2003 Polaris Trail Blazer 250 / 400 Service Manual

This comprehensive service manual covers the 2003 Polaris Trail Blazer 250 and 400 ATVs, detailing maintenance, engine, fuel, and electrical systems. Ref: PN 9918059.

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Document Details

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Document Number / Seller:
32047 / Michelle Perez
File Size:
29.05 MB
File Type:
PDF
Language:
English
Pages:
207
Printable:
Yes
Category:
ATV
Last updated / verified
Jan 21, 2025

Models Covered & Key Technical Specifications

2003 Polaris Trail Blazer 250 / 400 Service Manual: Polaris Illustrated Service Manual for 2003 Polaris Trail Blazer 250/400 ATVs Wiring-Compendium

Model Identification: 2003 Polaris Trail Blazer 250/400 (PN 9918059) | Engine Designation: EC25PFE15 / EC38PLE09

  • Calibrated Electrical Specs: Flywheel I.D. FF64; CDI Marking CU2167 for the 250, FF4576; CU2515 for the 400 units.
  • Rated Amperage Specs: Alternator Output is rated at 150 Watts for both models in the engine specification range.
  • Critical Ignition Specs: Timing for the 250/400 is specified at 25 degrees BTDC @ 3000 RPM for proper ignition timing.
  • Universal Piston Specs: The 250 uses a 68mm piston length, while the 400 uses a 78mm piston length as standard.
  • Maximum Dimensional Tolerance: The engine bore for the 250 is 2.8346" / 72mm, while the 400 is 3.270" / 83mm to ensure precise tolerances.
  • Documented Compression Specs: Compression pressure for both models is documented at 115 PSI to ensure optimal engine performance.

Professional Workshop Service Manual & Technical Specifications

2003 Polaris Trail Blazer 250 / 400 Service Manual: Polaris Illustrated Service Manual for 2003 Polaris Trail Blazer 250/400 ATVs Wiring-Compendium

Calibration-Scope: 2003 Polaris Trail Blazer 250/400 (PN 9918059) // Service-Level: ATV / Engine Logic // Engineering-Metrics: 207 Pages

Engine Specifications

Maintenance Schedule

Electrical System Components

Troubleshooting Guide

PVT System Operation

Fundamentally calling for regular maintenance, this manual documents the specifications for the 2003 Polaris Trail Blazer 250 and 400 ATVs. It includes detailed information on engine specifications, maintenance schedules, electrical system components, and a comprehensive troubleshooting guide for the PVT system, ensuring optimal performance and longevity for your vehicle.

Table: Metric Rating Framework
Engine Type 2 Cycle, Single Cyl. Specifications
Fuel Tank Capacity 3.5 gal. (15.1L) for 250, 4 gal. (15.1L) for 400 Fuel System
Alternator Output 150 Watts Electrical System
Compression Pressure 115 PSI Engine Performance
Drive Belt Width (New) 1.174 - 1.188" (2.98-3.02 cm) PVT System

Coverage is segmented into detailed sections covering Engine, Fuel System, Electrical Systems, and Troubleshooting. This rigorous manual provides essential procedures for maintaining peak performance.

FAQ

What does the **drive clutch** assembly sequence involve? keyboard_arrow_down

Drive clutch assembly involves installing the moveable sheave onto the fixed sheave, then torqueing the spider and cover bolts to specification.

Reference the **specific** service interval parameters for the PVT system. keyboard_arrow_down

Periodic inspection and maintenance are required for the PVT system, including checking the drive to driven clutch offset, belt width, and sheave faces for wear.

What are the **designated** engine specifications for both models? keyboard_arrow_down

The 250 model features a 244 cc engine, while the 400 model has a 379 cc engine, both being 2-cycle, single cylinder units.

Specify the **critical** tool requirements for drive clutch removal. keyboard_arrow_down

Critical tools include the Drive Clutch Holder (PN 9314177) and the Drive Clutch Puller (PN 2870506) for proper removal and installation procedures.

What is the **required** electrical system check for ignition timing? keyboard_arrow_down

Ignition timing requires setting the engine speed to 3000 +/- 200 RPM and checking the timing pointer against the marks on the flywheel using a timing light.

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Reviews (3)

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This manual has been a lifesaver for maintaining my 2003 Polaris Trail Blazer. The detailed instructions are easy to follow, and the troubleshooting guides are spot on. Highly recommend!
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Rated 4 out of 5 stars
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The download process was seamless, and I received the manual within minutes. Customer support was very responsive when I had questions. A great purchase for any Trail Blazer owner!