TRAIL BLAZER 250

Model #A03BA25CA

E 2002 Polaris Sales Inc. PARTS MANUAL PN 9917503 and MICROFICHE PN 9917504 7/02
This page left blank intentionally.
 TABLE OF CONTENTS
Trail Blazer A03BA25CA
Parts Manual

A G
A- ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 GEARCASE MOUNTING . . . . . . . . . . . . . . . C5
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . A11 H
C HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B2
CAB, FRONT . . . . . . . . . . . . . . . . . . . . . . . A3 HOUSING, REAR . . . . . . . . . . . . . . . . . . . . B9
CAB, REAR . . . . . . . . . . . . . . . . . . . . . . . . A4 M
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . C12 MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . C8
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . C1 O
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . A6
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C11
CONTROLS - MASTER OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . A12
CYLINDER/BRAKE LINE . . . . . . . . . . . B4
CONTROLS - THROTTLE ASM./CABLE . . . B12 P
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . C6 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . C7 R
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . C6 REAR BRAKE MASTER CYLINDER . . . . . . . B6
D REAR CALIPER MOUNTING . . . . . . . . . . . . B5
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A9 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . C10
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . B13 S
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . B14 SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
E SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . B7
STARTING MOTOR . . . . . . . . . . . . . . . . . . . C9
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . B10
STEERING POST . . . . . . . . . . . . . . . . . . . . . B11
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A7 STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A8 STRUT MOUNTING . . . . . . . . . . . . . . . . . . . B1
F SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . B7
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . B3 T
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . A5 TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . B10
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A10 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . C13
G W
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C2 WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . A14
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C3-4 WHEEL, REAR . . . . . . . . . . . . . . . . . . . . . . B8

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as-
sembly.
 FRONT CAB
TRAIL BLAZER 250 A03BA25CA

10
8 11
E 2002 Polaris Sales Inc. 9 12 13
8 14
3
2 4 15
5 7
3
1
16
6 17
18

32 24 19
22
31 21 20
19

22
30
29 21
22 24 23
27
28 25
26 21

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517386 2 Screw 18 2632671-053 1 Asm., Cab, Front, Yellow
2 5244482-067 1 Bracket, Cab Mount, LH (w/Warning Decals)
5244483-067 1 Bracket, Cab Mount, RH 19 7621472 8 Rivet
3 7670057 4 Nut, U-Type, Speed 20 7558201 2 Washer, Flat
4 1014084-067 1 Frame, Main 21 7542122 24 Nut, Nylok
5 4020149 4 Clip, Rosebud 22 7555859 20 Washer, Flat
6 7517685 4 Screw 23 5811831 1 Mudflap, Front, LH
7 4032093 2 Spring, Adjustment 5850150 1 Mudflap, Front, RH
8 7670095 3 Insert, Nut 24 7512282 24 Bolt
9 5241436-067 1 Bracket, Headlight Mounting 25 1013249-067 2 Pad, Foot
10 4030056 1 Bulb, Halogen, 55W 26 7661825 8 Rivet
11 7512084 2 Screw 27 5431484 1 Trim, Footrest
12 4010206 1 Headlight, Single Beam (Incl. 10) 28 7515179 6 Screw
13 4032094 1 Spring 29 5432763 1 Guard, Rock
14 7511886 1 Screw 30 5242525-067 2 Bracket, Cleat
15 5432179-177 1 Cover, Front, Black 31 7517916 4 Screw
16 7511887 2 Screw 32 5433457 1 Guard, Prop Shaft, Side
17 7517916 6 Screw
7/02

A3
 REAR CAB
TRAIL BLAZER 250 A03BA25CA

2 3
5
1
8

9
27 28 7 6
15 15
26
10
11
12

25
24
16 13
15
14

21 14 20

16 15 16
15 17
18
23

22
19
21

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7041607 1 Spring, Latch 16 7542122 16 Nut, Nylok
2 1040412 1 Latch, Seat 17 5241403-067 1 Guard, Clutch
3 5411392 1 Cap, Seat Latch 18 7661637 4 Rivet
4 2682453-070 1 Asm., Seat, Black w/White “POLARIS” 19 7079925 2 Decal, Reflector, Red
2681769-070 1 Covering, Seat, Black 20 5432831 2 Plug, End Cap, Ribbed
5 5431986 1 Tongue, Seat 21 7512282 14 Bolt
6 7621479 2 Rivet 22 ------- 1 Footpad
7 5412067 6 Bumper, Rubber (See Front Cab Pg. A3, Ref. 25)
8 5211033 1 Bracket, Lever Retainer 23 5812134 1 Mudflap, Rear, LH
9 7621403 1 Rivet 5850148 1 Mudflap, Rear, RH
10 7079901 1 Decal, Carb/Filter Information 24 5810957 1 Foil, Rear Cab
5810991 1 Foil, Rear Cab, Small
11 5434014-053 1 Cab, Rear, Med Yellow
25 5220880 2 Bracket, Rear Seat Holddown
12 7670057 2 Nut, U-Type Speed
26 7621472 4 Rivet
13 2632280 1 Asm., Muffler Shield
5811230 1 Foil 27 7512232 2 Screw
14 7517264 4 Screw 28 7512242 2 Screw
15 7555859 18 Washer, Flat
7/02

A4
 FRONT BUMPER and SHIELDS
TRAIL BLAZER 250 A03BA25CA

1
2

3
5

11

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5245415-067 1 Shield, Splash, LH 7 7547071 2 U-Nut
2 7517386 2 Screw 8 1012773-067 1 Bumper, Front
3 5211329-067 2 Plate, Reflector 9 7515399 2 Screw
4 7512329 2 Bolt 10 5434085 1 Guard, Splash, RH
5 7079924 2 Decal, Reflector, Amber 11 7670088 2 Clip, Plastic Dart
6 5810467 1 Plug, Frame
7/02

