The Trail Boss Project


This is the starting page for my 1994 Trail Boss 250 project ATV. I purchased it for $105 (don't ask) and have been tinkering with it for about a year and a half now. The ATV had been sitting for 5 to 10 years without being started before I bought it. Here's what I've done so far:

  • New carburetor (Finally found one that fits here:
  • New fuel tank petcock valve (I used this one:
  • New battery
  • New pull-start rope
  • Cleaned mouse nest out of transfer case
  • New in-line fuel filter
  • New fuel line


  • Figure out why it dies after running at 75%+ throttle for a few seconds
  • Figure out why transfer case makes a knocking noise going into gear (worse in reverse)
  • Find all screws/bolts to put it back together better after being apart for 1.5 years
  • Figure out how to "re-stretch" seat so that it fits again
  • Fix brakes - has no front brakes and back brakes only lock up
  • Fix leak in self-mixing oil line
  • Fix push-button starter