2000 Polaris Trail Blazer 250 Parts Manual

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

TABLE OF CONTENTS Trail Blazer 250 A00BA25CA Parts Manual

A

G

A-ARM/STRUT MOUNTING . . . . . . . . . . . . . . B4 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13

C CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . .

CONTROLS - MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . . .

CONTROLS THROTTLE ASM./CABLE . . . . . . . . . . . .

CRANKCASE and CYLINDER . . . . . . . . . . . .

CRANKSHAFT and PISTON . . . . . . . . . . . . . .

D1 C4 A8 B8 B7 C9 C10

D

H HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . B5

M MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C11

O OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . C14 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . A14

P PART NUMBER INDEX . . . . . . . . . . . . . . . . . . D3-7

R

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11 DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . B9 DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . B10

E ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . . C3 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . A9 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . A10

F FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . .

FRONT BUMPER and SHIELDS . . . . . . . . . . .

FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . C5 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . C6-7 GEARCASE MOUNTING . . . . . . . . . . . . . . . . C8

B3 A7 A5 B2 A12

REAR BRAKE MASTER CYLINDER . . . . . . . .

REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR CALIPER MOUNTING . . . . . . . . . . . . .

REAR HOUSING . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . .

RECOIL STARTER . . . . . . . . . . . . . . . . . . . . .

B14 A6 B13 C2 C1 C13

S SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . .

STARTING MOTOR . . . . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . . . . . .

STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING ARM/SHOCK MOUNTING . . . . . . . . . .

B11 C12 B6 B1 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

ENGINE 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 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

FRONT CAB Trail Blazer 250 A00BA25CA

9 10 11 12

7 8 7 3

13

4

2

14 5

1

6

3

15 16

17 33

18

25 30

23

31 25

29

26 27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

7517386 5224718-067 7670060 1012772-067 4020149 4032093 7670095 5241436-067 4030056 7512084 4010206 4032094 7511886 5432179-053 7511887 2631988-133

17 7558301

22

24 28

Ref. Part No.

Qty. Description

2 2 4 1 2 2 3 1 1 2 1 1 1 1 2 1

20

22

32 21

19

21

Screw Bracket, Cab Mount Nut Frame Clip, Rosebud Spring, Adjustment Insert, Nut Bracket, Headlight Mounting Bulb, Halogen, 55W Screw Headlight, Single Beam (Incl. 9) Spring Screw Cover, Front, Yellow Screw Asm., Cab, Front, White (w/Warning Decals) 2 Washer

22

Ref. Part No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

7522026 7621471 7558201 7555859 7542122 5211131-067 5811771 5850150 7512282 1012997-067 7661825 5431484 7515179 5432763 5242525-067 7621472 7517264

Qty. Description

2 2 2 16 24 1 1 1 24 2 8 1 6 1 2 6 4

Screw Rivet Washer Washer Nut, Nylok Bracket, Mudflap Mudflap, Front, LH Mudflap, Front, RH Bolt Footpad Rivet Trim, Footrest Screw Guard, Rock Bracket, Cleat Rivet Screw 2/99

A5

REAR CAB Trail Blazer 250 A00BA25CA 4 3

2

5

1

8 9

28

29 16

30

7

16

6

10 11 12 13 27 16

14 15 22

17 23

15

21

16

16 17

19

25

26

24 23

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

7041607 1040412-067 5411392 2682430-053 2681769-053 5431986 7621479 5410414 5211033 7621403 7073761 7072791 5432820-133 7670057 5432278-070 5811230 7517264 7555859

18

Qty. Description

1 1 1 1 1 1 2 6 1 1 1 1 1 2 1 1 4 16

Spring, Latch Latch, Seat Cap, Seat Latch Asm., Seat, Yellow Covering, Seat, Yellow Tongue, Seat Rivet Bumper Bracket, Lever Retainer Rivet Decal - Carb Information Decal - Filter Element Cab, Rear, White Nut Shield, Muffler Foil, Heat Shield Screw Washer

20

Ref. Part No.

17 18 19 20 21 22

Qty. Description

7542122 5241403-067 7661638 2670133 5432831 5810957 5810991 23 7512282 24 –––––––

16 1 4 2 2 1 1 16 1

25 5850147 5850148 26 5211131-067 27 5220880 28 7621472 29 7512232 30 7512242

1 1 2 2 4 2 2

Nut Guard, Clutch Rivet Reflector, Red Plug, End Cap, Ribbed Foil, Rear Cab Foil, Rear Cab, Small Bolt Footpad (See Front Cab Pg. A5, Ref. 26) Mudflap, Rear, LH Mudflap, Rear, RH Bracket, Mudflap Bracket, Rear Seat Holddown Rivet Screw Screw 11/98

A6

FRONT BUMPER and SHIELDS Trail Blazer 250 A00BA25CA

2 1 3 4 5

6 7 9

8

Ref. Part No.

1 2 3 4

5211329-067 7512329 2670134 5810467

Qty. Description

2 2 2 1

Ref. Part No.

Plate, Reflector Bolt Reflector, Amber Plug, Frame

5 6 7 8 9

7547071 5850125 1012773-067 7515399 7670088

Qty. Description

2 2 1 2 4

U-Nut Shield, Deflector Bumper, Front Screw Clip, Dart 2/99

A7

CONTROL PANEL Trail Blazer 250 A00BA25CA

1

7

2 3 6

9

8

4 5

4

Ref. Part No.

1 2 3 4

4010140 4040054 5430967 4110264 4110141 4110148

Qty. Description

1 1 1 1 1 1

Ref. Part No.

Indicator, Low Oil Indicator, Neutral/Reverse Plug, Indicator Hole Switch, Ignition (Incl. Key) Key, Ignition Key, Ignition NOTE: Order key by using the four digit number on the key.

5 6 7 8 9

5431976 7512026 2460777 5431975 7080371

Qty. Description

1 2 1 1 1

Panel, Control, Outer Screw Harness, Indicator Panel, Control, Inner Cable, Choke Control 11/98

A8

ENGINE MOUNTING Trail Blazer 250 A00BA25CA 5 3

6

7

4

8

2

1

9

37 30

38 10 36

11

35

37

5 30 1 26 25

12

34

1

33 32 30 31 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

7547108 7555806 3110026 5430802 7555823 7515321 7552901 7542411 5242898-067 7512232 4010132 3070156 4010129 5410346 7512457 1040687-067 7512566 7575202 5210748 5430261 –––––––

17 19 18 20

16 23 24

14 15 23

29

Ref. Part No.

1 2

13

28

27 1

5

Qty. Description

5 2 2 1 AR 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1

21 3

Nut Washer Mount, Motor Insulator, Motor Mount Washer Bolt Washer Nut Bracket, Engine Mount, Top Screw Cable, Ground, Engine, Small Hole Spark Plug, NGK BR8ES Cable, Solenoid/Starter Insulator, Cable Bolt Mount, Engine, Front Bolt Washer Washer, Clutch Retainer Bushing Asm., Drive Clutch, Basic ATV-08 (See Drive Clutch Pg. B9, Ref. 16)

22

25 26 Ref. Part No.

22 ––––––– 23 24 25 26 27 28

7080511 5410421 7552603 7512490 5242896-067 3084717

29 30 31 32 33 34 35 36 37 38

7075741 8450040-600 7051011 7052005 8360009-600 5242897-067 3110028 2530009 7080003 7542459

Qty. Description

1 Seal, Cover, Case (See Clutch Cover Pg. C4, Ref. 32) 2 Clamp 1 Boot, Clutch Intake 4 Washer 4 Bolt 1 Bracket, Engine Mount, Front 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.

1 Decal - Drain Recoil AR Line, Fuel 1 Valve, Check, Vent 1 Fitting, Tee AR Line, Fuel 1 Bracket, Engine Mount, Rear 1 Mount, Engine 1 Filter 4 Clamp, Hose, Red 1 Nut 2/99

A9

EXHAUST SYSTEM Trail Blazer 250 A00BA25CA

3 2 1 4 3 2

2

5 1

6

13

7

8 9

14 13

2

14

12 10

11

Ref. Part No.

1 2 3 4 5 6 7

5010368 5411058 7515394 7512232 5243116-067 1260922-029 –––––––

Qty. Description

2 4 2 2 1 1 2

Spacer Dampener Bolt, Carriage Screw Mount, Lower, Muffler Manifold Washer (See Crankcase and Cylinder Pg. C9, Ref. 37)

Ref. Part No.

8 ––––––– 9 10 11 12 13 14

7042029 1260740-029 7042031 1260910-029 7555716 7542324

Qty. Description

2 Nut (See Crankcase and Cylinder Pg. C9, Ref. 38) 2 Spring, Exhaust 1 Headpipe 2 Spring, Exhaust 1 Muffler 2 Washer 2 Nut, Nylok 11/98

A10

DECALS Trail Blazer 250 A00BA25CA 1 2

5

4

3

RH

10 8

12

11

9

7 6

2

13

LH 14

Ref. Part No.

1 2 3 4 5 6 7

7072786 7077789 7078354 7077791 7077788 7077790 7078315

Qty. Description

1 2 1 1 1 1 1

Decal - Warning, Heavy Loads Decal - “Trail Blazer” Decal - Discretionary Warning Decal - Concentric Drive System Decal - Tank Side, RH Decal - Front Cover, “250” Logo, 45th Anniversary

Ref. Part No.

8 9 10 11 12 13 14

7076202 7076274 7078253 7077787 7077920 7075725 7077919

Qty. Description

1 2 1 1 1 1 1

Decal - CE Regulation Decal - Override Switch, 2WD Decal - Age Warning Decal - Tank Side, LH Decal - Passenger Warning Decal - Tire Pressure Decal - Warning, General, CPSC 2/99

A11

FUEL TANK Trail Blazer 250 A00BA25CA 1 2 3 4 5 6 23

7

22

8 9 10 21

17 16

11

20 19

15 18

14 13 12

Ref. Part No.

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

5430725 5810144 5410842 8360009-600 5431053 7512310 7555734 7512208 5220916-067 7542324 7074637 –––––––

Qty. Description

1 1 1 AR 1 2 2 2 1 2 1 1

Cap, Gas Tank Gasket, Fuel Cap Grommet, Fuel Tank Hose, Vent, Gas Tank Vent, Tank Bolt Washer Screw Bracket, Tank Mount, Rear Nut, Nylok Decal - Fuel Lever Duct, Inlet Down Tube (See Clutch Cover Pg. C4, Ref. 20)

Ref. Part No.

