Download Baja WD400U-2 Specifications

MinimumAge Requirement 16
For Moreinformationon ATV Safety Contact
the Baja ATV Safety Hotline at: 866-260-8630
Always weara helmet; it couldsaveyour life!
Do not remove this operator'smanualfrom this vehicle, according to guidelines with the U.S.Consumer Product Safety Commission.
Pleaseobtain,review and follow provincial/municipalgovernmentsacts and
regulations pertainingto owningand operatingan off-roadvehicle.
REV.B (US)
012809
"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. Failureto follow these warningcan result in
SEVER INJURYOR DEATH.
Keep the owner's manualwith your vehicle at all times."
Failureto follow the agerecommendations
for thisATV.
Failureto supervisechildrenunder16 on ATVmodelsintendedfor theiruse.
Use bychildrenof ATVsthat are not recommendedfor theirage canlead to severe
injuryor deathof the child.
Eventhougha childmay bewithin theage groupfor whichanATV is recommended
he or she may nothavethe skills,abilities,or judgementneededto operatetheATV
safelyand may be involvedin a seriousaccident.
CategoryY (YouthModel)ATV.An ATVof appropriatesize intendedfor recreational
use underadultsupervisionbyan operatorunderage 16.YouthmodelATVs can
further be categorizedas follows:
CategoryY-6+ATV.A CategoryY-6+ATV is a youthmodelATVthat is intendedfor
use bychildrenage 6 or older
CategoryY-10+ATV.A CategoryY-10+ATVis a youthmodelATVthat is intendedfor
use bychildrenage 10 or older.
CategoryY-12+ATV.A CategoryY-12+ATVis a youthmodelATVthat is intendedfor
use bychildrenage 12 or older.
CategoryT (TransitionalModel)ATV.A CategoryT ATV is anATVof appropriate
size thatis intendedfor recreationaluseby an operatorage 14 or older underadult
supervision,or by an operatorage 16 or older.
Motorsports
Congratulations
on yourpurchaseof the BajaInc. WD400U-2ATV.
ThisATV is guaranteedto be free of manufacturing
defects in
materialand workmanshipfor a periodof 90 daysfrom the dateof
purchase.DuringthewarrantyperiodBAJAINC.will at itsoption,
repair,providereplacementpartsor replaceyour Baja Inc.400cc
ATVat no charge. Thiswarrantydoesnot covernormalwearitems
or damagecausedby neglector misuseof theproduct.
Engine Warranty- 90 days
FrameWarranty - 90 days
Warrantyis void if:
Frame is bent or broken due to abuse
The wheelsare bent or broken
Fenderbent or brokendue to abuse
Any signof impact,accident,jumping,spin-outsor rollover.
BAJAMOTORSPORTS
is notliablefor anydamageclaim or
liabilityclaimpersonalor otherwiseresultingfrom the operationof
this productin anyway.
Shouldyou experiencea problemwith yourvehicle,pleasecall Baja Inc.
customerserviceline tollfree at 1-888-863-2252betweenthehoursof
7am and 5proMondaythroughFridayMST(MountainStandardTime).
MDT(MountainDaylightTime)duringthedaylightsavingtime.You willbe
instructedhow to proceed.
A COPYOFTHE SALES RECEIPTIS REQUIRED.
III
This manualshould be consideredas a permanent
part of the vehicle and should remainwith the
vehicle when resold or otherwisetransferredto
a new owner or operator. The manual contains
importantsafety informationand instructions
which should be read carefully before operatingthe
vehicle.
The engine exhaust from this productcontains
chemicalsknownto the State of Californiato cause
cancer,birth defects or other reproductiveharm.
CALIFORNIAPROPOSITION65
IV
Tableof Contents
IMPORTANT........................................................................................................
3
FOREWORD........................................................................................................
3
NOTICETOTHE USER.......................................................................................
4
BAJAINC.WD400U-2ATV.................................................................................
8
FUELAND OIL.....................................................................................................
9
LOCATIONOFWARNINGLABELS...................................................................
10
INDICATORLIGHTS............................................................................................
12
HANDLEBAR& SWITCH....................................................................................
13
LEFTHANDLEBAR.....................................................................................
13
RIGHTHANDLEBAR
...................................................................................
14
REARFOOTBRAKE..................................................................................
14
FUELVALVE................................................................................................
15
FUELTANKCAP.........................................................................................
15
SEATLOCK.................................................................................................
16
RIDINGYOURATV..............................................................................................
17
BEFORERIDING.........................................................................................
17
INSPECTIONBEFORERIDING..................................................................
18
SAFETYGEAR............................................................................................
20
BREAK-IN....................................................................................................
21
STARTINGTHE ENGINE.............................................................................
25
STARTINGOFF ...........................................................................................
26
MANUALPULLSTART...............................................................................
27
DRIVESELECT.
............................................................................................
28
2WD/4WDBUTTON.....................................................................................
29
BRAKING.....................................................................................................
30
TURNING.....................................................................................................
31
OPERATIONON HILLS...............................................................................
32
RIDINGOVEROBSTACLES.......................................................................
35
SKIDDINGORSLIDING..............................................................................
36
RIDINGTHROUGHWATER........................................................................
37
RIDINGIN COLDWEATHER......................................................................
38
DRESSINGFORCOLDWEATHERRIDING...............................................
39
RIDINGON SNOWORICE.........................................................................
40
ACCESSORYUSEAND VEHICLELOADING....................................................41
INSPECTIONAND MAINTENANCE...................................................................
43
TOOLS.........................................................................................................
45
SPARKPLUG..............................................................................................
45
VALVEINSPECTION
.......................................................................................
47
BATTERYINSTALLATION..........................................................................
48
FUSEREPLACEMENT
................................................................................
52
Tableof Contents
HEADLIGHT/TAILLIGHT
REPLACEMENT
.................................................52
THROTTLELEVERADJUSTMENT............................................................
53
IDLESPEEDADJUSTMENT.......................................................................
54
FUELHOSE.................................................................................................
54
ENGINEOIL/OILFILTER.............................................................................
55
AIR FILTER..................................................................................................
57
FRONT/REARGEARCASELUBRICATION..............................................60
TIRES...........................................................................................................
61
FRONTDISKBRAKES...............................................................................
64
REARDRUMBRAKE .................................................................................
64
MUFFLER/SPARKARRESTER..................................................................
66
OIL COOLERCLEANINGPROCEDURE
....................................................68
GENERALLUBRICATION
...........................................................................
70
TROUBLESHOOTING
.........................................................................................
71
TRANSPORTING
.................................................................................................
74
CLEANINGPROCEDURE
...................................................................................
75
STORAGEPROCEDURE
....................................................................................
77
SERIALNUMBERLOCATION............................................................................
78
SPECIFICATIONS
................................................................................................
79
EMISSIONSYSTEMCONTROLWARRANTY
....................................................
Pleaseread this manualand follow all instructionscarefully.To emphasize
thespecialinformation,the symbolA and thewordsWARNINGor CAUTION
havesomespecialmeanings.Pay greatattentiontothe messages.
Indicatesa potentialhazardthatcouldresultin deathor injury.
-& CAUTION
Indicatesa potentialhazardthatcouldresultin vehicledamage.
NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONare arrangedlikethis:
The first partwill identify a POTENTIALHAZARD.
The secondpartwill describeWHATCOULDHAPPENif you ignore
theWARNINGor CAUTION.
The third partwilldescribeHOWTOAVOIDTHEHAZARD.
Thisuser'smanualcontainsimportantsafetyand maintenanceinformation.
Read it carefullybeforeriding. Failingto follow thewarningscontainedin this
manualcouldresultin INJURYor DEATH.
It is importantthatthis manualremainwith the vehiclewhenyou transferit to
anotheruser or owner.
All information,illustrations,photographsand specificationscontainedin
this manualare basedon the latestproductinformationavailableat the time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesin this manual. We reservetheright to makeproductchanges
at any time,withoutnoticeand withoutincurringanyobligationto makethe
sameor similar changesto thevehiclepreviouslybuiltor sold.
Webelieve
inconservation
andprotection
oftheearth's
natural
resources.
We
encourage
everyvehicle
owner
andoperator
todothesame
byobeying
posted
signsandridingonlyinareas
designated
andapproved
foroff-road
recreational
use.
NOTICE TO PARENTS
ThisATV is builtfor useby childrenage 16 andolder,butthe users manualis
writtenfor adultswho will besupervisingthechildren,we stronglyrecommend,
therefore,that you reviewthisentiremanualwithyour childand carefullyexplain
the instructions,requirements,and warningsit containsso thatyour childcan
understandthem.
Childrendifferin skills, physicalabilities,andjudgement. Somechildrenmaynot
beable to operateanATV safely. Parentsshouldsupervisetheirchild'suseof the
ATV at all times. Parentsshouldpermitcontinueduseonly if theydeterminethat
the child hastheability tooperatetheATV safely.
It is veryimportantthat everychildwho ridestheATVshouldcompletea training
course.
THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE. An ATV
handles differently from other vehicles including motorcycles and cars. 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.
SEVEREINJURYOR DEATHcanresultifyou do not follow theseinstructions:
Readthis manualand all labelscarefullyand follow the operatingprocedures
described.
NeveroperateanATVwithoutproperinstruction.Takea traininqcourse.
Beginnershouldreceivetrainingfrom a certifiedinstructor.Contactan
authorizedATVdealeror call SVIAat 1-800-887-2887to find out aboutthe
trainingcoursesnearestyou.
Alwaysfollow theseagerecommendations:
CategoryY (YouthModel)ATV.An ATVof appropriatesize intendedfor recreational
useunderadultsupervisionby an operatorunderage 16.YouthmodelATVscan
further be categorizedas follows:
CategoryY-6+ATV.A CategoryY-6+ATV isa youthmodelATVthat is intendedfor
useby childrenage 6 or older
Category
Y-10+
ATV.
ACategory
Y-10+
ATVisayouthmodel
ATVthatisintended
for use bychildrenage 10 or older.
CategoryY-12+ATV.A CategoryY-12+ATV is a youthmodelATV thatis intended
for use bychildrenage 12 or older.
CategoryT (TransitionalModel)ATV.A CategoryT ATV is anATVof appropriate
size thatis intendedfor recreationalusebyan operatorage 14 or older underadult
supervision,or by an operatorage 16 or older.
Neverallowa childunderage 16 to operateanATVwithoutadultsupervision,
and neverallowcontinueduse ofan ATVby a child if heor shedoes not have
theabilitiesto operateitsafely.
Nevercarrya passengeron anATV.
NeveroperateanATVon anypavedsurfaces,includingsidewalks,driveways,
parkinglots andstreets.
NeveroperateanATVon anypublicstreet, roador highway,evena dirtor
gravelone.
NeveroperateanATVwithoutwearingan approvedmotorcyclehelmetthat
fits properly.Youshouldalso weareye protection(gogglesor face shield),
gloves,boots,long-sleevedshirtor jacket,and long pants.
Neverconsumealcoholor drugs beforeor whileoperatingthisATV.
NeveroperatethisATVat excessivespeeds.Alwaysgo at a speedthatis
properfor the terrain,visibilityand operatingconditions,andyourexperience.