A5
 CONTROL PANEL
TRAIL BLAZER 250 A03BA25CA

7
2 6
3
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 4010319 1 Panel, Indicator w/Oil Light 3 5433733 1 Nut, Ignition
4010416 1 Bulb, Indicator 4 5434127 1 Panel, Control, Outer
2 4010390 1 Switch, Ignition (Incl. Key) 5 7080922 1 Nut, Choke
4010278 1 Blank, Key, Series 2000, 6700, 6800
4010321 1 Blank, Key, Series 2200, 2300, 2700, 6 5434128 1 Panel, Control, Inner
2800. NOTE: Your key can be dupli- 7 7081008 1 Cable, Choke Friction
cated only be obtaining a key blank
from Polaris and having it cut by mat-
ing it with your existing key.
5/02

A6
 ENGINE MOUNTING
TRAIL BLAZER 250 A03BA25CA

4 5
3 1
2
1 6

31
28
1
7
30 8
29
18 31
28
1

20 19
27 9
1
24 1
10
26 13
24 16
17 11
25 12
24 16 14
23 21 2
22 18 19 15
1
20
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7547108 8 Nut 18 7555823 AR Washer, Flat
2 3110026 2 Mount, Motor 19 7552603 4 Washer, Spring Lock
3 5430802 1 Insulator, Motor Mount 20 7512490 4 Screw
4 7512315 2 Bolt 21 5242896-067 1 Bracket, Engine Mount, Front
5 7552901 2 Washer, Spring Lock 22 3084717 1 Engine, Short Block (EC25PFE15)
6 5244119-067 1 Bracket, Engine Mount, Top NOTE: The Short Block assembly
contains a crankcase assembly, cylin-
7 7512232 1 Screw der and cylinder head assembly, and a
8 4010132 1 Cable, Ground, Engine, Small Hole piston & crankshaft assembly. Prior
9 3070156 1 Spark Plug, NGK BR8ES authorization required for warranty
consideration.
10 4010129 1 Cable, Solenoid/Starter
23 7078577 1 Decal, Drain Recoil
11 5410346 1 Insulator, Cable
24 8360009-600 AR Line, Fuel
12 7515481 2 Screw
25 7051011 1 Valve, Check, Vent
13 1040687-067 1 Mount, Engine, Front
26 7052005 1 Fitting, Tee
14 ------- 1 Asm., Drive Clutch, Basic ATV-08
(See Drive Clutch Pg. B13, Ref. 20) 27 5242897-067 1 Bracket, Engine Mount, Rear
15 - - - - - - - 1 Seal, Cover, Case 28 8450003-1525 AR Line, Fuel
(See Clutch Cover Pg. C1, Ref. 28) 29 3110028 1 Mount, Engine, Rubber
16 7080511 2 Clamp 30 2530009 1 Filter
17 5410421 1 Boot, Clutch Intake 31 7080003 4 Clamp, Hose, Red
2/02

A7
 EXHAUST SYSTEM
TRAIL BLAZER 250 A03BA25CA

3
2
1
4

3
2
2
5

1 6
7
13 8
14 9

2
13
14
12

10

11

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5010368 2 Spacer 8 ------- 2 Nut (See Crankcase and Cylinder Pg.
2 5411058 4 Dampener C6, Ref. 34)
3 7515394 2 Screw, Carriage 9 7042029 2 Spring, Exhaust
4 7517386 2 Screw 10 1261060-029 1 Headpipe
5 5243116-067 1 Mount, Lower, Muffler 11 7041687 2 Spring, Exhaust
6 1260922-029 1 Manifold 12 1260910-029 1 Muffler
7 ------- 2 Washer (See Crankcase and Cylinder 13 7555716 2 Washer, Flat
Pg. C6, Ref. 33) 14 7542324 2 Nut, Nylok
7/02

A8
 DECALS
TRAIL BLAZER 250 A03BA25CA
2

1 3

5 4

RH
8 9

7 10
11 12 13
6

14
15

LH

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2200891 1 Kit, Decal Application Solution 7 7171147 1 Decal, “Trail Blazer”, Tank Side, Top LH
(For Seat Decals) 7171148 1 Decal, “Trail Blazer”, Tank Side, Top RH
1 7170628 1 Decal, Rear Cab, Side, LH 8 7079906 2 Decal, Override Switch, 2WD
7170629 1 Decal, Rear Cab, Side, RH 9 7078253 1 Decal, Age Warning
2 7171161 1 Decal, “Trail Blazer”, Tank Side, LH 10 7077202 2 Decal, “POLARIS”, Seat
7171162 1 Decal, “Trail Blazer”, Tank Side, RH
11 7077920 1 Decal, Passenger Warning
3 7078465 1 Logo, Polaris Star
12 7079089 1 Decal, Tire Pressure/Load
4 7078577 1 Decal, Drain Recoil
13 7079946 1 Decal, “POLARIS”, Rear Cab
5 7077791 1 Decal, Concentric Drive System
14 7079085 1 Decal, Warning, Discretionary
6 7170627 1 Decal, “250”, Front Cover
15 7079083 1 Decal, Warning, General
7/02

A9
 FUEL TANK
TRAIL BLAZER 250 A03BA25CA

2
3

4
5

21
6
20

16
15 10
19
14
18
17 13
12

11
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5433687 1 Cap, Gas Tank (Incl. 2) 12 7511840 1 Screw
2 5812123 1 Gasket 13 5431021 1 Lever, Fuel
3 8360009-600 AR Line, Fuel 14 7041209 1 Spring, Lever, Compression
4 5431053 1 Vent, Tank 15 5431391 1 Extension, Fuel Lever
5 7512310 2 Bolt 16 5410021 1 Grommet
6 7555734 2 Washer, Flat 17 7555726 1 Washer, Flat
7 7512208 2 Screw 18 7515136 2 Screw
8 5220916-067 1 Bracket, Tank Mount, Rear 19 7051006 1 Asm., Fuel Valve (Incl. Gasket)
9 7542324 2 Nut, Nylok 5810859 1 Gasket, Fuel Valve
10 7074637 1 Decal, Fuel Lever 20 2520241 1 Asm., Tank, Fuel (Incl. 4,18,19)
11 ------- 1 Duct, Inlet Down Tube 21 5811527 1 Foam, Seal
(See Clutch Cover Pg. C1, Ref. 19)
7/02

