Hey there,
New to the forum. I have had a 2002 Trailblazer for 2 years now. No issues, has been running great. I put a new battery in it, and ever since, the CDI box keeps frying. When I turn the key on, black smoke comes out of it and it smells like rubber. Machine will no longer start. I replace it, it works fine for a bit, then frys again.

Any ideas?

Is it possible to bypass?

 

Start at the beginning and make sure you have the right 14aa2 or 14ahbs battery,plus you can't bypass the cdi. Sounds like a stator or other wiring problem is smoking cdis. Best to check the stator out and this 5 buck manual is cheaper than continuing to buy cdi modules.2002 Polaris Trail Blazer 250 Service Manual PDF Download

 

The battery I have in it is 14L-A2. Do you feel this could be causing the issue? Thanks for the download info, I did that, and will do some trouble shooting.

 

You have the right battery.The manual should give you stator resistance checks along with other electrical trouble shooting tips.

 

After taking the plastics off and trouble shooting, I found 2 black flat pieces behind the oil tank. (not sure what they are called) They were both fried as well. Good thing I bought a box of used parts for the Trailblazer on craig's list. My luck, there were two of them in there. I replaced them and 1 pull later the wheeler was purring like a kitten. Thanks for the guidance and giving me the courage to tinker.

 

One module is the regulator,the other is the reverse limiter. Items 25,27.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse I'd still get the cheap 5 buck manual for any future problems and repairs. Glad it's up and running.

 

Thanks for the link to the parts place, and I did download the manual. Will come in handy, with a 15 year old machine, I am sure I will need it at some point.

 

On the reverse limiter module you can disconnect the black wire from it and disable it as almost all of these failed at one time or another anyway. You can then have full power in reverse without having to push the over ride button.

 

When you are looking at the machine from the front, I am assuming that is the one on the right.

 

Module to the far left,at least as it shows on the parts breakdown I listed. Location may vary by model. The module with the red,yellow,yellow/red,brown is the regulator. The other module is the one you want.Just disconnect the black wire and it's defeated.