TRAIL BLAZER 250 Model #A99BA25CA Rev. 01
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1 TRAIL BLAZER 0 Model #ABACA Rev. 0 PARTS MANUAL PN and MICROFICHE PN /
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3 TABLE OF CONTENTS Parts Manual A-ARM/STRUT MOUNTING B AIR BOX A CARBURETOR C CLUTCH COVER C CONTROL PANEL A CONTROLS - MASTER CYLINDER/BRAKE LINE B CONTROLS - THROTTLE ASM./CABLE B CRANKCASE and CYLINDER C CRANKSHAFT and PISTON C DECALS A DRIVE CLUTCH B DRIVEN CLUTCH B ELECTRICAL/TAILLIGHT C ENGINE MOUNTING A EXHAUST SYSTEM A FRONT BRAKE B FRONT BUMPER and SHIELDS A FRONT CAB A FRONT WHEEL B FUEL TANK A A C D E F G GEAR SELECTOR C GEARCASE C- GEARCASE MOUNTING C H HANDLEBAR B MAGNETO M O C OIL PUMP C OIL TANK A P PART NUMBER INDEX D- REAR BRAKE MASTER CYLINDER.. B REAR CAB A REAR CALIPER MOUNTING B REAR HOUSING C REAR WHEEL DRIVE B RECOIL STARTER C STARTING MOTOR C STEERING POST B STRUT B SWING ARM/SHOCK MOUNTING.... B T TOOL KIT D R S The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
4 Type - Front Type - Rear Type - Auxiliary Type - Parking BRAKES CAPACITIES Fuel Tank (gallon) Gearcase Oil (ounces) Oil (quarts) Injector Oil, Engine, OW/0 (quarts) Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight (grams) Spring Color DRIVEN CLUTCH Helix Angle Spring Position DIMENSIONAL FEATURES Approx. Turning Radius Box, Tool (cubic inches) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (dry) Wheel Base (inches) Width (inches) GEARCASE Trans. Number and Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Final Drive (ratio) Chain Type TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center TRAIL BLAZER 0 SPECIFICATIONS ENGINE Hydraulic Disc Hydraulic Disc Hydraulic Hydraulic Lock N/A Accessory 0 Accessory 0 0 Accessory 0 Concentric PVT / G () Blue/Green PRD Side Lever N/A.0/./ / P 0 O-Ring Titan x- x- N/A N/A Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc s) Compression Ratio Cooling Alternator Output Elec. Start w/recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust GRAPHICS Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front/HDPE Fender, Rear/HDPE Footwell Frame/Steel Front Cover Handlebar Cover/TPE Headlight Pod/HDPE Rack, Front Rack, Rear Rims Seat Vinyl Side Panel/HDPE Spring, Front Spring, Rear ELECTRICAL Headlight (watts) Taillight (watts) Brake Light (watts) Other (Grill Mntd. Lights) Indicator Bulb Battery SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment ECPFE Cycle, Single Cyl. Oil Injection x0.: Effective Air 0W Standard VM0SS ().0.0 Turn DP NGKBRES USFS Appr. Pending N/A N/A Bright White Bright White Black Black Yellow Black N/A N/A N/A Bright White Yellow N/A Fire Red Fire Red Single Beam, V W V/. W V/. W N/A V/ W V AH MacPherson Strut. Progressive Rate Swing Arm. Gas Charged Monotube CAM Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.
