A downloadable Polaris Trail Blazer (TrailBlazer) repair manual, also termed Trail Blazer factory service manual (FSM) or Trail Blazer shop manual, is a digitally transmitted book of repair instructions that shows you how to service, maintain or fix the all-terrain vehicle (ATV) back to proper working order.
Download Manuals Available
| Year | Model |
| 1990-1995 | All Models |
| 1996-1998 | Trail Blazer 250 |
| 1999-2000 | Trail Blazer 250 |
| 2001 | Trail Blazer 250 |
| 2002 | Trail Blazer 250 |
| 2003 | Trail Blazer 250/400 |
| 2004-2006 | Trail Blazer 250 |
| 2007 | Trail Blazer 330 |
| 2008 | Trail Blazer 330 |
| 2009 | Trail Blazer 330 |
| 2010 | Trail Blazer 330 |
A Polaris Trail Blazer repair manual covers all aspects of repair—whether you’re performing periodic maintenance or overhauling the engine—the manual covers it all. It contains step-by-step procedures, easy-to-follow photographs and provides an in-depth look at specific areas of all-terrine vehicle repair.
Digitally transmitted Trail Blazer repair manuals are virtually identical to printed paperback versions. A Trail Blazer repair manual begins with a cover page followed by a chapter index page. Subsequent chapters are divided into subchapters and the subchapters outline each area of repair for the chapter.
CHAPTERS
Note: Actual chapters and sub-chapters or topics may differ depending on year and model.
General Information
- Four-wheeler identification
- Serial number location
- All-terrine vehicle dimensions
- Component specifications
- Publication numbers
- Paint codes
- Torque specifications
- Tap drill charts
- Decimal equivalent chart
- Unit of Measure conversion table
- Glossary of terms
Engine
- Torque specifications
- Torque patterns
- Piston identification
- Accessory component removal
- Engine removal and installation
- Engine disassembly
- Engine inspection crank endplay
- Engine assembly
- Oil pump end play adjustment
- Oil check valve testing
- Recoil disassembly and assembly
- Cooling system
- Cylinder and piston inspection and honing
- Connecting rod and crankcase inspection
- Spark plug fouling troubleshooting
- Piston damage troubleshooting
- Engine troubleshooting
Body And Suspension
- Steering and body assembly exploded views
- Torque specifications
- Panel and cover removal
- A-arm replacement
- Concentric swing arm removal, assembly, install
- Strut assembly exploded view
- Ball joint and front strut replacement
- Shock service
- Steering post assembly
- Decal replacement
Final Drive
- Specifications
- Torque specifications
- Front hub disassembly, checking and assembly
- Front hub install
- Front hub exploded view
- Rear axle removal, disassembly
- Rear axel assembly installation
- Rear housing removal and disassembly
- Rear housing install
- Rear axle exploded view
Transmission Service
- Torque specifications
- Transmission removal and install
- Transmission disassembly and assembly
- Troubleshooting
- Transmission exploded view
Brakes
- System specifications
- Torque specifications
- Troubleshooting
- Hydraulic brake system overview
- Brake system main components
- Dual hydraulic caliper bleeding
- Brake fluid bleeding procedures
- Brake fluid replacement
- Master cylinder disassembly and assembly
- Master cylinder install
- Front and rear brake pad removal
- Front and rear brake pad install
- Front and rear disc check, removal and replace
- Front and rear caliper removal, check, install
- Front and rear caliper exploded view
- Rear dis inspection
- Rear caliper assembly
- Troubleshooting
Maintenance
- Periodic maintenance schedules
- Pre-ride check
- Maintenance and lubrication charts
- Transmission lubrication
- Throttle and carb adjustments
- Throttle linkage adjustment
- Adjusting oil pump, bleeding and filter
- Fuel system maintenance
- Compression testing
- Battery maintenance
- Electrical maintenance
- Air filter service
- Recoil housing
- Toe alignment and steering
- Exhaust system maintenance
- Brake system servicing
- Sprocket and drive chain service
- Suspension service
- Wheel removal and installation
- Tire inspection
Fuel System
- Fuel system and oil tank exploded view
- Carburetor exploded view
- Carburetor system information
- Carburetor jetting chart
- Air screw adjustment
- Carb circuit operation
- Car bent systems
- Float height adjustment
- Needle and sea leakage test
- Pilot Jet and main jet part numbers
- Fuel flow diagram
- Troubleshooting
Clutch/PVT System
- Component specifications
- Torque specifications
- System overview
- Maintenance and inspection
- Drying
- Overheating
- Disassembly
- Assembly
- Sealing and ducting components
- Drive clutch spring specs
- Shift weights
- Drive clutch removal, disassembly
- Drive clutch checking and assembly
- Drive belt tension
- Drive belt removal, checking and installation
- Clutch alignment and offset
- Drive clutch busing service
- Driven clutch disassembly, check and assembly
- Driven clutch busing service
- Driven/drive clutch exploded view
- Troubleshooting
Electrical
- Crankshaft degree to position conversion
- Timing check and timing curve
- Transmission gear position switch
- Speed limit spec and troubleshooting
- Rever limit system diagram
- Electronic throttle control system overview
- Flywheel identification
- Ignition components exploded view
- Ignition troubleshooting
- CDI output test peak reading meter
- Charging system testing
- Alternator output test
- Battery initial service
- Headlamp and headlight adjust
- Taillight and indicator lamp replacement
- Oil level sensor and switch testing
- Headlamp and brake light switch
- Starter system troubleshooting
- Starter motor service
- Starter drive
- Wiring diagrams
Repair procedures outlined in this Trail Blazer repair manual provide a detailed series of actions the mechanic should conduct when performing service or repair; e.g. component testing, part removal, disassembly, cleaning, inspection, reassembly and installation.
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