A10
 AIR BOX
TRAIL BLAZER 250 A03BA25CA

3
4

1 5

2 6

8 9
19
10
18
11

12
17

13

15 14
16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5811660 1 Sleeve, Precleaner 11 7555716 2 Washer, Flat
2 7670117 4 Clip, Airbox 12 5433050 1 Airbox, Intake
3 7517541 4 Screw 13 1253389 1 Asm., Boot, Carb
4 5433052 1 Duct, Airbox Cover 14 7080140 1 Clamp
5 5411422 1 Gasket, Intake 15 7080865 1 Clamp, Wire
6 5433740 1 Baffle 16 5411765 1 Cap, Drain
7 5433051 1 Cover, Airbox 17 5411766 1 Bumper, Rubber
8 5811659 1 Seal, Cover 18 7080707 1 Clamp
9 7515180 2 Screw 19 1253355 1 Asm., Filter (Incl. 1)
10 7558301 2 Washer, Flat
7/02

A11
 OIL TANK
TRAIL BLAZER 250 A03BA25CA

1
2 4 7
3

9
17 13
14
10 11 12
15

16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5430779 1 Cap, Oil Tank 10 7080307 1 Clamp, Hose, Large Green
2 5810141 1 Gasket, Oil Cap 11 2530009 1 Filter
3 5431793 1 Tank, Oil 12 7080003 1 Clamp, Hose
4 7052077 1 Fitting 13 7081036 1 Clamp
5 8360009-600 AR Line, Fuel 14 7517916 1 Screw
6 4110265 1 Sensor, Oil Level w/Connector 15 8450040-600 AR Line, Fuel
7 7621460 2 Rivet 16 7080476 1 Clamp, Hose
8 7052153 1 Fitting 17 7555932 2 Washer, Nylon
9 8450003-1525 AR Line, Fuel
6/00

A12
 STRUT
TRAIL BLAZER 250 A03BA25CA
1
2
3

8 9

10

17
11

16 12

13
13
15

14

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7547104 2 Nut, Nylok 10 7041762 2 Strut, Front
2 7555749 2 Washer 11 7080367 2 Clamp, Cable
3 5810291 2 Spacer, Rubber 12 7542324 4 Nut, Nylok
4 5432872 2 Ball, Pivot, Top 13 7558402 6 Washer, Flat
5 5432871 2 Ball, Pivot, Bottom 14 7080306 2 Fitting, Lubrication
6 5132062 2 Spacer 15 7515339 4 Bolt
7 5243364 2 Retainer, Spring 16 5131039 1 Support, Strut and Spindle, LH
8 7041868-067 2 Spring, Compression, Black 5131040 1 Support, Strut and Spindle, RH
9 5411608 2 Bumper 17 5211115 2 Washer
7/02

A13
 FRONT WHEEL
TRAIL BLAZER 250 A03BA25CA

2
3 4

5 6

18
7

17
8

9
3
10
11
12

16
15
14 13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 ------- 1 Support, Strut and Spindle 10 7555721 2 Washer
(See Strut Pg. A13, Ref. 16) 11 7542712 2 Nut, Castle
2 3610020 2 Seal, Hub, Front 12 7661407 2 Pin, Cotter
3 3513519 4 Bearing, Ball 13 7511866 2 Screw
4 5243675 2 Disc, Brake 14 5433868 2 Cap, Hub
5 5130940 2 Hub, Wheel 15 5410470 2 O-Ring
6 5412324 2 Tire (23x7-10) 16 7542459 8 Nut, Flange Lock
7 1520175-133 2 Rim, Front 17 7515523 8 Stud
8 1525017 2 Valve, Rim 18 7512325 8 Bolt
9 5010256 2 Spacer, Hub, Front
7/02

A14
 A-ARM/STRUT MOUNTING
TRAIL BLAZER 250 A03BA25CA

2
1 3
4
E 2002 Polaris Sales Inc.
5

6
7
8

9
10
26

24 11
25
12
18
13
24 25 19

20
17
23 14
19 16
22
15
13
21

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542439 2 Nut, Nylok 15 7512284 4 Screw
2 5411291 2 Boot, Seal, Rod End 16 5410548 2 Boot, Rubber
3 7061034 2 Rod End, RH 17 7080927 2 Joint, Ball
4 7542711 2 Nut 18 ------- 1 Support, Strut and Spindle
5 5020927 2 Tie Rod (See Strut Pg. A13, Ref. 16)
6 7547028 2 Nut, LH 19 5434551 4 Bushing, A-Arm Long
7 5411920 2 Boot, Seal 20 7080433 2 Fitting, Lubrication
8 7061054 2 Rod End, LH 21 7542438 2 Nut, Castle
9 1820806 2 Asm., Tie Rod (Incl. 2-7) 22 2202276 1 Kit, A-Frame, LH (Incl. 13,19,23,24,25)
2202277 1 Kit, A-Frame, RH (Incl. 13,19,23,24,25)
10 7517909 2 Bolt
23 5133806 2 Shaft, A-Arm
11 7556099 4 Washer, Flat
24 7512492 4 Screw
12 7547177 2 Nut
25 7571611 4 Washer, Dish Lock
13 7661203 4 Pin, Cotter
26 7518033 22 Bolt
14 5240717 2 Bracket, Ball Joint
7/02

