Baja motorsports WD90 Owner's Manual
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Baja motorsports WD90 Owner's Manual

Model: 90cc
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Minimum
Age Requirement:
10
Model: 90cc
For MoreinformationonATV SafetyContact
the BajaATV SafetyHotlineat: 866-260-8630
REV.B
012209
Alwayswear a helmet; It could save your Life!
Pleaseobtain,review,and followprovincial/ municipal g overnment a cts and
regulationspertaining to owningand operatingan off-roadvehicle.

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Summary of Contents for Baja motorsports WD90

  • Page 1 Minimum Age Requirement: Model: 90cc For MoreinformationonATV SafetyContact REV.B the BajaATV SafetyHotlineat: 866-260-8630 012209 Alwayswear a helmet; It could save your Life! Pleaseobtain,review,and followprovincial/ municipal g overnment a cts and regulationspertaining to owningand operatingan off-roadvehicle.
  • Page 2 "YOUR ATVCAN BE HAZARDOUSTO OPERATE.A collision or rollovercan occur quickly,even during routine maneuverssuch as turning and drivingon hills or over obstacles, if you fail to take proper precautions. For your safety,understandand follow all the warnings contained in this owner's manualand the labels on your vehicle.
  • Page 3 Congratulationson your purchaseof the WD90 ATV. It is warrantedto befree of manufacturing defectsin the materialand workmanship for a periodof 90 daysfrom the dateof purchase.Duringthe warrantyperiodBAJAINC.will at its option,repair,providereplacement partsor replaceyour BAJAINC. 90ccATVat no charge. Thiswarrantydoes not covernormalwear itemsor damagecausedby neglector misuseof the product.
  • Page 4 This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator. The manual contains importantsafety information and instructions which should be read carefully before operating the vehicle.

  • Page 5: Table Of Contents

    SAFETY....................... IMPORTANT ......................NOTICETO THE USER ..................ATV90........................FUELANDOIL..................... LOCATION OF LABELS..................CONTROLFUNCTIONS ..................LEFT HANDLEBAR ..................RIGHTHANDLEBAR ................... FUELVALVE....................FUELTANK CAP..................SEATLOCK....................REMOTESTOPLANYARD ................RIDINGYOURATV....................WHATYOUSHOULDKNOWBEFORERIDING........17 INSPECTION BEFORERIDING..............BREAK-IN....................STARTING THE ENGINE ................SAFETYGEAR.................... STARTINGOFF................... BRAKING..................... TURNING ..................... OPERATION ON HILLS................
  • Page 6 IDLE SPEED ADJUSTMENT ............... FUELHOSE....................ENGINEOIL....................CHANGINGENGINEOIL ............... AIR FILTER ....................REMOVAL ..................WASHINGTHE ELEMENT............. DRIVECHAIN/SPROCKETS ............... DRIVECHAINCLEANING,OILINGAND ADJUSTING ......58 TIRES......................BRAKING ..................... FRONTDRUMBRAKES..............REARHYDRAULICDISCBRAKEAND PARKINGBRAKE....6 3 GENERALLUBRICATION ................TROUBLESHOOTING ..................FUELSUPPLYCHECK................IGNITIONSYSTEMCHECK................ TRANSPORTING ....................CLEANINGPROCEDURE ................... PREPARATION FOR CLEANING ..............

  • Page 7: Safety

    Pleaseread this manualand follow all instructions carefully.To emphasize the specialinformation, t hesymbol-_ and thewordsWARNING or CAUTION have somespecialmeanings.Payattentionto the messages. Indicatesa potentialhazardthatcouldresultin deathor injury. _& CAUTION Indicatesa potentialhazardthatcouldresultin vehicledamage. NOTE:Indicatingspecialinformation whichis to makemaintenance easieror instructions clearer. WARNING and CAUTION are arrangedlikethis: The first partwill identifya POTENTIAL HAZARD.

  • Page 8: Noticeto The User

    We believe inconservation and protection ofthe earth's n atural resources. We encourage every v ehicle o wner and operator todothe same byobeying p osted signs and riding onlyinareas d esignated and approved foroff-road recreational use. NOTICE TO PARENTS ThisATV isbuilt for use by children age 10 and older,butthe usersmanualis writtenfor adultswhowill besupervising the children,we stronglyrecommend, therefore,thatyou reviewthis entiremanualwithyour childand carefullyexplain the instructions, r equirements, and warningsit containsso thatyour childcan...
  • Page 9 Category Y-10+ ATV. ACategory Y-10+ ATV isayouth model ATV thatisintended for useby childrenage 10 or older. Category Y-12+ATV.A CategoryY-12+ATV isa youthmodelATVthat is intended for useby childrenage 12 or older. Category T (Transitional M odel)ATV.A Category T ATV isan ATVof appropriate sizethat is intendedfor recreational u se byan operatorage 14 or olderunderadult supervision, o r by anoperatorage 16 or older.
  • Page 10 Always follow properprocedures for climbinghillsas describedin this manual.Checktheterraincarefullybeforeyou start up any hill.Neverclimb hillswith excessively slipperor loosesurfaces.Shiftyou weightforward. Neveropenthethrottlesuddenlyor makesuddengearchanges.Nevergo overthe top of any hill at high speed. Alwaysfollow properprocedures for goingdownhills andfor brakingon hills as describedin this manual.Checktheterraincarefullybeforeyou start down anyhill.
  • Page 11 Never modify a nATV through i mproper installation oruse ofaccessories. Never exceed the stated l oad capacity for an ATV. Cargoshouldbe properly distributed and securelyattached.Reducespeedand follow instructions in this manualfor carryingcargo.Allowgreaterdistancefor braking. The combined weightof the riderand anyaccessories or cargomustnever exceedthevehicle'sloadcapacityof 220 Ibs.