13 14 15 16 17 18 19 20

7511840 5431021 7041209 5431391 5432291 7555726 7515136 7051006 5810859 21 8360026 22 1240049 23 5811527

Qty. Description

1 1 1 1 1 1 2 1 1 1 1 1

Screw Lever, Fuel Spring, Lever, Compression Extension, Fuel Lever Grommet Washer Screw Asm., Fuel Valve (Incl. Gasket) Gasket, Fuel Valve Pad, Fuel Tank Asm., Tank, Fuel (Incl. 5,19,20) Foam, Seal 2/99

A12

AIR BOX Trail Blazer 250 A00BA25CA

1 2 3

4

5

22 21 20 19 18

6

17

7

16 14

8

15

13 12

9 11 10

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11

5811102 5810444 5224708 5432178 5410506 7512246 7558302 7670060 5433174 5410549 5410529

Qty. Description

1 1 1 1 1 2 2 2 1 1 1

Collar, Foam Filter, Foam Retainer, Foam, Wire Box, Air Silencer Boot, Air Silencer Screw Washer Nut Box, Air Intake Valve, Umbrella Bushing, Molded

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22

7512275 7080413 7080140 5411580 5810310 7670080 7080369 5410510 5430884 5220980 7542127

Qty. Description

4 1 1 1 1 4 1 1 1 1 4

Bolt, Carriage Clamp Clamp Boot, Carburetor Tape, Foil, Air Box Palnut Filter Seal Cover, Air Intake Retainer, Cover Nut 11/98

A13

OIL TANK Trail Blazer 250 A00BA25CA

6 5 1

2 3

7

4

8

9

10 15 11

12

13

14

13

Ref. Part No.

1 2 3 4 5 6 7 8

5430779 5810141 5431793 7052077 8360009-600 4110265 7621460 7052153

Qty. Description

1 1 1 1 AR 1 2 1

Cap, Oil Tank Gasket, Oil Cap Tank, Oil Fitting Line, Fuel Sensor, Oil Level w/Connector Rivet Fitting

Ref. Part No.

9 10 11 12 13 14 15

7080568 8450003-1525 7080307 2530009 7080003 8450040-600 7555932

Qty. Description

2 AR 1 1 2 AR 2

Clamp Line, Fuel Clamp, Hose, Large Green Filter, Fuel Clamp, Yellow Line, Fuel Washer 11/98

A14

STRUT Trail Blazer 250 A00BA25CA 1 2 3 4

5 6 7 9

8

10

17

11 12

16

13 13 15

14

Ref. Part No.

1 2 3 4 5 6 7 8 9

7547104 7555749 5810291 5430806 5430807 5132062 5243364 7041850-067 5411608

Qty. Description

2 2 2 2 2 2 2 2 2

Nut Washer Spacer, Rubber Ball, Pivot, Top Ball, Pivot, Bottom Spacer Retainer, Spring Spring Bumper

Ref. Part No.

10 11 12 13 14 15 16

7041761 7080573 7542303 7558402 7080306 7515339 5131039 5131040 17 5211115

Qty. Description

2 2 4 6 2 4 1 1 2

Strut, Front Clamp, Rubber Coated Nut Washer Fitting, Lubrication Bolt Support, Strut and Spindle, LH Support, Strut and Spindle, RH Washer 2/99

B1

FRONT WHEEL Trail Blazer 250 A00BA25CA

1

2 3

4 5

6

17 7 16 8

9 3 10

11 12

15 14 13

Ref. Part No.

1 ––––––– 2 3 4 5 6 7 8

3610020 3513519 5211869 5130940 5411264 1520175-133 1525017

Qty. Description

1 Support, Strut and Spindle (See Strut Pg. B1, Ref. 16) 2 Seal, Front Hub 4 Bearing, Ball 2 Disc, Brake 2 Hub, Wheel 2 Tire, Front (23x7-10) 2 Rim, Front 2 Valve, Rim

Ref. Part No.

9 10 11 12 13 14 15 16 17

5010256 7555721 7542712 7661407 5431018 5410470 7542459 7515523 7512325

Qty. Description

2 2 2 2 2 2 8 8 8

Spacer, Front Hub Washer Nut, Castle Pin, Cotter Cap, Hub O-Ring Nut, Flange Stud Bolt 11/98

B2

FRONT BRAKE Trail Blazer 250 A00BA25CA

2

3

1

8 4

5

6 7

13 12

11

9 10

Ref. Part No.

1 2 3 4 5 6 7

1910271 1910264 1930642 7080352 7515489 5131115 5131116 5410779 5410780 5132294 5910026

Qty. Description

1 1 1 2 2 1 1 1 1 1 1

Asm., Front Brake Caliper, LH Asm., Front Brake Caliper, RH Kit - Front Brake Boot (Incl. 11,12) Screw, Bleeder Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH Ring, Square, Molded (.094) Ring, Square, Molded (.103 x .134) Piston, Brake Insulator, Caliper

Ref. Part No.

8 1930665 9 2200901

10 11 12 13

2201149 2200465 1910265 5410495 5410494 7517445

Qty. Description

1 Kit - Piston and Insulator Seal (Incl. 4-7) 1 Kit - Severe Duty Brake Pad, Front (Complete set of 2 pads) 1 Kit - Brake Pads, Front, Soft 1 Kit - Brake Pads, Front, General 2 Mount, Caliper 1 Boot, Bushing 1 Boot, Pin Seal 4 Bolt

2/99

B3

A-ARM/STRUT MOUNTING Trail Blazer 250 A00BA25CA

1

3 4 5 6

2

7 8

9 26

10

24 25

11 17 12

24 25

19

18

20

18

19

16

23 15

22

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

7542403 5333367 5411291 7061034 7542711 5020927 7547028 7061033 1820566 7555806 7546904 7661203 5240717 7512284

Qty. Description

2 2 2 2 2 2 2 2 2 4 2 4 2 4

Nut Bushing Boot, Seal, Rod End Rod End, RH Nut Tie Rod Nut, LH Rod End, LH Tie Rod Washer Nut Cotter Pin Bracket, Ball Joint Screw

Ref. Part No.

15 5410548 16 7080673 17 ––––––– 18 19 20 21 22 23 24 25 26

14

12

21

Ref. Part No.

13

5431596 5020677 7080433 7542438 2200560 2200561 5020681 7512492 7552603 7517527

Qty. Description

2 Boot, Rubber 2 Joint, Ball 1 Support, Strut and Spindle (See Strut Pg. B1, Ref. 16) 4 Bushing, A-Arm Long 4 Bushing 2 Fitting, Lubrication 2 Nut, Castle 1 Kit - A-Frame, LH 1 Kit - A-Frame, RH 2 Shaft, A-Arm 4 Screw 4 Washer 2 Bolt 11/98

B4

HANDLEBAR Trail Blazer 250 A00BA25CA

3

1

5

4

2 6

7 9

8

10

7 11

13 12 14 15 16

Ref. Part No.

1 ––––––– 2 3 4 5 6 7

5242988-067 7515189 5810379 7517395 5220946 2200774 5630616-067

Qty. Description

1 Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B7, Ref. 3) 1 Handlebar 4 Screw 1 Pad, Handlebar 2 Screw 1 Mount, Handlebar Pad 1 Kit - Handlebar Block (Incl. 3,15) 2 Block, Handlebar

Ref. Part No.

8 -–––––– 9 10 11 12 13 14 15 16

5432926 4110248 5431030 5432952 7517625 7080138 7542122 7080631

Qty. Description

1 Asm., Master Cylinder (See Controls Master Cylinder/Brake Line Pg. B8) 1 Spacer, Switch, LH 1 Switch, Handlebar, ON/OFF, LH 2 Grip, Handlebar 1 Plug 1 Screw 2 Cable Tie 4 Nut 1 Clip 11/98

B5

STEERING POST Trail Blazer 250 A00BA25CA 1 16 15

2 14

3

4

13 12 5

11

10

5 6 7 8

6 9

Ref. Part No.

1 2 3 4 5 6 7 8

1843077 5431573 7080510 7515321 5410772 7555878 5431571 7661633

Qty. Description

1 1 1 2 2 3 1 1

Asm., Steering Post (Incl. 12,13) Bushing, Steering Console Fitting, Zerk, 90 Degree Bolt O-Ring Washer Spacer, Steering Post Pin, Cotter

Ref. Part No.

9 10 11 12 13 14 15 16

7543203 5431570 7661632 5431574 7080433 5431572 5222999-067 7542324

Qty. Description

1 1 2 1 1 1 1 2

Nut Bushing, Steering, Lower Rivet Plug, Grease Fitting, Lubrication Bushing, Steering Console Bracket, Upper Steering Bushing Nut 11/98

B6

CONTROLS – THROTTLE ASM./CABLE Trail Blazer 250 A00BA25CA

6 1

2

5

3

4

Ref. Part No.

1 5432721 2 5411439 3 2010178

Qty. Description

Ref. Part No.

1 Cover, Throttle Control 1 O-Ring 1 Asm., Throttle Control (Incl. 1-4)

4 2010191 5 7080803 6 5410193

Qty. Description

1 Clamp, Throttle 1 Cable, Throttle 1 O-Ring 2/99

B7

CONTROLS – MASTER CYLINDER/BRAKE LINE Trail Blazer 250 A00BA25CA 3 4

5 6 2 1

7

14 15

8 16

24

13

17

23 18

19 9

12 10 20 11

21 22 Ref. Part No.