B1
 HANDLEBAR
TRAIL BLAZER 250 A03BA25CA

3 5
1 4

2
6

7
8 9
10

7
11
13
12
14

15

16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 ------- 1 Asm., Throttle Control (See Controls - 9 5433903 1 Spacer, Switch, LH
Throttle Asm./Cable Pg. B12, Ref. 3) 10 4010421 1 Switch, Handlebar, ON/OFF, LH
2 5244765-067 1 Tube, Handlebar 11 5433834-070 2 Grip, Handlebar
3 7515189 4 Screw 12 5432952 1 Plug, Hole
4 5433993 1 Pad, Handlebar 13 7517625 1 Screw
5 7517395 2 Screw 14 7080138 2 Cable Tie
6 5245051 1 Mount, Handlebar Pad 15 7542122 4 Nut, Nylok
7 5631146 1 Block, Handlebar, Pegged 16 7080631 1 Clip
5631147 1 Block, Handlebar
8 --- - - - - - 1 Asm., Master Cylinder (See Controls -
Master Cylinder/Brake Line Pg. B4)
7/02

B2
 FRONT BRAKE
TRAIL BLAZER 250 A03BA25CA

1
2
4 5
3
6

7
8 11
9
10

14

13

12

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1910695 1 Asm., Front Brake Caliper, LH 6 5133407 1 Caliper, Brake, LH
(Incl. 4-7) 5133408 1 Caliper, Brake, RH
1910696 1 Asm., Front Brake Caliper, RH 7 5410494 1 Boot, Pin Seal
(Incl. 4-7)
8 5410779 1 Ring, Square, Molded (.094)
1930642 1 Kit, Boot, Front Brake (Incl. 7,14)
9 5410780 1 Ring, Square, Molded (.103 x .134)
1 7512365 4 Screw
10 5132294 1 Piston, Brake, Long
2 7552901 4 Washer, Spring Lock
11 1930665 1 Kit, Piston and Seal (Incl. 8-10)
3 7558402 4 Washer, Flat
12 2202412 2 Asm., Brake Pad
4 7080352 2 Screw, Bleeder
13 1910412 2 Mount, Caliper
5 7515489 2 Screw, Socket Set
14 5410495 1 Boot, Bushing
6/02

B3
 CONTROLS - MASTER CYLINDER / BRAKE LINE
TRAIL BLAZER 250 A03BA25CA

4
1 4 5
6
2
16 3
15

9 13 10 11 7
9

12
13
8

14

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2010196 1 Asm., Master Cylinder (Incl. 1-16) 8 2201835 1 Kit, Master Cylinder Lever
1 1910472 1 Line, Brake, Pod (Incl. Pin, Lever, Clip)
2 4110164 1 Switch 9 7080138 8 Cable Tie
3 1910504 1 Line, Brake, Rear 10 7080539 1 Clamp, Nylon
4 7517899 2 Screw 11 7621462 1 Rivet, Pop
5 2201834 1 Kit, Master Cylinder Cap 12 1910502 1 Line, Brake, Left Front
(Incl. Cap, Screws, Sight, Gasket) 13 8360052-34 1 Tubing, Convoluted
6 2201836 1 Kit, Master Cylinder Park Brake Lever 14 7512024 2 Screw
(Incl. Lever, Spring) 15 1910503 1 Line, Brake, Right Front
7 2201833 1 Kit, Master Cylinder Clamp 16 7052292 1 Fitting, Cross
(Incl. Clamp, Screws)
6/02

B4
 REAR CALIPER MOUNTING
TRAIL BLAZER 250 A03BA25CA

Frame
5
1
7
2 6
4
3 5
7
6
4

17
8

16
9
15

14

13

10
11

12

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517231 2 Screw 9 5131759 1 Bushing, Caliper Mount
2 7555806 2 Washer, Flat 10 7558402 2 Washer, Flat
3 1910695 1 Asm., Caliper 11 7552901 2 Washer, Spring Lock
2201180 1 Kit, Caliper Seal 12 7512312 2 Bolt
2201428 2 Kit, Bleeder Replacement
2201467 1 Piston, Caliper, Rear 13 5131786 1 Mount, Caliper, Lower
4 5410988 4 Seal 14 5131787 1 Mount, Caliper, Upper
5 1910504 1 Line, Brake Rear 15 7512325 3 Bolt
6 1910506 1 Line, Brake, Rear 16 5242291-067 1 Guard, Brake Disc
7 7670102 5 Clip, Silencer Box 17 2201189 1 Kit, Brake Pad (Incl. Spacer and Pin)
8 1910499 2 Bolt, Banjo
6/02

B5
 REAR BRAKE MASTER CYLINDER
TRAIL BLAZER 250 A03BA25CA

1 2 10

3 8 9

6
5 9
7
4
6
11

24 12

13

13 14
12
23

22

21

20

16
17
18 16
19 15

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7670102 1 Clip 14 1910375-067 1 Mount, Brake
2 7512113 2 Bolt 15 1910499 1 Bolt, Banjo
3 5244091-067 1 Bracket, Reservoir Mount 16 5410988 2 Seal
4 7542122 2 Nut, Nylok 17 ------- 1 Line, Foot Brake, Rear (See Rear Cal-
5 7517386 1 Screw iper Mounting Pg. B5, Ref. 6)
6 7080003 2 Clamp, Hose, Red 18 7552801 2 Washer, Spring Lock
7 1910404 1 Hose, Reservoir 19 7515179 2 Screw
8 1930854 1 Reservoir 20 1910311 1 Asm., Foot Brake Master Cylinder
9 7517916 4 Screw 21 7542324 2 Nut, Nylok
10 5433457 1 Guard, Prop Shaft, Side 22 1910377-067 1 Rod, Brake
11 7661401 1 Pin, Cotter 23 7041750 1 Spring, Torsion
12 7555919 2 Washer 24 7515321 2 Screw
13 5431107 2 Bushing
12/01