Neverattemptwheelies,jumps,or otherstunts.
AlwaysinspectyourATVeachtimeyou use it to makesure it is in safe
operatingcondition.Alwaysfollow the inspectionand maintenance
proceduresandschedulesdescribedin this manual.
Alwayskeepboth handson the handlebarsand bothfeet on thefootrestsof
theATVduringoperation.
Alwaysgo slowlyand be extracarefulwhen operatingon unfamiliarterrain.
Alwaysbealert to changingterrain conditionswhenoperatingtheATV.
Neveroperateon excessivelyrough,slipperyor looseterrain untilyou have
learnedand practicedtheskillsnecessaryto controlthe ATVon such terrain.
Alwaysbeespeciallycautiouson thesekindsof terrain.
Alwaysfollow properproceduresfor turningas describedin this manual.
Practiceturningat low speedsbeforeattemptingto turnat faster speeds.Do
not turnat excessivespeeds.
NeveroperatethatATVon hills too steepfor theATVor for your abilities.
Practiceon smallerhills beforeattemptinglargerhills.
Always
follow
properproceduresfor climbinghillsas describedin this
manual.Checkthe terraincarefullybeforeyou startup any hill.Neverclimb
hillswith excessivelyslipperor loosesurfaces.Shiftyou weightforward.
Neveropenthethrottlesuddenlyor makesuddengearchanges.Nevergo
overthe top of any hillat high speed.
Alwaysfollow properproceduresfor goingdownhills andfor brakingon hills
as describedin this manual.Checktheterraincarefullybeforeyou startdown
anyhill. Shiftyourweightbackward.Nevergo downa hill at highspeed.Avoid
goingdowna hill at ananglethatwould causethevehicleto leansharplyto
one side.Gostraightdownthe hill wherepossible.
Alwaysfollow properproceduresfor crossingthe sideof a hillas described
in this manual.Avoidhillswith excessivelyslipperyor loosesurfaces.Shift
your weightto the uphillside ofthe ATV.Neverattemptto turn theATVaround
on any hill untilyou havemasteredtheturningtechniquedescribedin this
manualon levelground.Avoidcrossingthe sideof a steephill if possible.
Always useproperproceduresif you stall or roll backwardswhenclimbing
a hill. To avoidstalling,use propergearand maintaina steadyspeedwhen
climbinga hill.If you stall or roll backwards,follow the specialprocedurefor
brakingdescribedin this manual.Dismounton the uphillsideor to a side
if pointedstraightuphill.TurntheATVaroundand remount,following the
proceduredescribedin this manual.
Always checkfor obstaclesbeforeoperatingin a newarea.Neverattempt
to operateover largeobstacles,such as largerocksor fallen trees.Always
follow properprocedureswhenoperatingoverobstaclesas describedin this
manual.
Always becarefulwhenskiddingor sliding. Learnto safelycontrolskidding
or slidingby practicingat low speedsand on level,smoothterrain. On
extremelyslipperysurfaces,such as ice, go slowlyand bevery cautiousin
orderto reducethe chanceof skiddingor slidingout of control.
NeveroperateanATV in fast flowing wateror in waterdeeperthan that
specifiedin this manual. Rememberthatwet brakesmayhavereduced
stoppingability. Testyour brakesafterleavingwater. If necessary,apply
themseveraltimesto let friction dry out the linings.
Always usethesize and typetires specifiedin this manual.Alwaysmaintain
propertire pressureas describedin this manual.
Never
modify
anATVthrough
improper
installation
oruseofaccessories.
Never
exceed
thestated
loadcapacity
for an ATV. Cargoshouldbe properly
distributedand securelyattached.Reducespeedand follow instructionsin
this manualfor carryingcargo.Allowgreaterdistancefor braking.
The combinedweightof the riderand anyaccessoriesor cargomustnever
exceedthevehicle'sload capacityof 463 Ibs (210kg).
Do not towa trailer. Thisvehicleis not designedfor such use.
FOR MOREINFORMATION
ABOUTATV SAFETY,callthe ConsumerProductSafety
Commissionat 1-800-638-2772,SVIA 1-800-887-2877,
or BajaSafety Hotlineat
1-866-260-8630
WD400U-2
Fuel valve
Two/Fourwheel
Manual pull start
transforming button
Headlight
Front tire
Taillight
Oil fill
plug
Rear shock
[Left]
Rear luggage
carrier
Seat cushion
Fuel
cap
Front luggage
carrier
bumper
Exhaust
silencer
Rear tire
Front
shocks
Brake pedal
[Right]
FUELAND OIL
FUEL
The properfuel is very important for the engine. Ensurethatthere is no
dust,dirt,or waterwhichhas mixedin thefuel. Pleaseuseregularunleaded
gasoline
ENGINEOIL
Your400ccATVhasa four-stroke engine. Pleaseuseoil as describedin the
chartbelow. By usingthe prescribeoil, you will realizethe bestlubricationfor
theengine.
ENGINE
I
°C
-30
-20
-10
0
10
20
30
40
°F
-22
-4
14
32
50
68
86
104
TEMP,
Usethe chartto selecta viscosityratingbasedon the temperaturerangein
yourarea.
LOCATIONOF WARNING LABELS
Readand follow all of the warnings labels on yourATV. Makesureyou
understandall the labels. Keepthe labelson the ATV. Do not removethem
for any reason. If a labelcomesoff or becomesdifficultto read,you should
geta replacementby contactingBajaMotorsports.
10
Improper ATV use can result in
ALWAYS USE AN
APPROVED HELMET
AND PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
SEVERE INJURY
or DEATH
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER OPERATE :
•
•
•
•
Without proper training or instruction.
At speeds too fast for your skills or the condition.
On public roads, a collision can occur with
another vehicle.
With passenger-passengers
affect balance and
steering and increase risk of losing control.
NEVER ride as a passenger.
Passenger can cause a loss
of control, resulting in
SEVERE INJURY or DEATH.
ALWAYS :
•
•
Use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
Avoid paved surfaces-pavement may seriously affect
handling and control.
LOCATE AND READ OWNER'S MANUAL CAREFULLY BEFORE OPERATING.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
IMPROPER TIRE PRESSURE OR
OVERLOADING CAN CAUSE LOSS
OF CONTROL.
Operation
of the ATV by children under
the age of 16 increases the risk of severe
injury or death.
LOSS OF CONTROL CAN RESULT
IN SEVERE INJURY OR DEATH.
NEVER permit children under age 16
-to operate this ATV.
COLD TIRE PRESSURE:
Recommended: Front 5psi, Rear 5psi
Never set tire pressure below the
recommended level. It could cause the tire to
dislodge from the rim.
LOADING
Maximum vehicle capacity is: 210Kg (463 Ibs.)
Maximum capacity includes theweight of the
operator, cargo, and accessories plus the veritcal
weight on trailer hitch.
11
INDICATORLIGHTS
Headlight Fan
Kilometers/
hour
Milesper hour
FourWheelDrive
NeutralLight
Indicator
Indicator
Km/hto mphbutton
Oil Temperature
warning
ReverseLight
Indicator
Reverse light indicator- Lightwill illuminatewhentheATV is in Reverse.
Neutral light indicator- Lightwill illuminatewhen theATV isin Neutral.
Four wheel drive indicator- Lightwill illuminatewhen theATVis infour
wheel drive,2WD/4WDbuttonis pressedIn.
Oil Temperature warning- Lightwill illuminatewhen oiltemperatureistoo
hot.Stopthe engineas soonas possibleand allowengineto coolfor at least
10 minutes.
Fan- Lightwill illuminatewhenfan is"ON".
Headlight- Lightwill illuminatewhen headlightsare "ON".
Kilometers/hour- Lightwillilluminatewhenodometeris readingin kilometers.
Miles per hour- Lightwill illuminatewhen odometeris readingin miles.
12
LEFTHANDLEBARSWITCHES
AND PARKINGBRAKE
Parkit
Lig
On/Off
switch
StartButton
ManualChokelever
Closed
Open
Light switch
Whenswitch is in thetop positiontheheadlight,taillightand meterlightilluminates.Whenswitchis in the centerthetaillightand meterlightilluminates.
Whenswitch is in the bottompositionthe headlight,taillightand meterlight
willNOT comeon.
On/Off switch
On.Whenthe switchis placedin this positiontheengine ison.
Off.Whentheswitch is placedin this positionthe engineis off.
Start Button
Depressstart buttonto startthe engine.
Manual Choke switch
Whenswitch is left,the chokeis closed.Whenswitchis right,thechoke is
open.
Parking Brake
Whenthe parkingbrakeis set theATVwill not be able to move. To set: Hold
brakehandlein and pushparkingbrakedown.
13
RIGHTHANDLEBAR,FRONTBRAKE
LEVERAND THUMBTHROTTLE
Brakefluid reservoir
Frontbrake
lever
Throttlecable
adjustment
Throttlelever
2WD/4WDbutton
Throttle lever
Controlsengineand ATVspeed.Operatethis leverwithyour thumb.
Push itforwardto increaseengineandATV speed. Releaseit to
decreaseengineand ATVspeed.
Front brake lever
Squeezelevertowardhandgrip toapplyfront brakes.
2WD/4WD button
Whenthis buttonis depressedtheATV is in Fourwheeldrive.When
buttonis pressedagain(buttonout), theATV isTwowheeldrive.
Only pressthis buttonwhentheATV is stopped.Do not pressthis
buttonwhiletheATV is moving.
Throttle cable adjustment
Removecoverand rotatethrottlecableadjustingscrewto adjustthe
slackof throttlecable.
REARFOOTBRAKE
Footbrakelocatedon the right handside of the
ATV. Footbrakestopsthe rearwheels.
14
FUELVALVE
This vehicle has one manually operated fuel valve. There are 3 positions
"ON....
OFF....
RESERVE"
"ON" position (arrow pointing down)
In this position, fuel is allowedto flow into the carburetorwhen the
engineis running or being started.
"OFF" position(arrowpointingleft)
In this positionthe fuel is shutoff from the carburetor.Thefuel
valveneedsto be placedin this positionwhen theATV isnot in use
"RESERVE"position(arrow pointingup)
If the fuel level in the fuel tank becomesto low for the engineto
stay runningwhilethe fuel valve is in the "ON" position,turn
thefuel valveto "RESERVE". Thiswill allowtheengineto begin
usingthe reservefuel supply.Youwill needto re-fuelas soonas
possible.Oncere-fueled,turnthevalve backto the "ON "Position
FUELTANKCAP
Toopenthe fuel tank cap, takethe end of the
vent tube outfrom thevehiclebody;turnthe
fuel tank capcounterclockwise.To closethe
fuel tank cap,turn it clockwiseand close it
securely. Besure thatthevent tubesecurely
connectsto the capas shown
Fuellevel
15
Overfillingthefuel tank couldbe hazardous.
If you overfillthefuel tank, fuel may overflowwhen it expands.
Expandingis due to heatfrom engineor sun. Overheatedfuel could
easilycatchfire.
Stopaddingfuel whenthe fuel level reachesthe bottomofthe filler
neck.
