Polaris 6x6 Big Boss engine

[Rowski]

I have a 1992 Polaris Big Boss 6x6. The atv was given to me. Prior to my ownership it hadn't been run in 3 or 4 years. The years prior to that it wasn't running well. Was owned by second home owners and kids mostly used it. Anyways... After a new battery, brake hose, chain, lots of labor cleaning carb and fuel tank, bleeding brakes, free up frozen and rusted "things". Had it running very well. Went through about 4 tank fulls of gas and the engine let go, most likely piston skirt broke or similar.

My question....

Can four stroke engine (from another Polaris) be put into this Big Boss? I'm not looking for more power but more quiet and less smoke.

Thanks.

 

[TOMMYHPX4X4]

you'll find all the info you need on polaris in this froum . not saying we can't help you but this other forum might be able to give you some better info or maybe one of the guys in there have done it already and can tell you about it. i read up on polaris alot in there and they are a good group of guys .i'm sure with a torch and a welding machine any engine can go anyplace. you might have to do some engine mount moding




http://www.prcforum.com/

 

[Rowski]

Thanks.

I'm crafty and could most likely get it done. Just want to make sure I have the closest possible match.

I was going to use it more around the yard, its more a work machine, a lot of stop and go and not really getting to full operation temp. I still may have to rebuild it. I'm guessing a complete rebuild would run about $700ish. So I figured that if I could get salvaged one for a $1K it might be worth it. I have very little money in it.

I did find out some news. I called varoius dealers, some of which were very help full and others could care less. I seaching the Polaris on-line parts. I found that the Magnum 425 in the mid '90s might work best, i think.

So I'm looking for a Polaris Magnum 425.

 

[mars1952]

I have a 1992 Polaris Big Boss 6x6. The atv was given to me. Prior to my ownership it hadn't been run in 3 or 4 years. The years prior to that it wasn't running well. Was owned by second home owners and kids mostly used it. Anyways... After a new battery, brake hose, chain, lots of labor cleaning carb and fuel tank, bleeding brakes, free up frozen and rusted "things". Had it running very well. Went through about 4 tank fulls of gas and the engine let go, most likely piston skirt broke or similar.

My question....

Can four stroke engine (from another Polaris) be put into this Big Boss? I'm not looking for more power but more quiet and less smoke.

Thanks.

Congratulations on your great buy! Polaris Rangers are great machines. If you decide to swap out the engine now would be a great time to upgrade to one of the newer more powerful Polaris engines.
Here is an example I found on ebay (sorry it's closed already)

Like the other members said the The PCR Forum is a great source of info. However, the PCR guys are all about speed. They like to tinker with their Rangers to get all the HP and MPH they can get. This could be a good thing for you since many of the PCR members are looking to swap out their older smaller engines for the larger new ones.
Here is a link to a PCR thread about engine swapping.

Good Luck, Marshall

 

[Rowski]

Congratulations on your great buy! Polaris Rangers are great machines. If you decide to swap out the engine now would be a great time to upgrade to one of the newer more powerful Polaris engines.
Here is an example I found on ebay (sorry it's closed already)

Like the other members said the The PCR Forum is a great source of info. However, the PCR guys are all about speed. They like to tinker with their Rangers to get all the HP and MPH they can get. This could be a good thing for you since many of the PCR members are looking to swap out their older smaller engines for the larger new ones.
Here is a link to a PCR thread about engine swapping.

Good Luck, Marshall

I'm not very familair with the 6x6 Ranger. The Big Boss 6x6 is basically a 4 wheeler with an extra axle. The Rangers are wider and I'm not really sure if the engine and running gear are the same??

Thanks for the links!!

I'm at work now and don't get enough time to read.

I'll check it out tonite with a nice cold beer!!

Thanks again

 

[TOMMYHPX4X4]

keep me updated on the swapout i'm interested in how it comes out.

 

[mars1952]

I'm not very familair with the 6x6 Ranger. The Big Boss 6x6 is basically a 4 wheeler with an extra axle. The Rangers are wider and I'm not really sure if the engine and running gear are the same??

Thanks for the links!!

I'm at work now and don't get enough time to read.

I'll check it out tonite with a nice cold beer!!

Thanks again

How about some pictures?
Marshall

 

[Rowski]

How about some pictures?
Marshall

Link below is to Polaris it shows 2006 model. They call the sportsman 6x6. Mine is 1992 Big Boss 6x6 with a 250cc 2 stroke. Both very simmilar in looks.

I'm at home (enjoying that cold beer), my 6x6 is at the shop. I'll try and get a shot of it.

Polaris Industries.