  • Page 12: Atv90

    Gas Cap vent hose Gas Ca Spark plug Head lights Muffler Rear Tire Rear shock Oil cap RIGHT Thumb Seat Fuel valve Tail Light FrontTire _uretor LEFT...

  • Page 13: Fuelandoil

    FUEL Properfuel is very important f or theengine. Ensurethere is no dust,dirt, or waterwhichhas mixedin thefuel. Useregularunleadedgasolinewith an octanenumber90 or higher. ENGINE OIL Your90ccATV hasa four-stroke engine. Pleaseuseoil as describedin the chartbelow. By usingprescribeoil, you will realizethe bestlubrication for engine. ENGINE °C TEMP.

  • Page 14: Location Of Labels

    Read a nd follow all of the warningslabels on yourATV. Makesureyou understand all the labels. Keepthe labelson the ATV. Do not removethem for any reason. If a labelcomesoff or becomesdifficultto read,you should geta replacement by contactingBAJAINC. Operationofthe ATV by children underthe age of 10 increasesthe riskof severe injury or death.
  • Page 15 NEVERrideas a passenger, Passenger can causea loss of control,resultingin SEVEREINJURYor DEATH, ImproperATV use can result in SEVERE INJURYor DEATH ALWAYS USE AN NEVER USE NEVER CARRY NEVER USE APPROVED HELMET ON PUBLIC PASSENGERS WITH DRUGS AND PROTECTIVE ROADS OR ALCOHOL GEAR NEVER Operate: •...
  • Page 16 improper tire pressure or overloadingcan cause loss of control, Loss of control can result in SEVERE iNJURY or DEATH. ® Cold tire pressure: Front: 7 Psi (48 Kpa) Rear: 7 Psi (48 Kpa) ® Maximum weight capacity; 220 Ibs. (100 kg)

  • Page 17: Controlfunctions

    HANDLEBAR& Rear Brakelever SWITCHES LightSwitch LEFT HANDLEBAR EngineStop With the Enginestop switchin the "Stop" position ElectricStart switch The enginecannotbestarted. Button With the Enginestop in the "Run" position The enginecan be started. Rear brakelever Applythe rearbrakeby squeezing the rear brake levertowardsthe grip. Electricstartingbutton Pushelectricstartbuttonto startengine.

  • Page 18: Fuelvalve

    Usethe throttleadjustingscrewto restrictmaximum speedof theATV. Adjustthis limiteraccording to the rider'sskilland experience. Adjustinqprocedures: Loosenthe Locknut Turnthethrottleadjusting screw clockwiseto restrictmaximum speedof theATV. Turnthethrottleadjusting screw counterclockwise t o increasethe maximum speed of theATV. After finished, tightenthe locknut FUELVALVE Thereare three positions: "ON","OFF", and "RES". "ON"...

  • Page 19: Seatlock

    Overfilling thefuel tank couldbe hazardous. If you overfillthe fuel tank,fuel may overflowwhenit expands. Expanding is due to heatfrom engineor sun. Overheated fuel couldeasilycatchfire. Stop addingfuel when thefuel level reachesthe bottomof thefiller neck. Improper fueling of theATVcould behazardous. Failingto follow safety precautions when refuelingcouldresultin a fire or letyou to breathetoxic fumes.

  • Page 20: Remotestoplanyard

    REMOTESTOP LANYARD StopLanyard Stop Lanyard YourATVis equippedwith a remotestop lanyard.Thislanyardshould be usedwhentrainingbeginneroperators. T he adultsupervisor should graspthe lanyardand follow behindtheATV whilethebeginneris learningto operatetheATV.The adultsupervisorshouldpullthe lanyard to removethe remotestop pinwhichwill stopthe engine. NOTE:ThisATVwill not startor operatewithoutthe remotestop pinand lanyardin place.

  • Page 21: Ridingyouratv

    WHATYOUSHOULDKNOWBEFORERIDING Beforeriding,you shouldreadall the following information carefully.If you are properlyprepared, y ou will havea moreenjoyableride. Beforeriding,you shouldfind a goodplaceto practicetheskills. Finda flat, open areawith enoughspaceto practicethenewskills. OperatingthisATVwithoutproperinstruction. The riskof an accidentis greatlyincreased if the operatordoes not know how tooperatetheATV properlyin differentsituationsand on different typesofterrain.

  • Page 22: Inspection Beforeriding

    INSPECTION BEFORERIDING Failingto inspecttheATV beforeoperatingcouldbe hazardous.Failingto performpropermaintenance couldalso be hazardous. Failingto inspectand maintain yourATV couldincreasethe chances of an accidentor equipment d amage Always inspect yourATV eachtimebefore riding, andmake sureitisina safeoperating condition. Refer totheINSPECTION ANDMAINTENANCE section inthismanual. ITEMTO CHECK CONTENT Steering Smoothness;...