5 TRAIL BLAZER 0 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS 0 0
6 FRONT CAB 0 0 Screw -0 Mount, Cab 000 Nut, U-Clip Speed -0 Frame 000 Clamp, Wire Routing 00 Spring, Adjustment 00 Insert, Nut -0 Bracket, Headlight Mounting 000 Bulb, Halogen, W Screw 00 Headlight, Single Beam (Incl. ) 00 Spring Screw -0 Cover, Front, Yellow Screw - Asm., Cab, Front, White (w/warning Decals) 0 Washer A 0 Screw Rivet 0 0 Washer Washer, Flat Nut, Nylok -0 Bracket, Mudflap 00 Mudflap, Front, LH Mudflap, Front, RH Bolt -0 Footpad Rivet Trim, Footrest Screw 0 Guard, Rock -0 Cleat Rivet Screw /
7 REAR CAB 0 00 Spring, Latch 0-0 Latch, Seat Asm., Seat, Yellow Covering, Seat, Yellow Tongue, Seat Rivet Bumper 0 Bracket, Lever Retainer Rivet 0 Decal - Carb Information 0 Decal - Filter Element 0- Cab, Rear, White 00 Nut, U-Clip Speed Shield, Muffler Foil, Foam Screw Washer, Flat A Nut -0 Guard, Clutch, Outer Rivet 0 Reflector, Red 0 Plug, End Cap, Ribbed Foil, Rear Cab Foil, Rear Cab, Small Bolt Footpad (See Front Cab Pg. A, Ref. ) 0 0 Mudflap, Rear, LH Mudflap, Rear, RH -0 Bracket, Mudflap 00 Bracket, Rear Seat Holddown Rivet, Pop Screw Screw /
8 FRONT BUMPER and SHIELDS -0 Plate, Mount, Reflector Bolt 0 Reflector, Amber Plug, Frame 0 U-Nut 0 Shield, Deflector -0 Bumper, Front Screw 00 Clip, Dart / A
9 CONTROL PANEL 0 Plug, Indicator 000 Indicator, Neutral/Reverse Switch, Ignition (Incl. Key) Key, Ignition Key, Ignition NOTE: Ignition key may be ordered by using the four digit number on the key. Panel, Control, Outer Screw 0 Harness, Indicator Panel, Control, Inner 00 Cable, Choke Control / A
10 ENGINE MOUNTING Nut, FLEXLOC 0 Washer 00 Mount, Motor 00 Insulator, Mount, Motor AR Washer Bolt 0 Washer, Lock Nut, FLEXLOC -0 Bracket, Mount, Engine, Top 0 Fitting, Vent Screw 0 Cable, Ground/Engine, Small Hole 00 Spark Plug, NGK BRES 00 Cable, Solenoid Starter Insulator, Cable Bolt 0-0 Mount, Engine, Lower Bolt 0 Washer, Lock 0 Washer, Clutch Retainer 0 Bushing Asm., Drive Clutch, Basic ATV-0 (See Drive Clutch Pg. B, Ref. ) A Seal, Cover, Case (See Clutch Cover Pg. C, Ref. ) 00 Clamp, Band, Narrow Boot, Clutch Intake 0 Washer, Spring Lock 0 Bolt -0 Bracket, Mount, Engine, Front 0 Engine, ECPFE-Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration. 0 0 Decal - Drain Recoil AR Line, Fuel 0 Valve, Vent Check 000 Fitting, Tee AR Fuel Line -0 Bracket, Mount, Engine, Rear 00 Mount, Engine 000 Filter Sheath, Foil 00 Clamp, Hose, Yellow /
11 EXHAUST SYSTEM 0 Spacer 0 Dampener Bolt, Carriage Screw -0 Mount, Lower, Muffler 0-0 Manifold Washer, Lock (See Crankcase and Cylinder Pg. C, Ref. ) Nut (See Crankcase and Cylinder Pg. C, Ref. ) 00 Spring, Exhaust 00-0 Headpipe 00 Spring, Exhaust 0-0 Muffler Washer Nut, Nylok / A
12 DECALS RH LH 0 Decal - Warning, Heavy Loads 0 Decal - Trail Blazer 0 Decal - Discretionary Warning 0 Decal - Tank Side, RH 00 Decal - Front Cover, 0 0 Decal - Made in USA, Domed 0 Decal - Override Switch, WD 0 Decal - Age Warning 0 Decal - Tank Side, LH 00 Decal - Passenger Warning 0 Decal - Tire Pressure 0 Decal - Warning, General, CPSC / A
