Minimum AgeRequirement: 10 Model: 90cc For MoreinformationonATV SafetyContact the BajaATV SafetyHotlineat: 866-260-8630 Alwayswear a helmet; It could save your Life! Pleaseobtain,review,and followprovincial/ municipalgovernmentacts and regulationspertainingto 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 this ATV.
Congratulationson your purchaseof the WD90 ATV. It is warrantedto befree of manufacturingdefectsin the materialand workmanshipfor a periodof 90 daysfrom the dateof purchase.Duringthe warrantyperiodBAJAINC.will at its option,repair,providereplacement partsor replaceyour BAJAINC. 90ccATVat no charge. Thiswarrantydoes not covernormalwear itemsor damagecausedby neglector misuseof the product.
This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator. The manual contains importantsafety information and instructions which should be read carefully before operating the vehicle. The engine exhaust from this product contains chemicals known to the State of California to cause cancer,birth defects or other reproductive harm.
SAFETY............................................................................................................... 3 IMPORTANT........................................................................................................ 3 NOTICETO THE USER....................................................................................... 4 ATV90.................................................................................................................. 8 FUELANDOIL.....................................
IDLESPEED ADJUSTMENT....................................................................... 51 FUELHOSE................................................................................................. 51 ENGINEOIL................................................................................................. 52 CHANGINGENGINEOIL ............................................................... 53 AIR FILTER..................................................................................................
Pleaseread this manualand follow all instructionscarefully.To emphasizethe specialinformation,thesymbol-_ and thewordsWARNINGor CAUTIONhave somespecialmeanings.Payattentionto the messages. Indicatesa potentialhazardthatcouldresultin deathor injury. _& Indicatesa CAUTION potentialhazardthatcouldresultin vehicledamage. NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror instructionsclearer. WARNINGand CAUTIONare arrangedlikethis: The first partwill identifya POTENTIALHAZARD.
Webelieve inconservation andprotection oftheearth'snatural resources. We encourage everyvehicle owner andoperator todothesamebyobeying posted signsandridingonlyinareas designated andapproved foroff-road recreational use.
Category Y-10+ ATV. ACategory Y-10+ ATVisayouthmodel ATVthatisintended for useby childrenage 10 or older. CategoryY-12+ATV.A CategoryY-12+ATV isa youthmodelATVthat is intended for useby childrenage 12 or older. CategoryT (TransitionalModel)ATV.A CategoryT ATV isan ATVof appropriate sizethat is intendedfor recreationaluse byan operatorage 14 or olderunderadult supervision,or by anoperatorage 16 or older.
Always follow properproceduresfor climbinghillsas describedin this manual.Checktheterraincarefullybeforeyou start up any hill.Neverclimb hillswith excessivelyslipperor loosesurfaces.Shiftyou weightforward. Neveropenthethrottlesuddenlyor makesuddengearchanges.Nevergo overthe top of any hill at high speed. Alwaysfollow properproceduresfor goingdownhills andfor brakingon hills as describedin this manual.Checktheterraincarefullybeforeyou start down anyhill. Shiftyourweightbackward.
Never modify anATVthrough improper installation oruseofaccessories. Never exceed thestatedloadcapacity for an ATV. Cargoshouldbe properly distributedand securelyattached.Reducespeedand follow instructionsin this manualfor carryingcargo.Allowgreaterdistancefor braking. The combinedweightof the riderand anyaccessoriesor cargomustnever exceedthevehicle'sloadcapacityof 220 Ibs. Do not towa trailer. Thisvehicleis not designedfor such use.
Gas Cap vent hose Gas Ca Spark plug Head lights Muffler Rear Tire Rear shock Oil cap RIGHT Thumb Fuel valve Seat Tail Light FrontTire _uretor LEFT
FUEL Properfuel is very importantfor theengine. Ensurethere is no dust,dirt, or waterwhichhas mixedin thefuel. Useregularunleadedgasolinewith an octanenumber90 or higher. ENGINE OIL Your90ccATV hasa four-stroke engine. Pleaseuseoil as describedin the chartbelow. By usingprescribeoil, you will realizethe bestlubricationfor engine. ENGINE I °C -30 -20 -10 0 10 20 30 40 -22 -4 14 32 50 68 86 104 TEMP. oF Usethe chartto selecta viscosityratingbasedon the temperaturerangein yourarea.
