . . 3514807 7 C3. . . . . . . . . . 3515501 14 C3. . . . . . . . . .

21 C14. . 3515502 18 C3. . . . . . . . . 3554202 40 C13. . . . . . . . 3554506 6 B8. . . . . . . . . . .

7 C4. . . 3554507 17 B7. . . . . . . . . .

7 B8. . . 8 C4. . .

3554509 18 B7. . . . . . . . . 3576504 10 C8. . . . . . . . . 3576510 3 C8. . . . . . . . . . 3610013 4 C3. . . . . . . . . . .

20 C14. . 3610017 6 B5. . . . . . . . . . .

2 C4. . . 3610019 3 B8. . . . . . . . . . 3610024 8 C3. . . . . . . . . . 3610028 21 B7. . . . . . . . . 3610062 39 C13. . . . . . . . 4010093 34 D3. . . . . . . . . 4010094 33 D3. . . . . . . . . 4010095 28 D3. . . . . . . . . 4010132 3 A12. . . . . . . . . 4010202 3 A10. . . . . . . . . 4010248 22 D3. . . . . . . . . 4030015 29 B10. . . . . . . . 4030028 3 B3. . . . . . . . . . 4030042 22 B3. . . . . . . . . 4030043 17 D3. . . . . . . . . 4030047 7 C1. . . . . . . . . . 4030059 14 A7. . . . . . . . . 4032002 6 B3. . . . . . . . . . 4032003 9 B3. . . . . . . . . .

4032029 15 D3. . . . . . . . . 4032037 21 B3. . . . . . . . . 4032041 7 B3. . . . . . . . . . 4032042 15 B3. . . . . . . . . 4032045 18 D3. . . . . . . . . 4032046 16 D3. . . . . . . . . 4032063 4 B3. . . . . . . . . . 4032064 19 D3. . . . . . . . . 4032065 5 B3. . . . . . . . . . 4032066 2 B3. . . . . . . . . . 4060173 39 D3. . . . . . . . . 4060204 41 D3. . . . . . . . . 4110141 19 B3. . . . . . . . . 4110148 19 B3. . . . . . . . . 4110164 23 B13. . . . . . . . 4110205 10 B10. . . . . . . . 4110209 19 B3. . . . . . . . . 4110245 12 C1. . . . . . . . . 4110246 6 C1. . . . . . . . . . 4140006 32 D3. . . . . . . . . 4170010 19 B7. . . . . . . . . 4170013 10 A10. . . . . . . . 5010192 3 A13. . . . . . . . . 5010204 29 C3. . . . . . . . . .

22 C14. . 5010206 24 C14. . . . . . . . 5010379 1 C9. . . . . . . . . . 5010450 12 C4. . . . . . . . . 5020422 6 C8. . . . . . . . . . 5020468 2 C14. . . . . . . . . 5020474 8 B5. . . . . . . . . . 5020506 7 B9. . . . . . . . . . .

6 C2. . . 5020527 4 B5. . . . . . . . . . 5020530 2 C3. . . . . . . . . . 5020531 19 C3. . . . . . . . . 5020532 30 C3. . . . . . . . . 5020662 25 A8. . . . . . . . . 5020663 1 A6. . . . . . . . . . 5020677 22 B12. . . . . . . . .

5 D1. . . 5020681 23 B12. . . . . . . . 5020702 22 D5. . . . . . . . .

22 D6. . . 5020703 20 D5. . . . . . . . .

20 D6. . . 5020741 27 B10. . . . . . . . .

57 D8. . . 5020764 7 D1. . . . . . . . . . 5020765 9 D1. . . . . . . . . . 5020766 10 D1. . . . . . . . . 5020789 27 C14. . . . . . . . 5020793 12 C6. . . . . . . . . 5020803 13 C3. . . . . . . . . 5020839 7 A8. . . . . . . . . .

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Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E13

5020926 6 B12. . . . . . . . . 5020934 1 C4. . . . . . . . . . 5020937 30 A10. . . . . . . . 5130631 13 D2. . . . . . . . . 5130663 20 C3. . . . . . . . . .