Improperfueling of theATVcould behazardous.
Failingto follow safety precautionswhen refuelingcouldresultin a
fire or letyou to breathetoxicfumes.
Refuelin a well ventilatedarea. Makesure the engineisoff and
avoidspillingfuel on a hot engine. Do not smoke,and makesure
thereare no openflames or sparksin thearea. Avoidbreathing
gasolinevapors. Keepchildrenand petsawaywhenyou are
refuelingtheATV.
SEATLOCK
To removetheseat, pullthe seat locklever
up. Raisethe rearend of the seatand slideit
back
To lockthe seat,slidetheseat lever intoits
retainerand pushdownfirmly.
Improperlyinstallingtheseat couldbe hazardous.
Failingto installthe seat properlycouldallowtheseat to moveand
causethe riderto losecontrol.
Makesure you are in properpositionandthe seat is attached
securelywhen installed.
16
RIDINGYOURATV
WHATYOUSHOULDKNOWBEFORERIDING
Beforeriding,you shouldreadall the following informationcarefully.If you
are properlyprepared,you will havea moreenjoyableride.
Beforeriding,you shouldfind a goodplaceto practicetheskills. Finda flat,
openareawith enoughspaceto practicethe newskills.
OperatingthisATVwithoutproperinstruction.
The riskof an accidentis greatlyincreasedif the operatordoes not know
how tooperatetheATV properlyin differentsituationsand on different
typesofterrain.
Beginningand inexperienced
operatorsshouldcompletethe certified
trainingcourseofferedbySVIA (www.svia.org).
Theyshouldthen
regularlypracticethe skillslearnedin the courseandthe operating
techniquesdescribedin theowner'smanual.
Formore informationaboutthe trainingcourse,contactan authorized
ATVdealeror call SVIAat 1-800-887-2887.ForMoreinformationon ATV
SafetyContacttheBajaATVSafety Hotlineat: 866-260-8630
Makesurethatitis legalto ridein theareayouselected.Reviewthelocallawsand
makesureyou arenottrespassing.Callthepoliceifyoudon'tknowwhereyou
canride.
Protectyour ridingareas.Whenyou are riding,rememberto keeptheterrain
in good condition.Don'tdestroyplants,treesor othervegetation.Don'tlitter
and don'tbotherwildlife.Withyourhelp,your ridingareacanremainopenfor
usein thefuture.
After you havefound a goodplaceto practice,reviewthe controlsystemon
yourATV beforeriding.Learnto find thesecontrolswithoutlookingfor them,
becauseyouwill nothavetimeto lookfor themwhen you are riding.
Canadianresidentsmustobtain,review,andfollow all provincialandmunicipal
government
actsand regulations
pertaining
to owningandoperatinganoff-road
vehicle.
17
INSPECTIONBEFORERIDING
ITEMTO CHECK
CONTENT
Steering
Smoothness;Norestrictionofmovement;Noplayor
looseness
Brakes
Properbrake leverfree play;enoughbrakeforce;
Parkingbrakeeffectiveness
Tires
Properair pressure;Enoughtreaddepth;No cracks,
rips,or otherdamages
Fuel
Enoughfuel for theintendedtrip;Fuelhoseconnected
securely;Nodamagetofuel tankor cap;Fueltankcap
closedsecurely
Enginestopswitch
Properoperation
Engineoil
Properlevel- Checkoil by inspectingEngineOil
DipStick. The engineoil shouldbe betweenthe
Minimumand Maximumlines.
Throttle
Properfree play of throttlelever;smoothresponse;
quick returnto idle position
Generalcondition
Boltsand nutsare tight;no rattlefrom any partsof
the enginewhen running, no visibleevidenceof
Damage
Failingto inspectthe ATVbeforeoperatingcouldbe hazardous.Failing
to performpropermaintenancecouldalso be hazardous.
Failingto inspectand maintainyourATVcould increasesthechancesof
an accidentor equipmentdamage
Alwaysinspect
yourATVeachtimebeforeriding,andmakesureitisina safe
operating
condition.
RefertotheINSPECTION
ANDMAINTENANCE
sectionin
thismanual.
18
Operating
thisATVwithimproper
tires,or improper
tireairpressurecouldbehazardous.
If you use impropertires or improperair pressure,you may losecontrolof the
ATV. Thiswill causean accident.
Alwaysuse thetires with sizeand typetires specifiedin this user'smanual.
Alwaysmaintainpropertire air pressureas describedin the INSPECTIONAND
MAINTENANCEsection.
Overloadingcouldbe hazardous.
Overloading
couldcausechangesinvehiclehandlingandcouldleadto anaccident.
Neverexceedthe statedloadcapacityfor this ATV. Referto theACCESSORY
USEANDVEHICLELOADINGsectionin this manual.
OperatingthisATVwith impropermodificationscouldbe hazardous.
Improperinstallationof accessoriesor modificationsto thisvehiclemaycause
changesin handling. In somesituations,this couldleadto an accident.
NevermodifythisATV throughimproperinstallationor useof accessories.
Referto theACCESSORYUSEAND LOADINGsectionin this manual.
Checktheconditionof theATVtomakesurethattheATVdoesnothavemechanical
problemsor youcouldgetstrandedwhenyou ride. BeforeridingtheATV,besureto
checktheaboveitems. BesureyourATVisin goodconditiontoensurethesafetyof
therider.
Performingmaintenanceitemswhenthe engineis runningcouldbe hazardous.
Youcouldbe severelyinjuredif yourhandsor clothingget caughtin moving
ATVparts.
Shutthe engineoff when performingmaintenancechecks,exceptcheckingthe
enginestop switchand throttle.
19
SAFETY GEAR
A DOTapprovedmotorcyclehelmetis the mostimportantpart ofyour safetygear.
A DOTapprovedmotorcyclehelmetcan helppreventa serioushead injury. Choose
a helmetthatfits snugly. Motorcycledealerscanhelpin selectinga good quality
helmetwhichfits properly.
OperatingthisATVwithoutwearingan approvedmotorcyclehelmet,
eye protectionand protectiveclothing.
Operatingwithoutan approvedmotorcyclehelmetincreasesyour
chancesof a severehead injuryor death in the eventof an accident.
Operatingwithouteye protectioncanresultin an accidentand
increasesyourchancesof a severeinjuryin the eventof an accident.
Operatingwithoutprotectiveclothingincreasesyourchancesof
severeinjuryin the eventof an accident.
Alwayswearan approvedmotorcyclehelmetthatfits properly.
Youshouldalso wear:
• eye protection(gogglesor face shield)
• gloves
• boots
• long-sleevedshirtor jacket
• long pants
You shouldweareye protectionwhenyou ride. If a rockor a branchhits youreyes,
you couldbe severelyinjured. Weargogglesor a face shield.
Wear properclothingwhenyou ride. Properclothescan protectyou from injury.
Wear a goodpairof gloves,strongbootsthat areover theankle,long pants,and a
longsleeveshirt
Protection
Long.
Gloves
20
CAUTION
Failureto follow Break-Inprocedurescansignificantly
shortenthe life of your
vehicle.
Bynotfollowing Break-Inprocedure,
you riskcausingexcessivewear,and
damagingtheengine.
Becarefulto correctlyfollow Break-inProcedure.
BREAK-IN
The first monthis the mostimportant in the life ofyourvehicle. Proper
operationduringthis break-inperiodwill be helpfulfor assuringmaximum
life and performanceof yournewvehicle. Thefollowing guidelinesexplain
properbreak-inprocedures.
MaximumThrottleOpening Recommendation
Duringthe first 10 hoursof operation,you shouldalwaysuselessthan 1/2
throttleopening.
Varythe EngineRotatingSpeed
Varythe enginerotatingspeedduringthe break-inperiod. Thisallowsthe
partsto "load" and then "unload" (allowingthe partsto cool). Althoughit is
essentialto placesomestresson theenginecomponentsduringbreak-in,
you mustbe carefulnotto loadtheenginetoo much.
AvoidConstantLowRotatingSpeed
Operatingtheengineat constantlow rotatingspeed(lightload)can cause
partsto glazeand not sealproperly.Allowthe engineto acceleratefreely
withoutexceedingthemaximumthrottlelimit.
Allowthe EngineOil to CirculateBeforeRiding
Allowa few minutesof idlingtimeafterwarmor coldenginestarting. This
allowsthe lubricatingoil to reachall criticalenginecomponents.
ObserveYourInitialand MostCriticalService
The initialservice(break-inmaintenance)is the mostimportantservicethat
yourvehiclewill receive.Observinga properbreak-inoperation,will help
enginecomponentssealproperly.Maintenancerequiredas partof the initial
serviceincludesproperadjustments,tighteningof all bolts& nuts,and
replacementof dirty oil. Timelyperformanceof this servicewill helpyou get
the bestservicelife and performanceof theengine.
21
Carryinga passengeron this ATV.
Greatlyreducesyour ability to balanceand control
thisATV.Couldcausean accident,resulting in
harmto you and/oryour passenger.
Nevercarry a passenger.The longseat is
to allow the operatorto shift positionas neededduringoperation,it is
not for carryingpassenger.
Operatingthis ATVon pavedsurfaces.
TheATV'stiresare designedfor off-roaduse only,
notfor use on pavement.
Pavedsurfacesmay
seriouslyaffecthandlingand controlof theATV,
and maycausethe vehicleto go out of control.
Neveroperatethe ATV on any pavedsurfaces,includingsidewalks,
driveways,parkinglotsand streets.
Operatingthis ATVon publicstreets,roadsor highways.
You may collidewith anothervehicle.
Neveroperatethis ATVon any publicstreet,road
or highway,evena dirt or gravelone. in many
states is it illegalto operateATVson publicstreets,
roadsand highways.
Neveroperatethis ATVat night. Nightis defined as the periodof time
30 minutesbeforesunsetto 30 minutesaftersunrise.
You may collidewith anothervehicle,a stationaryobject,or hazard
found in the terrain.
22
Operatingthis ATVafterconsumingalcohol or drugs.
Couldseriouslyaffectyourjudgement.
Couldcauseyou to reactmoreslowly.
Couldaffectyour balanceand perception.
Couldresult in an accident.
Neverconsumealcohol or drugs beforeor whiledrivingthis ATV.
Operatingthis ATVat excessivespeeds.
increasesyourchancesof losingcontrolof the ATV,whichcan result
in an accident.
Alwaysgo at a speedthatis properfor the terrain,visibilityand
operatingconditions,and yourexperience.
Attemptingwheelies,jumps, and otherstunts.
increasesthe chanceof an accident,including
anoverturn.
Never attemptstunts,suchas wheeliesor
jumps. Don'ttry to show off.
23
Failureto inspectthe ATVbeforeoperating.
Failureto properlymaintainthe ATV.
increasesthe possibilityof an accidentor equipmentdamage.
AlwaysinspectyourATV eachtime you us it to makesurethe ATVis
in safeoperatingcondition.
Alwaysfollow the inspectionand maintenanceproceduresand
schedulesdescribedin the owner'smanual.
Removinghandsfrom handlebarsor feet from the footrestsduringoperation.
