POLARIS Manual PDF

TRAIL BLAZER 250
Model #A00BA25CA
Rev. 02
E 2000 Polaris Sales Inc.
PARTS MANUAL PN 9915482 and MICROFICHE PN 9916574 3/00
TABLE OF CONTENTS
Trail Blazer 250 A00BA25CA
Parts Manual
A-ARM/STRUT MOUNTING . . . . . . . . . . . . . B4
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
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
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . B9
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . B10
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C3
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A9
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A10
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER and SHIELDS . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
B3
A7
A5
B2
A12
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C5
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C6-7
GEARCASE MOUNTING . . . . . . . . . . . . . . . C8
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B5
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . C11
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C14

OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . A14
REAR BRAKE MASTER CYLINDER . . . . . . .

REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . .
REAR CALIPER MOUNTING . . . . . . . . . . . .
REAR HOUSING . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . .
RECOIL STARTER . . . . . . . . . . . . . . . . . . . .
B14
A6
B13
C2
C1
C13
SHOCK MOUNTING . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWING ARM/SHOCK MOUNTING . . . . . . . .
B11
C12
B6
B1
B12
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 (ccs)
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.
OWNERS
MANUAL
OWNERS
MANUAL
SUPPLEMENT
PARTS
MANUAL
PARTS
MICROFICHE
ASSEMBLY
INSTRUCTIONS
Trail Blazer 250
A00BA25CA
9915299
9915467
9915482
9916574
9915503
FRONT CAB
9
10
11 12
7
E 2000 Polaris Sales Inc.
8
7
13
14
5
15
16
17
33
18
25
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
30
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
1013249-067
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
Pad, Foot
Rivet
Trim, Footrest
Screw
Guard, Rock
Bracket, Cleat
Rivet
Screw
3/00
A5
REAR CAB
4
3
2
1
8
9
28
29
16
30
16
10
11
12
13
27
17
16
14
15
22
23
15
21
16 17
17
19
25
26
24
23
Ref. Part No.
1
2
3
4
Qty. Description
7041607
1040412-067
5411392
2682430-053
2681769-053
5431986
7621479
5410414
5211033
7621403
7073761
7072791
5432820-133
1
1
1
1
1
1
2
6
1
1
1
1
1
5434014-133
13 7670057
14 5432278-070
15 7517264
2
1
4
5
6
7
8
9
10
11
12
18
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
(If built before 7/06/00)
Cab, Rear, White
(If built after 7/06/00)
Nut
Asm., Muffler Shield
Screw
20
Ref. Part No.
16
17
18
19
20
21
22
Qty. Description
7555859
7542122
5241403-067
7661638
2670133
5432831
5810957
5810991
23 7512282
24 - - - - - - -
10
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
Washer
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
10/00
A6
FRONT BUMPER and SHIELDS

2
1
3
4
5
6
7
9
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
2
3
7
10
9
5
6
Ref. Part No.
1
2
3
4
4010140
4040054
5430967
4110264
4010278
4010321
Qty. Description
1
1
1
1
1
1
Indicator, Low Oil

Indicator, Neutral/Reverse
Plug, Indicator Hole
Switch, Ignition (Incl. Key)
Key, Blank, Series 2000, 6700, 6800.
NOTE: Spare key must be cut from
existing key.
Key, Blank, Series 2200, 2300, 2700,
2800. NOTE: Spare key must be cut
from existing key.
Ref. Part No.
5
6
7
8
9
10
5433733
5431976
7512026
2460777
5431975
7080371
Qty. Description
1
1
2
1
1
1
Nut, Ignition
Panel, Control, Outer
Screw
Harness, Indicator
Panel, Control, Inner
Cable, Choke Control
10/00
A8
ENGINE MOUNTING
3
7
8
9
37
30
38
10
36
35
11
37
5
30
1
26 25
12
34
33
13
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
7512315
7552901
7542411
5242898-067
7512232
4010132
3070156
4010129
5410346
7512457
1040687-067
7512566
7575202
5210748
5430261
-------
14
17
19 18
20
15
23
29
Ref. Part No.
16
23
24
1
2
28
27
Qty. Description
5
2
2
1
AR
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
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)
21
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
8/00
A9
EXHAUST SYSTEM
3
4
3
2
5
1
14
13
14
13
2
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
1
2
RH
10
12
11
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
1
2
3
4
5
23
22
8
9
10
21
17
20
19
16
11
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
1
2
3
22
21
20
19
18
17
16
14
15
13
12
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
9
11
10
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
6
5
1
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
1
2
3
4
5
6
7
9
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
4
5
17
7
16
10
11
12
15
14
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
13
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
7
4
12
11
10
8
9
Ref. Part No.
1
2
3
4
5
6
1910271
1910264
1930642
7080352
7515489
5131115
5131116
5410779
5410780
5132294
Qty. Description
1
1
1
2
2
1
1
1
1
1
Asm., Front Brake Caliper, LH