  • Page 23: Break-In

    Checkingmaintenance itemswhenthe engineis runningcouldbe hazardous. Youcouldbe severelyinjuredif yourhandsor clothingget caughtin moving ATVparts. Shutthe engineoffwhen performing maintenance checks,exceptcheckingthe enginestopswitchand throttle. BREAK-IN The first monthis the mostimportantin the life ofyour vehicle. Properoperation duringthis break-inperiodwill behelpfulfor assuringmaximumlife and performance of yournewvehicle. Thefollowing guidelinesexplainproperbreak-inprocedures. MaximumThrottleOpeningRecommendation Duringthefirst 10 hoursof operation,Youshouldalwaysuselessthan 1/2 throttle opening.

  • Page 24: Starting The Engine

    STARTING THE ENGINE Beforeattempting to startthe engine,makesure to follow thesesteps. Turnthe key switchto the "ON" position. Set the enginestop switchto the"RUN" position. If engineis cold,set chokeleverto the up (on) position. Applythe rearbrake leverand makesure that Ignitionkey the rearwheelsare in lockingcondition. switch Presstheyellowstarterbutton"START"...
  • Page 25 Running yourATVindoors where thereis littleor noventilation. Breathingin exhaustgasesfromthe ATVcouldcausesevereinjury. AlwaysrunyourATVoutdoorswherethereis fresh air. Carryinga passenger on this ATV. Greatlyreducesyour abilityto balance and controlthisATV. Couldcausean accident,resultingin harmto you and/oryour passenger. Nevercarry a passenger. The longseat is to allowthe operatorto shift positionas neededduringoperation.It is not for carryingpassenger.
  • Page 26 OperatingthisATV on pavedsurfaces. TheATV's tiresaredesigned for off-road use only,notfor useon pavement. Pavedsurfaces mayseriously affecthandling andcontrol o f theATV,and maycausethevehicletogo out of control. NeveroperatetheATVon anypavedsurfaces,including sidewalks, driveways, p arkinglotsand streets. Operatingthis ATVon publicstreets,roadsor highways. Youmay collidewith anothervehicle. NeveroperatethisATV on any publicstreet, roador highway, e vena dirt or gravelone.
  • Page 27 OperatingthisATV at excessivespeedscouldbe hazardous. Ridingat excessivespeedsincreasesyourchancesof losingcontrolofthe ATV,whichcouldresultin anaccident. Alwaysgo at a speedthat is properfor theterrain,visibility,operating conditions, o peratorskills, andoperatorexperience. Attemptingwheelies, j umps,and otherstunts. Increases the chanceof anaccident,including an overturn. Neverattemptstunts,such as wheeliesor jumps.Don'ttry to showoff. Checkingmaintenance itemswhen theengineis runningcouldbe hazardous. Youcould beseverelyinjuredif your handsor clothinggetcaughtin moving ATV parts.

  • Page 28: Safetygear

    SAFETY GEAR A DOTapprovedmotorcycle helmetis the mostimportantpart ofyour safety gear. A DOT approvedmotorcycle helmetcanhelppreventa seriousheadinjury. Choosea helmetthat fits snugly. Motorcycledealerscanhelp in selectinga good quality helmetwhichfits properly. OperatingthisATVwithoutwearingan approvedmotorcycle helmet, eye protection and protectiveclothing. Operatingwithoutan approvedmotorcycle helmetincreasesyour chancesof a severehead injuryor deathin the eventofan accident. Operatingwithouteye protectioncanresultin an accidentand increasesyourchancesof a severeinjuryin the eventof an accident.
  • Page 29 Failureto inspectthe ATVbeforeoperating. Failureto properlymaintain the ATV. Increases the possibilityof an accidentor equipmentdamage. AlwaysinspectyourATV eachtime you us it to makesurethe ATVis in safe operating condition. Alwaysfollow the inspection and maintenance procedures and schedulesdescribedin the owner'smanual. Removing handsfrom handlebars or feet from thefootrests duringoperation. Removing evenone handor foot can reduceyourabilityto controltheATV or couldcauseyou to lose yourbalanceand fall off ofthe ATV.If you remove a foot from the footrest, yourfoot or leg maycomeintocontactwith the rear...

  • Page 30: Startingoff

    Failureto useextracarewhenoperatingon excessively rough,slipperor looseterrain. Couldcauselossof tractionor vehiclecontrol, whichcouldresultin an accident,includinganoverturn. Do notoperate on excessively rough, s lippery or loose terrainuntilyouhavelearned andpracticed theskillsnecessary to control t heATV on suchterrain. A lwaysbeespecially cautious on thesekindsofterrain. The ATVmay startmovingas soonas you releasethe parkingbrake. Unexpected movement could causeyou to lose controlofthe ATV.

  • Page 31: Braking

    BRAKING FrontBrake RearBrake ThrottleLever To stop theATV,first releasethe throttle lever,then applythe rear and front brakessmoothly. BrakingwhileturningtheATVcould behazardous. Useof the brakewhenturningcouldcausetheATV to slideor roll over. Usethe braketo slowdownbeforeyou beginto turn. Brakinghardon slipperysurfacescouldbe hazardous. TheATV couldskidand go out of controlif you braketoo hard. Applythe brakeslightlyand carefullyon slipperysurfaces.