13 FUEL TANK 0 0 Cap, Gas Tank Gasket, Fuel Cap Grommet, Fuel Tank AR Hose, Gas Tank Vent Vent, Tank Bolt Washer Screw 0-0 Bracket, Tank Mount, Rear Nut, Nylok 0 Decal - Fuel Lever Duct, Inlet Down Tube (See Clutch Cover Pg. C, Ref. ) 0 Screw Lever, Fuel 0 Spring, Lever, Compression Extension, Fuel Lever Grommet Washer Screw 0 00 Asm., Fuel Valve (Incl. Gasket) Gasket, Fuel Valve 00 Pad, Fuel Tank Bracket 0 Asm., Tank, Fuel (Incl.,,0) 0 Foam, Seal / A
14 AIR BOX 0 Collar, Foam Filter, Foam 0 Retainer, Foam, Wire Box, Air Silencer 0 Boot, Air Silencer Screw 0 Washer 000 Nut, Speed Box, Air Intake Valve, Umbrella Bumper A Bolt, Carriage 00 Clamp, Narrow Band 00 Clamp 0 Boot, Carburetor Tape, Foil, Air Box 000 Palnut 00 Filter, Air Intake Seal, Air Intake Cover 0 0 Cover, Air Intake 00 Retainer, Air Intake Cover Nut, Wing /
15 OIL TANK 0 Cap, Oil Tank Gasket, Oil Cap Tank, Oil 00 Fitting AR Line, Fuel 0 Rivet 0 Fitting 00 Clamp 000- AR Line, Fuel 000 Clamp, Hose, Green, Large 000 Filter, Fuel 00 Clamp, Yellow AR Line, Fuel Washer / A
16 STRUT 0 Nut, FLEXLOC Washer Spacer, Rubber 00 Pivot, Ball Top 00 Pivot, Ball, Bottom 0 Spacer, Threaded 00 Retainer, Spring, Top 00-0 Spring Bumper, Strut 0 Strut, Front 00 Clamp, Rubber Coated 0 Nut, FLEXLOC 0 Washer 000 Fitting, Lubrication Bolt 0 Support, Strut and Spindle, LH Support, Strut and Spindle, RH Washer, Spring Retainer / B
17 FRONT WHEEL Support, Strut and Spindle (See Strut Pg. B, Ref. ) 00 Seal, Front Hub Bearing, Ball Disc, Brake 00 Hub, Wheel Tire, Front (x-) 0- Rim, Front 0 Valve, Rim 0 Spacer, Hub Front Washer Nut, Castle Pin, Cotter Cap, Hub 0 O-Ring Nut, Flange Stud Bolt / B
18 FRONT BRAKE Asm., Front Brake Caliper, LH Asm., Front Brake Caliper, RH 0 Kit - Front Brake Boot (Incl.,) 00 Screw, Bleeder Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH Ring, Square, Molded (.0) 0 Ring, Square, Molded (. x.) 000 Piston, Caliper 0 Insulator, Caliper 0 Kit - Piston and Insulator Seal (Incl. -) Kit - Severe Duty Brake Pad, Front (Complete set of pads) Kit - Brake Pads, Front, Soft Kit - Brake Pads, Front, General Mount, Caliper Boot, Bushing Boot, Pin Seal Bolt / B
19 A ARM/STRUT MOUNTING 0 0 Nut, FLEXLOC Bushing Boot, Seal, Rod End 0 Rod End, RH Nut 00 Tie Rod 0 Nut, LH 0 Rod End, LH 0 Asm., Tie Rod 0 Washer 0 Nut Cotter Pin 0 Bracket, Ball Joint Screw Boot, Rubber 00 Joint, Ball Support, Strut and Spindle (See Strut Pg. B, Ref. ) Bushing, A-Arm Long 00 Bushing 0 00 Fitting, Lubrication Nut, Castle Kit - A-Frame, LH Kit - A-Frame, RH 00 Shaft, A-Arm Screw 0 Washer, Spring Lock Bolt / B
20 HANDLEBAR Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) -0 Handlebar Screw Pad, Handlebar Screw 0 Mount, Handlebar Pad Kit - Handlebar Block (Incl.,) Block, Handlebar - Asm., Master Cylinder (See Controls - Master Cylinder/ Brake Line Pg. B for Details) Spacer, Switch, LH 0 Switch, LH, Handlebar, ON/OFF 0 Grip, Handlebar Plug Screw 00 Cable Tie Nut, Nylok 00 Clip, Tinnerman / B