1 2200809 2050073 2 ––––––– 3 1930797 4 1930796 5 1930795 6 2200808 7 1930799 8 1930804 9 2201034 10 ––––––– 11 1930806

Qty. Description

1 1 1 2 1 1 1 1 1 1

Kit - Master Cylinder Reservoir (Incl. 2-5) Asm., Master Cylinder (Incl. 1-14) Ring, Square Bolt, Cap Cap, Reservoir Diaphragm Kit - Clamp Piston Rivet Kit - Brake Lever w/Park Brake Latch (Incl. 8,10,12) 1 Spring, Flat 1 Nut

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22 23 24

2201090 1930792 1930805 1910336 4110164 1930873 7080539 7621462 1930752 7080492 7512024 1930753 7052194

Qty. Description

1 2 1 1 1 1 2 2 1 1 2 1 1

Kit - Park Brake Lever (Incl. 8,10,12) Bolt Bolt Line, Brake, Upper w/Fittings Switch Line, Brake, Hand, Rear Clamp Rivet Line, Brake, Left Front w/Fittings Cable Tie Screw Line, Brake, Right Front w/Fittings Fitting, Inverted Flare Cross 11/98

B8

DRIVE CLUTCH Trail Blazer 250 A00BA25CA

5 1

6

10

7 8

11

2 3

4

8

9

15

14

13 12

16

Ref. Part No.

1 2 3 4 5 6 7 8 9

7512176 7552801 3576510 7041157 5430945 1321457 5410610 5430768 5210752 5242981 5210753 5210754

Qty. Description

6 6 1 1 6 3 3 6 AR AR AR AR

Bolt Washer Bearing, Cover Spring, Clutch Washer, Multilube Roller and Bushing O-Ring Guide Button Spacer (.020″) Spacer (.025″) Spacer (.032″) Spacer (.050″)

Ref. Part No.

10 11 12 13 14 15 16

5630514 7512266 7541906 3576504 5020795 5410609 1321635

Qty. Description

3 3 3 1 3 3 1

Weight, Shift (G) Bolt Nut Bearing, Moveable, 1/2” Pin, Spider Washer Asm., Drive Clutch, Basic ATV-08 (Incl. All Less 4,10)

11/98

B9

DRIVEN CLUTCH Trail Blazer 250 A00BA25CA

1

2 4

3 16 17

15

5 14

6 7

13

12 11

10 9 8

4

Ref. Part No.

1 2 3 4 5 6 7 8

5010266 7556401 3211077 1322180 5220646 7552901 7515382 7555898 7556076 9 7556804

Qty. Description

1 AR 1 1 1 1 1 AR AR AR

Spacer Bushing (3 Max) Belt, Drive Asm., Driven Clutch (Incl. 8-17) Washer Washer Bolt Washer (.020) Washer (.025) Washer (.030)

Ref. Part No.

10 11 12 13 14 15 16 17

3576504 3576511 7041198 5131446 5210752 7710448 7511854 5430766

Qty. Description

1 1 1 1 1 1 3 3

Bearing, Moveable, 1/2” Bearing, Moveable, 1” Spring, Clutch Ramp, Stationary Spacer Ring, Retaining Bolt Button, Ramp

11/98

B10

SHOCK MOUNTING Trail Blazer 250 A00BA25CA

1 2 3

4 5

6

7

11

8 1

10

Ref. Part No.

1 2 3 4 5 6

7542439 5433213 7515415 5132022 5241147 7041778-067

Qty. Description

2 2 1 1 1 1

Nut, Nylok Bushing Screw Tube Retainer, Spring Spring

9

Ref. Part No.

7 8 9 10 11

7041773 5630921 5132021 5433212 7515438

Qty. Description

1 1 1 2 1

Shock Cam, Adjuster Tube Bushing Screw 11/98

B11

SWING ARM/SHOCK MOUNTING Trail Blazer 250 A00BA25CA

1 2

3

4

5 6

7

3 20 19

10

9 8

18

7 11 15

14 13

12

17 16

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

7661046 5432727 7080510 7547082 7556035 5432637 5131697 5131696 1541383 7077618

Qty. Description

2 1 2 1 1 2 2 1 1 1

Rivet Guide, Pad, Chain Fitting, Lubrication Nut Washer Bushing, Swing Arm, RH Bolt, Swing Arm Bushing, Pivot, RH Asm., Swing Arm (Incl. 3,6,19) Decal - Chain Free Play

Ref. Part No.

11 12 13 14 15 16 17 18 19 20

5432854 7515304 5332828 7558402 7542321 7542503 7555883 7512576 5432636 5131695

Qty. Description

1 1 1 1 1 2 2 2 1 1

Guard, Chain Screw Bushing Washer Nut Nut Washer Bolt Bushing, Swing Arm, LH Bushing, Pivot, LH 2/99

B12

REAR CALIPER MOUNTING Trail Blazer 250 A00BA25CA

6 Frame

4 1

6 5

3 4

2

7 5 3

17 8

16 9

15

14 13

10 11 12

Ref. Part No.

1 2 3 4 5 6 7 8 9

7517231 1910367 5410988 1930873 1930872 4020139 7670102 1930674 5131759

Qty. Description

2 1 4 1 1 2 2 2 1

Screw Caliper, Rear Seal Line, Brake, Hand, Rear Line, Brake, Foot, Rear Clip, Rosebud Clip Bolt, Banjo Bushing, Caliper Mount

Ref. Part No.

10 11 12 13 14 15 16 17

7558402 7552901 7512312 5131786 5131787 7512325 5242291-067 2201189

Qty. Description

2 2 2 1 1 3 1 1

Washer Washer Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt Guard, Brake Disc Kit - Brake Pad 2/99

B13

REAR BRAKE MASTER CYLINDER Trail Blazer 250 A00BA25CA

1

2 20 3

19

8 7

4 6

18

5 9 17

3

15 14

13

12

10

16

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

7512247 1930854 7080003 1910332 7661011 7041769 7555919 7661401 5431107 1012844-067

Qty. Description

2 1 2 1 1 1 2 1 2 1

Bolt Reservoir Clamp, Red Hose Pin, Cotter Spring Washer Pin, Cotter Bushing Brake, Foot

11

Ref. Part No.

11 12 13 14 15 16 17 18 19 20

7661843 1910314 7080644 7542129 5243066 8360012 7542122 1930899 7512208 5243220-067

Qty. Description

1 1 1 1 1 1 2 1 1 1

Pin, Clevis Asm., Plunger (Incl. 13-15) Clevis Nut Plunger Trim, Edge Nut, Nylok Master Cylinder, Brake, Foot Screw Bracket, Mount, Reservoir 11/98

B14

REAR WHEEL Trail Blazer 250 A00BA25CA

2 1

3 4

6 5 7

9 8

6

12 11

7 5

4

8

9 10

2 1

Ref. Part No.

1 2 3 4 5 6

7512673 5131777 7542714 7555796 7543005 7661404

Qty.

8 2 8 2 2 2

Description

Ref. Part No.

Bolt Hub, Rear Wheel, Large Flange Nut Washer Nut, Castle Pin, Cotter

7 8 9 10 11 12

5411164 7555745 1525017 7670081 1520183-133 5411266

Qty.

2 2 2 8 2 2

Description

Cover, Dust, Hub Washer Valve, Rim Pushnut Rim, Rear Tire (22x11-10) 11/98

C1

REAR HOUSING Trail Blazer 250 A00BA25CA 1

2

3

4 5 6 7 8 9

10 11

12 13

14

15 16 17

24

18

23 14 13 12

11

19 7

5 20 22

4 5

Ref. Part No.

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

7710472 5510313 7547031 5411555 7542439 5211849 7515513 1520259 7710405 5010462 5410889 3610070

Qty.

2 2 2 2 9 1 6 1 1 1 2 2

3 2

21

1

Description

Ref. Part No.

Ring, Retaining Retainer, Nut Nut Seal, Foam Nut, Nylok Disc, Brake Stud Hub, Brake Disc (Incl. 7) Ring, Retaining Spacer, Axle O-Ring Seal

13 14 15 16 17 18 19 20 21 22 23 24

3554518 3554517 5132098 7080306 3225026 5131968 3224056-078 5211585-067 5630586 3222065 1520258 7515540

Qty.

2 2 1 1 1 1 1 1 1 1 1 3

Description

Bearing, Cone, Tapered Bearing, Cup, Tapered Housing, Axle, Rear Fitting, Lubrication Link, Connector, 520 O-Ring Axle, Rear Chain, 520 O-Ring Guard, Sprocket Spacer Sprocket, 38T Asm., Hub, Sprocket (Incl. 7) Bolt 11/98

C2

ELECTRICAL/TAILLIGHT Trail Blazer 250 A00BA25CA

4

5

1

6 7 3

2

13

8 9 10

14

15 16 17

12

18 11 28 21

23

11

23

19

22

20

24

27 26

Ref. Part No.

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

2460778 7080138 2200593 2432038 7512088 4032085 4030043 4032086 4032087 7670093 7571602 7512027 5810290 5431769 2200361

Qty.

1 7 1 1 2 1 1 1 1 2 4 2 3 1 1

25

Description

Ref. Part No.

Harness, Main Wire Cable Tie Kit - Circuit Breaker, 20 AMP Light, Tail/Brake Screw Lens Bulb Gasket Backing Clip Washer Screw Pad, Battery Cover, Battery Kit - Battery Bolt, Short

16 17 18 19 20 21 22 23 24 25 26 27 28

4010095 7010032 5410424 5432077 7080303 4140006 4010094 4010064 7541925 7512007 4060208 7512024 4010186 7670109

Qty.

1 2 1 1 2 1 1 1 4 2 1 4 1 3

Description

Cable, Battery/Engine, Black Hook, Battery Strap Strap, Battery Holddown Line, Vent Clamp Battery Cable, Battery/Solenoid Cable, Solenoid/Starter Nut, Nylok Bolt Rectifier, LR391 Screw Limiter, LR491 Clip, Routing 11/98

C3

CLUTCH COVER Trail Blazer 250 A00BA25CA 2 3 1 2

39

4 38

3 5

2

36

35 27 23

28 29

30

31

24

7

6

37

32

34 33

8 13

14

12 25

22

26

9

15 11

10

16

21

17 12 18 19 20

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

5411553 7555748 7517542 5521301 5431961 7670051 7512093 7074946 7077377 7074782 7512094 7080492 5410421 7515194 5432302 7080511 7555783 7512018 5811373 5433258

Qty.

1 3 3 1 1 1 5 1 1 1 2 4 1 1 2 1 1 1 1 1

Description

Ref. Part No.

Qty.