Removingevenone handor foot can reduceyourability to controlthe ATV
or couldcauseyou to lose yourbalanceand fall off of the ATV.if you remove
a foot fromthe footrest,yourfoot or leg may comeintocontactwith the rear
wheels,whichcouldinjureyou or causean accident.
Alwayskeepbothhandson the handlebarsand bothfeet on the foot restsof
yourATVduringoperation.
Failingto use extracarewhen operatingthis
ATVon unfamiliar terrain.
You cancomeuponhiddenrocks,bumps,
or holes,withoutenoughtimeto react.
Couldresultin the ATVoverturning or going
out of control.
Go slowlyand be extracarefulwhen
operatingon unfamiliar terrain.
Alwaysbe alert to changingterrainconditionswhen operatingthe ATV.
24
STARTINGTHE ENGINE
Beforeattemptingto startthe engine,makesure to follow thesesteps.
1. Turnthefuel valveto the "ON" position
2.
Turnthekey switchto the ONposition.
3.
Set theenginestop switchto the"RUN" position.
4.
Applythe rearbrake leverand makesurethat the rearwheelsare in
lockingcondition.
5.
Pressthe starterbutton"START" to starttheengine.
TheATV couldstartmovingas soonas you starttheengine.
Unexpectedmovementcouldcauseyou to losecontrolof theATV.
Besure to set the parkingbrakebeforeyou startthe engine.
RunningyourATVindoorswherethereislittleor noventilationcouldbe
hazardous.
Breathingin exhaustgasesfrom theATV couldcausesevereinjury.
AlwaysrunyourATV outdoorswherethere is fresh air.
25
TheATV maystartmovingas soonas you releasethe parkingbrake.
Unexpectedmovementcouldcauseyou to losecontrolof theATV.
Makesure to applythe rearbrake beforeyou releasethe parking
brake.
Parkingbrake
Throttle
Whenyou are surethatthe
engineiswarm, releasethe
brakes..
Releasethe brakes and open
the throttlegraduallyto move
forward.
Openingthe throttlesuddenlycouldbe hazardous.
Thefront wheels couldleavethe groundand causelossof control
of theATV.
Alwaysopenthe throttlegraduallywhenyou wantto accelerate.
26
MANUALPULLSTART
Recoilstarter
Firmlygrasphandleand pull slightlyup untilengagementcan befelt. Then
pullforcefully, being carefulnot to pullthe ropeall the way out.
_A CAUTION:
Don'tstartthe enginein non-neutralor withoutsettingthe parking
brakesystem.
Putthetransmissionin neutraland set the parkingbrakebefore
startingtheengine.
27
DRIVE SELECT LEVER
The driveselectlever shiftstheATVfrom forwardto reverseor reverseto
forward.
To shiftATV in reverse:
1. Releasethrottle
2. Apply brakescomingto a completestop.
3. Shifttransmissionintoneutral.
4. Shiftdriveselectleverto "R" (reverse).Note: Whenin reverse,the reverseindicatorlightshouldilluminateon the console, if lightdoes not come
on, checkto see if vehicleis in first gear.
5. Checkfor peopleor obstaclesbehindyou.
6. Openthe throttlegraduallycontinuingto watchto therear whilebacking.
7. Whenfinished with reversebringvehicleto a completestop and lift up on
theshift lever.
Driveselectlever
Forward
Neutral
Reverse
28
Notlookingbehindvehiclebeforeand whilegoingin reversecould
behazardous.
Failureto lookbehindwhile backingcouldcausetheATVto run into
an obstacleor personresultingin an injury.
Beforegoingin reverse andwhilebacking,lookbehindthevehicle
for anyobstaclesor peopleto avoid.
_ACAUTION
Alwaysclosethe throttlewhileshiftinggears.
Failureto closethethrottlewhileshiftinggearscouldcausedamage
to the engineand drivetrain.
A CAUTION
Do not coastfor longperiodsof timewith theengine not running,and
do not towthe machinea long distance.
Evenwhenthe machineis in neutral,the gearsare not properly
lubricatedunlessthe engineis running, Towingthe machinewith the
enginenot running could causedamageto the drivetrain.
Besure to checkfor leaksin the gearcaseand keepoil up to the
prescribedlevel.
2WD/4WDbutton
2WD/4WDBUTTON
Toshift the 2WDto WD,stop the ATVand press
the button in, to 4WD position.To shiftthe 4WD
to 2WD,stoptheATVand pressbuttonlettingit
out,to 2WD position.
WARNING:
When driving the ATVand shifting2WD
to 4WDor 4WDto 2WD,the 2WD is different from
4WD in operation.Shifting2WDto 4WDwhen
drivingwill maketheATVencounterunexpected
control,whichwill increasetheaccidentrisk.
29
BRAKING
Rearhandbrake
Fronthandbrake
Tostop the ATV,first release
throttlelever.Andthen applythe
rear andfront brakessmoothly.
BrakingwhileturningtheATV couldbe hazardous.
Useof thebrakewhenturningcouldcausetheATVto slideor roll over.
Usethe braketo slow downbeforeyou beginto turn.
Brakinghardon slipperysurfacescould behazardous.
The ATVcouldskid and go out of controlif you braketoo hard.
Apply thebrakeslightlyand carefullyon slipperysurfaces.
Operatingthe parkingbrakewhenthe ATVis movingcouldbe
hazardous.
Thefront wheelscould lock,and it will causea skid and an accident.
Usethe parkingbrakeonlyafteryou stoptheATV.
30
TURNING
Turningimproperly.
ATV couldgo out of control,causinga collisionor overturn.
Alwaysfollow properproceduresfor turningas describedin theowner's
manual.
Practiceturningat lowspeedsbeforeattemptingtoturn at faster speeds.
Do notturn at excessivespeed.
To turntheATV,the rider mustuse thepropertechnique. Becausethis vehicle
hasa solidrear axle, bothrearwheelsalwaysturnat thesame speed. This means
that if the rearwheelsare gettingequaltraction,thevehiclewill tendto move
straightahead. This is becausethe rearwheelswill travelthe samedistance. For
the vehicleto turn, theoutsiderearwheel musttravela longerdistancethatthe
insiderearwheel. To makethis happen,the rider mustcreatelesstractionfor the
insidewheel,allowingit to skid. This allowsit to travela shorterdistancethan
the outsidewheel. This happenseventhoughbothwheelsarestill turningat the
same speed.
To turnATV,usethe followinqtechnique:
Moveyourbodyweightforward andto the
insideof theturn.
Turnthehandlebarwhile lookingin the
directionof theturn.
FOR HIGHER SPEEDS OR SHARPERTURNS
Usethesame techniquethatyou usewhenyou moveyourbodyweightfarther
towardthe insideof the turnto maintainyourbalance. Naturalturningforces
(whichcanpushthevehicleto theoutsideof theturn) increaseas the speedor
the turnsharpnessincreases.This meansyou mustleanyourbodyfarther into
the turnas you go faster or turnmore sharply.Thispreventsthe vehiclefrom
tippingover to theoutsideof theturn. If yourATVstartsto tip whileturning,lean
your bodyfarther intotheturnwhile graduallyreducingthe throttleand making
the turnwider,if possible.
31
OPERATIONON HILLS
Operatingon excessivelysteephills.
Thevehiclecanoverturnmoreeasilyon extremelysteephillsthan
on levelsurfacesor small hills.
NeveroperatetheATVon hillstoo steepfor theATVor for your
abilities.
Practiceon smallerhills beforeattemptinglargerhills.
Climbinga Hill
Climbinghillsimproperly.
Couldcauselossof controlor causeATV tooverturn.
Alwaysfollow the properproceduresfor climbinghills as describedin
this owner'smanual.
Alwayschecktheterraincarefullybeforeyou start up anyhill.
Neverclimbhillswith excessivelyslipperyor loosesurfaces.
Shiftyourweightforward.
Neveropenthethrottlesuddenlyor makesuddengear changes. The
ATVcouldflip overbackwards.
Nevergo over thetop of any hill at a highspeed. An obstacle,a sharp
drop,or anothervehicleor personcouldbe on the otherside of the hill.
32
Toclimba hill withthe ATV,followthe
directionsbelow.
.
.
.
.
Speedup and maintaina steadyspeed
beforereachingthe top of the hill.
Rememberthatyou mustrideat a
steadyspeedall the wayto the top of
the hill.
Shiftyourbodyforward bysliding
forward on the seat. Lean slightly
forward. For steephills,standon the
footrestsand leanforward.
Maintaina steadyspeedwhile
climbingthe hill.
Slowdowngraduallywhenyou reach
the top of the hill.
Couldcauselossof controlor causeATVto overturn.
Alwaysfollow properprocedures
for goingdownhillsas describedin theowners
manual.NOTE:a specialtechniqueis requiredwhenbrakingas yougo downa hill.
Alwayscheckthe terraincarefullybeforeyoustartdownany hill.
Shiftyourweightbackward.
Nevergodowna hillat highspeed.
Avoidgoingdowna hillat an anglethatwouldcausethe vehicleto leansharplyto
one side.Gostraightdownthe hillwherepossible.
33
To ridedowna hillwith theATV,follow the instructionsbelow.
1.
Checktheterraincarefullyfor any obstaclesbeforeyou go downthe hill.
2.
PointtheATV straightdownthe hill.
3.
Transferyour bodyto the rear by slidingbackon the seat.
4.
Ridedownthe hill slowlywith the throttlereleased.
5.
Applythe rearbraketo controlthe speed.
6.
Avoidgoingdowna hill at an anglethatwouldcausethevehicleto lean
sharplyto one side. Gostraightdownthe hill if possible.
Improperlycrossinghills or turningon hills.
Couldcauselossof controlor causeATVto overturn.
NeverattempttoturntheATVaroundon anyhilluntilyouhavemasteredthe
turningtechniqueasdescribedintheowner'smanualon levelground.
Beverycarefulwhenturningonanyhill.
Avoidcrossingthesideofa steephillif possible.
Whencrossinqthesideofa hill:
Alwaysfollow properprocedures
as describedin theowner'smanual.
Avoidhillswithexcessively
slipperyor loosesurfaces.
Shiftyourweighttothe uphillsideoftheATV.
34
Stalling,rollingbackwardsor improperlydismountingwhile climbinga hill.
Couldresultin ATVoverturning.
Usepropergearand maintainsteadyspeedwhen climbinga hill.
If you lose all forward speed:
Keepweightuphill.
Apply brakes.
Lock parkingbrake,afteryou are
stopped.
If you beqinrollinq backwards:
Keepweightuphill.
Neverapplytherear brakewhilerollingbackwards.
Apply thefront brake.
Whenfully stopped,applyrear brakeas well,and then lockthe
parkingbrake.
Dismounton uphillside or to a side ifpointedstraightuphill.
TurntheATVaroundand remount,following the proceduredescribedin the
owner'smanual.
RIDINGOVER OBSTACLES
Improperlyoperatingover obstacles.
Couldcauseloss of controlor a collision.CouldcausetheATVto overturn.
Beforeoperatingin a newarea,checkfor obstacles.
Neverattemptto rideover largeobstacles,such as largerocksor fallen trees.