6 C7. . . 23 C14. .

1 D2. . . 5130701 2 B5. . . . . . . . . . 5130712 9 C7. . . . . . . . . . 5130944 17 C3. . . . . . . . . 5130945 6 C3. . . . . . . . . . .

1 C7. . . 5130946 1 C11. . . . . . . . . 5131004 25 B1. . . . . . . . . 5131036 38 D3. . . . . . . . . 5131115 3 B9. . . . . . . . . . .

3 C2. . . 5131116 3 B9. . . . . . . . . . . 5131116 3 C2. . . . . . . . . . 5131175 1 C11. . . . . . . . . 5131379 19 B4. . . . . . . . . 5131446 13 C9. . . . . . . . . 5131643 42 C13. . . . . . . . 5131785 16 B1. . . . . . . . . 5132062 26 B7. . . . . . . . . 5210650 20 D3. . . . . . . . . 5210748 28 A12. . . . . . . . 5210752 9 C8. . . . . . . . . . .

14 C9. . . 5210753 9 C8. . . . . . . . . . 5210754 9 C8. . . . . . . . . . 5210953 6 C6. . . . . . . . . . 5211020-067 7 A5. . . . . . .

25 A6. . . 5211115 7 B7. . . . . . . . . . . 5211121 15 B12. . . . . . . . . 5211131-067 7 A5. . . . . . . .

25 A6. . . 5211148 4 B8. . . . . . . . . . . 5211189 18 B10. . . . . . . . . 5211326 2 B8. . . . . . . . . . .

10 C3. . . 5211391-067 6 D3. . . . . . 5211523 2 B1. . . . . . . . . . 5211547-067 12 A5. . . . . 5211633-067 23 A7. . . . . 5211804 6 B2. . . . . . . . . . 5220225 4 C6. . . . . . . . . . 5220646 5 C9. . . . . . . . . . 5220946 6 B10. . . . . . . . . 5220958 13 C6. . . . . . . . . 5220965-067 20 B3. . . . . .

2 B11. . 5222154-067 9 A14. . . . .

5222155-067 9 A14. . . . . 5222193 16 B7. . . . . . . . . 5222220-067 10 C7. . . . . 5222221-067 30 C7. . . . . 5222269-067 14 B10. . . . 5222299 2 B6. . . . . . . . . . 5222837-067 11 A6. . . . . 5222860-067 4 A7. . . . . . 5222999-067 8 B11. . . . . 5224531 20 C12. . . . . . . . 5224548 4 C12. . . . . . . . . 5224553 31 B2. . . . . . . . . 5240179-067 14 A13. . . . 5240244-067 27 A8. . . . . 5240328-067 5 A12. . . . . 5240336 4 B2. . . . . . . . . . 5240409-067 19 C10. . . . 5240424 2 B2. . . . . . . . . . 5240428 40 D3. . . . . . . . . 5240524 13 C12. . . . . . . . 5240525 5 C12. . . . . . . . . 5240526 11 C12. . . . . . . . 5240609-067 15 A12. . . . 5240898 10 A13. . . . . . . . 5240952 7 C6. . . . . . . . . . 5240993 7 C11. . . . . . . . . 5241018-067 5 C13. . . . . 5241213-067 23 C10. . . . 5241224-067 21 A7. . . . . 5241788-067 11 A10. . . . 5241921-067 24 A12. . . . 5242016-067 25 A7. . . . . 5242550 12 A10. . . . . . . . 5242981 9 C8. . . . . . . . . . 5243138-067 13 B10. . . . 5243364 25 B7. . . . . . . . . 5332828 17 C7. . . . . . . . . 5332935 22 C3. . . . . . . . . 5333170 34 A8. . . . . . . . . 5333172 6 D2. . . . . . . . . . 5333204 19 B1. . . . . . . . . 5333206 10 A14. . . . . . . . 5333254 25 C13. . . . . . . . 5333367 2 B12. . . . . . . . . 5410012 11 A5. . . . . . . . . .

1 A7. . . 5410241 24 A13. . . . . . . . 5410414 9 A6. . . . . . . . . . .

2 A7. . . 5410415 19 C14. . . . . . . . 5410421 25 A12. . . . . . . . 5410424 30 D3. . . . . . . . . 5410436 4 A13. . . . . . . . .