B6
 SWING ARM/SHOCK MOUNTING
TRAIL BLAZER 250 A03BA25CA

8
7 10
6
11
5
4 12 13
14
15
3 17
2 12
1 29
28
16
17
18
19

27
20
23
24
26 22
21
25

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542439 2 Nut, Nylok 16 5133167 1 Bushing, Swing Arm Pivot, RH
2 7515438 1 Screw 17 5131697 2 Bolt, Swing Arm Pivot
3 5630551 1 Cam, Adjusting 18 1541395 1 Asm., Swing Arm (Incl. 12,15,28)
4 7042142 1 Shock, Rear 19 7078572 1 Decal, Chain Free Play
5 7041865-067 1 Spring, Compression 20 5432854 1 Guard, Chain
6 5433550 1 Spacer, Spring 21 7515304 1 Screw
7 7041864-067 1 Spring, Compression 22 5332828 1 Bushing
8 5241147 1 Retainer, Shock 23 7558402 1 Washer, Flat
9 7515415 1 Screw 24 7542321 1 Nut, Flange
10 7661046 2 Rivet 25 7547066 2 Nut, Nylok
11 5432727 1 Guide, Chain, Center 26 7555883 2 Washer
12 7080510 2 Fitting 27 7512576 2 Bolt
13 7547082 1 Nut 28 5434545 1 Bushing, Swing Arm, LH
14 7556035 1 Washer, Flat 29 5133166 1 Bushing, Swing Arm Pivot, LH
15 5434546 2 Bushing, Swing Arm, RH
7/02

B7
 REAR WHEEL
TRAIL BLAZER 250 A03BA25CA

2
1

4 6
5
7
9
8

6
12

11

7
5 9
4
8
10
2
1

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512673 8 Bolt 7 5411164 2 Cover, Dust, Hub
2 5131777 2 Hub, Rear Wheel, Large Flange 8 7555745 2 Washer, Flat
3 7542714 8 Nut 9 1525017 2 Valve, Rim
4 7555796 2 Washer 10 7670081 8 Pushnut
5 7543005 2 Nut, Castle 11 1520183-133 2 Rim, Rear
6 7661404 2 Pin, Cotter 12 5412323 2 Tire (22x11-10)
7/02

B8
 REAR HOUSING
TRAIL BLAZER 250 A03BA25CA
5 6

1
2 7
3 8
4 9
10
11
12
13
14 15
16

17

25 18
24
14
13
12
11 19
7
20
21
23
4
3
5 22 2
1

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7710472 2 Ring, Retaining 14 3554517 2 Bearing, Cup, Tapered
2 5510313 2 Retainer, Nut 15 5132098 1 Housing, Axle, Rear
3 7547196 2 Nut 16 7080306 1 Fitting, Lubrication
4 5411555 2 Seal, Foam 17 3225026 1 Link, Connector, 520
5 7542439 12 Nut, Nylok 18 5133181 1 Axle, Rear
6 5246684 1 Disc, Brake 19 3224056-076 1 Chain, 520 O-Ring
7 7515513 6 Stud 20 7547108 3 Nut, Flange Lock
8 1520259 1 Hub, Brake Disc (Incl. 7) 21 5211585-067 1 Guard, Sprocket
9 7710405 1 Ring, Retaining 22 5630586 1 Spacer
10 5010462 1 Spacer, Axle 23 3222109 1 Sprocket, 36T
11 5410889 2 O-Ring 24 1520258 1 Asm., Hub, Sprocket (Incl. 7)
12 3610070 2 Seal 25 7512404 3 Bolt
13 3554518 2 Bearing, Cone, Tapered
7/02

B9
 ELECTRICAL/TAILLIGHT
TRAIL BLAZER 250 A03BA25CA

4 5

1 6

7
2 3 8 13
15
9 14 16
10 17
12
18
11
29
28 23 21
19
11
23
22
20
24

27

26 25

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2461056 1 Harness, Main 16 4010095 1 Cable, Battery/Engine, Black
2 7080138 7 Cable Tie 17 7010032 2 Hook, Battery Strap
3 2200593 1 Kit, Circuit Breaker, 20 AMP 18 5410424 1 Strap, Battery Holddown
4 2410319 1 Taillight, 12V 19 5432077 1 Tube, Battery Vent
5 7512088 2 Screw 7080303 2 Clamp
6 4032085 1 Lens 20 4140006 1 Battery
7 4030043 1 Bulb 21 4010094 1 Cable, Battery/Solenoid
8 4032086 1 Gasket 22 4010129 1 Cable, Solenoid/Starter
9 4032087 1 Backing 23 7541925 4 Nut, Nylok
10 7670093 2 Clip 24 7512007 2 Bolt
11 7571602 4 Washer 25 4060208 1 Rectifier, LR39-1
12 7512027 2 Screw 26 7512024 5 Screw
13 5810290 3 Pad, Battery 27 4010186 1 Limiter, LR491
14 5431769 1 Cover, Battery 28 4020149 3 Clip, Rosebud
15 2200361 1 Kit, Battery Bolt, Short 29 7670109 3 Clip, Routing
7/02

B10
 STEERING POST
TRAIL BLAZER 250 A03BA25CA

2
4
1
3
5
6

7
6

12
8
1
9

7
11

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542324 4 Nut, Nylok 7 7556162 2 Bushing
2 7080510 1 Fitting, Zerk 8 5222393 1 Flangette
3 5433866 2 Bushing, Steering, Upper 9 3514352 1 Bearing
4 1820982-067 1 Post, Steering 10 7547158 1 Nut
5 5246732 1 Bracket, Steering Upper 11 7661633 1 Pin, Cotter
6 7512377 4 Bolt, Carriage 12 7558402 2 Washer, Flat
7/02

B11
 CONTROLS - THROTTLE ASM./CABLE
TRAIL BLAZER 250 A03BA25CA

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434113 1 Cover, Throttle Control 5 7517665 2 Washer, External Tooth
2 5411439 1 O-Ring 6 7517575 2 Screw
3 2010204 1 Asm., Throttle Control (Incl. 4) 7 7080970 1 Cable, Throttle
4 2010191 1 Asm., Throttle Clamp (Incl. 5,6) 8 5410193 1 O-Ring
4/01