  • Page 32: Turning

    TURNING Toturn theATV,the rider mustusethe propertechnique. Because this vehicle hasa solid rearaxle, bothrearwheelsalwaysturn at the samespeed. This meansthatif therear wheelsaregettingequaltraction,thevehiclewill tend to movestraightahead. This is becausethe rearwheelswill travelthe same distance. Forthe vehicleto turn,the outsiderearwheel musttravel a longer distancethatthe insiderear wheel. To makethis happen,the ridermust createlesstraction for the insidewheel,allowingitto skid.

  • Page 33: Operation On Hills

    OPERATION ON HILLS Operatingon excessively steephills. Thevehiclecanoverturnmoreeasilyon extremelysteephillsthan on levelsurfacesor small hills. NeveroperatetheATVon hillstoo steepfor theATV or for your abilities. Practiceon smallerhillsbeforeattemptinglargerhills. CLIMBING A HILL Climbinghills improperly. Couldcauseloss of controlor cause ATV to overturn. Alwaysfollow the properprocedures for climbinghillsas describedin this owner'smanual.

  • Page 34: Descending A Hill

    To climba hill with theATV,follow the directions below. Speed up and maintain a steadyspeed beforereachingthe top of the hill. Remember thatyou mustride at a steady speedall theway to the top of the hill. Shift yourbodyforward by slidingforward on theseat. Leanslightlyforward. Forsteep hills,stand on thefootrests and leanforward.
  • Page 35 To ridedowna hillwith theATV,follow the instructions below. Checktheterraincarefullyfor any obstaclesbeforeyou go downthe hill. PointtheATV straightdownthe hill. Transfer your bodyto the rear by slidingbackon theseat. Ridedownthehill slowlywith the throttlereleased. Applythe rearbraketo controlthe speed. Avoidgoingdowna hill at an anglethat wouldcausethe vehicleto lean sharply to one side.

  • Page 36: Ridingoverobstacles

    Whentraversinga slope,you should: Leanyourbodyuphill. Steerslightlyuphill,ifnecessary, t o maintaina straightcourse. Stalling,rollingbackwards or improperly dismounting while climbing a hill. Couldresultin ATVoverturning. Usepropergearand maintainsteadyspeedwhenclimbinga hill. If you lose all forward speed: Keepweightuphill. Applybrakes. Lockparkingbrake,afteryou are stopped. If you beqinrollinq backwards: Keepweightuphill. Neverapplytherear brakewhilerollingbackwards. Applythefront brake.

  • Page 37: Skiddingor Sliding

    If you cometo an obstaclethatyou cannotavoid,you may beable to crossover it by usingthe following procedure. If theobstacleis in front of you,approachat walkingspeed. Riseup slightlyon thefootrests. Pulluponthehandlebar andapplya little throttle asthefrontwheels reach theobstacle. Leanforward and releasethe throttleafterthefront wheelsareover the obstacle. Remember thatsomeobstacles aretoo highfor yourATVor for yourabilities.Ifyou arenotsurethatyoucansafelycrossoveranobstacle, b ackupand ridearound the obstacle.

  • Page 38: Ridingthrough Water

    RIDING THROUGH WATER YoucanridetheATVthrough shallow water. Makesureit isnotmorethan10cm(4 inches) d eepandisnot moving fast. Choose a goodplaceto crossbefore you ride through thewater. Lookfor a spotwherethe banks aregentlysloped on bothsides andthebottom of thestreamishard. Ifyou areunfamiliar w iththearea,parkthe ATVandinspect t hestreamfirst tofind a suitable spotfor crossing. W hencrossing, operate theATVat a slow,steady speed.

  • Page 39: Ridingin Coldweather

    RIDING IN COLD WEATHER Pre-rideInspection Checkthatthe throttleandall controlleversmovefreely. Makesure thatthe footrests are free of iceor snow. MovetheATV forward and backwardto checkthatthewheelsroll freely. Ifyou cannot movetheATV,the tiresmay befrozen tothe ground,or the brakesmay befrozen to the wheels. If thetires arefrozen to the ground,pourwarmwateraroundthemto meltthe ice.

  • Page 40: Dressing Forcoldweatherriding

    DRESSING FOR COLD WEATHER RIDING OperatingyourATV in coldweatherwithoutproperclothingcouldbe hazardous. Continuedexposurein the coldweathercouldlead to hypothermia. Hypothermia isa conditionwhereyour body'sinnertemperature dropslow enoughto causeinjuryor death. Alwaysdressfor theworstweatherconditions you mightencounter. Be preparedfor bad weatherand ATVbreakdowns. Ridingin coldweathercanbe hazardous.At a temperature of 10°F(-12°C),the windchill createdby goingjust 10 mph(16kin/h)makesyou as coldas if you were standingstill at a temperature of -9°F (-23°C).