Whenyou go overobstacles,alwaysfollow properproceduresas described
in theowner'smanual.
35
NOTE: ThisATV usesresistor-typesparkplugto avoidjammingelectronic
parts. Improperspark plugselectionmay causeelectronicinterferencewith
yourATVsignitionsystem,resultingin the vehicleperformanceproblems.
Userecommendedspark plugs.
To installa spark plugturn it in as far as possiblewith yourfingers, then
tightenitwith a wrench.
A CAUTION
Improper installation of the sparkplug coulddamageyourATV.
An overlytight or crossthreadedspark plugwilldamagethe
aluminumthreadsof thecylinderhead.
Carefully turn the sparkplug by handinto the threads. If the spark
plug is new,tightenitwith a wrenchabout1/2turnpastfinger tight. If
you arereusingthe oldspark plug,tighten itwith a wrenchabout1/8
turnpastfinger tight.
A CAUTION
Dirt coulddamageyourATVif it enteredan open sparkplug hole of
cylinderhead.
Dirt coulddamage engineparts that move.
Cover the sparkplug hole while the spark plug is out of the hole.
To maintaina properfunctioning spark plug,keepthe plug free of carbon.
Removecarbonfrom the plugwith a wire or pin, and adjustthe gap to
0.6~0.7ram(.024- .028in)for good ignition. Usea thicknessgaugeto check
the gap.
46
VALVE INSPECTION
Referto maintenanceschedulein this owner'smanualfor valveadjustment
inspectionintervals.
Valveclearanceshouldbe:
Intake:
0.002inch(0.05ram)
Exhaust:
0.003inch(0.0762mm)
The enginewill makeexcessnoiseif thegap istoo largein air valve. If
gap is too smallvalveoperationwill be hinderedwhichcould resultin
valvemalfunctionand failure. Therefore,air valvegap mustbe checked
periodically.
If you havethe propertools andare mechanicallyproficient,instructionson
adjustingthevalveclearanceare givenin theservicemanual.Ifassistanceis
neededpleasecontactBaja Inc.to find your localservicecenter.
47
BATTERYINSTALLATION
INITIALSERVICEAND INSTALLATIONOF BATTERY:
The following procedureis very dangerousand shouldbe performed
with utmostcareand attention.Wear protectiveeye wear,rubber
gloves,and havewateravailableshouldelectrolytecomein contact
with your skinor eyes.KEEPALL CHILDRENAWAYFROMTHEAREA
WHILE THISPROCEDUREIS BEINGPERFORMED.
POISON- CAUSESSEVEREBURNS
Containssulfuricacid.
Avoid contactwith skin,eyes,or clothing
To preventaccidents,rinseemptycontainerwith water.
ANTIDOTE:
External- flush with water
Internal- Callphysicianimmediately.Drinklargequantities of wateror
milk.
Followwith milkof magnesia,beateneggsor vegetable.
Eyes- Flushwith waterfor 15 minutesand get promptmedical
attention.
KEEPOUT OF REACHOF CHILDREN.
48
Note:The following page isfor vehicleswith battery'scontainingseparate
electrolytepack. Mostbatterieswill comewith the electrolytealreadysealed
intothe battery.
Preparinqthe battery:
Placebatteryon levelsurface.Removesealing
tapefrom top. (seefigure 20)
Takethe electrolytecontainerout of the plastic
bag.
Placeelectrolytecontainerupsidedownwith the
sealedsilvermouthsof the electrolytebottlesin
linewith thesix filler holesofthe battery.(see
figure 21)
Figure20
Pushthe containerdownstronglyenoughto
breakthe silverseals.
As electrolytestartsflowing intobattery,air
bubbleswill comeup from the mouthsof the
plasticelectrolytebottles.
Leavebottlesupsidedownin batteryholesuntil
electrolyteis completelydrained.
Neverleavechildrenunattendedaroundbattery.
If air bubblesceaseto float to thetop of the
electrolytebottles,taplightlyon top.
Figure21
DO NOTremovecontainerfrom batterywhileit is
draining.
Nevercutor pierceelectrolytecontainer.
After all the electrolytehasdrainedfrom the
bottlesintothe battery,pull plasticelectrolyte
bottlesgentlyout of the battery.
Discardemptyelectrolytebottlesin a waste area
thatis inaccessibleto childrenand animals.
After filling, let batterystandfor at least30
minutesbeforecharging.Thisallowsthe
electrolyteto penetrateplatesfor optimum
performanceand ensureslongerbatterylife.
After 30 minutesthe batteryis readyfor its initial
charge.Placecapstrip looselyover thefilling
holesas shownin the picture.(see figure 23)
49
Figure23
Howto InitiallyCharqethe battery:
1.
Connectthe red positive(+) cableto the red positive
(+)poleof the battery.
(seefigure 24)
2.
Connectthe blacknegative(-) cableto the black
negative(-) poleof the battery.(seefigure 25)
Note:The red positive(+) cablehasa largerdiameter
thanthe blacknegativey cable.
.
Figure24
Chargingrate:Chargebattery@ 0.7Ampsfor
5 ~ 10 hours.
After chargingiscomplete,pressdownfirmly
with bothhandsto seatthe caps, (Do not pound
or hammer).The batteryis now sealed.(see
figure 26 )
Figure25
Installbatteryintobatterycompartment.The
batteryterminalsshouldbe facing thefront (see
figure 27)
Oncebatteryisfirmly seatedin battery
compartment
attachtheredpositivewiretothe
redpositiveterminalonthe battery.(seefigure 28)
Thenattachthe blacknegativewire to the black
negativeterminalon the battery.
(seefigure 28)
•
Figure26
Installthe batterybracket (see figure 28)
NEVERREMOVETHE STRIPOF CAPS
NORADDANYWATERORELECTROLYTE.
Figure27
Batterybracket
Red
Figure28
50
Black-
BatteryReplacement:
Removeold batteryfrom underseat. The batterybracketwill needto be
removed(see figure 28). Markwhichcableis connectedto thepositive
terminal(+)and whichcable is connectedto thenegative(-) terminal.
Cleancableconnectorswithwire brushor sandpaperto remove
oxidation.
Aftercharging,installnewbattery.Putdielectricgreaseon thebattery
terminalsto avoidcorrosion.Connectcablesto theproperterminals.
Positivecableto positiveterminalA and negativecableto negative
terminalY.
Positive(+)"A" cableis red and largerin diameter.Negative(-)"Y" cable
is blackand smallerof the two indiameter.CONNECTNEGATIVECABLE
LAST.
Torqueterminalboltsto 40 in./ Ibs.
Securelyfasten batteryto the vehicleusingmetalbatterystrap.
DO NOTopensealedcapsto addwaterto battery.
Alwayswearsafetyglassesand chargein a ventilatedarea.
If batterygetshot to thetouch,discontinuechargingandallow
batteryto
cooldown.
Do not usefast chargingunlessit is an emergency.
At the beginningor end of charging,turnoff the chargerfirst, in
orderto preventelectricsparkand explosion.
Chargein a wellventilatedarea.
DO NOTsmokearoundbatteriesand keepawayfrom openflame.
Toavoidpossibilityof explosion,alwaysconnectbatterycablein
theorder specified:RED first; BLACKlast.An explodingbattery
can causeseriousinjuryor death.
Batteriescontainsulfuricacid.
Alwaysshieldeyeswithprotectiveeyewearwhenworkingaround
batteryacid.
Batteryacid is poisonousand cancausesevereburns.
DO NOTsmokearoundbatteriesand keepawayfrom openflame.
51
Signalingsystemfuse 10A
FUSEREPLACEMENT
Ignitionfuse 15A
Mainfuse 30A
Headlightfuse 15A
Sparefuse
Fourwheeldrivefuse 3A
Fusemay be bad if there is no sparkwhiletryingto starttheATV.
Thefuse box is locatedundertheseat directlyin front of the battery.
To checkfuse follow the instructions
•
Turnoff mainkey switch
•
Lift seatand locatefuse box
•
Removefuse box cap
Good
Bad
•
Removefuse and check. Iffuse is bad,replaceitwith a 15 Ampfuse.
HEADLIGHTAND TAILLIGHTREPLACEMENT
Headlight
Headlighthousing
Bulbholder
Moistureprotector
Headlight bulb replacement.
•
Turnoff mainkey switch
•
Locatelightsunderfront fenders, removescrewsand headlighthousing.
•
Slidebackmoistureprotectorfrom headlight.
•
Pushin bulbholderandturn left (CCW)untiltabs lineup with groves.
•
Removebulb
Taillightreplacement
•
Turnoff mainkey switch
•
Locatescrewholesin rear
lens
•
Removelens
•
Removebulb by pushingin
and turningleft(CCW).
Screwholes
52
THEADJUSTMENTOF THROTTLELEVER
Adjustercover
3.0~5.0ram
(0.12~0.20in)
Toadjustthethrottlelever play:
1.
Removethe adjustercover(slidebackon cable).
2.
Loosenadjusternut and moveadjusterin or out to obtainthe correct
play.
3.
Tightenadjusternut
4.
Recheckthethrottleleverfree distance.
Readjustit if it is notwithin thecorrectlimits.
Operatingthevehiclewith an inadequatethrottleleverfree distance
couldbe hazardous.
Inadequatethrottleleverfree distancecould causeenginespeedto rise
suddenlywhenyou turnthe handlebars.Thiscan leadthe riderto lose
control.
Adjustthe throttleleverfree distanceso thatengineidlespeeddoes not
rise dueto handlebarmovement.
53
IDLESPEEDADJUSTMENT
Toadjustthe idlespeedproperly,you needa tachometer.Ifyou do not have
one,ask yourauthorizedservicecenterto performthis adjustment.
EngineIdleadjustment
Screw
Toadjustthe idlespeed:
1.
Starttheengineand warmit up.
2.
Turntheengineidlescrew in or out so thatthe engineidlespeed isat
1450~1550r/rain.
Improperadjustmentof the idlespeedcouldbe hazardous.
An idle speedthat is too high couldcausetheATVto launchforward
whenyou startthe engine. Thismay causean accident. Excessive
enginewear mayalso resultif idlespeed isadjustedimproperlyor
whenthe engineis notfully warmedup. Adjustthe idleto the correct
speed. Makesure theengineis fully warmbeforeadjustingthe engine
idlespeed.
FUELHOSE
FuelHose
Inspect the fuel hosefor damage
andfuel leakage. If anydefects
arefound, thefuel hose mustbe
replaced.
54
ENGINEOIL
To checkoil level:
1. Parkvehicle on level ground.
Oil capand dipstick
Minimum
Maximum
Level
2. Removedip stickand wipeoff with a cleanrag. Insert the dipstickin the
filler hole.
3. Removethe dipstickand inspectthe oil level.
4. Oil levelshouldbe in betweentheminimumand maximummarkson the
dipstick.
5. Addoil if oil is belowminimummarkon dipstick. Do Not fill above
maximummark. Referto page8 for correctengineoil type.
Enqineoil replacementand oilfilter elementcleaninq:
The engineoil shouldbe changedevery20 to 40 hoursof operation.It should
be changedmoreoften in dirtyand dustyareas.
Oil drainplug
1.
