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.
"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.
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.
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.
Tableof Contents IMPORTANT........................................................................................................ 3 FOREWORD........................................................................................................ 3 NOTICETOTHE USER....................................................................................... 4 BAJAINC.WD400U-2ATV................................................................................. 8 FUELAND OIL............................................
Tableof Contents HEADLIGHT/TAILLIGHT REPLACEMENT .................................................52 THROTTLELEVERADJUSTMENT............................................................ 53 IDLESPEEDADJUSTMENT....................................................................... 54 FUELHOSE................................................................................................. 54 ENGINEOIL/OILFILTER............................................................................. 55 AIR FILTER..........
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.
Webelieve inconservation andprotection oftheearth's natural resources. We encourage everyvehicle owner andoperator todothesame byobeying posted signsandridingonlyinareas designated andapproved foroff-road recreational use.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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 [] ...............
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.
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.
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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.
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.
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.
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.
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.
SPECIFICATIONS WD400U-2 DIMENSIONSAND DRYMASS Overalllength...................................................................... 1968mm(77.5 in) Overallwidth........................................................................ 1060ram(41.73in) Overallheight....................................................................... 1100ram(43.30in) Wheelbase............................................................................. 1233mm(48.5in) Groundclearance.............................................
ELECTRICAL Ignitiontype................................................................................... CDI Generatorsystem .......................................................................... A.C.Magneto Batterytype,voltage,capacity. .................................................... YTX14AH,12V,14ah, Headlight........................................................................................ 12V,30w/30wx 2 Taillight...........................................................................
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_ ...... / _ .....
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.
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.
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.
Baja INC. P.O.Box 61150 Phoenix, AZ.