Read andfollow all of the warningslabels 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 contactingBAJAINC. Operationofthe ATV by children underthe age of 10 increasesthe riskof severe injury or death. Adultsupervisionrequiresfor children under age 16. NEVER permitchildren underage 10 to operate thisATV.
NEVERrideas a passenger, Passengercan causea loss of control,resultingin SEVEREINJURYor DEATH, 3 ImproperATV use can result in SEVERE INJURYor DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER Operate: • Without propertraining or instruction. • • • At speedstoo fast for your skills or the condition. On public roads,a collisioncan occurwith anothervehicle.
4 improper tire pressure or overloadingcan cause loss of control, Loss of control can result in SEVERE iNJURY or DEATH. ® Cold tire pressure: Front: 7 Psi (48 Kpa) Rear: 7 Psi (48 Kpa) ® Maximum weight capacity; 220 Ibs.
HANDLEBAR& SWITCHES Rear Brakelever LightSwitch LEFT HANDLEBAR EngineStop With the Enginestop switchin the "Stop" position ElectricStart switch The enginecannotbestarted. Button With the Enginestop in the "Run" position The enginecan be started. Rear brakelever Applythe rearbrakeby squeezingthe rear brake levertowardsthe grip. Electricstartingbutton Pushelectricstartbuttonto startengine. RIGHT HANDLEBAR ThrottleLever Control the engineandATVspeedwith thethrottlelever. Operatethis leverwith yourthumb.
Usethe throttleadjustingscrewto restrictmaximumspeedof theATV. Adjustthis limiteraccordingto the rider'sskilland experience. Adjustinqprocedures: 1. Loosenthe Locknut 2. Turnthethrottleadjustingscrew clockwiseto restrictmaximumspeedof theATV. 3. Turnthethrottleadjustingscrew counterclockwise to increasethe maximumspeed of theATV. 4. After finished, tightenthe locknut FUELVALVE Thereare three positions: "ON","OFF", and "RES".
Overfilling thefuel tank couldbe hazardous. If you overfillthe fuel tank,fuel may overflowwhenit expands. Expanding is due to heatfrom engineor sun. Overheatedfuel couldeasilycatchfire. Stop addingfuel when thefuel level reachesthe bottomof thefiller neck. Improper fueling of theATVcould behazardous. Failingto follow safety precautionswhen refuelingcouldresultin a fire or letyou to breathetoxic fumes. Refuelin a well ventilatedarea. Makesure the engineisoff and avoid spillingfuel on a hot engine.
REMOTESTOP LANYARD StopLanyard Stop Lanyard YourATVis equippedwith a remotestop lanyard.Thislanyardshould be usedwhentrainingbeginneroperators.The adultsupervisorshould graspthe lanyardand follow behindtheATV whilethebeginneris learningto operatetheATV.The adultsupervisorshouldpullthe lanyard to removethe remotestop pinwhichwill stopthe engine. NOTE:ThisATVwill not startor operatewithoutthe remotestop pinand lanyardin place.
WHATYOUSHOULDKNOWBEFORERIDING Beforeriding,you shouldreadall the following informationcarefully.If you are properlyprepared,you will havea moreenjoyableride. Beforeriding,you shouldfind a goodplaceto practicetheskills. Finda flat, open areawith enoughspaceto practicethenewskills. OperatingthisATVwithoutproperinstruction. The riskof an accidentis greatlyincreasedif the operatordoes not know how tooperatetheATV properlyin differentsituationsand on different typesofterrain.
INSPECTIONBEFORERIDING Failingto inspecttheATV beforeoperatingcouldbe hazardous.Failingto performpropermaintenancecouldalso be hazardous. Failingto inspectand maintainyourATV couldincreasethe chancesof an accidentor equipmentdamage Alwaysinspect yourATVeachtimebeforeriding,andmakesureitisina safeoperating condition. RefertotheINSPECTION ANDMAINTENANCE sectioninthismanual.
Checkingmaintenanceitemswhenthe engineis runningcouldbe hazardous. Youcouldbe severelyinjuredif yourhandsor clothingget caughtin moving ATVparts. Shutthe engineoffwhen performingmaintenancechecks,exceptcheckingthe enginestopswitchand throttle. BREAK-IN The first monthis the mostimportantin the life ofyour vehicle. Properoperation duringthis break-inperiodwill behelpfulfor assuringmaximumlife and performance of yournewvehicle. Thefollowing guidelinesexplainproperbreak-inprocedures.
