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WD90 Read this manual carefully. It contains important safety information. Children under the age of 16 should be supervised by a responsible adult. OWNER’S MANUAL Minimum Age Requirement: 10 Model: 90cc For More information on ATV Safety Contact REV. B...
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“YOUR ATV CAN BE HAZARDOUS TO OPERATE. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. For your safety, understand and follow all the warnings contained in this owner’s manual and the labels on your vehicle.
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Congratulations on your purchase of the WD90 ATV. It is warranted to be free of manufacturing defects in the material and workmanship for a period of 90 days from the date of purchase. During the warranty period BAJA INC. will at its option, repair, provide replacement parts or replace your BAJA INC.
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WARNING 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 important safety information and instructions which should be read carefully before operating the vehicle.
TABLE OF CONTENTS SAFETY .......................3 IMPORTANT ......................3 NOTICE TO THE USER ..................4 ATV 90 ........................8 FUEL AND OIL .....................9 LOCATION OF LABELS ..................10 CONTROL FUNCTIONS ..................13 LEFT HANDLEBAR ..................13 RIGHT HANDLEBAR ...................13 FUEL VALVE ....................14 FUEL TANK CAP ..................14 SEAT LOCK ....................15 REMOTE STOP LANYARD................16 RIDING YOUR ATV ....................17 WHAT YOU SHOULD KNOW BEFORE RIDING ........17...
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TABLE OF CONTENTS IDLE SPEED ADJUSTMENT ...............51 FUEL HOSE ....................51 ENGINE OIL ....................52 CHANGING ENGINE OIL ...............53 AIR FILTER ....................54 REMOVAL ..................55 WASHING THE ELEMENT .............55 DRIVE CHAIN/SPROCKETS ...............57 DRIVE CHAIN CLEANING, OILING AND ADJUSTING ......58 TIRES ......................59 BRAKING .....................62 FRONT DRUM BRAKES ..............62 REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE ....63 GENERAL LUBRICATION ................64...
SAFETY Please read this manual and follow all instructions carefully. To emphasize the special information, the symbol and the words WARNING or CAUTION have some special meanings. Pay attention to the messages. WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in vehicle damage.
SAFETY We believe in conservation and protection of the earth’s natural resources. We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off-road recreational use. NOTICE TO PARENTS This ATV is built for use by children age 10 and older, but the users manual is written for adults who will be supervising the children, we strongly recommend , therefore, that you review this entire manual with your child and carefully explain...
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SAFETY Category Y-10+ ATV. A Category Y-10+ ATV is a youth model ATV that is intended for use by children age 10 or older. Category Y-12+ ATV. A Category Y-12+ ATV is a youth model ATV that is intended for use by children age 12 or older. Category T (Transitional Model) ATV.
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SAFETY · Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slipper or loose surfaces. Shift you weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.
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SAFETY · Never modify an ATV through improper installation or use of accessories. · Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. ·...
ATV 90 Gas Cap vent hose Gas Cap Spark plug Head lights Muffler Rear Tire Oil cap Rear shock RIGHT Thumb throttle Seat Fuel valve Front shocks Tail Light Front Tire Carburetor LEFT...
FUEL AND OIL FUEL Proper fuel is very important for the engine. Ensure there is no dust, dirt, or water which has mixed in the fuel. Use regular unleaded gasoline with an octane number 90 or higher. ENGINE OIL Your 90cc ATV has a four-stroke engine. Please use oil as described in the chart below.
LOCATION OF LABELS Read and follow all of the warnings labels on your ATV. Make sure you understand all the labels. Keep the labels on the ATV. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting BAJA INC.
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LOCATION OF LABELS WARNING NEVER ride as a passenger. Passenger can cause a loss of control, resulting in SEVERE INJURY or DEATH. WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN NEVER USE NEVER CARRY NEVER USE APPROVED HELMET ON PUBLIC...
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LOCATION OF LABELS WARNING Improper tire pressure or overloading can 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 lbs. (100 kg)
CONTROL FUNCTIONS HANDLEBAR & Rear Brake lever SWITCHES Light Switch LEFT HANDLEBAR Engine Stop With the Engine stop switch in the “Stop” position switch Electric Start The engine cannot be started. Button With the Engine stop in the “Run” position The engine can be started.
CONTROL FUNCTIONS Use the throttle adjusting screw to restrict maximum speed of the ATV. Adjust this limiter according to the rider’s skill and experience. Adjusting procedures: Loosen the Lock nut Turn the throttle adjusting screw clockwise to restrict maximum speed of the ATV. Turn the throttle adjusting screw counterclockwise to increase the maximum speed of the ATV.