21 STEERING POST 0 Asm., Steering Post (Incl.,) Bushing, Steering Console 00 Fitting, Zerk, 0 Degree Bolt O-Ring Washer Spacer, Steering Post Pin, Cotter 0 Nut 0 Bushing, Steering, Lower Rivet Plug, Grease 00 Fitting, Lubrication Bushing, Steering Console -0 Bracket, Upper Steering Bushing Nut, Nylok / B
22 CONTROLS THROTTLE ASM./CABLE Cover, Throttle Control O-Ring 0 Asm., Throttle Control (Incl. -) 0 Asm., Throttle Clamp 000 Cable, Throttle O-Ring / B
23 CONTROLS MASTER CYLINDER/BRAKE LINE Kit - Master Cylinder Reservoir (Incl. -) Asm., Master Cylinder (Incl. -) Ring, Square 0 Bolt, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Clamp 0 Asm., Piston 00 Rivet 0 Kit - Brake Lever w/park Brake Latch (Incl.,,) Spring, Flat 00 Nut 00 Kit - Park Brake Lever (Incl.,,) 0 Bolt 00 Bolt Line, Brake, Upper w/fittings 0 Switch 0 Line, Brake, Rear, Hand 00 Clamp Rivet 0 0 Line, Brake, Left Front w/fittings 00 Cable Tie Screw 0 Line, Brake, Right Front w/fittings 0 Fitting, Inverted Flare Cross / B
24 DRIVE CLUTCH Bolt 0 Washer, Spring Lock Bearing, Cover 0 Spring, Clutch 0 Washer, Multilube Roller and Bushing O-Ring 0 Guide Button AR AR AR AR Spacer (.00 ) Spacer (.0 ) Spacer (.0 ) Spacer (.00 ) 0 Weight, Shift (G) Bolt 0 Nut, FLEXLOC 0 Bearing, Moveable, / 00 Pin, Spider 0 Washer, Rubber Asm., Drive Clutch, Basic ATV-0 (Incl. All Less,) / B
25 DRIVEN CLUTCH 0 Spacer, Driven 0 AR Bushing ( Max) 0 Belt, Drive 0 Asm., Driven Clutch (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 AR AR Washer (.00) Washer (.0) 0 AR Washer (.00) B 0 Bearing, Moveable, / Bearing, Moveable, 0 Spring, Clutch Ramp, Stationary Spacer Ring, Retaining Bolt 0 Button, Ramp /
26 SWING ARM/SHOCK MOUNTING 0 0 Nut, Nylok 00 Bushing 0-0 Spring, Compression 0 Cam, Adjusting 00 Bushing 0 Tube 0 Shock 0 Adaptor, Spring Seat Sleeve, Spring Protector Retainer, Spring 0 Tube Screw Rivet Guide, Pad, Chain 00 Fitting, Lubrication 0 Nut 0 Washer B Bushing, Swing Arm, RH Bolt, Swing Arm 0 Bushing, Pivot, RH Asm., Swing Arm (Incl.,,) 0 Decal - Chain Free Play Guard, Chain 0 Screw Bushing 0 Washer Nut 0 Nut Washer 0 Bolt Screw Bushing, Swing Arm, LH Bushing, Pivot, LH /
27 REAR CALIPER MOUNTING Frame Screw Caliper, Rear Kit - Caliper Seal Kit - Bleeder Replacement Piston, Caliper, Rear Seal 0 Line, Brake, Hand, Rear 0 Line, Brake, Foot, Rear 00 Clip, Rosebud 0 Clip 0 Bolt, Banjo Bushing, Caliper Mount 0 Washer 0 Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt -0 Guard, Brake Disc 0 00 Kit - Brake Pad Spacer, Pad Pin / B
28 REAR BRAKE MASTER CYLINDER 0 Bolt 0 Reservoir 0000 Clamp, Red Hose Pin, Cotter 0 Spring Washer Pin, Cotter 0 Bushing -0 Brake, Foot Pin, Clevis Asm., Plunger (Incl. -) 00 Clevis Nut 0 Plunger 00-0 Trim, Edge Nut, Nylok 0 Master Cylinder, Brake, Foot Screw Bracket, Reservoir / B
29 REAR WHEEL Bolt Hub, Rear Wheel, Large Flange Nut, Flange Washer, Cone 00 Nut, Castle Pin, Cotter Cover, Dust, Hub Washer, Flat 0 Valve, Rim 00 Pushnut 0- Rim, Rear Tire (x-) / B