STARTINGTHE ENGINE ON OFF Beforeattemptingto startthe engine,makesure to follow thesesteps. 1. Turnthe key switchto the "ON" position. 2. Set the enginestop switchto the"RUN" position. 3. If engineis cold,set chokeleverto the up (on) position. 4. Applythe rearbrake leverand makesure that the rearwheelsare in lockingcondition. 5. Presstheyellowstarterbutton"START" to start the engine. Afterenginehaswarmedup,set choketodown 6. Ignitionkey switch (off)position.
RunningyourATVindoorswherethereis littleor noventilation. Breathingin exhaustgasesfromthe ATVcouldcausesevereinjury. AlwaysrunyourATVoutdoorswherethereis fresh air. Carryinga passengeron this ATV. Greatlyreducesyour abilityto balance and controlthisATV. Couldcausean accident,resultingin harmto you and/oryour passenger. Nevercarry a passenger.The longseat is to allowthe operatorto shift positionas neededduringoperation.It is not for carryingpassenger.
OperatingthisATV on pavedsurfaces. TheATV'stiresaredesignedfor off-roaduse only,notfor useon pavement.Pavedsurfaces mayseriouslyaffecthandlingandcontrolof theATV,and maycausethevehicletogo out of control. NeveroperatetheATVon anypavedsurfaces,includingsidewalks, driveways,parkinglotsand streets. Operatingthis ATVon publicstreets,roadsor highways. Youmay collidewith anothervehicle. NeveroperatethisATV on any publicstreet, roador highway,evena dirt or gravelone.
OperatingthisATV at excessivespeedscouldbe hazardous. Ridingat excessivespeedsincreasesyourchancesof losingcontrolofthe ATV,whichcouldresultin anaccident. Alwaysgo at a speedthat is properfor theterrain,visibility,operating conditions,operatorskills, andoperatorexperience. Attemptingwheelies,jumps,and otherstunts. Increasesthe chanceof anaccident,including an overturn. Neverattemptstunts,such as wheeliesor jumps.Don'ttry to showoff. Checkingmaintenanceitemswhen theengineis runningcouldbe hazardous.
SAFETY GEAR A DOTapprovedmotorcyclehelmetis the mostimportantpart ofyour safety gear. A DOT approvedmotorcyclehelmetcanhelppreventa seriousheadinjury. Choosea helmetthat fits snugly. Motorcycledealerscanhelp in selectinga good quality helmetwhichfits properly. OperatingthisATVwithoutwearingan approvedmotorcyclehelmet, eye protectionand protectiveclothing. Operatingwithoutan approvedmotorcyclehelmetincreasesyour chancesof a severehead injuryor deathin the eventofan accident.
Failureto inspectthe ATVbeforeoperating. Failureto properlymaintainthe ATV. Increasesthe possibilityof an accidentor equipmentdamage. AlwaysinspectyourATV eachtime you us it to makesurethe ATVis in safe operatingcondition. Alwaysfollow the inspectionand maintenanceproceduresand schedulesdescribedin the owner'smanual. Removinghandsfrom handlebarsor feet from thefootrests duringoperation.
Failureto useextracarewhenoperatingon excessivelyrough,slipperor looseterrain. Couldcauselossof tractionor vehiclecontrol, whichcouldresultin an accident,includinganoverturn. Do notoperateon excessivelyrough,slipperyor loose terrainuntilyouhavelearnedandpracticedtheskillsnecessaryto controltheATV on suchterrain.Alwaysbeespeciallycautiouson thesekindsofterrain. The ATVmay startmovingas soonas you releasethe parkingbrake. Unexpectedmovementcould causeyou to lose controlofthe ATV.
BRAKING FrontBrake RearBrake ThrottleLever To stop theATV,first releasethe throttle lever,then applythe rear and front brakessmoothly. BrakingwhileturningtheATVcould behazardous. Useof the brakewhenturningcouldcausetheATV to slideor roll over. Usethe braketo slowdownbeforeyou beginto turn. Brakinghardon slipperysurfacescouldbe hazardous. TheATV couldskidand go out of controlif you braketoo hard. Applythe brakeslightlyand carefullyon slipperysurfaces.
TURNING Toturn theATV,the rider mustusethe propertechnique. Becausethis vehicle hasa solid rearaxle, bothrearwheelsalwaysturn at the samespeed. This meansthatif therear wheelsaregettingequaltraction,thevehiclewill tend to movestraightahead. This is becausethe rearwheelswill travelthe same distance. Forthe vehicleto turn,the outsiderearwheel musttravel a longer distancethatthe insiderear wheel. To makethis happen,the ridermust createlesstractionfor the insidewheel,allowingitto skid.