B12
 DRIVE CLUTCH
TRAIL BLAZER 250 A03BA25CA

12 13 14
15
11
5 6 7 8 10
1 2
3 4
9

17
18
19 16
8

20

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512176 6 Bolt 10 5630514 3 Weight, Shift (G)
2 7552801 6 Washer, Spring Lock 11 7512266 3 Bolt, Shoulder
3 3576510 1 Bearing, Cover 12 5430261 1 Bushing
4 7041157 1 Spring, Clutch 13 5210748 1 Washer, Flat
5 5430945 6 Washer, Multilube 14 7575202 1 Washer, Interlock
6 1321457 3 Roller and Bushing 15 7512457 1 Bolt
7 5410610 3 O-Ring 16 7541906 3 Nut, FLEXLOC
8 5430768 6 Button, Guide 17 3576504 1 Bearing, Moveable, 1/2”
9 5210752 AR Spacer (.020²) 18 5020795 3 Pin, Spider
5242981 AR Spacer (.025²) 19 5410609 3 Washer, Rubber
5210753 AR Spacer (.032²)
5210754 AR Spacer (.050²) 20 1322003 1 Asm., Drive Clutch, Wide
(Incl. All Less 4,10)
7/02

B13
 DRIVEN CLUTCH
TRAIL BLAZER 250 A03BA25CA

1
2

16
17
15

5
6
14
7
13

12
11

10
9

4 8

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5010266 1 Spacer 9 7556804 AR Washer (.030)
2 7556120 AR Bushing (3 Max) 10 3576504 1 Bearing, Moveable, 1/2 Inch
3 3211077 1 Belt, Drive 11 3576511 1 Bearing, Moveable, 1 Inch
4 1322180 1 Asm., Driven Clutch (Incl. 8-17) 12 7041198 1 Spring, Clutch
5 5220646 1 Washer, Domed 13 5131446 1 Ramp, Stationary
6 7552901 1 Washer, Spring Lock 14 5210752 1 Spacer
7 7515382 1 Bolt 15 7710448 1 Ring, Retaining
8 7555898 AR Washer (.020) 16 7511854 3 Bolt
7556076 AR Washer (.025) 17 5430766 3 Button, Ramp
10/00

B14
 CLUTCH COVER
TRAIL BLAZER 250 A03BA25CA
2 3

1
2
35
3
4
34
5

6
33 32
31 30
24 7
25 8
23 26 27 28
29
9

13 12 11
14 10
6
22

15

16
21 20 17

19
18

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411180 1 Seal, Cover 19 5433258 1 Duct, Inlet, Clutch
2 7555748 3 Washer 20 5411822 1 Boot, Air Inlet, Upper
3 7517860 3 Bolt and Washer 21 7080492 2 Cable Tie
4 5521301 1 Seal, Clutch Cover 22 5433450 1 Duct, Clutch Inlet
5 5434255-070 1 Cover, Clutch, Outer 23 7512084 1 Screw
6 7512094 9 Screw 24 2202418 1 Kit, Cover, Clutch, Inner
7 5410542 1 O-Ring (Incl. 4,6,28,31)
8 5434264 1 Plug, Drain 25 7555932 1 Washer, Nylon
9 7074782 1 Decal, Automatic Transmission 26 5242693-067 1 Bracket, Clutch Cover, Front
10 7078689 1 Decal, Warning, Clutch Cover 27 7555935 1 Washer
11 7080761 2 Cable Tie 28 5410749 1 Seal, Cover, Case
12 5411489 1 Boot, Duct 29 5222877-067 1 Bracket, Retainer, Seal
13 5434160 1 Duct, Clutch, Out 30 ------- 4 Screw and Washer (See Crankcase
and Cylinder Pg. C6, Ref. 23)
14 7517916 1 Screw
31 7512098 1 Screw
15 7080511 1 Clamp
32 7661637 2 Rivet
16 7555783 1 Washer, Flat
33 7517386 2 Screw
17 7512018 1 Screw
34 5242208-067 1 Bracket, Clutch Cover
18 5811373 1 Tape, Foil
35 7547076 3 Nut
7/02

C1
 GEAR SELECTOR
TRAIL BLAZER 250 A03BA25CA

2 1

15

9
14
13
12
5
11

10
7
9

6
8

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411007 1 Knob 9 7518001 2 Screw
5411006 1 Cover 10 7547198 1 Nut, LH
2 7512024 1 Screw 11 1821206 1 Asm., Shift Linkage (Incl. 8,10-13)
3 5411008 1 Grommet, Gear Shifter 5133290 1 Rod, Shift Linkage
4 1012810-067 1 Selector, Gear 12 7547083 1 Nut, RH
5 5433103 2 Mount, Gear Selector 13 7061102 1 Rod End, RH
6 7515133 2 Screw 14 7556250 1 Washer
7 7546707 2 Nut 15 5131976 2 Spacer, Shifter
8 7061101 1 Rod End, LH
7/02

C2
 GEARCASE
TRAIL BLAZER 250 A03BA25CA

1
2 3 4 6
5
7 8
9 10 11 12
13
14
15
16
17
18
28
19
21 20
29 30
31 32 33 26 34 35

22
23
24 26
25

27

38 37 36

12
41
39 40 1
42

C3
 GEARCASE
TRAIL BLAZER 250 A03BA25CA

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341274 1 Asm., Gearcase (Incl. 1-42) 22 3233680 1 Bullet, Shifting
1 3233018 2 Bearing, Ball 23 3233681 1 Spring, Compression
2 3233177 1 Ring, Retaining 24 3233324 1 Washer
3 3233673 1 Washer, Thrust 25 3233682 1 Plug, Detent, Extension
4 3233674 1 Sprocket, 19T 26 3233248 2 Seal
5 3233010 1 Washer, Thrust 27 3233478 1 Dipstick
6 3233675 1 Dog, Engagement, High/Reverse 28 3233524 1 Tube, Vent
7 3233676 1 Shaft, Input 29 3233683 1 Gearcase, RH
8 3233677 1 Gear, 21T 30 3233529 2 Pipe, Knock
9 3233678 1 Bushing 31 3233684 1 Shaft, Shift
10 3233105 1 Washer 32 3233685 1 Fork, Shift
11 3233106 2 Ring, Retaining 33 3233686 1 Gearcase, LH
12 3233019 2 Bearing, Ball 34 3233636 1 Decal, Switch
13 3233055 1 Nut, FLEXLOC 35 3233252 9 Screw
14 3233054 1 Washer 36 3233687 1 Plug
15 3233153 1 Bellcrank, HLR 37 3233527 1 Bushing, Pivot
16 3233045 1 Ring, Retaining 38 3233035 1 Washer
17 3233040 1 Washer 39 3233111 1 Chain, Silent, 60P, 11W
18 3233548 1 O-Ring 40 3233688 1 Sprocket, 51T
19 3233679 1 Shaft, Shift 41 3233689 1 Shaft, Output
20 3233635 1 Switch 42 3233690 1 Gear, 64T
21 3233616 4 Screw
11/98