  • Page 41: Ridingyouatvon Snowand Ice

    RIDING YOUR ATV ON SNOW AND ICE Ridingon snow-covered terrain,evenwith care, couldbe hazardous. The snowmay be coveringrocks,holes,iceor otherhazardsthatcan causeloss of control. Severeinjuryor deathcouldoccurif you lose controlofthe ATV. Goslowlyand be carefulwhen ridingon snow-covered terrain. Alwaysbealert to changing terrain conditions. Ridingon a frozen lakeor rivercouldbe hazardous. Seriousinjuryor death couldoccurif theice breaksand you couldfall intothe coldwater.

  • Page 42: Accessory Useand Vehicleloading

    ACCESSORY USE AND VEHICLE LOADING OperatingthisATVwith improper modifications couldbe hazardous. Improperinstallation of accessories or modifications ofthe vehiclemay causechangesin handlingwhichcouldleadto an accident. NevermodifytheATVwith improperinstallation or useof improper accessories.All partsand accessories addedto theATVshouldbe genuinepartsor theirequivalentdesignedfor useon this ATV. Install and usethemaccording to their instructions.Ifyou haveany questions, contactyourdealer.
  • Page 43 Distributecargoweightevenlybetweenthefront and rearof the vehicleas well as bothsides of thevehicle. Locatecargoweightas closeto the centerof the vehicleif possible. Secure yourload well.Shifting weight c anaffect y ourability tohandle the vehicle safely. Rideat slow speedsand avoidhillswhen carryingcargo. Carrying loadswouldaffect thestabilityand handlingof yourATV. Allowenoughstoppingdistance. Stoppingdistanceincreases if you carry loads.

  • Page 44: Inspection And Maintenance

    MAINTENANCE SCHEDULE It is very important t o inspectand maintain yourATVregularly. Followthe guidelinesin the chart. The intervalsbetweenperiodicservicesin monthsare shown. At the end of eachintervalbe sure to lerform the maintenance listed. __nterval Initial1 month/ Every3 Every6 Item 20 hrs months/50 hrs months/100 Air Cleaner tExhaust pipebolt and mufflerbolt...
  • Page 45 Improper maintenance failing to performrecommended maintenance couldbe hazardous. If you performimpropermaintenance or do not maintain yourATVyou may havean accident. KeepyourATV in good condition.Askyourauthorizedservicecenter or a qualified mechanicto do the maintenance itemsmarkedwith an asterisk(*). Youmay performthe unmarked maintenance itemsby referringto the instructions in this sectionif you havemechanical experience.If you are not sure howto do the maintenance ask your authorizedserviceor call Baja Inc.

  • Page 46: Tools

    TOOLS A tool kit is provided with your ATV. SPARK PLUG YourATV is equipped with a Tl136 sparkplug. To determineif thestandard spark plug isin goodcondition,checkthe colorof the plug'scenterelectrode insulator aftervehicleoperation.A browncolor indicates thatthe plug is correct. Awhite or dark insulatorindicatesthatthe enginemayneed adjustment,or anotherplugtypemay be needed.

  • Page 47: Valveinspection

    NOTE: ThisATV usesresistor-type sparkplugto avoidjammingelectronic parts. Impropersparkplugselectionmay causeelectronicinterference with yourATVsignitionsystem,resultingin the vehicleperformance problems. Use recommended spark plugs. To installa spark plugturn it in as far as possiblewith yourfingers, thentighten it witha wrench. ,_, CAUTION Improperinstallation of the sparkplugcoulddamageyourATV. An overlytightor crossthreadedsparkplugwill damagethe aluminumthreads ofthe cylinderhead.

  • Page 48: Batteryinstallation

    BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATIONOF BATTERY: EyeProtection RubberGloves Thefollowing procedureisvery dangerous and shouldbe performed with the utmostcareand attention.Wear protective eyewear,rubbergloves,ant havewateravailableshouldelectrolytecomein contactwith skin or eyes. KEEPALLCHILDREN AWAYFROMTHE AREAWHILETHISPROCEDURE IS BEINGPERFORMED. POISON- CAUSESSEVEREBURNS Containssulfuricacid. Avoidcontactwith skin,eyes,or clothing To preventaccidents, r inseemptycontainerwith water. ANTIDOTE: External- flush with water Internal- Callphysicianimmediately.
  • Page 49 Note:The following page isfor vehicleswith battery'scontaining separate electrolyte pack. Mostbattery'swill comewith theelectrolytealreadysealed intothe battery. Preparinq the battery: Placebatteryon level surface.Removesealingtape from top.(see figure 20) Taketheelectrolytecontainerout of the plasticbag. Placeelectrolytecontainerupsidedownwith the sealedsilvermouthsof theelectrolytebottlesin line with the sixfiller holesofthe battery.(seefigure 21) Pushthecontainerdownstronglyenoughto break the silverseals.
  • Page 50 Howto InitiallyCharqethe battery: Connectthe red positive(+) cableto thered positive(+) poleof the battery. (seefigure 23) Connectthe blacknegative(-) cableto the blacknegative(-) poleof the battery.(see figure 24) Note:The red positive(+) cablehasa larger Figure23 diameterthan the blacknegative(-) cable. Chargingrate:Chargebattery@ 0.7Ampsfor 5 ~ 10 hours. •...
  • Page 51 Battery Replacement: DO NOTopensealedcapsto addwaterto battery. Alwayswearsafety glassesand chargein a ventilatedarea. If batterygetshot to the touch,discontinuechargingandallow batteryto cooldown. Do not usefast charging unlessit is an emergency. Atthe beginning or end of charging,turn offthe chargerfirst, in orderto preventelectricsparkand explosion. Chargein a well ventilatedarea. DO NOTsmokearoundbatteriesand keepawayfrom openflame.