Seal, Clutch Cover, Inner Washer Screw Seal, Clutch Cover Cover, Clutch, Front Clip, Clutch Cover Screw Decal - Clutch Cover Decal - Engine/Clutch Modification Decal - Automatic Transmission Screw Cable Tie Boot, Clutch Intake Screw Clip Clamp Washer Screw Tape, Foil Duct, Inlet Down Tube

21 22 23 24 25 26 27

5410509 5431794 7512084 7556091 7670116 7558301 2201402

1 1 1 1 1 1 1

28 29 30 31 32 33 34

7555932 5242693-067 7555935 5433323 5410749 5222877-067 –––––––

1 1 1 1 1 1 4

35 36 37 38 39

7512098 7512232 7661638 5242208-067 7547076

1 2 2 1 3

Description

Boot, Intake Duct, Inlet, Top Screw Spacer Clip, Routing Washer Kit - Cover, Clutch, Inner (Incl. 4,7,11,32,35) Washer Bracket, Clutch Cover Washer Duct, Air Outlet, Clutch Seal, Cover, Case Bracket, Retainer, Seal Screw and Washer (See Crankcase and Cylinder Pg. C9, Ref. 26) Screw Screw Rivet Bracket, Clutch Cover Nut 2/99

C4

GEAR SELECTOR Trail Blazer 250 A00BA25CA 1 2

3

4

5

14 6

6

7

12 11 8

10 13 9 7

Ref. Part No.

1 2 3 4 5 6 7

5411006 7512024 5411007 5411008 5131976 5433103 7546707

Qty.

1 1 1 1 2 2 2

Description

Ref. Part No.

Cover Screw Knob, Gear Selector Grommet, Shifter, Gear Spacer, Shifter Mount, Gear Selector Nut

8 9 10 11 12 13 14

7061014 7546701 5020955 7546702 7061013 7515133 1012810-067

Qty.

1 1 1 1 1 2 1

Description

Rod End, 6mm, RH Nut, RH Rod, Shift Linkage Nut, LH Rod End, 6mm, LH Bolt Selector, Gear 11/98

C5

GEARCASE Trail Blazer 250 A00BA25CA 1

2 3 4

6

5

7

8 9

21

24

23

13 14 15 16 17 18 19 20

10 11

12

28 30 31

29

32

33

22 26

25

27

38 37 36

12 41 39

1

40

42

43

45 44 44

C6

26

34

35

GEARCASE Trail Blazer 250 A00BA25CA Ref. Part No.

Qty.

1341274 3233018 3233177 3233673 3233674 3233010 3233675 3233676 3233677 3233678 3233105 3233106 3233019 3233055 3233054 3233153 3233045 3233040 3233548 3233679 3233635 3233616 3233680

1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 4 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Description

Ref. Part No.

Asm., Gearcase (Incl. 1-42) Bearing, Ball Ring, Retaining Washer, Thrust Sprocket, 19T Washer, Thrust Dog, Engagement, High/Reverse Shaft, Input Gear, 21T Bushing Washer Ring, Retaining Bearing, Ball Nut, FLEXLOC Washer Bellcrank, HLR Ring, Retaining Washer O-Ring Shaft, Shift Switch Screw Bullet, Shifting

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

3233681 3233324 3233682 3233248 3233478 3233524 3233683 3233529 3233684 3233685 3233686 3233636 3233252 3233687 3233527 3233035 3233111 3233688 3233689 3233690 5433207 7512232 7558301

Qty.

1 1 1 2 1 1 1 2 1 1 1 1 9 1 1 1 1 1 1 1 1 4 2

Description

Spring, Compression Washer Plug, Detent, Extension Seal Dipstick Tube, Vent Gearcase, RH Pipe, Knock Shaft, Shift Fork, Shift Gearcase, LH Decal - Switch Screw Plug Bushing, Pivot Washer Chain, Silent, 60P, 11W Sprocket, 51T Shaft, Output Gear, 64T Guard, Prop Shaft, Side Screw Washer 11/98

C7

GEARCASE MOUNTING Trail Blazer 250 A00BA25CA 1 2 5

1

2

6

4

2

7

3 8 9

8 19

2

7

7 18 17

10

8 14 16

Ref. Part No.

1 2 3 4 5 6 7 8 9

7517632 7542423 5242456-067 5333048 5243175-067 5243416-067 7512492 7555806 5210764 5211065 5211517

11

13

15

8 7

Qty.

2 5 1 1 1 1 5 4 AR AR AR

2

Description

Ref. Part No.

Screw Nut Bracket, Transmission Mount Spacer Bracket, Transmission Mount Bracket, Air Box Screw Washer Shim (.020) Shim (.010) Shim (.030)

10 11 12 13 14 15 16

1012886-067 5243296-067 5243306 7517646 7517631 7542440 –––––––

17 7710434 18 3221043 19 7517647

12

Qty.

Description

1 1 1 1 1 1 1

Mount, Transmission Spacer Mount, Transmission Screw Bolt, Torque Stop Nut Plug, Drain (See Gearcase Pg. C7, Ref. 36) 1 Ring, Retaining 1 Sprocket, 11T 1 Screw 2/99

C8

CRANKCASE and CYLINDER Trail Blazer 250 A00BA25CA 1

3

2

4 5

3

7 6 8 9

38 37

10

35 36 34 33

11 12

13

4 32 14

16 15

17

31 30

18

16 29 23 22 21 28 27 Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

3083931 3082910 3083932 3083929 3083730 3083731 3083732 3086108 3084015 3083930 3084292 3085013 3086786 3082257 3081497 3080746 3080006 3080103 3085889

Qty.

1 6 2 4 2 2 2 1 1 2 1 1 2 1 1 4 1 4 1

21 22

19 20

24 18 19 26

25

Description

Ref. Part No.

Fin Damper 3 Nut, Flange Fin Damper 4 Fin Damper 1 Bolt and Washer Mount, Rubber Collar Head, Cylinder Gasket Fin Damper 2 O-Ring Adapter (Incl. 11) Bolt, Allen Asm., Band (Incl. 15) Screw, Pan Head Stud Seal, Oil Pin, Dowel Asm., Crankcase (Incl. 16-18,21-25,27-29)

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

3084018 3082758 3083767 3085890 3084580 3080739 3081635 3084581 3083615 3082096 3083337 3084016 3082911 3085541 3085326 3080283 3084017 3080530 3080285

Qty.

1 1 2 1 1 2 4 1 2 1 1 1 4 1 2 6 1 2 2

Description

Gasket, Starter Gasket, Aluminum Plug Bearing, Ball Bearing, Ball Bolt and Washer Screw and Washer Seal, Oil (PTO) Bolt and Washer Bolt and Washer Valve, Check Gasket, Cylinder Nut, Flange Cylinder (Incl. 34,35) Stud Stud Gasket, Exhaust Washer Nut 11/98

C9

CRANKSHAFT and PISTON Trail Blazer 250 A00BA25CA

1

4

2 3 4

7 5 6

8

17 9

10 11

15 6 16

12 13 14 Ref. Part No.

Qty.

1 3083546 3083678 3083717 3083974 2 3083942 3083943 3083944 3083972 3 3083838 4 3083839 5 3082796 6 3083804 7 3082790 8 3083626

2 2 2 2 1 1 1 1 1 2 1 2 1 1

Description

Ring, Piston (Std.) Ring, Piston (0.25mm/.010” O/S) Ring, Piston (0.50mm/.020” O/S) Ring, Piston (1.00mm/.040” O/S) Piston (Std.) Piston (0.25mm/.010” O/S) Piston (0.50mm/.020” O/S) Piston (1.00mm/.040” O/S) Pin, Piston Clip, Piston Pin Crank Pin 2 Spacer, Crank Pin Rod, Connecting Bearing, End, Small

Ref. Part No.

Qty.

9 10 11 12 13 14

1 1 1 1 1 1 1 1 1 AR AR

3084580 3083745 3080130 3083904 3083905 3085893 3083899 15 3083803 16 3085891 17 3084778 3085892

Description

Bearing, Ball Gear, Crankshaft (O/I) Key, Woodruff Washer Nut, Lock Asm., Crankshaft (Incl. 5-7,9,10,14-16) Crankshaft 1 Bearing, End, Large Crankshaft 2 Spacer 1 (0.2mm) Spacer 3 (0.1mm)

11/98

C10

MAGNETO Trail Blazer 250 A00BA25CA 1 2

3

4 5

7 6

8

9 15 14

10 11 13 12

20

16 19 18

17

Ref. Part No.

1 2 3 4 5 6 7 8 9

4020129 3083423 3083939 3083422 3083976 3081256 3083774 3083357 3083979 3083634 10 3081296

Qty.

1 2 1 1 1 1 2 2 1 1 1

Description

Ref. Part No.

Cap, Spark Plug Screw and Washer Flywheel w/Ring Gear Coil, Exciting Stator 1 Screw and Washer Screw and Washer Washer Asm., Plate (Incl. 2,4,5,6,9-15) Plate, Coil Clamp

11 12 13 14 15 16 17 18 19 20

3081260 3083909 3083978 3083773 3083736 3083923 3083977 3085521 3080077 3083073

Qty.

1 1 1 1 2 1 1 1 2 2

Description

Screw and Washer Coupler, 3P Harness, Wire (Incl. 12,14) Grommet Screw and Washer Ignition Coil C.D.I. System Magnetic Switch Washer, Spring Lock Nut 11/98

C11

STARTING MOTOR Trail Blazer 250 A00BA25CA 3

1 2

4 5

8 6

9 7

19 10 18 11 17

16 14 15

4

13

20

12 21

23 22

24

Ref. Part No.

1 3083649 2 3084406 3 3085392 4 5 6 7 8 9 10 11 12

3085393 3084405 3085032 3082758 3083568 3084408 3084407 3083650 3081665 3083754

Qty.

Description

1 Nut, Flange 1 Brush 1 Asm., Starting Motor (Incl. 1-5,8,9,12-18,20-24) 1 Asm., Starter (Incl. 1,2,4,5,8,9,12-17) 2 Ring, Rubber 1 Cover, Rear 1 Gasket, Aluminum 1 Bolt, Flange 2 O-Ring 2 Bolt 1 Bracket 4 Bolt and Washer 1 Washer Set

Ref. Part No.

13 14 15 16 17 18 19 20 21 22

3084404 3083934 3083777 3083741 3085305 3083737 3082038 3084409 3084410 3085394

23 3084411 24 3084412

Qty.