30 REAR HOUSING 0 Ring, Retaining Retainer, Nut 0 Nut, Jam Seal, Foam Nut, Nylok Disc, Brake Stud 0 Hub, Brake Disc (Incl. ) 0 Ring, Retaining 0 Spacer, Axle O-Ring 00 Seal Bearing, Cone, Tapered Bearing, Cup, Tapered 0 Housing, Axle, Rear 000 Fitting, Lubrication 0 Link, Connector, 0 O-Ring Axle, Rear 0-0 Drive Chain, 0 O-Ring 0-0 Guard, Sprocket 0 Spacer 0 Sprocket, T 0 Asm., Hub, Sprocket (Incl. ) 0 Bolt / C
31 ELECTRICAL/TAILLIGHT Harness, Main Wire 00 Cable Tie 00 Kit - Circuit Breaker, 0 AMP 0 Light, Tail/Brake Screw 00 Lens 000 Bulb 00 Gasket 00 Backing 00 Clip 0 Washer Screw 0 Pad, Battery Cover, Battery 00 Kit - Battery Bolt, Short 00 Cable, Battery/Engine, Black 00 Hook, Battery Strap Strap, Battery Holddown Line, Vent Clamp 0 00 Battery 00 Cable, Battery/Solenoid 00 Cable, Solenoid/Starter Nut, Nylok 0 Bolt 000 Rectifier, LR Screw 0 Limiter, LR Rivet 000 Board, Terminal 0 0 Clip, Routing / C
32 CLUTCH COVER 0 0 Seal, Clutch Cover, Inner Washer Screw 0 Seal, Clutch Cover Cover, Clutch, Front 00 Clip, Clutch Cover Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 Decal - Automatic Transmission Screw 00 Cable Tie Boot, Clutch Intake Screw 0 Washer Screw 0 Clip 00 Clamp Washer 0 Screw Tape, Foil Duct, Inlet Down Tube 0 Boot, Intake Duct, Inlet Top Screw 0 Spacer 0 Kit - Cover, Clutch, Inner (Incl.,,,,) Washer -0 Bracket, Clutch Cover 0 Duct, Air Outlet, Clutch Seal, Cover, Case -0 Bracket, Retainer Seal Screw and Washer (See Crankcase and Cylinder Pg. C, Ref. ) Screw Rivet 0-0 Bracket, Clutch Cover 0 Nutsert / C
33 GEAR SELECTOR 00 Cover Screw 00 Knob, Gear Selector 00 Grommet, Shifter, Gear Spacer, Shifter Mount, Gear Selector 0 Nut, FLEXLOC 0 Rod End, mm, RH 0 Nut, RH 00 Rod, Shift Linkage 0 Nut, LH 0 Rod End, mm, LH Bolt -0 Selector, Gear / C
34 C GEARCASE 0 0 0
35 GEARCASE Asm., Gearcase (Incl. -) 0 Bearing, Ball Ring, Retaining Washer, Thrust Sprocket, T 0 Washer, Thrust Dog, Engagement, High/Reverse Shaft, Input Gear, T Bushing Washer Ring, Retaining 0 Bearing, Ball 0 Nut, FLEXLOC 0 Washer Bellcrank, HLR 0 Ring, Retaining 00 Washer O-Ring Shaft, Shift 0 Switch Screw 0 Bullet, Shifting Spring, Compression Washer Plug, Detent, Extension Seal Dipstick Tube, Vent Gearcase, RH 0 Pipe, Knock Shaft, Shift Fork, Shift Gearcase, LH Decal - Switch Screw Plug Bushing, Pivot 0 Washer Chain, Silent, 0P, W 0 Sprocket, T Shaft, Output 0 Gear, T 0 Guard, Prop Shaft, Side Screw 0 Washer / C
36 GEARCASE MOUNTING Screw Nut, Flange -0 Bracket, Transmission Mount 0 Spacer -0 Bracket, Transmission Mount -0 Bracket, Air Box Screw 0 Washer 0 AR AR AR Shim (.00) Shim (.0) Shim (.00) -0 Mount, Transmission -0 Spacer 0 Mount Screw Bolt, Torque Stop 0 Nut Plug, Drain (See Gearcase Pg. C, Ref. ) Ring, Retaining Sprocket, T Screw / C
