Polaris TrailBlazer 250 service manual repair 2004-2006

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Locations 1.2 ................... Specifications 1.3--1.5 ............................ Replacement Keys 1.6 ........................ Optional Springs 1.6 .......................... Publication Numbers 1.6 ...................... Color Codes 1.6 ............................. Special Tools 1.1.7--1.11 ............................. Standard Torque Specifications 1.12 ............. Tap Drill Charts 1.13 ........................... Decimal Equivalent Chart 1.13 .................. Unit of Measure Conversion Table 1.14 .......... Glossary of Terms 1.15 ........................ Specs 2004-2006 Trailblazer 250

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 06 BA 25 CA Color or Model Option ENGINE DESIGNATION NUMBERS EC250PFE154 Single, Air Cooled, 2 Stroke, Electric Start ........... VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A B A 2 5 C * 6 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow. UNIT MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is located on top of the transmission, right side of machine.

GENERAL INFORMATION 1.3 MODEL: 2004 -- 2006 TRAIL BLAZER 250 .......... MODEL NUMBER: A04BA25CA/CB / A05BA23CA/CB / A05BA23CA . ENGINE MODEL: EC250PFE .. Category Dimension / Capacity Length 75 in./190.5 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 48 in./121.9 cm Dry Weight 461 lbs./209.1 kg Gross Vehicle Weight 765 Lbs. / 346.9 kg Tow Capacity 850 lbs./385.5 kg Tongue Weight (Accesory) 85 lbs./38.5 kg Front Rack Capacity (Accesory) 30 lbs./13.6 kg Rear Rack Capacity (Accesory) 60 lbs./27.2 kg 2005 TRAILBLAZER 250 2004 TRAILBLAZER 250 2006 TRAILBLAZER 250

GENERAL INFORMATION 1.4 MODEL: 2004 TRAIL BLAZER 250 .......... MODEL NUMBER: A04BA25CA/CB . ENGINE MODEL: EC250PFE153 .. Engine Platform Fuji Single Cylinder Engine Model Number EC250PFE153 Engine Displacement 244cc Number of Cylinders 1 Bore & Stroke 72 x 60 mm 2.8346I x 2.3622I Compression Ratio 6.1/1 Effective Compression Pressure 115 psi minimum Engine Idle Speed 700 Rpm ± 100 Engine Max Operating Rpm 5800 Rpm ± 200 Overheat Warning n/a Lubrication Oil Injection Oil Requirements / Capacity Polaris 2 cycle / 2 qt. (1.9L) Exhaust System Single Pipe Carburetion Carburetor model Mikuni VM30SS Main Jet 130 Pilot Jet 40 Starter Jet 1.5 Jet Needle -- Clip Position 5DP7--3 Needle Jet O--4 (169) Pilot Screw 1 Turn Out Reference point only -- actual setting varies Cut away 2.0 Float Height Parallel w/body ± 1 mm / ± .040“ Fuel Delivery Gravity Feed Fuel Capacity / Requirement 3.5 gal US / 13.2 ltr 87 Octane (min), 89 Oxygenated Electrical Alternator Output 150 w @ 4000 RPM Voltage Regulator LR 49--1 Lights : Head 55 watts Brake 8.26 watts Tail 26.9 watts Ignition System CDI Ignition RPM Limit 6000 RPM Ignition Timing 25° BTDC @ 3000 RPM ± 250 19.5° BTDC @ 6000 RPM ± 250 Spark Plug NGK BR8ES / 0.28 (0.7 mm) Battery / Model / Amp Hr Low Maintenance 12 Volt -- 14 Amp Hr Circuit Breakers Harness 20 amp Starting Electric Drivetrain Transmission Type H/N/Rev Transmission Capacity 11.3 oz. / 0.33 L Gear Ratio : Low Rev High Rear Drive / Chain n/a 3.05:1 2.68:1 11/36 76 Pitch Chain Type 520 O--ring PVT Type / Belt Non--EBS / 3211094 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.83 cm Rear Suspension / Shock Progressive Rate Swing Arm Gas Charged Rear Travel 10.5 in. / 26.67 cm Ground Clearance 5.5 in. / 13.97 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- Cam Adjuster Turning Radius 63 in. / 160 cm unloaded Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 23x7--10 / 4--156 Wheel Size / Pattern -- Rear Steel 22x11--10 / 4--102 Front Tire Model / Size Carlisle 23x7--10 Rear Tire Model / Size Carlisle 22x11--10 Recommended Air Pressure F/R 4 psi Front 3 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc JETTING CHART AMBIENT TEMPERATURE Altitude Below 0°F 0_ to +40_F +40_to +80_F Above +80_F Altitude Below 0 F Below -18°C 0 to +40 F -18_to +5_C +40 to +80 F +5_ to +26_C Above +80 F Above +26_C Meters 0-900 120 Meters (Feet) 0-900 (0-3000) 150 140 130 120 (Feet) 900-1800 140 130 120 110 900-1800 (3000-6000) 140 130 120 110 1800-2700 125 120 110 100 1800-2700 (6000-9000) 125 120 110 100 2700-3700 115 110 100 95 2700-3700 (9000-12000) 115 110 100 95 = Turn air screw out 1/2 turn CCW from seat Raise needle clip 1 position to lower jet needle CLUTCH CHART Shift D i Cl t h D i Cl t h Helix/ Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/ Spring Altitude Weight Spring Spring Spring Setting Meters (Feet) 0-1800 G Blue/Green Red 40_ (5131446) (Feet) 0-1800 (0-6000) G (5630514) Blue/Green (7041157) Red (7041198) (5131446) 2--2 1800-3700 F Blue/Green Red 40_ (5131446) 1800-3700 (6000-12000) F (5630515) Blue/Green (7041157) Red (7041198) (5131446) 2--2