5410463 7 B5. . . . . . . . . . . 11 C4. . .

5410469 8 B14. . . . . . . . . 5410470 20 B8. . . . . . . . . 5410494 12 B9. . . . . . . . .

12 C2. . . 5410495 11 B9. . . . . . . . .

11 C2. . . 5410535 8 D2. . . . . . . . . . 5410537 15 C3. . . . . . . . . 5410541 3 C3. . . . . . . . . . 5410546 30 B10. . . . . . . . 5410548 17 B12. . . . . . . . 5410575 20 C10. . . . . . . . 5410584 8 A10. . . . . . . . . 5410607 19 A10. . . . . . . . 5410766 4 C11. . . . . . . . . 5410767 4 C11. . . . . . . . . 5410772 17 B11. . . . . . . . 5410774 8 A6. . . . . . . . . . 5410779 4 B9. . . . . . . . . .

4 C2. . . 5410780 5 B9. . . . . . . . . .

5 C2. . . 5410828 18 B1. . . . . . . . . 5410829 28 B2. . . . . . . . . 5410831 26 B2. . . . . . . . . 5410889 11 B1. . . . . . . . . 5410947 16 B8. . . . . . . . . 5410948 3 C5. . . . . . . . . . .

6 C14. . 5410988 26 B13. . . . . . . . 5411036 12 B1. . . . . . . . . 5411042 17 B1. . . . . . . . . 5411106 5 B6. . . . . . . . . . . 5411108 1 A10. . . . . . . . . . 5411164 6 C5. . . . . . . . . . . .

14 C14. . 5411180 2 C10. . . . . . . . . . 5411291 3 B12. . . . . . . . . 5411297 21 B13. . . . . . . . .

22 B13. . 5411321 6 B1. . . . . . . . . . .

16 B2. . . 5411362 24 B2. . . . . . . . . 5411489 15 C10. . . . . . . . 5411608 5 B7. . . . . . . . . . 5430261 27 A12. . . . . . . . 5430725 3 A14. . . . . . . . . 5430743 27 A10. . . . . . . . 5430766 17 C9. . . . . . . . . 5430776 16 C7. . . . . . . . . 5430806 4 B7. . . . . . . . . . .

12 D2. . . 5430807 27 B7. . . . . . . . . .

14 D2. . .

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Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

E14

5430945 7 C8. . . . . . . . . . 5430971-195 15 A5. . . . . 5430995 23 B3. . . . . . . . . 5431021 16 A14. . . . . . . . 5431030 11 B10. . . . . . . . 5431053 5 A14. . . . . . . . . 5431102 22 C7. . . . . . . . . 5431107 6 C12. . . . . . . . . 5431149 20 B12. . . . . . . . 5431150 20 B12. . . . . . . . 5431197-195 14 A5. . . . . 5431201-132 11 B3. . . . . 5431310 13 C7. . . . . . . . . 5431391 21 A14. . . . . . . . 5431484 28 A7. . . . . . . . . 5431524 8 A8. . . . . . . . . . 5431556 28 D2. . . . . . . . . 5431570 12 B11. . . . . . . . 5431571 13 B11. . . . . . . . 5431572 9 B11. . . . . . . . . 5431573 4 B11. . . . . . . . . 5431574 18 B11. . . . . . . . 5431596 21 B12. . . . . . . . .