Description

1 1 1 1 1 1 2 1 1 1

Asm., Armature (Incl. 14,15) O-Ring Bearing, Ball O-Ring Front Cover (Incl. 16) Washer, Gear Shaft Bolt and Washer Clip Spring, Return Asm., Gear Shaft (Incl. 18,20,21,23,24) 1 Spring, Weight 1 Clip 11/98

C12

RECOIL STARTER Trail Blazer 250 A00BA25CA 1

3 4

2

5 6 7 8

17 9

16 15 12 11

14

10

13

18

28 19

27 20 21

22

23 24 25 26

Ref. Part No.

Qty.

1 3083815 2 3083924 3083911 3 3083732 4 3083731 5 3083926 6 3082228 7 3083817 8 3083814 9 3083826 10 3083914 11 3083828 2870621 12 3083660 13 3083659

1 1 1 1 1 1 4 1 1 4 1 1 AR 1 1

Description

Ref. Part No.

Spring, Spiral Recoil Starter (Incl. 1,2,7-13,20-28) Starter Case B Collar Mount, Rubber Bolt and Washer Bolt and Washer Grommet Reel Bolt, Flange Starter Case Asm., Rope (Incl. 11-13) Recoil Rope Cap, Knob Starter Knob

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

3083729 3083669 3083453 3082956 3083915 3081665 3083827 3083819 3083820 3083818 3083821 3083912 3083925 3084176 3083913

Qty.

1 1 1 1 1 3 1 1 1 1 1 1 1 4 1

Description

Bolt and Washer Bushing, Starter Plug Gasket Pulley, Starting Bolt and Washer Spring, Return Ratchet Pin, Ratchet Hook, Spring Guide, Ratchet Spring, Friction Case, Spring Screw and Washer Guide 11/98

C13

OIL PUMP Trail Blazer 250 A00BA25CA

2 1

3

1

4 5

8

7 9

6

10

11

17

16 15 14

13 12 Ref. Part No.

1 2 3 4 5 6 7 8

3083141 3084467 3083125 3083126 3085624 3083783 3083758 3085625 3085626 9 3083757

Qty.

2 1 1 1 1 2 1 1 1 1

Description

Ref. Part No.

Clamp, Hose Pipe, Vinyl Screw, Air Vent Packing Asm., Oil Pump (Incl. 3,4,7-12) Screw and Washer Cap Lever & Spring Set Lever, Control Collar, Camshaft

10 11 12 13 14 15 16 17

3083121 3083120 3083127 3083671 3083672 3083673 3083353 3083129 3083429 3083428

Qty.

1 1 1 AR AR AR 1 1 1 1

Description

Washer, Spring Nut O-Ring Spacer 1 (.15mm) Spacer 2 (.3mm) Spacer 3 (.6mm) Bushing, Oil Pump O-Ring Gear, Small Spacer 11/98

C14

CARBURETOR Trail Blazer A00BA25CA 1

2

3 30

4

7

5

8 9

6 29

10 11

28

12 13

27 15 24

26 25

14

23 22 21 20

16

19 18 17 Ref. Part No.

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

3130060 3130354 3130002 3130356 3130355 3130420 3130359 3130006 3130328 3130012 3130011 3130010 3130324 3130067 3130014

Qty. Description

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Cap Spring, Throttle Plate, Throttle Needle, Jet (5DP7-2) Washer Valve, Throttle (2.0) Cap, Plunger Spring, Plunger Plunger, Starter Spring, Air Adjuster Screw, Air Spring, Throttle Adjuster Screw, Throttle Stop Jet, Pilot (#40) Washer, Jet, Main

Ref. Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

3130025 3130321 3130239 3130662 3130441 3130021 3130237 3130020 3130360 3130018 3130361 3130017 3130661 3130409 3130003

Qty. Description

4 1 1 1 1 2 2 1 1 1 1 1 1 1 1

Screw and Washer Bolt, Banjo O-Ring Jet, Main (#130) Float Chamber Float Cap Packing, Float Chamber Valve, Needle (2.5) Arm, Float Pin, Float Packing, Needle Valve Asm., Carburetor (Incl. 1-30) Jet, Needle (0-4) E-Ring 11/98

D1

TOOL KIT Trail Blazer A00BA25CA

1

2 3 8

4 5

6

7

Ref. Part No.

1 2 3 4 5

2690124 3083612 3083613 3083843 2870725

Qty. Description

1 1 1 1 1

Ref. Part No.

Pouch, Tool Kit Wrench, Box, Special Wrench, 10-12 Spanner Screwdriver Gauge, Tire Pressure

6 2870694 7 2871095-067 8 9915299 9915467

Qty. Description

1 1 1 1

Asm., Tool Kit (Incl. 1-5) Wrench, Spanner Manual, Owners, ’00 ATV Supplement, Manual, Owners, ’00 Trail Blazer 250 11/98

D2

PART NUMBER INDEX Trail Blazer 250 A00BA25CA Part No.

Ref. No.

1012772-067 . . . . 4 . .

1012773-067 . . . . 7 . .

1012810-067 . . . 14 . .

1012844-067 . . . 10 .

1012886-067 . . . 10 . .

1012997-067 . . . 26 . .

1040412-067 . . . . 2 . .

1040687-067 . . . 16 . .

1240049 . . . . . . . 22 .

1260740-029 . . . 10 .

1260910-029 . . . 12 .

1260922-029 . . . . 6 .

1321457 . . . . . . . . 6 . .

1321635 . . . . . . . 16 . .

1322180 . . . . . . . . 4 .

1341274 . . . . . . . . . . . . .

1520175-133 . . . . 7 . .

1520183-133 . . . 11 . .

1520258 . . . . . . . 23 . .

1520259 . . . . . . . . 8 . .

1525017 . . . . . . . . 8 . .

9...

1541383 . . . . . . . . 9 .

1820566 . . . . . . . . 9 . .

1843077 . . . . . . . . 1 . .

1910264 . . . . . . . . . . . . .

1910265 . . . . . . . 10 . .

1910271 . . . . . . . . . . . . .

1910314 . . . . . . . 12 .

1910332 . . . . . . . . 4 .

1910336 . . . . . . . 15 . .

1910367 . . . . . . . . 2 .

1930642 . . . . . . . . . . . . .

1930665 . . . . . . . . 8 . .

1930674 . . . . . . . . 8 .

1930752 . . . . . . . 20 . .

1930753 . . . . . . . 23 . .

1930792 . . . . . . . 13 . .

1930795 . . . . . . . . 5 . .

1930796 . . . . . . . . 4 . .

1930797 . . . . . . . . 3 . .

1930799 . . . . . . . . 7 . .

1930804 . . . . . . . . 8 . .

1930805 . . . . . . . 14 . .

1930806 . . . . . . . 11 . .

1930854 . . . . . . . . 2 .

1930872 . . . . . . . . 5 .

1930873 . . . . . . . 17 . .

4..

1930899 . . . . . . . 18 .

2010178 . . . . . . . . 3 . .

2010191 . . . . . . . . 4 . .

2050073 . . . . . . . . 1 . .

2200361 . . . . . . . 15 . .

2200465 . . . . . . . . 9 . .

2200560 . . . . . . . 22 . .

Grid No.

Part No.

A5 A7 C5 B14 C8 A5 A6 A9 A12 A10 A10 A10 B9 B9 B10 C7 B2 C1 C2 C2 B2 C1 B12 B4 B6 B3 B3 B3 B14 B14 B8 B13 B3 B3 B13 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B14 B13 B8 B13 B14 B7 B7 B8 C3 B3 B4

2200561 2200593 2200774 2200808 2200809 2200901 2201034 2201090 2201149 2201189 2201402 2432038 2460777 2460778 2530009

Ref. No.

Grid No.

. . . . . . . 22 . . ........ 3 .. ........ 7 .. ........ 6 .. ........ 1 .. ........ 9 .. ........ 9 .. . . . . . . . 12 . . ........ 9 .. . . . . . . . 17 . . . . . . . . 27 . . ........ 4 .. ........ 7 .. ........ 1 .. . . . . . . . 36 . .

12 . .

2631988-133 . . . 16 . .

2670133 . . . . . . . 20 . .

2670134 . . . . . . . . 3 . .

2681769-053 . . . . 4 . .

2682430-053 . . . . 4 . .

2690124 . . . . . . . . 1 . .

2870621 . . . . . . . 11 .

2870694 . . . . . . . . 6 . .

2870725 . . . . . . . . 5 . .

2871095-067 . . . . 7 . .

3070156 . . . . . . . 12 . .

3080006 . . . . . . . 17 . .

3080077 . . . . . . . 19 .

3080103 . . . . . . . 18 . .

3080130 . . . . . . . 11 .

3080283 . . . . . . . 35 . .

3080285 . . . . . . . 38 . .

3080530 . . . . . . . 37 . .

3080739 . . . . . . . 25 . .

3080746 . . . . . . . 16 . .

3081256 . . . . . . . . 6 .

3081260 . . . . . . . 11 .

3081296 . . . . . . . 10 .

3081497 . . . . . . . 15 . .

3081635 . . . . . . . 26 . .

3081665 . . . . . . . 11 .

19 . .

3082038 . . . . . . . 19 .

3082096 . . . . . . . 29 . .

3082228 . . . . . . . . 6 .

3082257 . . . . . . . 14 . .

3082758 . . . . . . . 21 . .

6..

3082790 . . . . . . . . 7 .

3082796 . . . . . . . . 5 .

3082910 . . . . . . . . 2 . .

3082911 . . . . . . . 32 . .

3082956 . . . . . . . 17 .

3083073 . . . . . . . 20 .

3083120 . . . . . . . 11 .

D3

B4 C3 B5 B8 B8 B3 B8 B8 B3 B13 C4 C3 A8 C3 A9 A14 A5 A6 A7 A6 A6 D2 C13 D2 D2 D2 A9 C9 C11 C9 C10 C9 C9 C9 C9 C9 C11 C11 C11 C9 C9 C12 C13 C12 C9 C13 C9 C9 C12 C10 C10 C9 C9 C13 C11 C14

Part No.