C4
 GEARCASE MOUNTING
TRAIL BLAZER 250 A03BA25CA

1
2

2
5

1 4
2

3 6
7

7
17
2

6 6
16
15

7 9
12
11 10
13
7
14 6 2 2

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517632 2 Screw 9 1012886-067 1 Mount, Transmission
2 7547089 7 Nut, Flange 10 5243296-067 1 Spacer
3 5242456-067 1 Bracket, Transmission Mount 11 7517646 1 Screw
4 5333048 1 Spacer 12 7517631 1 Screw
5 5243175-067 1 Bracket, Transmission Mount 13 7542440 1 Nut
6 7512492 5 Screw 14 ------- 1 Plug, Drain
7 7555806 5 Washer, Flat (See Gearcase Pg. C4, Ref. 36)
8 5210764 AR Shim (.020) 15 7710434 1 Ring, Retaining
5211065 AR Shim (.010) 16 3221043 1 Sprocket, 11T
5211517 AR Shim (.030) 17 7517647 1 Screw
7/02

C5
 CRANKCASE and CYLINDER
TRAIL BLAZER 250 A03BA25CA

1 2 3
4

5
6
34 31 7
33
32
30
29 8 9
10
4

28
12 11 13
27 13 14
26
20
19 21 15
18 15

25 16
24 23 22 18 16
19 17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083931 1 Fin Damper 3 18 3082758 2 Gasket, Aluminum
2 3082910 6 Nut, Flange 19 3086744 2 Plug
3 3083932 2 Fin Damper 4 20 3085890 1 Bearing, Ball
4 3083929 4 Fin Damper 1 21 3084580 1 Bearing, Ball
5 3086841 1 Head, Cylinder 22 3086784 2 Bolt and Washer
6 3084015 1 Gasket 23 3081635 4 Screw and Washer
7 3083930 2 Fin Damper 2 24 3084581 1 Seal, Oil (PTO)
8 3084292 1 O-Ring 25 3083615 2 Bolt and Washer
9 3085013 1 Adapter (Incl. 8) 26 3086783 1 Bolt and Washer
10 3086786 2 Bolt, Allen 27 3084016 1 Gasket, Cylinder
11 3082257 1 Asm., Band (Incl. 12) 28 3082911 4 Nut, Flange
12 3081497 1 Screw, Pan Head 29 3087049 1 Cylinder (Incl. 30,31)
13 3080746 4 Stud 30 3085326 2 Stud
14 3080006 1 Seal, Oil 31 3080283 6 Stud
15 3086741 4 Pin, Dowel 32 3086757 1 Gasket, Exhaust
16 3087048 1 Asm., Crankcase 33 3080530 2 Washer
(Incl. 13-15,18-22,24-26) 34 3086787 2 Nut
17 3085283 1 Gasket, Starter
7/02

C6
 CRANKSHAFT and PISTON
TRAIL BLAZER 250 A03BA25CA

7
5
6 8

17
9
10

15 11
6
16
12
13

14
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083546 2 Ring, Piston (Std.) 8 3083626 1 Bearing, End, Small
3083678 2 Ring, Piston (0.25mm/.010” O/S) 9 3084580 1 Bearing, Ball
3083717 2 Ring, Piston (0.50mm/.020” O/S)
3083974 2 Ring, Piston (1.00mm/.040” O/S) 10 3083745 1 Gear, Crankshaft (O/I)
2 3083942 1 Piston (Std.)(Incl. 3) 11 3080130 1 Key, Woodruff
3083943 1 Piston (0.25mm/.010” O/S)(Incl. 3) 12 3086767 1 Washer
3083944 1 Piston (0.50mm/.020” O/S)(Incl. 3) 13 3083905 1 Nut, Lock
3083972 1 Piston (1.00mm/.040” O/S)(Incl. 3)
14 3087056 1 Asm., Crankshaft (Incl. 5-7,9,10,14-16)
3 3083838 1 Pin, Piston 3083899 1 Crankshaft 1
4 3083839 2 Clip, Piston Pin 15 3083803 1 Bearing, End, Large
5 3082796 1 Crank Pin 2 16 3085891 1 Crankshaft 2
6 3083804 2 Spacer, Crank Pin 17 3086765 AR Spacer 1 (0.2mm)
7 3082790 1 Rod, Connecting 3085892 AR Spacer 3 (0.1mm)
7/02

C7
 MAGNETO
TRAIL BLAZER 250 A03BA25CA

3
4
5
7
8 6

9
15

14
10

11

13

12
20
19
18
16

17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 4020129 1 Cap, Spark Plug 11 3081260 1 Screw and Washer
2 3083423 2 Screw and Washer 12 3083909 1 Coupler, 3P
3 3083939 1 Flywheel w/Ring Gear 13 3083978 1 Harness, Wire (Incl. 12,14)
4 3083422 1 Coil, Exciting 14 3083773 1 Grommet
5 3083976 1 Stator 1 15 3083736 2 Screw and Washer
6 3081256 1 Screw and Washer 16 3083923 1 Ignition Coil
7 3086788 2 Screw and Washer 17 3083977 1 C.D.I. System
8 3086789 2 Washer 18 3085521 1 Magnetic Switch
9 3083979 1 Asm., Plate (Incl. 2,4,5,6,9-15) 19 3080077 2 Washer, Spring Lock
3083634 1 Plate, Coil 20 3083073 2 Nut
10 3081296 1 Clamp
6/99