2.
Parkvehicleon levelground.
Removeoil dipstick
3.
Removeoil drainplug (locatedunderengine). Drainoil intocontainer.
55
4. Removeoil filter cover
5. Removeoil filter
Oil filter cover
6. Replaceoil filter with newfilter.
7. Reinstalloilfilter andoil filter cover.
8. Tightendrainplug and oilfilter capto specifiedtorque.
9. Fill crankcasewithspecifiedoil. Referto Pg. 9 for correctoil.
Newand usedoil couldbe hazardous.
Childrenand pets maybe harmedby swallowingnewor usedoil.
Continuouscontactwith usedoil can causeskin cancerin laboratory
animals. Briefcontactwith the usedoil may irritatetheskin.
Keepnewand used oil awayfrom childrenand pets. To minimize
yourexposureto usedoil, weara long-sleeveshirt and moistureproofgloves(suchas dishwashinggloves)whenchangingoil. If oil
contactsyourskin,washthoroughlywithsoap andwater. Launderany
clothingor rags ifwet with oil. Recycleor properlydisposeof usedoil.
Failureto usethecorrectoil couldharmyourATV.
I A CAUTION
Besuretousetheoilspecifiedin theFUELANDOILRECOMMENDATION
section.
Ak CAUTION
Running the enginewithout an adequateamount of engineoil could
causesevereenginedamage.
Running the enginewithout any engineoil couldcauseengine
overheating.
Always checkthe amount of engineoil before startingthe engine.
56
AIR FILTER
The air filter elementmustbe keptcleanto providegoodenginepower. If you
useyourvehicleundernormal,lowdust conditions,you shouldservicethe air
filter at the intervalsspecified. Ifyou ridein dusty,wet, or muddyconditions,
youwill need to inspectthe air filter elementmuchmorefrequently. Usethe
following proceduresto removethe elementand inspectit.
Operatingtheenginewithoutthe air filter elementin placecouldbe
hazardous.
If the air filter elementdid not filter dirt, severeenginedamagewould
occurif thedirt enteredthe runningengine.
Neverrunthe enginewithoutthe air filter elementin place.
,& CAUTION
Failingto inspectthe air filter elementfrequently if thevehicleis used in
dusty,wet, or muddyconditionscoulddamageyourATV.
The air filter elementcouldbecomecloggedundertheseconditions,
and enginedamagemay result.
Alwayscheckthe air filter elementafterridingin severeconditions.
Cleanor replacetheelementsas necessary.If watergetsin theair filter
case,immediatelyclean theelementand the insideof the case.
57
Air Filter
AIR FILTERREMOVAL
Cover
1.
2.
3.
4.
5.
6.
7.
LocateAir Filter Box underseat and
removecover.
Removeair filter.
Foam
Removefoam coverfrom Air filter
cover
element.
TaptheAir filter elementgentlyto removemostof
thedust and dirt. Blowout remainingdustwith
compressedair. If the elementis damaged,replace
it.
Washthe foam coverper instructionsbelow.
Reinstallfoam coverto the air filter element.
Reinstallair filter and closecover.
Air filter element
WASHINGFOAMCOVER
Washwith
water
Washthefoam coveras the
following:
1. Removefoam coverfrom
air filter element.
2. Washfoam covergently
in wateror a mildnon
flammable solvent
3. Squeezewaterout offoam
coverand let dry.
Squeezeout
excesswater
58
4. Reinstallfoam coverover
air filter element
CAUTION
A tornair filter coulddamageyourATV.
Dirtand dust may getinsideof theengine ifthe elementis torn.
Examinecarefullythe elementfor 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. Dispose
of usedoil and solventproperly.
.
Reinstallthe cleanedelementin reverseorderof removal. Besure that
theelementis securelyin positionand is properlysealed.
_CAUTION
Failing to position the air cleanerelementproperly coulddamageyour
ATV.
Airwill bypasstheair cleanerelementif the elementis not positioned
properly.Thiswill causethe enginepartstowear morerapidly.
Besure to positionthe air cleanerelementproperly.
POTENTIALHAZARD
Usinggasolineor lowflash pointsolventsfor cleaningATVparts.
WHATCAN HAPPEN
A fire or explosioncould result.
HOWTOAVOIDTHE HAZARD
Useonlya nonflammableor high flash pointsolventto cleanATV parts.
59
FRONTAND REARGEARCASE LUBRICATION
To checkfront and rear clearcase oil:
Frontgear casefill cap
1. Placevehicleon levelground
2. Removegear casefill cap.
3. Inspectoil level. Oil level shouldbe up to
the brimof the hole.
4. If oil is low,add specifiedoil (SAE80 API
Hypoidgearoil)".
5. Tightenfill capto 23Nm (17ft.lb)
Rear gearcase
fill cap
To chanqeqearoil:
Gearcover
Drainplug
1.
2.
3.
4.
5.
6.
7.
Placevehicleon level ground
Removegear casecover.
Placecontainerundergearcase.
Removefill cap.
Removeoil plug.
Letoil drainout completely
Installthe drain plugand tightento
23Nm(12.6ft Ib).
8. Installgear coverandtightenbolts
9. Add gearoil (SAE80 API "G-4 Hypoid Gear
oil") fill to brimof hole (approx.3 oz)
10. Installfill capand tightento23Nm
(17 ft lb.)
-A,CAUTION
Failingto havethe properamountof gear oil in the front and rear
transfercasewill damageyourATV.
Lowor no gear oilwill causewear on the gearscausinggearsto seize.
Be sureto checkfor leaksin the gear caseand keepoil up to the
prescribedlevel.
60
TIRES
TheATV isequippedwith low pressuretubelesstires of thesize and type listedbelow:
_'_
Size
Front
Rear
AT25x8-12
AT25x10-12
OperatingthisATVwith impropertires,or even impropertire air
pressurecouldbe hazardous.
Ifyou useimpropertiresor impropertire airpressure,you maylosecontrol
oftheATV.
Always usethesize and typetires specified.Alwaysmaintainproper
tire air pressureas describedin this section.
TireTreadCondition
] mm (0.16in)
Usingworntires couldbe hazardous.
Thetractionofthevehiclewillbedecreased.
Thisincreases
yourriskofhavingan
accident.
Replace
thefront andreartireswhenthedepthonthetreadis4.0mm(0.16in)or less.
TireAir Pressure
Checktheair pressurein all tires beforeriding. Improperair pressurewouldaffect
handling,steeringresponse,traction,tire life and ridercomfort. Be sure thatthe tires
are inflatedto the pressuresshownbelow. Tirepressureshouldonly bemeasuredor
adjustedwhen the tiresare cold.
Maximum
pressure
Front
34.47kpa(5psi)
Rear
34.47kpa(5psi)
61
OperatingthisATVwith impropertires,or with improperor uneventire pressure.
Useof impropertireson thisATV,or operationof this ATVwith improperor
uneventire pressure,may causelossof control,increasingyour riskof an
accident.
Alwaysuse thesize and typeof tires specified.Alwaysmaintainpropertire air
pressureas describedin this section.
OperatingthisATVwith impropermodifications.
Improperinstallationof accessoriesor modificationsto thisvehiclemaycause
changesin handlingwhichin somesituationscould leadto an accident.
NevermodifythisATV throughimproperinstallationor useof accessories.
All partsand accessoriesaddedto this vehicleshouldbe genuineBajaInc.or
equivalentcomponentsdesignedfor use on thisATVand shouldbe installed
and usedaccordingto instructions.If you havequestions, consulta Baja Inc.
authorizedATVdealer.
OverloadingthisATV or carryingor towingcargoimproperly.
Couldcausechangesinvehiclehandlingwhichcouldleadto anaccident.
Neverexceedthe statedloadcapacityfor this ATV.
Cargoshouldbe properlydistributedand securelyattached.
Reducespeedwhen carryingcargo.Allow greaterdistancefor braking.
Alwaysfollow the instructionsin your owner'smanualfor carryingcargo.
62
Overfillingthetireswith air couldcausethemto burstwhichcould
resultin severeinjury.
Checktheair pressurefrom timeto timewhile inflatingthe tire
gradually,until thespecifiedair pressureis obtained.
TireReplacement
YourATVhas low-pressuretubelesstires. Air is sealedby thecontact
surfacesof the innerwheel rim and thetire bead. If the innerwheel rimor
tire bead isdamaged,air mayleak. Be extremelycarefulnot to damagethese
sectionswhen replacingtires.
It is very importantto usethe propertoolswhen repairingor replacingtires
in order to protectthe tire beador wheelrims. Havethis workdone byyour
authorizedservicecenteror a qualified tire repairstation.
Whenbreakingthetire beadloosefrom thewheel,be extremelycarefulnot to
damagethe innerwheelrim surfaceor thetire bead.
Usingtires thathavebeen installedincorrectlycouldbe hazardous.
TheATV mayhaveunusualhandlingif thetires are installed
incorrectly.
The tiresare intendedto rotatein a specificdirection,as indicatedby
thearrowson thesidewallof eachtire. Installtires correctlyso they
rotatein the properdirection.
TubelessTire Repair
If a leakor flat tire occursdue to a puncture,thetire maybe repairedusing
a plugtypepatch.If the damageis from a cut,or if the puncturecannotbe
repairedusinga plug,the tire shouldbe replaced.WhenoperatingyourATV
in areaswheretransportationor servicefacilities are not readilyavailable,it is
stronglyrecommendedthatyou bringa plugtyperepairkit and a tire air pump
withyou.
63
FRONTHYDRAULICDISK BRAKE INSPECTION
Brakefluid reservoir
Lowermark
Brakefluid cap
Brake
Frontdisk brakecaliper
Brakefluid level
Brakedisk
Brakehose
1. Inspectthefront disk brake caliperfor leakage.If brakefluid leaks,the
safetyof ridingcould beaffected.
2.
Inspectthe brakehosefor cracks,and thejoint for leakage.
3. Checkthe brakefluid levelin the brakefluid reservoir,if levelis at or
belowthe LOWERmark, inspectbrakepadsfor wearand hydraulicsystem
for leaks.
4. To add brakefluid, unscrewthe 4 screwson top of the bakefluid
container.Add DOT3or DOT4brakefluid. Do not mixbrakefluid types.
REARBRAKES
5~7ramfree play
(0.2~0.3in)
Adjust nut
Rear handbrake locatedon leftside of handlebar
64
Rearhandandfoot brakeadjustment.
1.
Tryto movethe vehiclebackwardand
forward when therear handbrakeis
applied. If the rearwheelscanturn,
adjustthe braketo lock thewheels
securely.
2.
Tryto movethe vehiclebackwardand
forward when therear foot brakeis
applied. If the rearwheelscanturn,
adjustthe braketo lock thewheels
securely.
.
,
Measuretheamountof free playin the
rear handbrakelever. The free play
shouldbe about5~7ram(0.2~0.3in).
Afterany adjustmentof the brake
adjustmentnuts,checkagainto make
sure thefront wheelscannotturnwhen
Brakecableadjust
Brakerod adjust
nut (handbrake)
nut (foot brake)
the brakeis applied.