3083121 3083125 3083126 3083127 3083129 3083141 3083337 3083353 3083357 3083422 3083423 3083428 3083429 3083453 3083546 3083568 3083612 3083613 3083615 3083626 3083634 3083649 3083650 3083659 3083660 3083669 3083671 3083672 3083673 3083678 3083717 3083729 3083730 3083731 3083732 3083736 3083737 3083741 3083745 3083754 3083757 3083758 3083767 3083773 3083774 3083777 3083783 3083803 3083804 3083814 3083815 3083817 3083818 3083819 3083820

Ref. No.

. . . . . . . 10 . ........ 3 . ........ 4 . . . . . . . . 12 . . . . . . . . 15 . ........ 1 . . . . . . . . 30 . . . . . . . . . 14 . ........ 8 . ........ 4 . ........ 2 . . . . . . . . 17 . . . . . . . . 16 . . . . . . . . 16 . ........ 1 . ........ 7 . ........ 2 .. ........ 3 .. . . . . . . . 28 . . ........ 8 . ........ 9 . ........ 1 . . . . . . . . 10 . . . . . . . . 13 . . . . . . . . 12 . . . . . . . . 15 . . . . . . . . 13 . . . . . . . . 13 . . . . . . . . 13 . ........ 1 . ........ 1 . . . . . . . . 14 . ........ 5 .. ........ 6 ..

4.. ........ 7 ..

3.. . . . . . . . 15 . . . . . . . . 18 . . . . . . . . 16 . . . . . . . . 10 . . . . . . . . 12 . ........ 9 . ........ 7 . . . . . . . . 22 . . . . . . . . . 14 . ........ 7 . . . . . . . . 15 . ........ 6 . . . . . . . . 15 . ........ 6 . ........ 8 . ........ 1 . ........ 7 . . . . . . . . 23 . . . . . . . . 21 . . . . . . . . 22 .

Grid No.

C14 C14 C14 C14 C14 C14 C9 C14 C11 C11 C11 C14 C14 C13 C10 C12 D2 D2 C9 C10 C11 C12 C12 C13 C13 C13 C14 C14 C14 C10 C10 C13 C9 C9 C13 C9 C13 C11 C12 C12 C10 C12 C14 C14 C9 C11 C11 C12 C14 C10 C10 C13 C13 C13 C13 C13 C13

PART NUMBER INDEX Trail Blazer 250 A00BA25CA Part No.

3083821 3083826 3083827 3083828 3083838 3083839 3083843 3083899 3083904 3083905 3083909 3083911 3083912 3083913 3083914 3083915 3083923 3083924 3083925 3083926 3083929 3083930 3083931 3083932 3083934 3083939 3083942 3083943 3083944 3083972 3083974 3083976 3083977 3083978 3083979 3084015 3084016 3084017 3084018 3084176 3084292 3084404 3084405 3084406 3084407 3084408 3084409 3084410 3084411 3084412 3084467 3084580

Ref. No.

. . . . . . . 24 . ........ 9 . . . . . . . . 20 . . . . . . . . 11 . ........ 3 . ........ 4 . ........ 4 .. . . . . . . . 14 . . . . . . . . 12 . . . . . . . . 13 . . . . . . . . 12 . ........ 2 . . . . . . . . 25 . . . . . . . . 28 . . . . . . . . 10 . . . . . . . . 18 . . . . . . . . 16 . ........ 2 . . . . . . . . 26 . ........ 5 . ........ 4 .. . . . . . . . 10 . . ........ 1 .. ........ 3 .. . . . . . . . 14 . ........ 3 . ........ 2 . ........ 2 . ........ 2 . ........ 2 . ........ 1 . ........ 5 . . . . . . . . 17 . . . . . . . . 13 . ........ 9 . ........ 9 .. . . . . . . . 31 . . . . . . . . . 36 . . . . . . . . . 20 . . . . . . . . . 27 . . . . . . . . 11 . . . . . . . . . 13 . ........ 4 . ........ 2 . ........ 9 . ........ 8 . . . . . . . . 20 . . . . . . . . 21 . . . . . . . . 23 . . . . . . . . 24 . ........ 2 . . . . . . . . 24 . .

9..

3084581 . . . . . . . 27 . .

3084717 . . . . . . . 28 . .

3084778 . . . . . . . 17 .

Grid No.

Part No.

Ref. No.

C13 C13 C13 C13 C10 C10 D2 C10 C10 C10 C11 C13 C13 C13 C13 C13 C11 C13 C13 C13 C9 C9 C9 C9 C12 C11 C10 C10 C10 C10 C10 C11 C11 C11 C11 C9 C9 C9 C9 C13 C9 C12 C12 C12 C12 C12 C12 C12 C12 C12 C14 C9 C10 C9 A9 C10

3085013 . . . . . . . 12 3085032 . . . . . . . . 5 3085305 . . . . . . . 17 3085326 . . . . . . . 34 3085392 . . . . . . . . 3 3085393 . . . . . . . . 3 3085394 . . . . . . . 22 3085521 . . . . . . . 18 3085541 . . . . . . . 33 3085624 . . . . . . . . 5 3085625 . . . . . . . . 8 3085626 . . . . . . . . 8 3085889 . . . . . . . 19 3085890 . . . . . . . 23 3085891 . . . . . . . 16 3085892 . . . . . . . 17 3085893 . . . . . . . 14 3086108 . . . . . . . . 8 3086786 . . . . . . . 13 3110026 . . . . . . . . 3 3110028 . . . . . . . 35 3130002 . . . . . . . . 3 3130003 . . . . . . . 30 3130006 . . . . . . . . 8 3130010 . . . . . . . 12 3130011 . . . . . . . 11 3130012 . . . . . . . 10 3130014 . . . . . . . 15 3130017 . . . . . . . 27 3130018 . . . . . . . 25 3130020 . . . . . . . 23 3130021 . . . . . . . 21 3130025 . . . . . . . 16 3130060 . . . . . . . . 1 3130067 . . . . . . . 14 3130237 . . . . . . . 22 3130239 . . . . . . . 18 3130321 . . . . . . . 17 3130324 . . . . . . . 13 3130328 . . . . . . . . 9 3130354 . . . . . . . . 2 3130355 . . . . . . . . 5 3130356 . . . . . . . . 4 3130359 . . . . . . . . 7 3130360 . . . . . . . 24 3130361 . . . . . . . 26 3130409 . . . . . . . 29 3130420 . . . . . . . . 6 3130441 . . . . . . . 20 3130661 . . . . . . . 28 3130662 . . . . . . . 19 3211077 . . . . . . . . 3 3221043 . . . . . . . 18 3222065 . . . . . . . 22 3224056-078 . . . 19 3225026 . . . . . . . 17

D4

Grid No.

.. . . .. . . . . .. . . . .. .. . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. ..

C9 C12 C12 C9 C12 C12 C12 C11 C9 C14 C14 C14 C9 C9 C10 C10 C10 C9 C9 A9 A9 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 B10 C8 C2 C2 C2

Part No.

3233010 3233018 3233019 3233035 3233040 3233045 3233054 3233055 3233105 3233106 3233111 3233153 3233177 3233248 3233252 3233324 3233478 3233524 3233527 3233529 3233548 3233616 3233635 3233636 3233673 3233674 3233675 3233676 3233677 3233678 3233679 3233680 3233681 3233682 3233683 3233684 3233685 3233686 3233687 3233688 3233689 3233690 3513519 3554517 3554518 3576504 3576510 3576511 3610020 3610070 4010064 4010094 4010095 4010129 4010132 4010140

Ref. No.

........ 5 .. ........ 1 .. . . . . . . . 12 . . . . . . . . . 38 . . . . . . . . . 17 . . . . . . . . . 16 . . . . . . . . . 14 . . . . . . . . . 13 . . . . . . . . . 10 . . . . . . . . . 11 . . . . . . . . . 39 . . . . . . . . . 15 . . ........ 2 .. . . . . . . . 26 . . . . . . . . . 35 . . . . . . . . . 24 . . . . . . . . . 27 . . . . . . . . . 28 . . . . . . . . . 37 . . . . . . . . . 30 . . . . . . . . . 18 . . . . . . . . . 21 . . . . . . . . . 20 . . . . . . . . . 34 . . ........ 3 .. ........ 4 .. ........ 6 .. ........ 7 .. ........ 8 .. ........ 9 .. . . . . . . . 19 . . . . . . . . . 22 . . . . . . . . . 23 . . . . . . . . . 25 . . . . . . . . . 29 . . . . . . . . . 31 . . . . . . . . . 32 . . . . . . . . . 33 . . . . . . . . . 36 . . . . . . . . . 40 . . . . . . . . . 41 . . . . . . . . . 42 . . ........ 3 .. . . . . . . . 14 . . . . . . . . . 13 . . . . . . . . . 13 . .

10 . . ........ 3 .. . . . . . . . 11 . ........ 2 .. . . . . . . . 12 . . . . . . . . . 22 . . . . . . . . . 21 . . . . . . . . . 16 . . . . . . . . . 13 . . . . . . . . . 11 . . ........ 1 ..

Grid No.

C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 C7 B2 C2 C2 B9 B10 B9 B10 B2 C2 C3 C3 C3 A9 A9 A8

PART NUMBER INDEX Trail Blazer 250 A00BA25CA Part No.

4010186 4010206 4020129 4020139 4020149 4030043 4030056 4032085 4032086 4032087 4032093 4032094 4040054 4060208 4110141 4110148 4110164 4110248 4110264 4110265 4140006 5010256 5010266 5010368 5010462 5020677 5020681 5020795 5020927 5020955 5130940 5131039 5131040 5131115 5131116 5131446 5131695 5131696 5131697 5131759 5131777 5131786 5131787 5131968 5131976 5132021 5132022 5132062 5132098 5132294 5210748 5210752

Ref. No.

. . . . . . . 27 . . . . . . . . . 11 . . ........ 1 . ........ 6 . ........ 5 .. ........ 7 .. ........ 9 .. ........ 6 .. ........ 8 .. ........ 9 .. ........ 6 .. . . . . . . . 12 . . ........ 2 .. . . . . . . . 25 . . ........ 4 .. ........ 4 .. . . . . . . . 16 . . . . . . . . . 10 . . ........ 4 .. ........ 6 . . . . . . . . 20 . . ........ 9 .. ........ 1 . ........ 1 . . . . . . . . 10 . . . . . . . . . 19 . . . . . . . . . 23 . . . . . . . . . 14 . . ........ 6 .. . . . . . . . 10 . . ........ 5 .. . . . . . . . 16 . . . . . . . . . 16 . . ........ 3 .. ........ 3 .. . . . . . . . 13 . . . . . . . . 20 . ........ 8 . ........ 7 . ........ 9 . ........ 2 .. . . . . . . . 13 . . . . . . . . 14 . . . . . . . . 18 . . ........ 5 .. ........ 9 . ........ 4 . ........ 6 .. . . . . . . . 15 . . ........ 6 .. . . . . . . . 19 . . ........ 9 ..