Asm., Front Brake Caliper, RH
Kit - Front Brake Boot (Incl. 10,11)
Screw, Bleeder
Screw, Socket Set
Caliper, Brake, LH
Caliper, Brake, RH
Ring, Square, Molded (.094)
Ring, Square, Molded (.103 x .134)
Piston, Brake
Ref. Part No.
7 1930665
8 2200901
9
10
11
12
2201149
2200465
1910265
5410495
5410494
7517445
Qty. Description
1 Kit - Piston and Insulator Seal (Incl. 4-6)

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
10/00
B3
A-ARM/STRUT MOUNTING
5
6
7
8
10
27
9
11
25
26
12
18
25 26
20
13
19
21
19
20
17
16
23
1
2
3
4
5
6
7
8
9
10
11
12
13
7542403
5333367
5411291
7061034
7542711
5020927
7547028
7061033
7061054
5411920
1820566
1820806
7555806
7556099
7546904
7661203
Qty. Description
2
2
2
2
2
2
2
2
2
2
2
2
4
2
2
4
Nut
Bushing
Boot, Seal, Rod End
Rod End, RH
Nut
Tie Rod
Nut, LH
Rod End, LH (If built before 8/16/99)
Rod End, LH (If built after 8/16/99)
Boot, Seal
Tie Rod (If built before 8/16/99)
Tie Rod (If built after 8/16/99)
Washer (If built before 8/16/99)
Washer, Flat (If built after 8/16/99)
Nut
Cotter Pin
15
13
22
Ref. Part No.
14
24
Ref. Part No.
Qty. Description
14
15
16
17
18
5240717
7512284
5410548
7080673
-------
2
4
2
2
1
19
20
21
22
23
5431596
5020677
7080433
7542438
2200560
2200561
5020681
7512492
7552603
7517527
4
4
2
2
1
1
2
4
4
2
24
25
26
27
Bracket, Ball Joint

Screw
Boot, Rubber
Joint, Ball
Support, Strut and Spindle
(See Strut Pg. B1, Ref. 16)
Bushing, A-Arm Long
Bushing
Nut, Castle
Kit - A-Frame, LH
Kit - A-Frame, RH
Shaft, A-Arm
Screw
Washer
Bolt
3/00
B4
HANDLEBAR
2
6
10
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
1
16
15
2
14
3
13
12
5
11
10
6
8
7
6
9
Ref. Part No.
1
2
3
4
5
6
7
8
1843077
5433415
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
5433416
5222999-067
7542324
Qty. Description
1
1
2
1
1
1
1
2
Nut
Bushing, Steering, Lower
Rivet
Plug, Grease
Bushing, Steering Upper
Bracket, Upper Steering Bushing
Nut
3/00
B6
CONTROLS - THROTTLE ASM./CABLE

6
1
5
3
Ref. Part No.
1 5433806
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
3/00
B7
CONTROLS - MASTER CYLINDER/BRAKE LINE

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

1
2
5
6
3
20
19
10
18
15
11
14
13
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
7661046
5432727
7080510
7547082
7556035
5432637
5131697
5131696
1541383
7077618
12
16
Qty. Description
2
1
2
1
1
2
2
1
1
1
Rivet
Guide, Pad, Chain
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

6
Frame
4
1
3
4
7
3
17
8
16
9
15
14
13
10
11
12
Ref. Part No.
1 7517231
2 1910367
2201428
2201467
2201385
3 5410988
4 1930873
5 1930872
6 4020139
7 7670102
8 1930674
9 5131759
Qty. Description
2
1
1
1
1
4
1
1
2
2
2
1
Screw
Caliper, Rear
Kit, Bleeder Replacement
Piston, Caliper DH2P, Rear
Kit, Caliper Seal
Seal
Line, Brake, Hand, Rear
Line, Brake, Foot, Rear
Clip, Rosebud
Clip
Bolt, Banjo
Bushing, Caliper Mount
Ref. Part No.
Qty. Description
10 7558402
2 Washer
11
12
13
14
15
16
17
2
2
1
1
3
1
1
1
1
7552901
7512312
5131786
5131787
7512325
5242291-067
2201189
1910339
1930860
Washer
Bolt
Mount, Caliper, Lower
Mount, Caliper, Upper
Bolt
Guard, Brake Disc
Kit - Brake Pad (Incl. Spacer and Pin)
Spacer
Pin
9/02
B13
REAR BRAKE MASTER CYLINDER