CONTROL FUNCTIONS WARNING Overfilling the fuel tank could be hazardous. If you overfill the fuel tank, fuel may overflow when it expands. Expanding is due to heat from engine or sun. Overheated fuel could easily catch fire. Stop adding fuel when the fuel level reaches the bottom of the filler neck. WARNING Improper fueling of the ATV could be hazardous.
CONTROL FUNCTIONS REMOTE STOP LANYARD Stop Lanyard Stop Lanyard Your ATV is equipped with a remote stop lanyard. This lanyard should be used when training beginner operators. The adult supervisor should grasp the lanyard and follow behind the ATV while the beginner is learning to operate the ATV.
RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING Before riding, you should read all the following information carefully. If you are properly prepared, you will have a more enjoyable ride. Before riding, you should find a good place to practice the skills. Find a flat, open area with enough space to practice the new skills.
RIDING YOUR ATV INSPECTION BEFORE RIDING WARNING Failing to inspect the ATV before operating could be hazardous. Failing to perform proper maintenance could also be hazardous. Failing to inspect and maintain your ATV could increase the chances of an accident or equipment damage Always inspect your ATV each time before riding, and make sure it is in a safe operating condition.
RIDING YOUR ATV WARNING Checking maintenance items when the engine is running could be hazardous. You could be severely injured if your hands or clothing get caught in moving ATV parts. Shut the engine off when performing maintenance checks, except checking the engine stop switch and throttle.
RIDING YOUR ATV STARTING THE ENGINE Before attempting to start the engine, make sure to follow these steps. Turn the key switch to the “ON” position. Set the engine stop switch to the “RUN“ position. If engine is cold, set choke lever to the up (on) position.
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RIDING YOUR ATV WARNING Running your ATV indoors where there is little or no ventilation. Breathing in exhaust gases from the ATV could cause severe injury. Always run your ATV outdoors where there is fresh air. WARNING Carrying a passenger on this ATV. Greatly reduces your ability to balance and control this ATV.
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RIDING YOUR ATV WARNING Operating this ATV on paved surfaces. The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
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RIDING YOUR ATV WARNING Operating this ATV at excessive speeds could be hazardous. Riding at excessive speeds increases your chances of losing control of the ATV, which could result in an accident. Always go at a speed that is proper for the terrain, visibility, operating conditions, operator skills, and operator experience.
RIDING YOUR ATV SAFETY GEAR A DOT approved motorcycle helmet is the most important part of your safety gear. A DOT approved motorcycle helmet can help prevent a serious head injury. Choose a helmet that fits snugly. Motorcycle dealers can help in selecting a good quality helmet which fits properly.
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RIDING YOUR ATV WARNING Failure to inspect the ATV before operating. Failure to properly maintain the ATV. Increases the possibility of an accident or equipment damage. Always inspect your ATV each time you us it to make sure the ATV is in safe operating condition.
RIDING YOUR ATV WARNING Failure to use extra care when operating on excessively rough, slipper or loose terrain. Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
RIDING YOUR ATV BRAKING Front Brake Rear Brake Throttle Lever To stop the ATV, first release the throttle lever, then apply the rear and front brakes smoothly. WARNING Braking while turning the ATV could be hazardous. Use of the brake when turning could cause the ATV to slide or roll over. Use the brake to slow down before you begin to turn.
RIDING YOUR ATV TURNING To turn the ATV, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to move straight ahead.
RIDING YOUR ATV OPERATION ON HILLS WARNING Operating on excessively steep hills. The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the ATV on hills too steep for the ATV or for your abilities.
RIDING YOUR ATV To climb a hill with the ATV, follow the directions below. Speed up and maintain a steady speed before reaching the top of the hill. Remember that you must ride at a steady speed all the way to the top of the hill. Shift your body forward by sliding forward on the seat.
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RIDING YOUR ATV To ride down a hill with the ATV, follow the instructions below. Check the terrain carefully for any obstacles before you go down the hill. Point the ATV straight down the hill. Transfer your body to the rear by sliding back on the seat.
RIDING YOUR ATV When traversing a slope, you should: Lean your body uphill. Steer slightly uphill, if necessary, to maintain a straight course. WARNING Stalling, rolling backwards or improperly dismounting while climbing a hill. Could result in ATV overturning. Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
RIDING YOUR ATV If you come to an obstacle that you cannot avoid, you may be able to cross over it by using the following procedure. If the obstacle is in front of you, approach at walking speed. Rise up slightly on the footrests. Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle.
RIDING YOUR ATV RIDING THROUGH WATER You can ride the ATV through shallow water. Make sure it is not more than 10cm (4 inches) deep and is not moving fast. Choose a good place to cross before you ride through the water. Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard.