37 CRANKCASE and CYLINDER Fin Damper 0 Nut, Flange 0 Fin Damper 0 Fin Damper 00 Bolt and Washer 0 Mount, Rubber 0 Collar 0 Head, Cylinder 00 Gasket 00 Fin Damper 0 O-Ring 00 Adapter (Incl. ) 00 Bolt, Allen 0 Asm., Band (Incl. ) 0 Screw, Pan Head 00 Stud 0000 Seal, Oil 00 Pin, Dowel 0 Asm., Crankcase (Incl. -,-,-) C 0 00 Gasket, Starter 0 Gasket, Aluminum 0 Plug 00 Bearing, Ball 00 Bearing, Ball 00 Bolt and Washer 0 Screw and Washer 0 Seal, Oil (PTO) 0 Bolt and Washer 00 Bolt and Washer 0 0 Valve, Check 00 Gasket, Cylinder 0 Nut, Flange 0 Cylinder (Incl.,) 0 Stud 00 Stud 00 Gasket, Exhaust 000 Washer, Spring Lock 00 Nut /
38 CRANKSHAFT and PISTON Ring, Piston (Std.) Ring, Piston (0.mm/.0 O/S) Ring, Piston (0.0mm/.00 O/S) Ring, Piston (.00mm/.00 O/S) Piston (Std.) Piston (0.mm/.0 O/S) Piston (0.0mm/.00 O/S) Piston (.00mm/.00 O/S) 0 Pin, Piston 0 Clip, Piston Pin 0 Crank Pin 00 Spacer, Crank Pin 00 Rod, Connecting 0 Bearing, End, Small C 00 Bearing, Ball 0 Gear, Crankshaft (O/I) 000 Key, Woodruff 00 Washer 00 Nut, Lock 0 0 Asm., Crankshaft (Incl. -,,,-) Crankshaft 00 Bearing, End, Large 0 Crankshaft 0 0 AR AR Spacer (0.mm) Spacer (0.mm) /
39 MAGNETO 0 00 Cap, Spark Plug 0 Screw and Washer 0 Flywheel w/ring Gear 0 Coil, Exciting 0 Stator 0 Screw and Washer 0 Screw and Washer 0 Washer 0 0 Asm., Plate (Incl.,,,,-) Plate, Coil 0 Clamp 00 Screw and Washer 00 Coupler, P 0 Harness, Wire (Incl.,) 0 Grommet 0 Screw and Washer 0 Ignition Coil 0 C.D.I. System 0 Magnetic Switch 000 Washer, Spring Lock 0 00 Nut / C
40 STARTING MOTOR 0 0 Nut, Flange 00 Brush 0 0 Asm., Starting Motor (Incl. -,,,-,0-) Asm., Starter (Incl.,,,,,,-) 00 Ring, Rubber 00 Cover, Rear 0 Gasket, Aluminum 0 Bolt, Flange 00 O-Ring 00 Bolt 00 Bracket 0 Bolt and Washer 0 Washer Set C 00 Asm., Armature (Incl.,) 0 O-Ring 0 Bearing, Ball 0 O-Ring 00 Front Cover (Incl. ) 0 Washer, Gear Shaft 00 Bolt and Washer 0 00 Clip 0 Spring, Return 0 Asm., Gear Shaft (Incl.,0,,,) 0 Spring, Weight 0 Clip /
41 RECOIL STARTER 0 0 Spring, Spiral 0 0 Recoil Starter (Incl.,,-,0-) Starter Case B 0 Collar 0 Mount, Rubber 0 Bolt and Washer 0 Bolt and Washer 0 Grommet 0 Reel 0 Bolt, Flange 0 Starter Case 0 0 AR Asm., Rope (Incl. -) Recoil Rope 00 Cap, Knob 0 Starter Knob 0 Bolt and Washer 0 Bushing, Starter 0 Plug 0 Gasket 0 Pulley, Starting 0 Bolt and Washer 0 0 Spring, Return 0 Ratchet 00 Pin, Ratchet 0 Hook, Spring 0 Guide, Ratchet 0 Spring, Friction 0 Case, Spring 0 Screw and Washer 0 Guide / C
42 OIL PUMP 0 Clamp, Hose 0 Pipe, Vinyl 0 Screw, Air Vent 0 Packing 0 Asm., Oil Pump (Incl.,,-) 0 Screw and Washer 0 Cap 0 0 Lever & Spring Set Lever, Control 0 Collar, Camshaft C 0 Washer, Spring 0 Nut 0 O-Ring AR AR AR Spacer (.mm) Spacer (.mm) Spacer (.mm) 0 Bushing, Oil Pump 0 O-Ring 0 Gear, Small 0 Spacer /
43 CARBURETOR Cap 0 Spring, Throttle 000 Plate, Throttle 0 Needle, Jet (DP-) 0 Washer 00 Valve, Throttle (.0) 0 Cap, Plunger 000 Spring, Plunger 0 Plunger, Starter 00 Spring, Air Adjuster 00 Screw, Air 00 Spring, Throttle Adjuster 0 Screw, Throttle Stop 00 Jet, Pilot (#0) 00 Washer, Jet, Main C 00 Screw and Washer 0 Bolt, Banjo 0 O-Ring 0 Jet, Main (#0) 0 0 Float Chamber 00 Float 0 Cap 000 Packing, Float Chamber 00 Valve, Needle (.) 00 Arm, Float 0 Pin, Float 00 Packing, Needle Valve 0 Asm., Carburetor (Incl. -0) 00 Jet, Needle (0-) E-Ring /