GENERAL INFORMATION 1.5 MODEL: 2005--2006 TRAIL BLAZER 250 .......... MODEL NUMBER: A05BA25CA/CB / A06BA25CA . ENGINE MODEL: EC250PFE154 .. Engine Platform Fuji Single Cylinder Engine Model Number MY’ 05: EC250PFE154 MY’ 05: EC250PFE155 Engine Displacement 244cc Number of Cylinders 1 Bore & Stroke 72 x 60 mm 2.8346I x 2.3622I Compression Ratio 6.1/1 Effective Compression Pressure 115 psi minimum Engine Idle Speed 700 Rpm ± 100 Engine Max Operating Rpm 5800 Rpm ± 200 Overheat Warning n/a Lubrication Oil Injection Oil Requirements / Capacity Polaris 2 cycle / 2 qt (1.9L) Exhaust System Single Pipe Carburetion Carburetor model Mikuni VM30SS Main Jet 130 Pilot Jet 40 Starter Jet 1.5 Jet Needle -- Clip Position 5DP7--3 Needle Jet O--4 (169) Pilot Screw 1 Turn Out Reference point only -- actual setting varies Cut away 2.0 Float Height Parallel w/body ± 1 mm / ± .040“ Fuel Delivery Gravity Feed Fuel Capacity / Requirement 3.5 gal US / 13.2 ltr 87 Octane (min) 89 Oxygenated Electrical Alternator Output 150 w @ 4000 RPM Voltage Regulator LR 49--1 Lights : Head 55 watts Brake 8.26 watts Tail 26.9 watts Ignition System CDI Ignition RPM Limit 6000 RPM Ignition Timing 25° BTDC @ 3000 RPM ± 250 19.5° BTDC @ 6000 RPM ± 250 Spark Plug NGK BR8ES / 0.28 (0.7 mm) Battery / Model / Amp Hr Low Maintenance 12Volt -- 14 Amp Hr Circuit Breakers Harness 20 amp Starting Electric Drivetrain Transmission Type H/N/Rev Transmission Capacity 11.3 oz. / 0.33 L Gear Ratio : Low Rev High Rear Drive / Chain n/a 3.05:1 2.68:1 11/36 76 Pitch Chain Type 520 O--ring PVT Type / Belt Non--EBS / 3211094 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Swing Arm Gas Charged Rear Travel 10.5 in. / 26.7 cm Ground Clearance 5.5 in. / 13.97 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- Cam Adjuster Turning Radius 63 in. / 160 cm unloaded Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 23x7--10 / 4--156 Wheel Size / Pattern -- Rear Steel 22x11--10 / 4--102 Front Tire Model / Size Carlisle 23x7--10 Rear Tire Model / Size Carlisle 22x11--10 Recommended Air Pressure F/R 4 psi Front 3 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc JETTING CHART AMBIENT TEMPERATURE Altitude Below 0°F 0_ to +40_F +40_to +80_F Above +80_F Altitude Below 0 F Below -18°C 0 to +40 F -18_to +5_C +40 to +80 F +5_ to +26_C Above +80 F Above +26_C Meters 0-900 120 Meters (Feet) 0-900 (0-3000) 150 140 130 120 (Feet) 900-1800 140 130 120 110 900-1800 (3000-6000) 140 130 120 110 1800-2700 125 120 110 100 1800-2700 (6000-9000) 125 120 110 100 2700-3700 115 110 100 95 2700-3700 (9000-12000) 115 110 100 95 = Turn air screw out 1/2 turn CCW from seat Raise needle clip 1 position to lower jet needle CLUTCH CHART Shift D i Cl t h D i Cl t h Helix/ Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/ Spring Altitude Weight Spring Spring Spring Setting Meters (Feet) 0-1800 G Blue/Green Red 40_ (5131446) (Feet) 0-1800 (0-6000) G (5630514) Blue/Green (7041157) Red (7041198) (5131446) 2--2 1800-3700 F Blue/Green Red 40_ (5131446) 1800-3700 (6000-12000) F (5630515) Blue/Green (7041157) Red (7041198) (5131446) 2--2