4 D1. . . 5431610 9 A10. . . . . . . . . 5431673 21 A10. . . . . . . . 5431675-195 15 A5. . . . . 5431677 10 B1. . . . . . . . . 5431698 27 B2. . . . . . . . . 5431769 26 D3. . . . . . . . . 5431845 13 D1. . . . . . . . . 5431861-132 10 B3. . . . . 5431863 18 B2. . . . . . . . . 5431895 25 A10. . . . . . . . 5431936 5 C8. . . . . . . . . . 5431964 24 B3. . . . . . . . . 5431972 15 C6. . . . . . . . . 5431977 8 C6. . . . . . . . . . 5432077 31 D3. . . . . . . . . 5432090 25 B3. . . . . . . . . 5432091 12 D1. . . . . . . . . 5432254 14 C13. . . . . . . . 5432291 18 A14. . . . . . . . 5432294 15 A10. . . . . . . . 5432572 5 B4. . . . . . . . . . 5432593 29 A10. . . . . . . . 5432607 36 B2. . . . . . . . . 5432611 21 B8. . . . . . . . . 5432691 11 B2. . . . . . . . . 5432698 1 C10. . . . . . . . . 5432798 13 A6. . . . . . . . . 5432849 7 C10. . . . . . . . . 5432953 17 C10. . . . . . . . 5433141 20 A10. . . . . . . . 5433142 20 A10. . . . . . . .

5433198 9 B10. . . . . . . . . 5433199 32 B10. . . . . . . . 5521279 19 D2. . . . . . . . . 5521301 6 C10. . . . . . . . . 5630351 3 D2. . . . . . . . . . 5630362 14 B14. . . . . . . . 5630513 12 C8. . . . . . . . . 5630616-067 7 B10. . . . . 5810144 2 A14. . . . . . . . . 5810279 26 A10. . . . . . . . 5810290 25 D3. . . . . . . . . 5810291 3 B7. . . . . . . . . . .

11 D2. . . 5810379 3 B10. . . . . . . . . 5810439 13 B7. . . . . . . . . 5810442 19 B10. . . . . . . . 5810444 32 B2. . . . . . . . . 5810455 9 A7. . . . . . . . . . .

10 A8. . . 5810467 17 A7. . . . . . . . . 5810859 24 A14. . . . . . . . 5810948 3 B2. . . . . . . . . . 5810957 23 A6. . . . . . . . . 5810988 30 B2. . . . . . . . . 5810991 23 A6. . . . . . . . . 5811012 7 B2. . . . . . . . . . 5811054 22 C13. . . . . . . . 5811141 9 B2. . . . . . . . . . . 5811373 10 A12. . . . . . . . 5811502 4 B4. . . . . . . . . . 5811519 22 B4. . . . . . . . . 5811757 18 C13. . . . . . . . 5811758 20 C13. . . . . . . . 5811759 19 C13. . . . . . . . 5811760 17 C13. . . . . . . . 5830053 3 B1. . . . . . . . . . 5850103 24 A6. . . . . . . . . 5850104 24 A6. . . . . . . . . 5850109 24 A6. . . . . . . . . 5850126 8 A5. . . . . . . . . . 5850130 8 A5. . . . . . . . . . 5850135 23 B1. . . . . . . . . 5910026 8 B9. . . . . . . . . . .

7 C2. . . 7010032 29 D3. . . . . . . . . 7030011-195 16 A8. . . . . 7041157 4 C8. . . . . . . . . . 7041198 12 C9. . . . . . . . . 7041209 20 A14. . . . . . . . 7041220 5 C6. . . . . . . . . . 7041301 36 A8. . . . . . . . . 7041302 9 A8. . . . . . . . . . 7041303-067 7 D2. . . . . . 7041305-067 1 C6. . . . . . 7041365 3 C12. . . . . . . . .

7041450-067 24 B7. . . . . 7041761 6 B7. . . . . . . . . . 7042029 12 A13. . . . . . . . .

18 C12. . 7042031 8 A13. . . . . . . . . 7042032 14 A6. . . . . . . . . 7051524 22 B1. . . . . . . . . 7052045 15 B8. . . . . . . . . 7052065 23 A10. . . . . . . . 7052075 12 A12. . . . . . . . 7052083 20 A13. . . . . . . . 7052103 20 B13. . . . . . . . 7052106 14 B1. . . . . . . . . 7052152 9 B1. . . . . . . . . . 7052163 4 B1. . . . . . . . . . .

19 B2. . . 7052164 10 B2. . . . . . . . . 7052181 28 A10. . . . . . . . 7052190 23 A14. . . . . . . . 7061013 21 D5. . . . . . . . .

