2000 Polaris Trail Blazer 250 Parts Manual

PARTS MANUAL PN 9915482 and MICROFICHE PN 9916182 9/99 TRAIL BLAZER 250 Model #A00BA25CA Rev. 01

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TABLE OF CONTENTS Trail Blazer 250 A00BA25CA Parts Manual A A-ARM/STRUT MOUNTING B4 . . . . . . . . . . . . . . AIR BOX A13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . C CARBURETOR D1 . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER C4 . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL A8 . . . . . . . . . . . . . . . . . . . . . CONTROLS - MASTER CYLINDER/BRAKE LINE B8 . . . . . . . . . . . . . CONTROLS - THROTTLE ASM./CABLE B7 . . . . . . . . . . . . CRANKCASE and CYLINDER C9 . . . . . . . . . . . . CRANKSHAFT and PISTON C10 . . . . . . . . . . . . . . D DECALS A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH B9 . . . . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH B10 . . . . . . . . . . . . . . . . . . . . . . E ELECTRICAL/TAILLIGHT C3 . . . . . . . . . . . . . . . . ENGINE MOUNTING A9 . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM A10 . . . . . . . . . . . . . . . . . . . . F FRONT BRAKE B3 . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER and SHIELDS A7 . . . . . . . . . . . FRONT CAB A5 . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL B2 . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK A12 . . . . . . . . . . . . . . . . . . . . . . . . . . G GEAR SELECTOR C5 . . . . . . . . . . . . . . . . . . . . . GEARCASE C6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . GEARCASE MOUNTING C8 . . . . . . . . . . . . . . . . H HANDLEBAR B5 . . . . . . . . . . . . . . . . . . . . . . . . . M MAGNETO C11 . . . . . . . . . . . . . . . . . . . . . . . . . . O OIL PUMP C14 . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK A14 . . . . . . . . . . . . . . . . . . . . . . . . . . . P PART NUMBER INDEX D3-7 . . . . . . . . . . . . . . . . . . R REAR BRAKE MASTER CYLINDER B14 . . . . . . . . REAR CAB A6 . . . . . . . . . . . . . . . . . . . . . . . . . . REAR CALIPER MOUNTING B13 . . . . . . . . . . . . . REAR HOUSING C2 . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL DRIVE C1 . . . . . . . . . . . . . . . . . . . RECOIL STARTER C13 . . . . . . . . . . . . . . . . . . . . . S SHOCK MOUNTING B11 . . . . . . . . . . . . . . . . . . . . STARTING MOTOR C12 . . . . . . . . . . . . . . . . . . . . STEERING POST B6 . . . . . . . . . . . . . . . . . . . . . . STRUT B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING ARM/SHOCK MOUNTING B12 . . . . . . . . . . T TOOL KIT D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

2000 TRAIL BLAZER 250 SPECIFICATIONS BRAKES Type - Front Type - Rear Type - Auxiliary Type - Parking Hydraulic Disc Hydraulic Disc Hydraulic Hydraulic Lock CAPACITIES Fuel Tank (gallon) Oil, Gearcase (ounces) Oil, Injector (quarts) Oil, Engine, OW/40 (quarts) Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight 4 11 2 N/A Accessory 30 Accessory 60 30 Accessory 850 DRIVE TRAIN Type Concentric DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight (grams) Spring Color PVT 10 1/2 G (48) Blue/Green DRIVEN CLUTCH Helix Angle Spring Position 40° 2-2 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) 60″ 77 6 46 74.5 33 440 49.75 46.5 GEARCASE Trans. Number and Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Final Drive (ratio) Chain Type PRD Side Lever N/A 3.05/1 2.68/1 11/38 78P 520 O-Ring TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center Titan 23x7-10 22x11-10 N/A 4 3 N/A ENGINE 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 EC25PFE13 2 Cycle, Single Cyl. Oil Injection 72x60 244 6.1:1 Effective Air 150W Standard 1 VM30SS 130 40 0-4 (169) 2.0 1.0 Turn 5DP7-3 CDI 25 @ 3000 .028 NGKBR8ES USFS Appr. Pending 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 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 ELECTRICAL Headlight (watts) Taillight (watts) Brake Light (watts) Other (Grill Mntd. Lights) Indicator Bulb Battery 1 Single Beam, 12 V 55 W 12 V/8.26 W 12 V/26.9 W N/A 12 V/1 W 12 V 14 AH SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment MacPherson Strut 6.7 Progressive Rate Swing Arm 8.2 2″ 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.

2000 TRAIL BLAZER 250 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER’S MANUAL OWNER’S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Trail Blazer 250 A00BA25CA 9915299 9915467 9915482 9916182 9915503

A5 FRONT CAB Trail Blazer 250 A00BA25CA 14 16 22 21 25 22 23 24 30 4 26 27 28 20 19 3 3 17 7 8 6 10 11 12 15 13 7 9 5 33 1 2 21 25 22 29 18 32 31 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517386 2 Screw 2 5224718-067 2 Bracket, Cab Mount 3 7670060 4 Nut 4 1012772-067 1 Frame 5 4020149 2 Clip, Rosebud 6 4032093 2 Spring, Adjustment 7 7670095 3 Insert, Nut 8 5241436-067 1 Bracket, Headlight Mounting 9 4030056 1 Bulb, Halogen, 55W 10 7512084 2 Screw 11 4010206 1 Headlight, Single Beam (Incl. 9) 12 4032094 1 Spring 13 7511886 1 Screw 14 5432179-053 1 Cover, Front, Yellow 15 7511887 2 Screw 16 2631988-133 1 Asm., Cab, Front, White (w/Warning Decals) 17 7558301 2 Washer 18 7522026 2 Screw 19 7621471 2 Rivet 20 7558201 2 Washer 21 7555859 16 Washer 22 7542122 24 Nut, Nylok 23 5211131-067 1 Bracket, Mudflap 24 5811771 5850150 1 1 Mudflap, Front, LH Mudflap, Front, RH 25 7512282 24 Bolt 26 1012997-067 2 Footpad 27 7661825 8 Rivet 28 5431484 1 Trim, Footrest 29 7515179 6 Screw 30 5432763 1 Guard, Rock 31 5242525-067 2 Bracket, Cleat 32 7621472 6 Rivet 33 7517264 4 Screw 2/99

