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post #1 of 19 (permalink) Old 07-22-2019, 03:20 AM Thread Starter
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Big Boss 250 ID and Repair

Hi all, I recently picked up a Big Boss 250 to use on the farm I work at. I am struggling to correctly ID it so that I can acquire the correct set of manuals before I start working on it later this week.

The frame is stamped “2082577” up in the right side front fender. I was told it’s a 2000 model but believe this to be incorrect. It has a single brake, a L-H-N-R shift pattern, and is obviously a 250. Can anyone help me ID this unit’s exact year? I did email Polaris support about ID as well.

A few other details: I was told it hasn’t been run in 4-6 years, that the electric starter doesn’t work, and had a couple of bare red wires on the left side pointed out. Also nothing happens if you pull on the brake with plenty of fluid in the reservoir. So she’s going to need some work.
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post #2 of 19 (permalink) Old 07-22-2019, 05:36 AM
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The number you provided appears to be a part number, but it does not come up on any of the part search apps that I use.

Depending on the year model, the number you are looking for is either a 7 digit number starting with a 'W' on the RH side frame down tube near the shifter box or a 17 digit number on the LH frame tube in front of floorboard and behind the front wheel most likely starting with 4XA. Look in those locations, maybe take some pics and post them - sometimes the have to be ID'd by appearance.

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post #3 of 19 (permalink) Old 07-22-2019, 06:26 AM Thread Starter
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Thanks for the reply. That is the number in front of the shifter box on the frame. A tag has been welded onto the frame. While googling for info this morning I found a couple posts like mine with similar seven digit 2xxxxxx codes.

I attached a photo of the left front lower rail where there is nothing, a photo showing the general location of the tag, and of the tag itself.

Edit: I checked the 85-95 service manual and I believe the number I posted to be the serial number since it has a square tube frame. I can't seem to locate any numbers on the engine where the service manual suggests they are. I'd have to remove the exhaust to see more.

Edit 2: More googling resulted in one 22xxxxx serial number corresponding to a 1995 unit. I believe this to be a 1993 but I can't confirm that quite yet.

Edit 3: Found the sticker on the footwell side of the tube by the serial number. It is a 1993, W938727.
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Last edited by ct937; 07-22-2019 at 07:45 AM.
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post #4 of 19 (permalink) Old 07-22-2019, 10:03 AM
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Yep - that's it - a 93 model 8727 250 6x6

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post #5 of 19 (permalink) Old 07-22-2019, 10:07 AM Thread Starter
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I went ahead and drained the tank, popped in a fresh battery, and tried firing it on some starting fluid. Ran on the first pull! That's a good sign.

It's going to need a new throttle cable and fresh spark plug before I test drive it. Polaris Parts wants $138 for a freakin' #7080531 generic double pull throttle cable. It's only $19 on Amazon... Hmmm. I do expect to have to replace the carb but I'm not going to buy one until I'm sure I need it.

The right brake handle/master cylinder is connected to the fronts and the smaller center brake. I haven't opened the reservoir but I'd imagine the whole system is going to need work. I'm never lucky with brakes lol.

Everything for the rears is missing forward of the T block including the left side handle. What is still there is in pretty poor shape. Bummer.

Last edited by ct937; 07-22-2019 at 10:12 AM.
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post #6 of 19 (permalink) Old 07-22-2019, 10:22 AM
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There's 4 different calipers on the rear - middle L & R and rear L & R

Price I got for the throttle cable from Polaris is $160 - part 7080375 - yep, $20 from China and chances are it's the same cable Polaris is selling

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post #7 of 19 (permalink) Old 07-23-2019, 04:59 AM Thread Starter
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Thanks for the info. You don’t happen to know the rear brake component part numbers, do you?

FWIW I bought the cheap throttle cable because I already overpaid for this unit considering it was not working order when I picked it up.

Looking at potential costs ahead I priced out brakes on eBay, looks like about $210 to overhaul front and middle brakes. That’s the cost of rotors, pads, calipers, and a new RH master cylinder.

It does not include the LH master cylinder, lines, or any rear brake components. I still need to look up those part numbers.