21 D6. . . 7061014 18 D5. . . . . . . . .

18 D6. . . 7061033 8 B12. . . . . . . . . 7061034 4 B12. . . . . . . . . 7072528 26 B3. . . . . . . . . 7072715 24 A9. . . . . . . . . 7072724 2 C1. . . . . . . . . . 7072766 11 A9. . . . . . . . . 7073761 2 A6. . . . . . . . . . 7073862 26 A9. . . . . . . . . 7074109 12 A9. . . . . . . . . 7074177 16 C6. . . . . . . . . 7074214 21 C7. . . . . . . . . 7074220 21 A9. . . . . . . . . 7074782 12 C10. . . . . . . . 7074929 4 A9. . . . . . . . . . 7074935 19 A9. . . . . . . . . 7074946 14 A9. . . . . . . . . .

10 C10. . 7074956 9 B4. . . . . . . . . . 7075339 4 C13. . . . . . . . . 7075705 7 A9. . . . . . . . . . 7075719 13 A9. . . . . . . . . 7075741 23 A9. . . . . . . . . 7076202 2 A9. . . . . . . . . . 7076273 3 A9. . . . . . . . . . 7076558 10 A9. . . . . . . . . 7077365 15 A9. . . . . . . . . 7077377 11 C10. . . . . . . . 7077446 15 A6. . . . . . . . . 7077765 1 A9. . . . . . . . . . 7077902 5 A9. . . . . . . . . . 7077903 20 A9. . . . . . . . . 7077904 17 A9. . . . . . . . .

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Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

F1

7077905 22 A9. . . . . . . . . 7077906 6 A9. . . . . . . . . . 7077907 8 A9. . . . . . . . . . 7077908 9 A9. . . . . . . . . . 7077909 25 A9. . . . . . . . . 7078254 18 A9. . . . . . . . . 7078261 32 D2. . . . . . . . . 7078355 16 A9. . . . . . . . . 7080003 19 A12. . . . . . . . .

13 A14. . 5 B1. . .

7080138 3 D3. . . . . . . . . . 7080229 27 B3. . . . . . . . . 7080306 3 B5. . . . . . . . . . .

14 B7. . . 5 C3. . .

10 C4. . . 7 C7. . .

26 C14. . 29 D2. . .

7080307 9 A12. . . . . . . . . 7080352 1 B9. . . . . . . . . . .

2 B14. . 1 C2. . . 8 C11. .

7080433 10 B11. . . . . . . . . 25 B12. . 41 C13. .

6 D1. . . 7080438 19 C6. . . . . . . . . 7080474 13 B1. . . . . . . . . 7080476 12 B2. . . . . . . . . 7080483 13 B2. . . . . . . . . 7080487 15 B2. . . . . . . . . 7080496 2 A8. . . . . . . . . . 7080510 3 B11. . . . . . . . . 7080511 26 A12. . . . . . . . .

25 C10. . 7080524 11 D3. . . . . . . . . 7080539 14 B13. . . . . . . . 7080544 21 B2. . . . . . . . . 7080573 8 B7. . . . . . . . . . 7080598 33 B2. . . . . . . . . 7080614 2 A10. . . . . . . . . 7080627 12 B6. . . . . . . . . 7080631 15 B10. . . . . . . . 7080649 13 C1. . . . . . . . . 7080656 29 B2. . . . . . . . . 7080673 14 B12. . . . . . . . 7080694 48 A12. . . . . . . . 7080696 40 A12. . . . . . . . 7080699 23 B2. . . . . . . . . 7080727 16 B3. . . . . . . . . 7080761 14 C10. . . . . . . .

7511840 17 A14. . . . . . . . 7511848 1 B1. . . . . . . . . . 7511854 16 C9. . . . . . . . . 7511862 17 B3. . . . . . . . . 7511881 25 B2. . . . . . . . . 7512007 36 D3. . . . . . . . . 7512017 8 B3. . . . . . . . . . 7512018 35 D3. . . . . . . . . 7512024 17 B13. . . . . . . . .

16 C12. . 2 D5. . . 2 D6. . .

7512027 22 B8. . . . . . . . . . 14 D3. . .

7512084 24 A10. . . . . . . . . 19 B12. .

