"00-"02 TrailBlazer 250 Exhaust issue - Polaris ATV Forum
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post #1 of 4 (permalink) Old 03-11-2019, 08:30 AM Thread Starter
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"00-"02 TrailBlazer 250 Exhaust issue

I have been rebuilding a "00-"02 (can't recall exact model year and frame # too hard to read) TrailBlazer 250 at my highschool with a teacher and we ran into the issue of reinstalling a stock exhaust pipe. We removed the aftermarket one and placed the stock front piece back on correctly but when installing the pipe that runs to the back, It doesn't align properly with the pipe from the motor. It is mounted on the right spot but the gap is too large and the bend doesn't seem right. I've attached some photos below to try and help visually. I've got the exhaust springs as well. There is a bracket the previous owner added which we plan to cut off as well. It isn't on the parts bike that is sitting behind this one.

Thanks,

Jackson
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Last edited by T3RMINATOR; 03-11-2019 at 08:32 AM. Reason: Needed to add more information
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post #2 of 4 (permalink) Old 03-11-2019, 11:05 AM
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Can you align the pipes properly and mount it to the machine in the right places? It looks like that is the same as the 250 xplorer I have and all the 250 engines are pretty much the same. I will check in the shop

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
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post #3 of 4 (permalink) Old 03-11-2019, 12:38 PM
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I'd leave all the mounting hardware for the main pipe loose. Take the springs back off the manifold at the engine. Install the springs on the pipe joint and then wiggle it all around to ensure the fit before finally putting the springs back on the manifold and tightening the muffler hardware.
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post #4 of 4 (permalink) Old 03-11-2019, 01:28 PM
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Looks like the pipes on the 250 Xplorer in my shop. And the silly thing turned sideways.....
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Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
stave7119 is online now  
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