14 . .

5210753 . . . . . . . . 9 . .

5210754 . . . . . . . . 9 . .

5210764 . . . . . . . . 9 . .

Grid No.

Part No.

Ref. No.

C3 A5 C11 B13 A5 C3 A5 C3 C3 C3 A5 A5 A8 C3 A8 A8 B8 B5 A8 A14 C3 B2 B10 A10 C2 B4 B4 B9 B4 C5 B2 B1 B1 B3 B3 B10 B12 B12 B12 B13 C1 B13 B13 C2 C5 B11 B11 B1 C2 B3 A9 B9 B10 B9 B9 C8

5211033 . . . . . . . . 8 . .

5211065 . . . . . . . . 9 . .

5211115 . . . . . . . 17 . .

5211131-067 . . . . 23 . .

26 . . .

5211329-067 . . . . 1 . .

5211517 . . . . . . . . 9 . .

5211585-067 . . . 20 . .

5211849 . . . . . . . . 6 . .

5211869 . . . . . . . . 4 . .

5220646 . . . . . . . . 5 .

5220880 . . . . . . . 27 . .

5220916-067 . . . . 9 .

5220946 . . . . . . . . 6 . .

5220980 . . . . . . . 21 .

5222877-067 . . . 33 . .

5222999-067 . . . 15 . .

5224708 . . . . . . . . 3 .

5224718-067 . . . . 2 . .

5240717 . . . . . . . 13 . .

5241147 . . . . . . . . 5 .

5241403-067 . . . 18 . .

5241436-067 . . . . 8 . .

5242208-067 . . . 38 . .

5242291-067 . . . 16 .

5242456-067 . . . . 3 . .

5242525-067 . . . 31 . .

5242693-067 . . . 29 . .

5242896-067 . . . 27 . .

5242897-067 . . . 34 . .

5242898-067 . . . . 9 . .

5242981 . . . . . . . . 9 . .

5242988-067 . . . . 2 . .

5243066 . . . . . . . 15 .

5243116-067 . . . . 5 .

5243175-067 . . . . 5 . .

5243220-067 . . . 20 .

5243296-067 . . . 11 . .

5243306 . . . . . . . 12 . .

5243364 . . . . . . . . 7 . .

5243416-067 . . . . 6 . .

5332828 . . . . . . . 13 .

5333048 . . . . . . . . 4 . .

5333367 . . . . . . . . 2 . .

5410193 . . . . . . . . 6 . .

5410346 . . . . . . . 14 . .

5410414 . . . . . . . . 7 . .

5410421 . . . . . . . 24 . .

13 . . .

5410424 . . . . . . . 18 . .

5410470 . . . . . . . 14 . .

5410494 . . . . . . . 12 . .

5410495 . . . . . . . 11 . .

5410506 . . . . . . . . 5 .

5410509 . . . . . . . 21 . .

5410510 . . . . . . . 19 .

D5

Grid No.

A6 C8 B1 A5 A6 A7 C8 C2 C2 B2 B10 A6 A12 B5 A13 C4 B6 A13 A5 B4 B11 A6 A5 C4 B13 C8 A5 C4 A9 A9 A9 B9 B5 B14 A10 C8 B14 C8 C8 B1 C8 B12 C8 B4 B7 A9 A6 A9 C4 C3 B2 B3 B3 A13 C4 A13

Part No.

5410529 5410548 5410549 5410609 5410610 5410749 5410772 5410779 5410780 5410842 5410889 5410988 5411006 5411007 5411008 5411058 5411164 5411264 5411266 5411291 5411392 5411439 5411553 5411555 5411580 5411608 5430261 5430725 5430766 5430768 5430779 5430802 5430806 5430807 5430884 5430945 5430967 5431018 5431021 5431030 5431053 5431107 5431391 5431484 5431570 5431571 5431572 5431573 5431574 5431596 5431769 5431793 5431794 5431961 5431975 5431976 5431986

Ref. No.

. . . . . . . 11 . . . . . . . 15 . . . . . . . 10 . . . . . . . 15 ........ 7 . . . . . . . 32 ........ 5 ........ 4 ........ 5 ........ 3 . . . . . . . 11 ........ 3 ........ 1 ........ 3 ........ 4 ........ 2 ........ 7 ........ 6 . . . . . . . 12 ........ 3 ........ 3 ........ 2 ........ 1 ........ 4 . . . . . . . 15 ........ 9 . . . . . . . 20 ........ 1 . . . . . . . 17 ........ 8 ........ 1 ........ 4 ........ 4 ........ 5 . . . . . . . 20 ........ 5 ........ 3 . . . . . . . 13 . . . . . . . 14 . . . . . . . 11 ........ 5 ........ 9 . . . . . . . 16 . . . . . . . 28 . . . . . . . 10 ........ 7 . . . . . . . 14 ........ 2 . . . . . . . 12 . . . . . . . 18 . . . . . . . 14 ........ 3 . . . . . . . 22 ........ 5 ........ 8 ........ 5 ........ 5

Grid No.

. .. . .. .. .. .. .. .. . .. . .. .. .. . .. .. .. .. .. .. .. .. . .. .. . . .. . .. .. .. . .. .. .. . .. . . . .. .. .. .. .. .. .. .. . .. .. .. .. ..

A13 B4 A13 B9 B9 C4 B6 B3 B3 A12 C2 B13 C5 C5 C5 A10 C1 B2 C1 B4 A6 B7 C4 C2 A13 B1 A9 A12 B10 B9 A14 A9 B1 B1 A13 B9 A8 B2 A12 B5 A12 B14 A12 A5 B6 B6 B6 B6 B6 B4 C3 A14 C4 C4 A8 A8 A6

PART NUMBER INDEX Trail Blazer 250 A00BA25CA Part No.

Ref. No.

5432077 . . . . . . . 19 5432178 . . . . . . . . 4 5432179-053 . . . 14 5432278-070 . . . 14 5432291 . . . . . . . 17 5432302 . . . . . . . 15 5432636 . . . . . . . 19 5432637 . . . . . . . . 6 5432721 . . . . . . . . 1 5432727 . . . . . . . . 2 5432763 . . . . . . . 30 5432820-133 . . . 12 5432831 . . . . . . . 21 5432854 . . . . . . . 11 5432926 . . . . . . . . 9 5432952 . . . . . . . 12 5433103 . . . . . . . . 6 5433174 . . . . . . . . 9 5433207 . . . . . . . 43 5433212 . . . . . . . 10 5433213 . . . . . . . . 2 5433258 . . . . . . . 20 5433323 . . . . . . . 31 5510313 . . . . . . . . 2 5521301 . . . . . . . . 4 5630514 . . . . . . . 10 5630586 . . . . . . . 21 5630616-067 . . . . 7 5630921 . . . . . . . . 8 5810141 . . . . . . . . 2 5810144 . . . . . . . . 2 5810290 . . . . . . . 13 5810291 . . . . . . . . 3 5810310 . . . . . . . 16 5810379 . . . . . . . . 4 5810444 . . . . . . . . 2 5810467 . . . . . . . . 4 5810859 . . . . . . . 20 5810957 . . . . . . . 22 5810991 . . . . . . . 22 5811102 . . . . . . . . 1 5811230 . . . . . . . 14 5811373 . . . . . . . 19 5811527 . . . . . . . 23 5811771 . . . . . . . 24 5850125 . . . . . . . . 6 5850147 . . . . . . . 25 5850148 . . . . . . . 25 5850150 . . . . . . . 24 5910026 . . . . . . . . 7 7010032 . . . . . . . 17 7041157 . . . . . . . . 4 7041198 . . . . . . . 12 7041209 . . . . . . . 15 7041607 . . . . . . . . 1 7041761 . . . . . . . 10

.. . .. .. . .. . . .. . .. .. .. . .. .. .. . .. . . .. .. .. .. .. .. .. . . . .. .. . .. . .. . .. .. . .. .. . .. .. .. .. .. .. .. .. . . .. ..

Grid No.

Part No.

Ref. No.

C3 A13 A5 A6 A12 C4 B12 B12 B7 B12 A5 A6 A6 B12 B5 B5 C5 A13 C7 B11 B11 C4 C4 C2 C4 B9 C2 B5 B11 A14 A12 C3 B1 A13 B5 A13 A7 A12 A6 A6 A13 A6 C4 A12 A5 A7 A6 A6 A5 B3 C3 B9 B10 A12 A6 B1

7041769 . . . . . . . . 6 .

7041773 . . . . . . . . 7 .

7041778-067 . . . . 6 .

7041850-067 . . . . 8 . .

7042029 . . . . . . . . 9 .

7042031 . . . . . . . 11 .

7051006 . . . . . . . 20 .

7051011 . . . . . . . 31 . .

7052005 . . . . . . . 32 . .

7052077 . . . . . . . . 4 .

7052153 . . . . . . . . 8 .

7052194 . . . . . . . 24 . .

7061013 . . . . . . . 12 . .

7061014 . . . . . . . . 8 . .

7061033 . . . . . . . . 8 . .

7061034 . . . . . . . . 4 . .

7072786 . . . . . . . . 1 .

7072791 . . . . . . . 11 . .

7073761 . . . . . . . 10 . .

7074637 . . . . . . . 11 .

7074782 . . . . . . . 10 . .

7074946 . . . . . . . . 8 . .

7075725 . . . . . . . 13 .

7075741 . . . . . . . 29 . .

7076202 . . . . . . . . 8 .

7076274 . . . . . . . . 9 .

7077377 . . . . . . . . 9 . .

7077618 . . . . . . . 10 .

7077787 . . . . . . . 11 .

7077788 . . . . . . . . 5 .

7077789 . . . . . . . . 2 .

7077790 . . . . . . . . 6 .