7512093 9 C10. . . . . . . . . 7512094 13 C10. . . . . . . . 7512095 21 C10. . . . . . . . 7512103 31 A8. . . . . . . . . 7512111 12 A8. . . . . . . . . . 7512113 32 A8. . . . . . . . . .

7 A10. . 7512126 19 A7. . . . . . . . . 7512130 3 A7. . . . . . . . . . 7512176 1 C8. . . . . . . . . . 7512208 14 A8. . . . . . . . . 7512232 16 A5. . . . . . . . . .

3 A6. . . 26 A7. . . 14 A10. .

7512242 21 B1. . . . . . . . . 7512252 6 B4. . . . . . . . . . .

19 C7. . . 17 D2. . .

7512266 13 C8. . . . . . . . . 7512269 21 C13. . . . . . . . 7512282 10 A5. . . . . . . . . .

20 A6. . . 1 A8. . .

17 A13. . 7512284 17 A8. . . . . . . . . .

16 B12. . 7512315 8 A12. . . . . . . . . 7512325 1 B8. . . . . . . . . . .

25 C7. . . 7512329 15 A7. . . . . . . . . 7512365 11 B7. . . . . . . . . .

15 B9. . . 15 C2. . .

7512392 35 A8. . . . . . . . . 7512490 22 A12. . . . . . . . 7512492 39 A8. . . . . . . . . .

26 B12. .

7512492 6 C4. . . . . . . . . . . 3 D1. . .

7512520 5 C7. . . . . . . . . . 7512564 15 B4. . . . . . . . . 7512566 30 A12. . . . . . . . 7512569 3 C7. . . . . . . . . . 7512576 8 C7. . . . . . . . . . .

30 D2. . . 7512583 21 B4. . . . . . . . . 7512660 10 C5. . . . . . . . . 7512666 21 A13. . . . . . . . 7512673 3 C14. . . . . . . . . 7512702 14 C6. . . . . . . . . 7512703 20 C6. . . . . . . . . 7515101 12 C12. . . . . . . . 7515117 21 D2. . . . . . . . . 7515136 22 A14. . . . . . . . 7515137 30 A8. . . . . . . . . 7515140 19 A13. . . . . . . . 7515150 37 B2. . . . . . . . . 7515151 8 B2. . . . . . . . . . 7515158 24 B1. . . . . . . . . 7515180 5 A6. . . . . . . . . . .

35 B2. . . 16 C10. .

7515181 27 D5. . . . . . . . . . 28 D6. . .

7515189 2 B10. . . . . . . . . 7515304 18 C7. . . . . . . . . 7515306 37 A8. . . . . . . . . 7515314 24 A8. . . . . . . . . 7515321 35 A12. . . . . . . . .

1 B11. . . 13 C13. . 20 D2. . .

7515327 7 C9. . . . . . . . . . 7515339 23 B7. . . . . . . . . 7515341 18 A8. . . . . . . . . 7515345 1 C13. . . . . . . . . 7515355 10 A7. . . . . . . . . 7515378 22 B10. . . . . . . . 7515383 23 A13. . . . . . . . 7515384 16 C13. . . . . . . . 7515399 22 A7. . . . . . . . . 7515415 29 B12. . . . . . . . .

3 C6. . . 7515438 39 A12. . . . . . . . .

18 C6. . . 7515472 35 C13. . . . . . . . 7515484 31 C13. . . . . . . . 7515485 37 C13. . . . . . . . 7515488 11 C3. . . . . . . . . .

16 C14. . 7515489 2 B9. . . . . . . . . .

2 C2. . .

Page 73: BIG BOSS 500 6x6 Model #A99AE50AA INT’L BIG BOSS 500 6X6 ...pi54.com/corp/manuals/Parts/9914920.pdf · 1999 BIG BOSS 500 6X6 (INT’L) SPECIFICATIONS BRAKES Type - Front Type -

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

F2

7515520 27 C3. . . . . . . . . 7515522 17 B4. . . . . . . . . .