REARBRAKESHOEINSPECTION
1. Locatebrakewear indicatoron outsideof
brakedrum
2. Checkwearindicatorto see if it hasreached
the maximumwear limit
3. If maximumwearlimithas beenreached
(needlehas reachedthe end of tab),
replacebrakeshoesas a set.
Weartab
Brakewear
indicator
Maximumwear
limit
65
Failingto maintainthe brakeshoesor padscouldbe hazardous.
Ridingwith wornbrakeshoes,pads,or shoesthat areseriouslyworn,
will increaseyour chanceof havingan accident.
If you needto replacebrakeshoe pads,haveyourauthorizedservice
centerdo thework. Inspectingand maintainingthe brakeshoe pads is
recommended.Replacethe shoepads in sets.
SPARKARRESTERCLEANING
Drainbolt
Periodicallythesparkarrestorwillneed cleaning
1. Selecta well ventilatedareaand makesure theexhaustpipeis cool
2. Removethe drain bolt
3. Startthe engine,blockthe end of theexhaustpipewitha dowel, this will
increasethespeedof the enginebecauseof backpressure.
4. Stopthe engineand letthe exhaustpipecool.
5. Installthe drainbolt backintotheexhaustpipeandtighten
66
The hot exhaustmufflercouldburn you,
The mufflerwill be hot enoughto burnyou afterstoppingthe engine.
Waituntilthe exhaustmufflercoolsto removeit.
Runningthe engineindoorsor in a garagecouldbe hazardous.
Exhaustgascontainscarbonmonoxidethatis colorlessand
odorless. It couldcauseseriousinjuryor death.
Onlyrun theengineoutdoorswhere there isfresh air.
Ridingan ATVwith improperlytighteneddrainboltcould be
hazardous.
Runningthe enginewith a loosedrainboltor withouta drain bolt
will let hot carbon particlesto escape. Thiscan causea fire.
Tightenthe drainbolt securely.
67
CLEANINGAND INSPECTIONOF OIL COOLER
The oilcoolershouldbe checkedfor mudand debrisbefore each ride,the
following stepsshouldbe takento ensuretheoil cooleris in properworking
order.
1. Locateoil coolerunderfront
fender assembly.
Oil Cooler
Cooler GuardScreen
2. Remove"Cooler GuardScreen"
located on top of oil cooler. Remove
mudand/oranyothertypeof debrisfrom
screen.Cleanscreenwith fresh water.
68
3. Withscreenstillremovedfrom oil
cooler, removesedimentfrom oil cooler
byallowingrunningwaterto flow through
the coolerfins.
CoolerGuard
Screen
4. Re-installCoolerguardscreen.
5. Checkto makesurewire connectionon
bothHeatlight sensorand Fan sensorare
secureandare in place. If sensorwiresare
loose,squeezeconnectorsgentlywith a
pairof pliersto providea tight connection.
Note:
Thefan sensoris thetop sensorlocated
on the oil cooler. 1 purplewire and 1 Black
wire shouldbe
attachedto this sensor.
The Heatlightsensoris locatedon the
bottomof the oil cooler. 1 orangewire and
1 blackwire shouldbe attachedto this
sensor.
69
Coolingfan sensor
1 purplewire, 1 blackwire
Heatlightsensor
1 orangewire, 1 blackwire
GENERALLUBRICATION
Properlubricationis importantfor safe,smoothoperationand longlife of your
vehicle. Besure thatall lubricationis performedduringperiodicmaintenance
on the vehicle. Increaseintervalswhenyou useyourATV in severe
conditions.Yourauthorizedservicecentershoulddo generallubrication
as shownin the MAINTENANCECHART.The authorizedservicecenterwill
lubricatethe vehiclesuchas wheel bearings,swingarm bearings,steering
shaftholder,cables,etc.
[]
............... Oil
[]
............... Grease
Q
Steeringshaft - Greasebottom
with lithiumbasedgrease
Q
Brakecable
Q
Throttlecable
Q
Throttlelever
r4
70
TROUBLESHOOTING
Thistroubleshootingguideis providedto helpyou to findthe causeof some
commoncomplaints.
COMPLAINT:Engineis hardto startor does not startat all. Somethingis
probablywrongwith the fuel systemor ignitionsystem.
A, CAUTION
Failingtotroubleshoota problemcorrectlywould damageyourATV.
Improper repairsor adjustmentsmay damagethe vehicle. Such
damagemay not be coveredunderwarranty. If you are not sureabout
the properaction,consultyourauthorizedservicecenteror Baja
Motorsportsaboutthe problem.
FuelSupplyingCheck
1.
Makesure there is adequatefuel in the fuel tank.
2.
Checkthattheenginestop switchis in the "RUN "position.
3.
Checkthatthefuel valve is in the "ON" position.
4.
Makesure there is enoughfuel reachingthe carburetorfrom thefuel tank.
Drainingfuel from the carburetorcouldbe hazardous.
Fuelcouldcatchfire if you do not handleit properly.
Whendrainingthe carburetor,be sure to shutthe engineoff. Do not
smokeand makesure thereare no openflames or sparksin thearea
whereyou drainor refuel. Do not spillthe fuel oryou maycreatea fire
hazard. Disposeof drainedfuel properly.
a.
Loosenthe drainscrewwhich is locatedunderthe carburetor.Drainthe
fuel from the carburetorintoa container.
b.
Tightenthedrain screw.
c.
Runthe enginefor a few seconds. Shut off engine.
d.
Loosenthe drainscrewand checkthatthe carburetorisfilled backup
withfuel.
e.
If fuel is reachingthe carburetor,the ignitionsystemshouldbe checked
next.
71
IgnitionSystemCheck
1.
,
Removethe sparkplugand reattachitto thespark pluglead.
Turnignitionkey to the"RUN" position. Slidethe enginestop switch
to the "Run" position. Pushtheelectricbutton"START "(grey button).
Applythe rearbrake leverto makesure the rearwheelsare locked. If the
ignitionsystemisoperatingproperly,a bluesparkshouldjump across
thespark pluggap. If there isno spark,takeyour machineto your
servicecenter.
Performingthe sparktest improperlycouldbe hazardous.
Youcouldgeta highvoltageelectricalshockifyou arenotfamiliar with
thisprocedure.
Do not performthis checkif you are notfamiliar with the procedure.
Do not pointthe sparkplug nearthe sparkplug holeduringthistest.
Do not do this test if you havea heart conditionor weara pacemaker.
Do not performthis test near anyopenfuel containersor fuel which
hasspilledon the ground,on the engine,or anypart of theATV.
COMPLAINT:Enginestalls
1.
Makesure there is enoughfuel in thefuel tank.
2.
Checkto see thatthe sparkplug is notfouled. Removethe sparkplug
and cleanit. Replaceit, if necessary.
3.
Makesure the fuel valve is not clogged,andthe fuel tankis not clogged,
either.
4.
Checkthe idlespeed. If necessary,adjustit usinga tachometer.The
correctidlespeed is 1400-1600r/rain.
72
D
m
--5-
E
o
o
.o
o_
E
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u
11
Z
m
I.--
0
0
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ILl
ml
8
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4.o
0
I.--
73
TRANSPORTING
It is bestto transporttheATV in thenormalposition.
Carburetor
drainscrew
BeforetransportinqtheATVdrainthe fuel from the carburetoras follows:
1. Drainfuel fromcarburetorintoan emptycontainerby looseningthe
carburetordrainscrew.
2.
Whenthe fuel hasbeen drained,retightenthe drainscrew.
Drainingfuel fromthe carburetorcould behazardous.
Fuelcouldcatchfire if you do not handleit properly.
Whendrainingfuel from thecarburetor,
besuretoshutthe engineoff. Do
notsmoke,andneverdrainor refuelin anareawherethereareopenflames
or sparks.Do notspillthefuel oryou maycreatea fire hazard.Disposeof
thedrainedfuel properly.
A, CAUTION
Failingto securetheATV properlycouldbe hazardous.
Failingto securethevehicleproperlymay resultin anaccidentor
damageto thevehicle.
When transporting theATV,lock the parkingbrakeleverand tie down
the vehiclesecurelywithstraps,rope,or someothersuitablemeans.
Useextratie downswhenyou transportthe vehiclein the standing
position.
74
CLEANING PROCEDURE
Athoroughcleaningof yourATVisa necessarypartof maintenance.Itwillhelp
keepyourATVlookingandperforming
best. Propercleaningcanalsoextendthe
lifeofyourATV.
It is importantto cleanand inspectyourATVaftereveryride, especiallyif it is
used in mud,brush,grass,water,saltwater,or verydusty conditions
The build-upof mud,brush,grass,etc.especiallyon the engineand exhaust
system,canreduceenginecoolingability,concealdamage,or increasewear
of certainparts.It is importantto removeall debrisduringcleaning.
PREPARATION
FORCLEANING
WashtheATVbeforeany muddrieson the ATV.
Blockor sealthe end ofthe exhaustpipe(muffler)usinga pieceof plastic
wrap,clothrag or anothermethodto preventwaterfrom enteringengine.
-& CAUTION
High pressurewasherscoulddamageyourATV.
High pressurewashers,suchas thosefound at coin-operatedcar
washes,haveenoughpressureto damagethe partsof yourATV. Water
cancauserust,corrosionand increasewear.
Do not use highpressurewashersto cleanyourATV.
75
WASHINGYOURATV
Withsomecare,yourATV canbe washedin a similarmannerto washingan
automobile.
Note: Avoidsprayingor allowingwaterto flow over thefollowing places:
Ignitionswitch
Sparkplug
Fueltankcap
Carburetor
Usea gardenhoseat low pressureto removethe majorityof dirtor other
debris. HandwashyourATVwith mildsoapor detergentand water. Tryto
thoroughlyremoveall dirtand debriswithoutexcessivewaterpressure,even
at remoteareassuchas betweenenginecoolingfins, linkagesor mounting
brackets. Clothrags,washingmittsor cleaningbrushescanbe used. Be
carefulwith brushesas they mayscratchplasticor paintedsurfaces. Rinse
theATVthoroughlywith cleanwater. Dry all areasusinga chamoisor soft
absorbentcloth.
INSPECTIONAFTERCLEANING
Removethe ragsor wrappingfrom the exhaustpipe. Forextendedlifeof your
ATV,lubricateaccordingto GENERALLUBRICATIONsection.
Followthe proceduresin the INSPECTIONBEFORERIDINGsectionto check
yourATVfor any problemsthat may haveoccurredduringyour lastride.
OperatingtheATVwith wet brakescouldbe hazardous.
Wet brakesmay not provideas muchstoppingpoweras dry brakes.
Thiscould leadto an accident.
Testyour brakesafterwashingtheATV,ridingat a slowspeed. If
necessary,applybrakeseveraltimesto let thefriction dryout the
linings.
76
STORAGEPROCEDURE
If you do not useyourATVfor a longtime, it willneed specialservice
requiringappropriatematerials,equipmentand skill. For this reason,we
recommendthatyou trustthis maintenancework to yourauthorizedservice
center. If you wishto servicethe machinefor storageyourself,follow the
generalguidelinesbelow:
VEHICLE
Placethe vehicleon levelgroundand washthe entirevehicle.