  • Page 52: Enginespeedgovernor

    ENGINESPEEDGOVERNOR TheATV governorisset bythe factory to limitspeedofATVto 15mph (24kin/h)directlyout of crate. Thegovernorcanbe adjustedto allowthe ATVto travelup to 30mph(48kin/h). Any adjustmentto governorshouldbe performedbya responsible adult. Changingtop speedof ATVshouldmatch ridersability. The enginespeed governorispart of the CDI (A)locatedunderthe gastank of theATV. The governorshouldonlybe adjustedby a responsible adultor qualified servicetechnicianworkingunderthe direction of the adultowner.
  • Page 53 Faster Slower Adjustment screws (E) (H) Low Speed Limit Regulator 5-15mph (8-24kin/h) 1. RemoveLowspeedadjustment screwcover(D)from CDIgovernor 2. AdjustLowspeedadjustment screw(E) to desiredsetting: CW (clockwise) f aster, CGW(Counterclockwise) s lower. Re-install adjustment screwcover(D). Note: Low speedadjustment(5-15mph) canonly be performed with metaljumper(F) in place. TheATV is shippedwith metaljumper(F) in place.

  • Page 54: Throttleleveradjustment

    THEADJUSTMENT OF THROTTLELEVER Operating the vehiclewith an inadequate throttleleverfree distancecould be hazardous. Inadequate throttleleverfree distancecouldcauseenginespeedto rise suddenlywhenyou turnthe handlebars.This canlead therider to lose control. Adjustthe throttleleverfree distanceso thatengineidlespeeddoes not risedue to handlebar movement. Throttleleveradjustmentnut Measurethethrottlelever play. 3.0~5.0ram (0.12-0.20inches) Toadjustthethrottleleverfree distance: Loosenthe throttleleveradjustment nut Turnthe largeadjustment nut in or outto obtainthe correctplay.

  • Page 55: Idlespeedadjustment

    IDLESPEEDADJUSTMENT Improperadjustment of the idlespeedcouldbe hazardous. An idle speedthat is too high couldcausetheATVto launchforward when you starttheengine. This may causean accident. Excessiveenginewear mayalso resultif idlespeed isadjustedimproperly or when the engineis not fully warmedup. Adjustthe idleto the correctspeed. Makesurethe engineisfully warmbeforeadjustingtheengineidlespeed. To adjustthe idle speedproperly, y ou need a tachometer.If you do not have one,ask yourauthorizedservicecenterto performthis adjustment.

  • Page 56: Engineoil

    ENGINEOIL Newand usedoil couldbe hazardous. Children and pets maybe harmedby swallowing newor usedoil. Continuous contactwith usedoil can causeskin cancerin laboratory animals. Briefcontactwith the usedoil may irritatetheskin. Keep newand used oil awayfrom childrenand pets. To minimizeyour exposure to usedoil, weara long-sleeve shirtand moisture-proof g loves (suchas dishwashinggloves)when changing oil.

  • Page 57: Changingengineoil

    Changing engine oil The engineoil shouldbe changed every20 to 40 hoursof operation.It should be changedmoreoften in dirtyand dustyareas. To chanqeoil: Parkthevehicleon level ground. Oil Cap Removethe oil cap. Oil drain bolt Removethe drainboltand drain oil intopropercontainer. Reinstallthe drainbolt Pourfresh oil of the specified typethroughtheoil fill hole. NOTE: Approximately 900ml(1 Qt) of oil is required.

  • Page 58: Air Filter

    AIR CLEANER Operatingtheenginewithoutthe air cleanerelementin placecouldbe hazardous. If the air cleanerelementdid not filter dirt, severeenginedamagewould occurif thedirt enteredthe runningengine. Neverrunthe enginewithoutthe air cleanerelementin place. _&, C AUTION Failingto inspectthe air cleanerelement frequently if thevehicleis used in dusty,wet,or muddyconditionscoulddamageyourATV. The air cleanerelementcould becomecloggedundertheseconditions, and enginedamagemay result.

  • Page 59: Removal

    REMOVAL 1. Removeair filter. Loosenclamps Air filter cover Clamp 2. Removeair filter cover. 3. Removefoam air filter element. Foamair filter element WASHING THE ELEMENT Washthe elementas the followinq: 1. Filla washingpan largeenoughto hold the elementwith a nonflammable cleaningsolvent. Immersethe element in thesolventand washit.
  • Page 60 _k CAUTION A tornair filter coulddamageyourATV. Dirtand dust may getinside of theengine if the elementis torn. Examinecarefullytheelementfor tearsbeforeand aftercleaningit. Replacethe elementwith a newone if it is torn. Oil and solventcouldbe hazardous. Childrenand pets couldbe harmedfrom the oil and solvent. Be sureto keepoil and solventawayfrom childrenand pets. Disposeof usedoil and solventproperly.