9 C13. . 7515523 8 B8. . . . . . . . . . 7515547 24 A7. . . . . . . . . 7517102 7 B1. . . . . . . . . . 7517219 5 C10. . . . . . . . . 7517242 26 A8. . . . . . . . . 7517303 10 B4. . . . . . . . . 7517377 3 A8. . . . . . . . . . 7517395 5 B10. . . . . . . . . 7517433 2 D2. . . . . . . . . . 7517451 6 A14. . . . . . . . . 7517475 13 A10. . . . . . . . 7517527 28 B12. . . . . . . . 7541906 11 C8. . . . . . . . . 7541925 23 D2. . . . . . . . .

23 D3. . . 7542101 23 A8. . . . . . . . . 7542105 29 A8. . . . . . . . . .

17 A12. . 7542122 6 A5. . . . . . . . . . .

22 A6. . . 8 A7. . . 4 A8. . .

33 A10. . 16 B10. .

7542124 9 C12. . . . . . . . . 7542127 1 B2. . . . . . . . . . 7542143 15 A14. . . . . . . . 7542301 7 A13. . . . . . . . . 7542303 36 A12. . . . . . . . .

10 B7. . . 7542321 15 C7. . . . . . . . . 7542324 12 A7. . . . . . . . . .

21 A8. . . 1 A13. .

24 B10. . 6 B11. .

31 C7. . . 25 D2. . .

7542403 6 A12. . . . . . . . . . 1 B12. .

25 C3. . . 34 C13. .

7542404 36 C13. . . . . . . . 7542411 1 A12. . . . . . . . . 7542438 18 B12. . . . . . . . 7542439 19 A6. . . . . . . . . .

2 C6. . . 7542449 38 A8. . . . . . . . . .

14 B4. . . 29 C13. .

7542459 23 B8. . . . . . . . .

7542503 1 B4. . . . . . . . . . . 28 C7. . . 26 D2. . .

7542507 9 D2. . . . . . . . . . 7542522 2 C7. . . . . . . . . . 7542602 10 C6. . . . . . . . . 7542711 5 B12. . . . . . . . . 7542714 4 C5. . . . . . . . . . .

11 C14. . 7542810 18 B8. . . . . . . . . .

15 C4. . . 7543005 7 C5. . . . . . . . . . .

9 C14. . 7543203 15 B11. . . . . . . . 7543601 31 C3. . . . . . . . . 7546701 23 D5. . . . . . . . .

23 D6. . . 7546702 19 D5. . . . . . . . .

19 D6. . . 7546707 24 D5. . . . . . . . .

24 D6. . . 7546904 11 B12. . . . . . . . 7547004 17 A10. . . . . . . . 7547028 7 B12. . . . . . . . . 7547104 1 B7. . . . . . . . . . 7552603 23 A12. . . . . . . . .

18 B4. . . 27 B12. .

8 C13. . 2 D1. . .

7552605 6 A10. . . . . . . . . . 16 A12. . 23 C13. .

7552606 15 C13. . . . . . . . 7552801 18 A7. . . . . . . . . .

7 A14. . 2 C8. . .

7552901 7 A12. . . . . . . . . . 12 B7. . . 14 B9. . . 14 C2. . . 27 C7. . .

6 C9. . . 2 C13. .

7555701 12 C13. . . . . . . . 7555716 2 A13. . . . . . . . . 7555725 21 B10. . . . . . . . 7555726 19 A14. . . . . . . . 7555740 15 D2. . . . . . . . . 7555745 8 C5. . . . . . . . . .

8 C14. . 7555748 4 C10. . . . . . . . . 7555749 2 B7. . . . . . . . . . .

10 D2. . .

7555764 1 C14. . . . . . . . . 7555781 5 A13. . . . . . . . . 7555788 14 C4. . . . . . . . . 7555796 12 C14. . . . . . . . 7555801 2 A12. . . . . . . . . 7555806 34 A12. . . . . . . . .

16 B4. . . 10 B12. . 15 C12. . 38 C13. .

7555815 4 C4. . . . . . . . . . 7555824 6 A8. . . . . . . . . . 7555832 38 A12. . . . . . . . .

13 B4. . . 1 D1. . .

7555843 10 C12. . . . . . . . . 24 C13. .

7555859 5 A5. . . . . . . . . . . 4 A6. . .