7077791 . . . . . . . . 4 .

7077919 . . . . . . . 14 .

7077920 . . . . . . . 12 .

7078253 . . . . . . . 10 .

7078315 . . . . . . . . 7 .

7078354 . . . . . . . . 3 .

7080003 . . . . . . . 37 . .

13 . .

3..

7080138 . . . . . . . 14 . .

2...

7080140 . . . . . . . 14 .

7080303 . . . . . . . 19 . .

7080306 . . . . . . . 14 . .

16 . . .

7080307 . . . . . . . 11 .

7080352 . . . . . . . . 1 . .

7080369 . . . . . . . 18 .

7080371 . . . . . . . . 9 . .

7080413 . . . . . . . 13 .

7080433 . . . . . . . 20 . .

13 . . .

7080492 . . . . . . . 21 . .

12 . . .

D6

Grid No.

B14 B11 B11 B1 A10 A10 A12 A9 A9 A14 A14 B8 C5 C5 B4 B4 A11 A6 A6 A12 C4 C4 A11 A9 A11 A11 C4 B12 A11 A11 A11 A11 A11 A11 A11 A11 A11 A11 A9 A14 B14 B5 C3 A13 C3 B1 C2 A14 B3 A13 A8 A13 B4 B6 B8 C4

Part No.

Ref. No.

7080510 . . . . . . . . 3 . .

3..

7080511 . . . . . . . 23 . .

16 . . .

7080539 . . . . . . . 18 . .

7080568 . . . . . . . . 9 .

7080573 . . . . . . . 11 . .

7080631 . . . . . . . 16 . .

7080644 . . . . . . . 13 .

7080673 . . . . . . . 16 . .

7080803 . . . . . . . . 5 . .

7511840 . . . . . . . 13 .

7511854 . . . . . . . 16 .

7511886 . . . . . . . 13 . .

7511887 . . . . . . . 15 . .

7512007 . . . . . . . 24 . .

7512018 . . . . . . . 18 . .

7512024 . . . . . . . 22 . .

26 . . .

2...

7512026 . . . . . . . . 6 . .

7512027 . . . . . . . 12 . .

7512084 . . . . . . . 10 . .

23 . . .

7512088 . . . . . . . . 5 . .

7512093 . . . . . . . . 7 . .

7512094 . . . . . . . 11 . .

7512098 . . . . . . . 35 . .

7512176 . . . . . . . . 1 . .

7512208 . . . . . . . . 8 .

19 . .

7512232 . . . . . . . 29 . .

10 . . .

4..

36 . . .

44 . . .

7512242 . . . . . . . 30 . .

7512246 . . . . . . . . 6 .

7512247 . . . . . . . . 1 .

7512266 . . . . . . . 11 . .

7512275 . . . . . . . 12 .

7512282 . . . . . . . 25 . .

23 . . .

7512284 . . . . . . . 14 . .

7512310 . . . . . . . . 6 .

7512312 . . . . . . . 12 .

7512325 . . . . . . . 17 . .

15 . .

7512329 . . . . . . . . 2 . .

7512457 . . . . . . . 15 . .

7512490 . . . . . . . 26 . .

7512492 . . . . . . . 24 . .

7...

7512566 . . . . . . . 17 . .

7512576 . . . . . . . 18 .

7512673 . . . . . . . . 1 . .

7515133 . . . . . . . 13 . .

Grid No.

B6 B12 A9 C4 B8 A14 B1 B5 B14 B4 B7 A12 B10 A5 A5 C3 C4 B8 C3 C5 A8 C3 A5 C4 C3 C4 C4 C4 B9 A12 B14 A6 A9 A10 C4 C7 A6 A13 B14 B9 A13 A5 A6 B4 A12 B13 B2 B13 A7 A9 A9 B4 C8 A9 B12 C1 C5

PART NUMBER INDEX Trail Blazer 250 A00BA25CA Part No.

7515136 7515179 7515189 7515194 7515304 7515321 7515339 7515382 7515394 7515399 7515415 7515438 7515489 7515513 7515523 7515540 7517231 7517264 7517386 7517395 7517445 7517527 7517542 7517625 7517631 7517632 7517646 7517647 7522026 7541906 7541925 7542122

7542127 7542129 7542303 7542321 7542324

7542403 7542411 7542423 7542438 7542439 7542440 7542459

Ref. No.

. . . . . . . 19 . . . . . . . . 29 . . ........ 3 .. . . . . . . . 14 . . . . . . . . . 12 . ........ 6 ..

4... . . . . . . . 15 . . ........ 7 . ........ 3 . ........ 8 .. ........ 3 . . . . . . . . 11 . ........ 2 .. ........ 7 .. . . . . . . . 16 . . . . . . . . . 24 . . ........ 1 . . . . . . . . 33 . .

15 . . . ........ 1 .. ........ 5 .. . . . . . . . 13 . . . . . . . . . 26 . . ........ 3 .. . . . . . . . 13 . . . . . . . . . 14 . . ........ 1 .. . . . . . . . 13 . . . . . . . . . 19 . . . . . . . . . 18 . . . . . . . . . 12 . . . . . . . . . 23 . . . . . . . . . 22 . .

17 . . .

15 . . .

17 . . . . . . . . . 22 . . . . . . . . 14 . . . . . . . . 12 . . . . . . . . . 15 . . . . . . . . 14 .

10 . .

16 . . . ........ 1 .. ........ 8 .. ........ 2 .. . . . . . . . 21 . . ........ 1 .

5... . . . . . . . 15 . . . . . . . . . 38 . .

15 . . .

Grid No.

Part No.

A12 A5 B5 C4 B12 A9 B6 B1 B10 A10 A7 B11 B11 B3 C2 B2 C2 B13 A5 A6 A5 B5 B3 B4 C4 B5 C8 C8 C8 C8 A5 B9 C3 A5 A6 B5 B14 A13 B14 B1 B12 A10 A12 B6 B4 A9 C8 B4 B11 C2 C8 A9 B2

7542503 7542711 7542712 7542714 7543005 7543203 7546701 7546702 7546707 7546904 7547028 7547031 7547071 7547076 7547082 7547104 7547108 7552603 7552801 7552901

7555716 7555721 7555726 7555734 7555745 7555748 7555749 7555783 7555796 7555806

7555823 7555859 7555878 7555883 7555898 7555919 7555932 7555935 7556035 7556076 7556091 7556401 7556804 7558201 7558301

Ref. No.

Grid No.

. . . . . . . 16 . ........ 5 .. . . . . . . . 11 . . ........ 3 .. ........ 5 .. ........ 9 .. ........ 9 .. . . . . . . . 11 . . ........ 7 .. . . . . . . . 11 . . ........ 7 .. ........ 3 .. ........ 5 .. . . . . . . . 39 . . ........ 4 . ........ 1 .. ........ 1 .. . . . . . . . 25 . .

25 . . . ........ 2 .. ........ 7 ..

6..

11 . . . . . . . . . 13 . . . . . . . . 10 . . . . . . . . . 18 . ........ 7 . ........ 8 .. ........ 2 .. ........ 2 .. . . . . . . . 17 . . ........ 4 .. ........ 2 ..

10 . . .

8... ........ 5 .. . . . . . . . 21 . .

16 . . . ........ 6 .. . . . . . . . 17 . ........ 8 . ........ 7 . . . . . . . . 15 .

28 . . . . . . . . . . 30 . . ........ 5 . ........ 8 . . . . . . . . 24 . . ........ 2 . ........ 9 . . . . . . . . 20 . . . . . . . . . 17 . .

26 . . .

D7

B12 B4 B2 C1 C1 B6 C5 C5 C5 B4 B4 C2 A7 C4 B12 B1 A9 A9 B4 B9 A9 B10 B13 A10 B2 A12 A12 C1 C4 B1 C4 C1 A9 B4 C8 A9 A5 A6 B6 B12 B10 B14 A14 C4 C4 B12 B10 C4 B10 B10 A5 A5 C4

Part No.

Ref. No.

7558301 . . . . . . . 45 . .

7558302 . . . . . . . . 7 .

7558402 . . . . . . . 13 . .

14 . .

10 . .

7571602 . . . . . . . 11 . .

7575202 . . . . . . . 18 . .

7621403 . . . . . . . . 9 . .

7621460 . . . . . . . . 7 .

7621462 . . . . . . . 19 . .

7621471 . . . . . . . 19 . .

7621472 . . . . . . . 32 . .

28 . . .

7621479 . . . . . . . . 6 . .

7661011 . . . . . . . . 5 .

7661046 . . . . . . . . 1 .

7661203 . . . . . . . 12 . .

7661401 . . . . . . . . 8 .

7661404 . . . . . . . . 6 . .

7661407 . . . . . . . 12 . .

7661632 . . . . . . . 11 . .

7661633 . . . . . . . . 8 . .

7661638 . . . . . . . 19 . .

37 . . .

7661825 . . . . . . . 27 . .

7661843 . . . . . . . 11 .

7670051 . . . . . . . . 6 . .

7670057 . . . . . . . 13 . .

7670060 . . . . . . . . 3 . .

8..

7670080 . . . . . . . 17 .

7670081 . . . . . . . 10 . .

7670088 . . . . . . . . 9 . .

7670093 . . . . . . . 10 . .

7670095 . . . . . . . . 7 . .

7670102 . . . . . . . . 7 .

7670109 . . . . . . . 28 . .

7670116 . . . . . . . 25 . .

7710405 . . . . . . . . 9 . .

7710434 . . . . . . . 17 . .

7710448 . . . . . . . 15 .

7710472 . . . . . . . . 1 . .

8360009-600 . . . 33 . .

4..

5..

8360012 . . . . . . . 16 .

8360026 . . . . . . . 21 .

8450003-1525 . . 10 .

8450040-600 . . . 30 . .

14 . .

9915299 . . . . . . . . 8 . .

9915467 . . . . . . . . 8 . .

Grid No.

C7 A13 B1 B12 B13 C3 A9 A6 A14 B8 A5 A5 A6 A6 B14 B12 B4 B14 C1 B2 B6 B6 A6 C4 A5 B14 C4 A6 A5 A13 A13 C1 A7 C3 A5 B13 C3 C4 C2 C8 B10 C2 A9 A12 A14 B14 A12 A14 A9 A14 D2 D2