  • Page 61: Drivechain/Sprockets

    DRIVECHAIN/SPROCKETS The conditionand adjustment of thedrivechainshouldbe checkedbefore riding. Alwaysfollow theguidelinesbelowfor inspecting and servicingthe chain. Failingto maintain the chainproperlybeforeeachridingcouldbe hazardous. Ridingwith the chainin poor conditioncouldleadto anaccident. Besureto inspect a nd maintain the chainbeforeriding, a ccording tothese guidelines. Inspectingthe Drive Chain Wheninspectinq thechain, lookfor thefollowinq: Loosepins Damagedrollers Dry or rustedlinks...

  • Page 62: Drivechaincleaning,Oilingandadjusting

    DRIVECHAINCLEANING,OILINGANDADJUSTING Clean and oil the chain as the following: Washthe chainwithwater. Dry the chain,and then oilthe linkswith Chainlubeor equivalent. Failingto inspectthedrivechainslackbeforeeachuseof theATV could be hazardous. Toomuchchainslackcould causethe chainto comeoff thesprockets, resultingin an accidentor seriousdamageto theATV. Inspectthedrive chainslackbeforeeachuse. Adjusting the Drive Chain 20-30 mm (0.8-1.2 inches) The drivechainshouldbeadjustedand makesure there is20-30 mm...

  • Page 63: Tires

    TIRES OperatingthisATVwith improper tires,or with improper or uneventire pressure. Useof improper tires on thisATV,or operation of this ATVwith improper or uneventire pressure,may causelossof control,increasing yourrisk of an accident. Alwaysusethesize and typeof tires specified. A lwaysmaintainpropertire air pressureas describedin this section. OperatingthisATVwith improper modifications.
  • Page 64 Usingworntires couldbe hazardous. Thetraction ofthevehicle willbedecreased. Thisincreases yourrisk ofhaving anaccident. Replace t hefront andreartires when thedepthonthetread is4.0mm (0.16inches) or less. TheATV is equipped with low pressuretubelesstires of the sizeand type listedbelow: Front Rear Size AT 16X8-7 AT16X8-7 4.0 mm (0.16inches) TireTreadCondition TireAir Pressure Checktheair pressurein all tires beforeriding.
  • Page 65 Overfillingtheair to thetires couldbe hazardous. If you put too muchair intothetire, the tire mayburstcausingsevere injury. Checkthe air pressure from timeto timewhilegraduallyinflatingthe tire, untilthe specifiedair pressureisobtained. Usingtiresthat havebeen installedincorrectly couldbe hazardous. TheATV mayhaveunusualhandlingif thetires are installedincorrectly. The tiresare intendedto rotatein a specificdirection,as indicatedbythe arrowson the sidewallof eachtire.

  • Page 66: Braking

    BRAKING TheATV hastwofront drumbrakesand one reardisk brake. Failingto inspectand maintainyourATV'sbrakesystemproperlycould be hazardous. Impropermaintenance of the brake increases your chanceof havingan accident. Besure to inspectthebrakebeforeridingaccording to the INSPECTION BEFORERIDINGsection. Alwaysmaintain your brakesaccordingto the MAINTENANCE SCHEDULE. OperatingtheATVin harshconditionscouldbe hazardous if you do not inspectbrakewear often.
  • Page 67 Rear Hydraulic Disk Brake Failingto maintain the brakeshoesor padscouldbe hazardous. Ridingwith wornbrakeshoes,pads,or shoesthatare seriouslyworn,will increaseyour chanceof havingan accident. If you needto replacebrakeshoe pads,haveyour authorized service centerdo thework. Inspecting and maintaining the brakeshoepads is recommended.Replacethe shoe padsin sets. Brakefluid Brakefluid cap Brakefluid hose reservoir Brakefluid Level...

  • Page 68: Generallubrication

    GENERALLUBRICATION Properlubrication is importantfor safe,smoothoperation and longlife of your vehicle. Besure thatall lubrication is performedduringperiodicmaintenance on the vehicle. Increaseintervalswhenyou useyourATV in severe conditions.Yourauthorizedservicecentershoulddo generallubrication as shownin the MAINTENANCE CHART.The authorizedservicecenterwill lubricatethe vehiclesuchas wheel bearings, s wingarm bearings, s teering shaftholder,cables,etc. [] ....

  • Page 69: Troubleshooting

    Ak CAUTION Failingtotroubleshoot a problemcorrectly would damageyourATV. Improper repairsor adjustments may damagethe vehicle. Suchdamage may not be coveredunderwarranty. If you are notsure aboutthe proper action,consultyourauthorizedservicecenteror BAJAINC. aboutthe problem. Drainingfuel from thecarburetorcouldbe hazardous. Fuelcouldcatchfire if you do not handleit properly. Whendrainingthe carburetor, b e sureto shut theengineoff. Do not smoke,and neverdrain or refuelin an areawherethere areopenflames or sparks.

  • Page 70: Ignitionsystemcheck

    IgnitionSystemCheck Performing thesparktest improperlycouldbe hazardous. Youcouldgeta highvoltage electrical s hockifyouarenotfamiliar withthis procedure. Do not performthis checkifyou arenot familiar with the procedure.Do not pointthespark plug nearthespark plugholeduringthis test. Do not do this test if you havea heartconditionor wear a pacemaker. D o not performthis test nearany openfuel containers for nearfuel whichhas spilledon the ground,on engine,or any part of theATV.