RIDING YOUR ATV RIDING IN COLD WEATHER Pre-ride Inspection Check that the throttle and all control levers move freely. Make sure that the footrests are free of ice or snow. Move the ATV forward and backward to check that the wheels roll freely. If you cannot move the ATV, the tires may be frozen to the ground, or the brakes may be frozen to the wheels.
RIDING YOUR ATV DRESSING FOR COLD WEATHER RIDING WARNING Operating your ATV in cold weather without proper clothing could be hazardous. Continued exposure in the cold weather could lead to hypothermia. Hypothermia is a condition where your body’s inner temperature drops low enough to cause injury or death.
RIDING YOUR ATV RIDING YOUR ATV ON SNOW AND ICE WARNING Riding on snow-covered terrain, even with care, could be hazardous. The snow may be covering rocks, holes, ice or other hazards that can cause loss of control. Severe injury or death could occur if you lose control of the ATV. Go slowly and be careful when riding on snow-covered terrain.
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ACCESORY USE AND VEHICLE LOADING ACCESSORY USE AND VEHICLE LOADING WARNING Operating this ATV with improper modifications could be hazardous. Improper installation of accessories or modifications of the vehicle may cause changes in handling which could lead to an accident. Never modify the ATV with improper installation or use of improper accessories.
ACCESORY USE AND VEHICLE LOADING Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle. Locate cargo weight as close to the center of the vehicle if possible. Secure your load well. Shifting weight can affect your ability to handle the vehicle safely.
INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE It is very important to inspect and maintain your ATV regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed. Interval Initial 1 month/ Every 3...
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INSPECTION AND MAINTENANCE WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your ATV you may have an accident. Keep your ATV in good condition. Ask your authorized service center or a qualified mechanic to do the maintenance items marked with an asterisk (*).
INSPECTION AND MAINTENANCE TOOLS A tool kit is provided with your ATV. SPARK PLUG Your ATV is equipped with a T1136 spark plug. To determine if the standard spark plug is in good condition, check the color of the plug’s center electrode insulator after vehicle operation.
INSPECTION AND MAINTENANCE NOTE: This ATV uses resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interference with your ATVs ignition system, resulting in the vehicle performance problems. Use recommended spark plugs. To install a spark plug turn it in as far as possible with your fingers, then tighten it with a wrench.
INSPECTION AND MAINTENANCE BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: Eye Protection Rubber Gloves WARNING The following procedure is very dangerous and should be performed with the utmost care and attention. Wear protective eyewear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes. KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
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INSPECTION AND MAINTENANCE Note: The following page is for vehicles with battery’s containing separate electrolyte pack. Most battery’s will come with the electrolyte already sealed into the battery. Preparing the battery: · Place battery on level surface. Remove sealing tape from top.
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INSPECTION AND MAINTENANCE How to Initially Charge the battery: Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 23) Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure 24) Note: The red positive (+) cable has a larger Figure 23...
INSPECTION AND MAINTENANCE Battery Replacement: WARNING · DO NOT open sealed caps to add water to battery. · Always wear safety glasses and charge in a ventilated area. · If battery gets hot to the touch, discontinue charging and allow battery to cool down.
INSPECTION AND MAINTENANCE ENGINE SPEED GOVERNOR The ATV governor is set by the factory to limit speed of ATV to 15mph (24km/h) directly out of crate. The governor can be adjusted to allow the ATV to travel up to 30mph (48km/h). Any adjustment to governor should be performed by a responsible adult.
INSPECTION AND MAINTENANCE THE ADJUSTMENT OF THROTTLE LEVER WARNING Operating the vehicle with an inadequate throttle lever free distance could be hazardous. Inadequate throttle lever free distance could cause engine speed to rise suddenly when you turn the handlebars. This can lead the rider to lose control.
INSPECTION AND MAINTENANCE IDLE SPEED ADJUSTMENT WARNING Improper adjustment of the idle speed could be hazardous. An idle speed that is too high could cause the ATV to launch forward when you start the engine. This may cause an accident. Excessive engine wear may also result if idle speed is adjusted improperly or when the engine is not fully warmed up.
INSPECTION AND MAINTENANCE ENGINE OIL WARNING New and used oil could be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used oil can cause skin cancer in laboratory animals. Brief contact with the used oil may irritate the skin. Keep new and used oil away from children and pets.
INSPECTION AND MAINTENANCE Changing engine oil The engine oil should be changed every 20 to 40 hours of operation. It should be changed more often in dirty and dusty areas. To change oil: Park the vehicle on level ground. Oil Cap Remove the oil cap.