44 TOOL KIT 0 Pouch, Tool Kit 0 Wrench, Box, Special 0 Wrench, - Spanner 0 Screwdriver 0 Gauge, Tire Pressure 0 Asm., Tool Kit (Incl. -) -0 Wrench, Spanner 0 Manual, Owners, ATV Supplement, Manual, Owners, Trail Blazer 0 / D
45 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A A C B A C A A A A A A B B B C B B B B C C B.. B B B B B B B B B B B B B B B B B B B B B B B B B B B B B.. B B B B B C B B B C B B B B B B B B B C B B C C A A.. A A A A A A D C D D D A C C C C C C C C C C C C C C C C.. C C C C C C.. C C C C C C C C C C C C D C C C C C C C C C C C C D D C C C C C C C C C C C C C C C C.. C C.. C C C C C C C C C C C C C C C C C C C C C C C C C C C D C C C
46 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C... C C A C C C C C C C C C C C C C C C C C C C A A C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C B C C C C C C C C C C C C C C C C C C C C C C C C C C C D C C C C C C C C C C C C C C C C C C C B C C B.. B B B B C A... C C C A C A C B C A C C C A A A C C A A B A B C B B A C B B B B B C
47 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid B B B B B B B B B B B B B B C C B B C A B.. B B B C A C B A... A A C C C B B B A A B A C B A A B B A A C B C A C A A A B B B A C B C C C B C B B A A A... C C B B B A C A A B A B B C B B B A C B C C C A B B B B B B C C A A A B B A A B B A B A B A B B A B A D A B B B B B B C C C A A A C A A A A C B B B B A A A B B B C A A C C C C C B B B C B A A C B A B A A A A A A A A C A A A A A B
48 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid C B B A A B B B B B A A A A A A A A B C C B B A A A A C C A A A C B A A A A A A A A A B B... C A A.. A C B... C A B A A A B... B B... C B.. B A.. A... C B A B B B B B A B A A C C B... C... C A C A... C C C C C B A.. B A... A... A.. A... C... C A A B B A A... A B A B B.. B A A A B A B B C A A B C D B A... B B B A A B B C B C B C B... A... A B B B C B C C C C A B C A... B.. B... A A B B B A.. A... B A... B A C B B... C C B B B B B B B B C C C B B C
49 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A C B A... B B A.. B.. B A B A A B C B C B A... B... C A A... A... C B B B B A B B C B B A A... C... C A B.. B.. B C A C A A B A A... A A B B B B B B B B A... C A B C A A.. A A B A C A B C C C B C A.. A.. A B A A A.. A A D D D
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51 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0
52 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN
53 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0
54 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN
55 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0
56 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN
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58 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /
TRAIL BLAZER 250 Model #A00BA25CA Rev. 02. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00
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