A6 REAR CAB Trail Blazer 250 A00BA25CA 4 12 22 30 28 27 16 26 14 10 16 25 23 20 18 19 9 8 2 1 21 5 7 6 11 24 16 23 16 13 15 17 15 17 16 29 3 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7041607 1 Spring, Latch 2 1040412-067 1 Latch, Seat 3 5411392 1 Cap, Seat Latch 4 2682430-053 2681769-053 1 1 Asm., Seat, Yellow Covering, Seat, Yellow 5 5431986 1 Tongue, Seat 6 7621479 2 Rivet 7 5410414 6 Bumper 8 5211033 1 Bracket, Lever Retainer 9 7621403 1 Rivet 10 7073761 1 Decal - Carb Information 11 7072791 1 Decal - Filter Element 12 5432820-133 1 Cab, Rear, White 13 7670057 2 Nut 14 5432278-070 5811230 1 1 Shield, Muffler Foil, Heat Shield 15 7517264 4 Screw 16 7555859 16 Washer 17 7542122 16 Nut 18 5241403-067 1 Guard, Clutch 19 7661638 4 Rivet 20 2670133 2 Reflector, Red 21 5432831 2 Plug, End Cap, Ribbed 22 5810957 5810991 1 1 Foil, Rear Cab Foil, Rear Cab, Small 23 7512282 16 Bolt 24 ––––––– 1 Footpad (See Front Cab Pg. A5, Ref. 26) 25 5850147 5850148 1 1 Mudflap, Rear, LH Mudflap, Rear, RH 26 5211131-067 2 Bracket, Mudflap 27 5220880 2 Bracket, Rear Seat Holddown 28 7621472 4 Rivet 29 7512232 2 Screw 30 7512242 2 Screw 11/98

A7 FRONT BUMPER and SHIELDS Trail Blazer 250 A00BA25CA 2 5 4 6 7 9 8 3 1 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5211329-067 2 Plate, Reflector 2 7512329 2 Bolt 3 2670134 2 Reflector, Amber 4 5810467 1 Plug, Frame 5 7547071 2 U-Nut 6 5850125 2 Shield, Deflector 7 1012773-067 1 Bumper, Front 8 7515399 2 Screw 9 7670088 4 Clip, Dart 2/99

A8 CONTROL PANEL Trail Blazer 250 A00BA25CA 2 4 5 6 9 8 4 7 3 1 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 4010140 1 Indicator, Low Oil 2 4040054 1 Indicator, Neutral/Reverse 3 5430967 1 Plug, Indicator Hole 4 4110264 4110141 4110148 1 1 1 Switch, Ignition (Incl. Key) Key, Ignition Key, Ignition NOTE: Order key by us- ing the four digit number on the key. 5 5431976 1 Panel, Control, Outer 6 7512026 2 Screw 7 2460777 1 Harness, Indicator 8 5431975 1 Panel, Control, Inner 9 7080371 1 Cable, Choke Control 11/98

A9 ENGINE MOUNTING Trail Blazer 250 A00BA25CA 3 4 6 9 17 18 19 20 21 12 14 23 24 23 3 26 27 28 31 32 33 34 26 35 11 8 13 1 1 1 1 30 16 15 37 36 30 37 30 25 25 22 5 5 2 1 29 2 10 38 7 30 5 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7547108 5 Nut 2 7555806 2 Washer 3 3110026 2 Mount, Motor 4 5430802 1 Insulator, Motor Mount 5 7555823 AR Washer 6 7515321 2 Bolt 7 7552901 2 Washer 8 7542411 1 Nut 9 5242898-067 1 Bracket, Engine Mount, Top 10 7512232 1 Screw 11 4010132 1 Cable, Ground, Engine, Small Hole 12 3070156 1 Spark Plug, NGK BR8ES 13 4010129 1 Cable, Solenoid/Starter 14 5410346 1 Insulator, Cable 15 7512457 2 Bolt 16 1040687-067 1 Mount, Engine, Front 17 7512566 1 Bolt 18 7575202 1 Washer 19 5210748 1 Washer, Clutch Retainer 20 5430261 1 Bushing 21 ––––––– 1 Asm., Drive Clutch, Basic ATV-08 (See Drive Clutch Pg. B9, Ref. 16) 22 ––––––– 1 Seal, Cover, Case (See Clutch Cover Pg. C4, Ref. 32) 23 7080511 2 Clamp 24 5410421 1 Boot, Clutch Intake 25 7552603 4 Washer 26 7512490 4 Bolt 27 5242896-067 1 Bracket, Engine Mount, Front 28 3084717 1 Engine, Short Block (EC25PFE13) 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. 29 7075741 1 Decal - Drain Recoil 30 8450040-600 AR Line, Fuel 31 7051011 1 Valve, Check, Vent 32 7052005 1 Fitting, Tee 33 8360009-600 AR Line, Fuel 34 5242897-067 1 Bracket, Engine Mount, Rear 35 3110028 1 Mount, Engine 36 2530009 1 Filter 37 7080003 4 Clamp, Hose, Red 38 7542459 1 Nut 2/99

2000 Polaris Trail Blazer 250 Parts Manual

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