C8
 STARTING MOTOR
TRAIL BLAZER 250 A03BA25CA

4
5
8
9 6
7

19
10
18
11
16 17

4
14 15

13 20
12

21

23
22
24

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083649 1 Nut, Flange 12 3083754 1 Washer Set
2 3084406 1 Brush 13 3084404 1 Asm., Armature (Incl. 14,15)
3 3087043 1 Asm., Starting Motor 14 3083934 1 O-Ring
(Incl. 1-5,8,9,12-18,20-24) 15 3083777 1 Bearing, Ball
3085393 1 Asm., Starter (Incl. 1,2,4,5,8,9,12-17)
16 3083741 1 O-Ring
4 3084405 2 Ring, Rubber
17 3085305 1 Front Cover (Incl. 16)
5 3085032 1 Cover, Rear
18 3083737 1 Washer, Gear Shaft
6 3082758 1 Gasket, Aluminum
19 3082038 2 Bolt and Washer
7 3086782 1 Bolt, Flange
20 3084409 1 Clip
8 3084408 2 O-Ring
21 3084410 1 Spring, Return
9 3084407 2 Bolt
22 3087030 1 Asm., Gear Shaft (Incl. 18,20,21,23,24)
10 3083650 1 Bracket
23 3084411 1 Spring, Weight
11 3081665 4 Bolt and Washer
24 3084412 1 Clip
6/00

C9
 RECOIL STARTER
TRAIL BLAZER 250 A03BA25CA

1
2 3

5
6
15
14 7

13

10

16 9
26 12
17
25 8
18 11

19 20 21
22
23

24

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083815 1 Spring, Spiral 14 3086749 1 Plug
2 3083924 1 Recoil Starter (Incl. 1,2,5-11,18-26) 15 3082956 1 Gasket
3083911 1 Starter Case B 16 3083915 1 Pulley, Starting
3 3082926 1 Bolt and Washer 17 3081665 3 Bolt and Washer
4 3082228 4 Bolt and Washer 18 3083827 1 Spring, Return
5 3083817 1 Grommet 19 3083819 1 Ratchet
6 3083814 1 Reel 20 3083820 1 Pin, Ratchet
7 3083826 4 Bolt, Flange 21 3083818 1 Hook, Spring
8 3083914 1 Starter Case 22 3083821 1 Guide, Ratchet
9 3083828 1 Asm., Rope (Incl. 9-11) 23 3083912 1 Spring, Friction
2870621 AR Recoil Rope
24 3083925 1 Case, Spring
10 3083660 1 Cap, Knob
25 3084176 4 Screw and Washer
11 3083659 1 Starter Knob
26 3083913 1 Guide
12 3083729 1 Bolt and Washer
13 3083669 1 Bushing, Starter
7/02

C10
 OIL PUMP
TRAIL BLAZER 250 A03BA25CA

2 1

1 3
4

7
8
6
9

10
11

17

16

15

14

13
12

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083141 2 Clamp, Hose 10 3083121 1 Washer, Spring
2 3087047 1 Pipe, Vinyl 11 3083120 1 Nut
3 3083125 1 Screw, Air Vent 12 3083127 1 O-Ring
4 3083126 1 Packing 13 3083671 AR Spacer 1 (.15mm)
5 3087044 1 Asm., Oil Pump (Incl. 3,4,7-12) 3083672 AR Spacer 2 (.3mm)
3083673 AR Spacer 3 (.6mm)
6 3086778 2 Screw and Washer
14 3083353 1 Bushing, Oil Pump
7 3083758 1 Cap
15 3083129 1 O-Ring
8 3086844 1 Lever & Spring Set
3086845 1 Lever, Control 16 3083429 1 Gear, Small
9 3083757 1 Collar, Camshaft 17 3083428 1 Spacer
6/00

C11
 CARBURETOR
TRAIL BLAZER 250 A03BA25CA
1

30
4
7
5 8
9
6

29

10
28 11
12
27 13

15
24 14
26
25 23
22
21

20
19
18
17 16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 ------- 1 Cap 16 3130025 4 Screw and Washer
2 3130354 1 Spring, Throttle 17 3130321 1 Bolt, Banjo
3 3130002 1 Plate, Throttle 18 3130239 1 O-Ring
4 3130356 1 Needle, Jet (5DP7-2) 19 3130109 1 Jet, Main (#130)
5 3130355 1 Washer 20 3130441 1 Float Chamber
6 3130420 1 Valve, Throttle (2.0) 21 3130021 2 Float
7 3130359 1 Cap, Plunger 22 3130237 2 Cap
8 3130006 1 Spring, Plunger 23 3130020 1 Packing, Float Chamber
9 3130328 1 Plunger, Starter 24 3131459 1 Valve, Needle (2.5)
10 3130012 1 Spring, Air Adjuster 25 3130018 1 Arm, Float
11 3130011 1 Screw, Air 26 3130361 1 Pin, Float
12 3130010 1 Spring, Throttle Adjuster 27 3130017 1 Packing, Needle Valve
13 3130324 1 Screw, Throttle Stop 28 3131381 1 Asm., Carburetor (Incl. 1-30)
14 3130067 1 Jet, Pilot (#40) 29 3130409 1 Jet, Needle (0-4)
15 3130014 1 Washer, Jet, Main 30 3130003 1 E-Ring
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 TOOL KIT
TRAIL BLAZER 250 A03BA25CA

3
7
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2682572 1 Pouch, Tool Kit 6 3083675 1 Asm., Tool Kit (Incl. 1-5)
2 3083612 1 Wrench, Box, Special 7 9917492 1 Manual, Owners, ’03 ATV
3 3083613 1 Wrench, 10-12 Spanner 9917502 1 Supplement, Manual, Owners, ’03
Trail Blazer
4 3083843 1 Screwdriver
5 2870725 1 Gauge, Tire Pressure
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PRINTED IN THE USA PARTS MANUAL PN 9917503 and MICROFICHE PN 9917504 7/02