  • Page 71: Transporting

    Drainingfuel from thecarburetorcouldbe hazardous. Fuelcouldcatchfire if you do not handleit properly. Whendraining fuel from the carburetor, besuretoshuttheengine off. Donot smoke, a ndneverdrainor refuelin anareawherethereareopenflamesor sparks.Donotspillthefuel or youmaycreatea fire hazard.Dispose ofthe drained fuel properly. -& CAUTION Failingto securetheATV properlycouldbe hazardous. Failingto securethevehicleproperlymay resultin an accidentor damage to thevehicle.

  • Page 72: Cleaningprocedure

    -& CAUTION High pressure washers coulddamage your ATV. High pressure washers such as those found at coin-operated carwashes have enough pressure to damagethe parts of your ATV. It may cause rust, corrosionand increase wear. Do not use high pressure washers to cleanyour ATV. Athorough cleaning of yourATVis a necessary partof maintenance.

  • Page 73: Washing Youratv

    WASHING YOURATV Withsomecare,yourATV canbe washedin a similarmannerto washingan automobile. Note: Avoidsprayingor allowingwaterto flow over thefollowing places: Ignitionswitch Sparkplug Fueltankcap Carburetor Usea gardenhoseat low pressure to removethe majorityof dirtor other debris. HandwashyourATVwith mildsoapor detergentand water. Tryto thoroughly removeall dirtand debriswithoutexcessivewaterpressure,even at remoteareassuchas betweenenginecoolingfins, linkagesor mounting brackets.

  • Page 74: Storageprocedure

    If you do notuseyourATVfor an extendedperiod,itwill needspecialservice requiring appropriatematerials,equipment a nd skill. Forthis reason,we recommend thatyou trustthis maintenance work to yourauthorizedservice center. If you wishto servicethe machinefor storageyourself,follow the general guidelinesbelow: VEHICLE Placethevehicleon levelgroundandwashthe entirevehicle. FUEL Drainingthe fuel couldbe hazardous. Fuelcouldcatchfire if you do not handleit properly.

  • Page 75: Serialnumberlocation

    Youneedto knowtheframe and engineserialnumbersto get title documents for yourATV.You also needthesenumbers to helpyour authorizedservicecenteror BAJAINC.order parts. Theframe/vin number is stampedon the front of theframe as shownin the photograph.The engineserialnumberis stampedon the leftside of the crankcase. Frame/kinnumber Engineserialnumber Writedownthe serialnumbersherefor yourfuture reference FrameNo.: EngineNo.:...

  • Page 76: Specifications

    DIMENSIONS AND DRYMASS Overalllength ................. 1400ram(51.2in) Overallwidth..................0mm (37.4in) Overallheight ................... 930ram(36.6in) Wheelbase ..................930mm(36.6 in) Fronttread..................630mm(24.8in) Reartread ..................630mm(24.8in) Groundclearance ................. 100mm(4 in) Seat height ..................650ram(25.61in) Dryweight ..................115Kg(250Ibs) ENGINE Type ..................four stroke,air cooled Number of cylinders ....................BoreX Stroke ..................

  • Page 78: Emission Control Systemwarranty

    BAJAINC. - EMISSION CONTROLSYSTEM WARRANTY YOURWARRANTY RIGHTS AND OBLIGATIONS The emissioncontrolsystemwarrantyperiodfor this vehiclebeginson the datethevehicleis deliveredto thefirst purchaserotherthan anauthorized dealer,or thedate it is first usedas a demonstrator, lease,or company vehicle,whichevercomesfirst and continues for 60 monthsafterthatdate, or 5,000kin, w hichevercomesfirst, provided there hasbeen no abuse,neglector impropermaintenance of yourvehicle.
  • Page 79 Youremissioncontrolsystemwarrantycoverscomponents whosefailure wouldincreasean engine'semission,including electroniccontrols, f uel injec- tionsystem,carburetor, t he ignitionsystem,catalyticconverter, o r any other systemutilizedin this vehicleto controlemissionif it is originallyequipped. Alsoincludedmay be hoses,connectors and otheremission-related assem- blies. Replacing or repairingothercomponents (including parts,labor,and othercosts)not coveredby thisemissioncontrolsystemwarrantyor the standard warrantyisthe responsibility ofthe owner. Coverage of repairsunderthis warrantyappliesonlywhen repairsare com- pletedat an authorized dealeror repairfacility.
  • Page 80 • Useof replacement partsor accessories not conforming to the origi- nal specifications whichadverselyaffect performance • Physicaldamage,corrosion, o r defectscausedby fire, explosionsor similarcausesbeyondthe controlof theDistributor. • Failuresnot causedby a defectin materialor workmanship. Useof thevehiclein any typeof competitive racingor relatedeventsimmedi- atelyand completely voidsthis and all otherwarranties. LIMITEDLIABILITY The liabilityof the Distributor underthis EmissionControlSystemWarranty is limitedsolelyto the remedying of defectsin materialworkmanship by an...
  • Page 81 Motorsports _ Baja, IN(3. RO. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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