7555878 16 B11. . . . . . . . 7555883 2 B4. . . . . . . . . . .

29 C7. . . 27 D2. . .

7555893 17 B2. . . . . . . . . 7555896 8 B1. . . . . . . . . . 7555898 8 C9. . . . . . . . . . 7555904 23 C7. . . . . . . . . 7555911 9 C6. . . . . . . . . . 7555916 5 D3. . . . . . . . . . 7555919 7 C12. . . . . . . . . 7555925 18 A6. . . . . . . . . 7555935 22 C10. . . . . . . . 7556004 17 B8. . . . . . . . . 7556033 4 B10. . . . . . . . . 7556076 10 C9. . . . . . . . . 7556401 2 C9. . . . . . . . . . 7556804 9 C9. . . . . . . . . . 7558201 16 A10. . . . . . . . .

2 C12. . 7558212 10 A6. . . . . . . . . 7558301 21 A6. . . . . . . . . .

7 A7. . . 13 A8. . . 32 A10. . 16 A13. .

8 A14. . 20 B1. . . 34 B2. . . 20 C7. . . 18 D2. . . 26 D5. . . 27 D6. . .

7558402 16 A7. . . . . . . . . . 9 B7. . .

13 B9. . .

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PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Big Boss 500 6X6 A99AE50AA and Int’l Big Boss 500 6X6 SL A99AE50DA

F3

7558402 7 B11. . . . . . . . . . 13 C2. . . 14 C7. . .

3 C13. . 24 D2. . .

7571602 24 D3. . . . . . . . . 7571605 11 B6. . . . . . . . . 7571611 5 C4. . . . . . . . . . 7575202 29 A12. . . . . . . . 7621336 9 D3. . . . . . . . . . 7621403 12 A6. . . . . . . . . 7621432 13 A5. . . . . . . . . 7621433 12 C7. . . . . . . . . 7621460 3 A5. . . . . . . . . . 7621462 15 A13. . . . . . . . .

13 B13. . 7621470 8 D3. . . . . . . . . . 7660701 17 B10. . . . . . . . 7661010 8 C12. . . . . . . . . 7661203 12 B12. . . . . . . . .

21 C12. . 7661401 19 B8. . . . . . . . . .

17 C12. .

7661402 16 C4. . . . . . . . . 7661404 5 C5. . . . . . . . . . .

13 C14. . 7661632 11 B11. . . . . . . . 7661633 14 B11. . . . . . . . 7661638 5 A7. . . . . . . . . . .

24 C10. . 7661640 14 C12. . . . . . . . 7661645 24 C7. . . . . . . . . 7661820 2 C11. . . . . . . . . 7661825 27 A7. . . . . . . . . 7661913 10 B6. . . . . . . . . 7670051 8 C10. . . . . . . . . 7670054 4 D3. . . . . . . . . . 7670060 1 A5. . . . . . . . . . .

13 A13. . 30 C13. .

7670063 1 C12. . . . . . . . . 7670064 12 B3. . . . . . . . . 7670065 13 B3. . . . . . . . . 7670066 14 B3. . . . . . . . . 7670081 5 C14. . . . . . . . . 7670090 18 A10. . . . . . . . 7670091 4 B6. . . . . . . . . .

7670101 3 B4. . . . . . . . . . 7710405 25 C14. . . . . . . . 7710414 1 C3. . . . . . . . . . 7710433 27 C13. . . . . . . . 7710434 32 C13. . . . . . . . 7710448 15 C9. . . . . . . . . 8360009-600 20 A12. . . . .

4 A14. . 8360011-15 42 D3. . . . . . . 8360012-13 21 D3. . . . . . 8360026 25 A14. . . . . . . . 8360031-30 16 B13. . . . . 8360031-38 18 B13. . . . . 8450003-1525 22 A10. . . .

11 A12. . 8450040-600 10 A12. . . . .

12 A14. . 8450050-305 34 A10. . . . 8450051-600 14 B2. . . . . 8450073-600 20 B2. . . . . 8450080-65 21 A12. . . . . .

11 A14. . 9914919 9 D4. . . . . . . . . .

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