INSPECTION AND MAINTENANCE AIR CLEANER WARNING Operating the engine without the air cleaner element in place could be hazardous. If the air cleaner element did not filter dirt, severe engine damage would occur if the dirt entered the running engine. Never run the engine without the air cleaner element in place.
INSPECTION AND MAINTENANCE REMOVAL 1. Remove air filter. Loosen clamps Air filter cover Clamp 2. Remove air filter cover. 3. Remove foam air filter element. Foam air filter element WASHING THE ELEMENT Wash the element as the following: 1. Fill a washing pan large enough to hold the element with a nonflammable cleaning solvent.
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INSPECTION AND MAINTENANCE CAUTION A torn air filter could damage your ATV. Dirt and dust may get inside of the engine if the element is torn. Examine carefully the element for tears before and after cleaning it. Replace the element with a new one if it is torn. WARNING Oil and solvent could be hazardous.
INSPECTION AND MAINTENANCE DRIVE CHAIN/SPROCKETS The condition and adjustment of the drive chain should be checked before riding. Always follow the guidelines below for inspecting and servicing the chain. WARNING Failing to maintain the chain properly before each riding could be hazardous.
INSPECTION AND MAINTENANCE DRIVE CHAIN CLEANING, OILING AND ADJUSTING Clean and oil the chain as the following: Wash the chain with water. Dry the chain, and then oil the links with Chain lube or equivalent. WARNING Failing to inspect the drive chain slack before each use of the ATV could be hazardous.
INSPECTION AND MAINTENANCE TIRES WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
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INSPECTION AND MAINTENANCE WARNING Using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident. Replace the front and rear tires when the depth on the tread is 4.0 mm (0.16 inches) or less.
INSPECTION AND MAINTENANCE WARNING Overfilling the air to the tires could be hazardous. If you put too much air into the tire, the tire may burst causing severe injury. Check the air pressure from time to time while gradually inflating the tire, until the specified air pressure is obtained.
INSPECTION AND MAINTENANCE BRAKING The ATV has two front drum brakes and one rear disk brake. WARNING Failing to inspect and maintain your ATV’s brake system properly could be hazardous. Improper maintenance of the brake increases your chance of having an accident.
INSPECTION AND MAINTENANCE Rear Hydraulic Disk Brake WARNING Failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, or shoes that are seriously worn, will increase your chance of having an accident. If you need to replace brake shoe pads, have your authorized service center do the work.
INSPECTION AND MAINTENANCE GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and long life of your vehicle. Be sure that all lubrication is performed during periodic maintenance on the vehicle. Increase intervals when you use your ATV in severe conditions.
TROUBLESHOOTING CAUTION Failing to troubleshoot a problem correctly would damage your ATV. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty. If you are not sure about the proper action, consult your authorized service center or BAJA INC. about the problem.
TROUBLESHOOTING Ignition System Check WARNING Performing the spark test improperly could be hazardous. You could get a high voltage electrical shock if you are not familiar with this procedure. Do not perform this check if you are not familiar with the procedure. Do not point the spark plug near the spark plug hole during this test.
TRANSPORTING WARNING Draining fuel from the carburetor could be hazardous. Fuel could catch fire if you do not handle it properly. When draining fuel from the carburetor, be sure to shut the engine off. Do not smoke, and never drain or refuel in an area where there are open flames or sparks.
CLEANING PROCEDURE CAUTION High pressure washers could damage your ATV. High pressure washers such as those found at coin-operated car washes have enough pressure to damage the parts of your ATV. It may cause rust, corrosion and increase wear. Do not use high pressure washers to clean your ATV. A thorough cleaning of your ATV is a necessary part of maintenance.
CLEANING PROCEDURE WASHING YOUR ATV With some care, your ATV can be washed in a similar manner to washing an automobile. Note: Avoid spraying or allowing water to flow over the following places: · Ignition switch · Spark plug · Fuel tank cap ·...
STORAGE PROCEDURE If you do not use your ATV for an extended period, it will need special service requiring appropriate materials, equipment and skill. For this reason, we recommend that you trust this maintenance work to your authorized service center. If you wish to service the machine for storage yourself, follow the general guidelines below: VEHICLE Place the vehicle on level ground and wash the entire vehicle.
SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your ATV. You also need these numbers to help your authorized service center or BAJA INC. order parts. The frame/vin number is stamped on the front of the frame as shown in the photograph.
BAJA INC. – EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
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Your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injec- tion system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assem- blies.
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• Use of replacement parts or accessories not conforming to the origi- nal specifications which adversely affect performance • Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. • Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immedi- ately and completely voids this and all other warranties.