GENERAL INFORMATION 1.6 REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 OPTIONAL SPRINGS SPRING TYPE SOFT STANDARD FIRM Rear Compression Spring N/A 7042281-067 Standard 110/180 lb/in. 7041865-067 Option 180/280 lb/in. Front Strut Spring N/A 7041868-067 Standard 55/80 lb/in. 7041776-067 Option 60/85 lb/in. PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2004 Trail Blazer 250 A04BA25CA 9918751 9918620 9918621 2005 Trail Blazer 250 A05BA25CA 9919472 9919473 9919474 2006 Trail Blazer 250 A06BA25CA 9920148 9920149 9920150 COLOR CODES PART COLOR DESCRIPTION POLARIS NUMBER 2004--2006 Trail Blazer Frame Black P-067 2004--2005 Trail Blazer Springs Scream’in Yellow P-216 2006 Trail Blazer Springs Indy Red P-293 2004 Trail Blazer Rims Bright White P-133 2005--2006 Trail Blazer Rims Silver P--486 NOTE: Refer to ATV Quick Reference PN 9914899 for paint ordering information. 31XX Key Series Number KEY COVER P/N 5533534

GENERAL INFORMATION 1.7 SPECIAL T OOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 2870872 Shock Spanner Wrench 2, 7 2871043 Flywheel Puller 3 2870773 C--Clip Installation Tool 3 2870975 Mity Vact 3, 4, 9 2870569 Crankshaft Truing Tool 3 2872314 Carburetor Float Adjustment Tool 4 2870871 Ball Joint Replacement Tool 5 2870623 Shock Absorber Tool 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 2871071 Shock Body Holding Tool 5 2871199 Seal Sleeve Installation Tool Kit 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clutch Compression Tool 6 2871710 10” Center Distance Tool 8 PV--43568 Fluket77 Digital Multimeter 10 2870836 Battery Hydrometer 10 2870630 Timing Light 10 8712100 or 8712500 Tachometer 10

GENERAL INFORMATION 1.8 SPECIAL T OOLS Special Tools maybe required while servicing your machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine T ools PU--45432 -- Caliperor A Basic Caliper Basic Micrometer 2870773 -- C--Clip InstallTool PV--43527 Oil Filter Wrench 2870390 -- Piston Support Block PV--35667--A -- CylinderLeak down Tester Standard Tools and Engine T ools 2870303 -- Hone Kit 2870305 -- Stone Replacement Kit 2870459 -- Dial Indicator 2870588 -- Hone Oil (12 oz.) 2200634 -- ValveSeat Reconditioning Kit

GENERAL INFORMATION 1.9 Clutch (PVT) T ools 2870506 -- Drive Clutch Puller 2870913 -- Driven Clutch Puller 2870654 -- ATVClutch Align Tool 9914177--A -- Drive Clutch Holding Tool 8700220 -- Clutch Compression Tool 2870341 -- Drive Clutch Spider Removal Tool 2870910 -- RollPin Tool Clutch (PVT) T ools 2871226 -- Clutch Bushing Replacement Kit 2870338 -- Spider Nut Socket 2871358 -- Clutch Holding Fixture 2871025 -- Clutch Bushing Replace Tool Kit 2871710 -- Center Distance Tool

GENERAL INFORMATION 1.10 Suspension T ools 2870871 -- ATV Ball Joint Tool Kit 2871071 -- Shock Body Holding Tool 2870623 -- Shock Spring Compressor 2871573 & 2871574 -- Strut Spring Compressor 2870772 -- 1.75” Wrench Suspension T ools 2870872 -- Shock Spanner Wrench 2872608 -- Roll Pin Removal Tool 2871351 -- Shock IFPDepth Tool

Polaris TrailBlazer 250 service manual repair 2004-2006

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