20
3
19
8
7
18
17
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
3
4
6
7
12
11
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
1
4 3
5
6
7
8
9
10
11
12
13
14
15
16
23
17
22
13
12
11
10
18
6
3
19
21
4
3
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7710472
5510313
7542439
5411555
5211849
7515513
1520259
7710405
5010462
5410889
3610070
3554518
Qty.
2
2
12
2
1
6
1
1
1
2
2
2
20
Description
Ref. Part No.
Ring, Retaining
Retainer, Nut
Nut, Nylok
Seal, Foam
Disc, Brake
Stud
Hub, Brake Disc (Incl. 6)
Ring, Retaining
Spacer, Axle
O-Ring
Seal
Bearing, Cone, Tapered
13
14
15
16
17
18
19
20
21
22
23
3554517
5132098
7080306
3225026
5131968
3224056-078
5211585-067
5630586
3222065
1520258
7515540
Qty.
2
1
1
1
1
1
1
1
1
1
3
Description
Bearing, Cup, Tapered

Housing, Axle, Rear
Link, Connector, 520 O-Ring
Axle, Rear
Chain, 520 O-Ring
Guard, Sprocket
Spacer
Sprocket, 38T
Asm., Hub, Sprocket (Incl. 6)
Bolt
3/00
C2
ELECTRICAL/TAILLIGHT
6
7
13
8
9
10
14
15
16
17
12
18
11
28
23
21
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
2
1
2
39
4
38
3
5
2
36
27
23
35
28
29
30
31
24
32
34
33
8
13
14
25
22
37
26
12
15
9
11
16
21
10
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
2200792
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
3/00
C4
GEAR SELECTOR
1
2
14
6
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
1
21
25
24
23
13
14
15
16
17
18
19
20
2 3 4
10 11
12
28
30
31
29
32
33
22
26
27
38 37 36
12
41
39
40
42
43
44
45
44
C6
26
34
35
GEARCASE
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
1
2
5
3
8
9
8
19
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
Qty.
2
5
1
1
1
1
5
4
AR
AR
AR
8
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

1
4
3
38
37
7 6
35
8
10
36
34
33
11 12
13
4
32
14
16 15
31
17
30
18
16
29
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
24
23
21
22
19
20
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

2
3
4
5
6
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)
Piston (Std.)
Piston (0.25mm/.010 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
1
2
4
8
5
6
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
3
1
2
4
9
19
10
18
11
17
16
14 15
12
13
20
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
1
3 4
5
6
7
8
17
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
2
1
4
5
7
9
10
11
17
16
15
14
13
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
12
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
3
30
8
9
6
29
10
11
28
12
27
26
15
24
25
13
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
2
3
8
4
5
6
Ref. Part No.
1
2
3
4
5
2682572
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
3/00
D2
PRINTED IN THE USA
PARTS MANUAL PN 9915482 and MICROFICHE PN 9916574 3/00

POLARIS Manual PDF

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TRAIL BLAZER 250

E 2000 Polaris Sales Inc.

PARTS MANUAL PN 9915482 and MICROFICHE PN 9916574 3/00

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C14

REAR BRAKE MASTER CYLINDER . . . . . . .

2000 TRAIL BLAZER 250 SPECIFICATIONS

TIRES & WHEELS

Engine Model Number

2000 TRAIL BLAZER 250 ATV PUBLICATION NUMBERS

Trail Blazer 250

Ref. Part No.

Ref. Part No.

Ref. Part No.

FRONT BUMPER and SHIELDS

Ref. Part No.

Ref. Part No.

Ref. Part No.

Indicator, Low Oil

Ref. Part No.

Ref. Part No.

1 Seal, Cover, Case

Ref. Part No.

Ref. Part No.

2 Nut (See Crankcase and Cylinder Pg.

Ref. Part No.

Decal - Warning, Heavy Loads

Ref. Part No.

Ref. Part No.

Cap, Gas Tank

Ref. Part No.

Ref. Part No.

Ref. Part No.

Cap, Oil Tank

Ref. Part No.

Ref. Part No.

Ref. Part No.

Ref. Part No.

1 Support, Strut and Spindle

Ref. Part No.

Spacer, Front Hub

Ref. Part No.

Asm., Front Brake Caliper, LH

Ref. Part No.

1 Kit - Piston and Insulator Seal (Incl. 4-6)

Ref. Part No.

Ref. Part No.

Bracket, Ball Joint

Ref. Part No.

Ref. Part No.

Ref. Part No.

Asm., Steering Post (Incl. 12,13)

Ref. Part No.

CONTROLS - THROTTLE ASM./CABLE

Ref. Part No.

Ref. Part No.

1 Cover, Throttle Control

CONTROLS - MASTER CYLINDER/BRAKE LINE

Kit - Master Cylinder Reservoir (Incl. 2-5)

Ref. Part No.

Kit - Park Brake Lever (Incl. 8,10,12)

Ref. Part No.

Ref. Part No.

Weight, Shift (G)