I know I’ll need a couple of wheel studs too and would like to find them for less than $5-6/each #85-1090’s that pull up on my searches. But that’s just me being cheap. 😉

I also picked up a #07-452 Mikuni rebuild kit for the VM30SS Zinc with the correct 140 main jet. If my carb ends up giving me fits I’ll swap out a regular old VM30 with a flange adapter. That’ll cost me another $80-90 if I need it.

Last edited by ct937; 07-23-2019 at 05:01 AM. Reason: Typos
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post #8 of 19 (permalink) Old 07-23-2019, 07:24 AM
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Need other drawings? Look up OEM parts HERE

# Add Part# Description Quantity
1 7080352 SCREW, BLEEDER 1 USAGE
2 1910047 ASM., BRAKE CALIPER, REAR (Incl. 1-3,7,9) 1 USAGE
2 1910047 ASM., BRAKE CALIPER, REAR (Incl. 1-3,7,9) 1 USAGE
2 1910047 ASM., BRAKE CALIPER, REAR (Incl. 1-3,7,9) 1 USAGE
2 5130713 CALIPER, BRAKE, REAR 1 USAGE
2 5130713 CALIPER, BRAKE, REAR 1 USAGE
2 5130713 CALIPER, BRAKE, REAR 1 USAGE
3 7661820 PIN, BRAKE CALIPER 2 USAGE
4 2200464 KIT, PADS, REAR BRAKE (Incl. 3) 1 USAGE
5 5410518 RING, SEAL (.120 Sq) 1 USAGE
6 5410519 RING, SEAL (.066 Sq) 1 USAGE
7 5020521 PISTON, BRAKE 1 USAGE
8 1930666 KIT,BRAKE SEALS&PISTON (Incl. 5,6,7) 1 USAGE
9 5222232 SPRING,ANTI-RATTLE 1
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post #9 of 19 (permalink) Old 07-23-2019, 10:20 AM Thread Starter
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Thanks again for the info latebird.

Looks like the #1910047 is unavailable from just about anywhere. Guess that explains why someone tore the rear brake lever and lines out and left the rest to rot. Better to know than to not know I suppose!

If time permits I'll begin brake system diagnostics and see if she'll run off of fresh gas later tonight.
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post #10 of 19 (permalink) Old 07-23-2019, 10:37 AM
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Just so you know - that caliper was used on the following models:

And there's one HERE on Ebay for $75

1989 BIG BOSS (W899627) - Rear Brake Assembly
1989 BIG BOSS (W899627) - Right Hand Gearcase & Brake Mounting
1989 BIG BOSS 4X6 (W898627) - Right Hand Gearcase & Brake Mounting
1989 BIG BOSS 4X6 (X898627) - Rear Brake Assembly
1989 BIG BOSS 4X6 (X898627) - Right Hand Gearcase & Brake Mounting
1989 TRAIL BOSS 2X4 (W897527) - Right Hand Gearcase & Brake Mounting
1990 BIG BOSS 4X6 (W908627) - Rear Brake Assembly
1991 BIG BOSS 4X6 (W918627) - Rear Brake Assembly Big Boss 4X6
1991 BIG BOSS 4X6 (W918627) - Right Hand Gearcase & Brake Mounting Big Boss 4X6
1991 BIG BOSS 6X6 (W918727) - Gearcase/Brake Mounting 6X6
1991 BIG BOSS 6X6 (W918727) - Rear Brake Assembly 6X6
1992 BIG BOSS 4X6 (W928627) - Rear Brake Assembly 250 4X6
1992 BIG BOSS 4X6 (W928627) - Rh Gearcase/Brake Mounting 250 4X6
1992 BIG BOSS 6X6 (W928727) - Rear Brake Assembly 250 6X6
1992 BIG BOSS 6X6 (W928727) - Gearcase / Brake Assembly 250 6X6
1992 EURO BIG BOSS 6X6 (S928727) - Rear Brake Assembly 250 6X6 / W928727
1992 EURO BIG BOSS 6X6 (S928727) - Gearcase / Brake Assembly 250 6X6 / W928727
1993 250 4X4 (W938127) - Gearcase/Brake Mounting 4X4 250
1993 250 6X6 (W938727) - Gearcase/Brake Mounting 6X6 250
1993 250 6X6 (W938727) - Rear Brake Assembuy 6X6 250

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