FUEL
Drainthefuel from thefuel tank bya handpump. Drainthefuel from the
carburetorby releasingthe carburetordrainscrew.
Drainingthe fuel couldbe hazardous.
Fuelcouldcatchfire if you do not handleit properly.
Whendrainingthefuel from thefuel tank,besuretoshuttheengineoff.
Do notsmoke,andneverdrainfuel in anareawherethereareopenflames
or sparks.Keeppetsandchildrenawayfrom thefuel, anddisposeof the
drainedfuel properly.
TIRES
Inflatetires to the normalpressure.
EXTERNAL
1.
Sprayall vinyland rubberpartswith rubberprotection.
2.
Sprayunpaintedsurfaceswith rust preventative.
3.
Coat paintedsurfaceswith carwax.
PROCEDUREFORRETURNINGTO SERVICE
1. Cleanthe entirevehicle.
2.
Makesure thatthe vehicleis properlylubricated.
3.
Performthe INSPECTIONBEFORERIDINGas listedin this manual.
4.
Startthevehicleas outlinedin this manual.
77
SERIALNUMBERLOCATION
Youneedto knowtheframe and engineserialnumbersto gettitle documents
for yourATV.You also needthesenumbersto helpyour authorizedservice
centeror BajaMotorsportsorderparts.
The Framenumberis stampedon front of ATVframe. The enginenumberis
locatedon the rightside of theenginehousing.
Framenumber
Engineserialnumber
Writedownthe serialnumbersherefor future reference
FrameNo.:
EngineNo.:
78
SPECIFICATIONS
WD400U-2
DIMENSIONSAND DRYMASS
Overalllength......................................................................
1968mm(77.5 in)
Overallwidth........................................................................
1060ram(41.73in)
Overallheight.......................................................................
1100ram(43.30in)
Wheelbase.............................................................................
1233mm(48.5in)
Groundclearance..................................................................
245mm(9.65in)
Minimumturningradius......................................................
3000ram(118.1in)
Seat height.............................................................................
827mm(32.6 in)
Dryweight .............................................................................
259.9kg(5731bs)
ENGINE
Type.....................................................................................
Four stroke,air cooled
Numberof cylinders...........................................................
1
BoreX Stroke......................................................................
83.0x71.6
Displacement
......................................................................
387.4cm3
CorrectedCompressionratio............................................
9.50:1
Carburetor...........................................................................
Vacuumfilm piecetype
Air cleaner...........................................................................
Paperwith
PolyurethaneFoam
Element
TRANSMISSION
Primaryreductionsystem................................................
V-belt
Secondaryreductionsystem...........................................
ShaftDrive
TransmissionType...........................................................
V-beltautomatic
79
ELECTRICAL
Ignitiontype...................................................................................
CDI
Generatorsystem
..........................................................................
A.C.Magneto
Batterytype,voltage,capacity.
....................................................
YTX14AH,12V,14ah,
Headlight........................................................................................
12V,30w/30wx 2
Taillight...........................................................................................
12V,5w/21wx 1
Neutralindicator............................................................................
12V,1.7wx 1
Reverseindicator...........................................................................
12V,1.7wx 1
Highbeamindicator......................................................................
12V,1.7wx 1
Oil Temperature
..............................................................................
12V,1.7wx 1
EngineOil
Oilchangewithoilfilter replacement
...........................................
2.5QT
Totalamountofgearoil..................................................................
3 ouncesper
differential
Fuel
Mainfuel tank capacity
...................................................................
11.8QT
Reservefuel tank capacity.
............................................................
2.64QT
Brakes
Frontbraketype..............................................................................
HydraulicDisc
Operation
........................................................................................
Righthandoperation
Rearbraketype...............................................................................
Drumbrake
Operation
.........................................................................................
Lefthandoperation/
rightfoot
Suspension......................................................................................
Supportingrod
Front.................................................................................................
Doublewishbone
Rear..................................................................................................
1 Spring oil
dampenershock
Tires
SizeFront........................................................................................
AT25x8-12
SizeRear.
........................................................................................
AT25x10-12
Frame
Frametype......................................................................................
SteelTube
Casterangle....................................................................................
4 deg.
Trail..................................................................................................
21mm
8O
I
G/W
Right switch assembly
W/R
Ngear
I
indicator_
Y/W
CDI Comp.
light
_
R/W
WWW
B
I__
B R
R/B
DG
Y1
Y1
DG
Y1
Y2
R/Br
\
R
BI/B
T
Sparkplug
B/W
ZZ
Battery
12V 12Ah
ea '
t
12vsw/21w
Wl
T
Front
B
F1
r2v
Power lock
¢
4wd
Master
B - black
DG - deep green
W - white
BI- blue
G - green
O-orange
Br- brown
P-pink
R - red
Lb-light
Y-yellow
blue
fuse
box
shift
switch
tlSsd_
......
/
_
.....
side
iW
light
2
I
BAJA MOTORSPORTS- EMISSIONCONTROLSYSTEM
WARRANTY
YOURWARRANTYRIGHTSANDOBLIGATIONS
The emissioncontrolsystemwarrantyperiodfor this vehiclebeginson the date
thevehicleis deliveredto thefirst purchaserotherthanan authorizeddealer,or
thedate it is first usedas a demonstrator,lease,or companyvehicle,whichever
comesfirst and continuesfor 60 monthsafterthat date,or 5,000kin,whichever
comesfirst, providedthere hasbeenno abuse,neglector impropermaintenance
ofyour vehicle. Wherea warrantableconditionexists,the Distributorwill repair
yourvehicleat no costto you,includingdiagnosis,partsand labor. If anemission-relatedparton yourvehicleis defective,the partwill be repairedor replaced
by the Distributor.This is youremissioncontroldefectswarranty.
OWNER'SWARRANTYRESPONSIBILITIES
As thevehicleowner,you are responsiblefor the performanceof the required
maintenance.Youshouldmaintaina recordof all maintenanceperformedon your
vehicleand retainall receiptscoveringmaintenanceon yourvehicle. You maynot
be denieda warrantyclaimsolelybecauseofyourfailure to ensuretheperformanceof all scheduledmaintenanceor lackof maintenancerecordsor receipts.
Youare responsiblefor presentingyourvehicleto an authorizeddealeras soon
as a problemexists.The warrantyrepairsshouldbe completedin a reasonable
amountof time,not to exceed30 days.
As thevehicleowner,you shouldbeawarethatyou may be deniedyourwarranty
coverageif yourvehicleor a part hasfailed due to abuse,neglect,impropermaintenance,or unapprovedmodifications.
WARRANTYCOVERAGE
The Distributorwarrantsthat eachnew2009and latervehicle:
•
is designed,built,and equippedso as to conformat thetime of initial
retailpurchasewith all applicableregulationsof the UnitedStatesEnvironmental
ProtectionAgency,and the CaliforniaAir ResourcesBoard;and
•
is free from defectsin materialand workmanshipwhichcausesuch
vehicleto fail to confirmwith applicableregulationsof the UnitedStates EnvironmentalProtectionAgencyor the CaliforniaAir ResourcesBoardfor the periods
specifiedabove.
82
Youremissioncontrolsystemwarrantycoverscomponentswhosefailure would
increasean engine'semission,includingelectroniccontrols,fuel injection
system,carburetor,the ignitionsystem,catalyticconverter,or anyothersystem
utilizedin this vehicleto controlemissionif it is originallyequipped.Also
includedmaybe hoses,connectorsand otheremission-relatedassemblies.Replacingor repairingothercomponents(includingparts,labor,and othercosts)
notcoveredby this emissioncontrolsystemwarrantyor the standardwarranty
isthe responsibilityof theowner.
Coverageof repairsunderthiswarrantyappliesonlywhen repairsare completed at anauthorizeddealeror repairfacility. The Distributorwill not coverrepairs
performedoutsideof anauthorizeddealeror repairfacility. The use of replacementparts not equivalentto the originalpartsmay impairtheeffectivenessof
yourvehicle'semissioncontrolsystem. If such a replacementpart is usedand
an authorizeddealerdeterminesit is defectiveor causesa failure of a warranted
part,your claimfor repairto bringyourvehicleintocompliancewith applicable
standardsmay bedenied.
This EmissionControlSystemWarrantyis in additionto the standardLimited
Warranty.
EXCLUSIONS
AND LIMITATIONS
Thiswarrantydoes notcoverthe following:
•
Failuresor malfunctionsof theemissioncontrolsystemscausedby
abuse,alteration,accident,misuse,theuse of leadedgasoline.
•
Replacementof expendablemaintenanceitemsunlessthey areoriginal
equipmentdefectivein materialor workmanshipundernormaluse,and the first
requiredreplacementintervalfor the itemhas not been reached. Expendable
maintenanceitemsincludebut not limitedto sparkplugs,filters, coolant,lubricants,gaskets,hoses,and belts.
•
Replacementsof parts andotherservicesand adjustmentsfor required
maintenance.
•
Any vehicleequippedwithan odometeror hourmeterwhere the readingis alteredso thatactual mileagecannotbe readilydetermined.
•
Repairsor replacementsas a resultof:
•
Accident
•
Misuse
•
Useof replacementpartsor accessoriesnot conformingto theoriginal
specificationswhichadverselyaffectperformance
•
Physicaldamage,corrosion,or defectscausedby fire, explosionsor
similarcausesbeyondthecontrolof the Distributor.
•
Failuresnot causedby a defectin materialor workmanship.
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Useof thevehiclein any typeof competitiveracingor relatedeventsimmediately
and completelyvoidsthis and all otherwarranties.
LIMITEDLIABILITY
The liabilityof the Distributorunderthis EmissionControlSystemWarrantyis liraited solelyto the remedyingof defectsin materialworkmanshipby an authorized
dealerat its placeof businessduringcustomarybusinesshours.Thiswarranty
doesnot cover inconvenienceor lossof useof the vehicleor transportationof the
vehicleto/fromthe authorizeddealer.The Distributoris not liableto any personfor
incidental,consequentialor specialdamagesof anydescription,whetherarising
out of expressor impliedwarrantyor anyothercontract,negligenceor othertort
or otherwise.
No expressemissioncontrolsystemwarrantyisgivenby the Distributorexcept
as specificallyset forth herein. Any emissioncontrolsystemwarrantyimpliedby
law,includinganywarrantyof merchantabilityor fitness for a particularpurposeis
limitedto theexpressemissioncontrolsystemwarrantytermsstatedin thiswarranty. The foregoing statementsofwarrantyare exclusiveand in lieuof all other
remedies.All expresswarrantiesnot statedin thiswarrantyare disclaimed.Some
statesdo not allowlimitationson how longan impliedwarrantylasts,so the above
limitationsmay not applyif it is inconsistentwiththe controllingstatelaw.
No dealeris authorizedto modifythis EmissionControlSystemWarranty.If
you haveanyquestions regardingyourwarrantyrightsand responsibilities,
you
shouldcontactBAJAMOTORSPORTS.1-888-863-2252
84
Baja INC.
P.O.Box 61150
Phoenix, AZ. 85082
Tel: 602-443-9180
Toll Free: 888-863-2252
85