OPERATION ON HILLS Operatingon excessivelysteephills. Thevehiclecanoverturnmoreeasilyon extremelysteephillsthan on levelsurfacesor small hills. NeveroperatetheATVon hillstoo steepfor theATV or for your abilities. Practiceon smallerhillsbeforeattemptinglargerhills. CLIMBING A HILL Climbinghills improperly. Couldcauseloss of controlor cause ATV to overturn. Alwaysfollow the properproceduresfor climbinghillsas describedin this owner'smanual. Always checkthe terraincarefully beforeyou startup any hill.
To climba hill with theATV,follow the directions below. . , . 4. Speed up and maintaina steadyspeed beforereachingthe top of the hill. Rememberthatyou mustride at a steady speedall theway to the top of the hill. Shift yourbodyforward by slidingforward on theseat. Leanslightlyforward. Forsteep hills,stand on thefootrests and leanforward. Maintaina steadyspeedwhileclimbingthe hill. Slow downgraduallywhenyou reachthetop of thehill.
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 theseat. 4. Ridedownthehill slowlywith the throttlereleased. 5. Applythe rearbraketo controlthe speed. . Avoidgoingdowna hill at an anglethat wouldcausethe vehicleto lean sharply to one side. Gostraightdownthe hillif possible. Improperlycrossinghills or turningon hills.
Whentraversinga slope,you should: 1. Leanyourbodyuphill. 2. Steerslightlyuphill,ifnecessary,to maintaina straightcourse. Stalling,rollingbackwardsor improperlydismountingwhile climbinga hill. Couldresultin ATVoverturning. Usepropergearand maintainsteadyspeedwhenclimbinga hill. If you lose all forward speed: Keepweightuphill. Applybrakes. Lockparkingbrake,afteryou are stopped. If you beqinrollinq backwards: Keepweightuphill. Neverapplytherear brakewhilerollingbackwards. Applythefront brake.
If you cometo an obstaclethatyou cannotavoid,you may beable to crossover it by usingthe following procedure. 1. If theobstacleis in front of you,approachat walkingspeed. 2. Riseup slightlyon thefootrests. 3. Pulluponthehandlebar andapplya littlethrottleasthefrontwheelsreachtheobstacle. 4. Leanforward and releasethe throttleafterthefront wheelsareover the obstacle. Remember thatsomeobstaclesaretoo highfor yourATVor for yourabilities.
RIDING THROUGH WATER YoucanridetheATVthroughshallowwater. Makesureit isnotmorethan10cm(4 inches)deepandisnot movingfast. Choosea goodplaceto crossbeforeyou ride throughthewater. Lookfor a spotwherethe banksaregentlyslopedon bothsides andthebottomof thestreamishard. Ifyou areunfamiliarwiththearea,parkthe ATVandinspectthestreamfirst tofind a suitablespotfor crossing.Whencrossing, operatetheATVat a slow,steadyspeed. Becarefulnotto damagebankswhen crossing. OperatingthisATVthroughdeepor fast flowing water.
RIDING IN COLD WEATHER Pre-rideInspection Checkthatthe throttleandall controlleversmovefreely. Makesure thatthe footrests are free of iceor snow. MovetheATV forward and backwardto checkthatthewheelsroll freely. Ifyou cannot movetheATV,the tiresmay befrozen tothe ground,or the brakesmay befrozen to the wheels. If thetires arefrozen to the ground,pourwarmwateraroundthemto meltthe ice. If the brakesarefrozen, bringtheATVto a warmerareato thawout the brakes. After theenginehaswarmedup,checkthebrakes.
DRESSING FOR COLD WEATHER RIDING OperatingyourATV in coldweatherwithoutproperclothingcouldbe hazardous. Continuedexposurein the coldweathercouldlead to hypothermia. Hypothermiaisa conditionwhereyour body'sinnertemperature dropslow enoughto causeinjuryor death. Alwaysdressfor theworstweatherconditionsyou mightencounter. Be preparedfor bad weatherand ATVbreakdowns. Ridingin coldweathercanbe hazardous.
RIDING YOUR ATV ON SNOW AND ICE Ridingon snow-coveredterrain,evenwith care, couldbe hazardous. The snowmay be coveringrocks,holes,iceor otherhazardsthatcan causeloss of control. Severeinjuryor deathcouldoccurif you lose controlofthe ATV. Goslowlyand be carefulwhen ridingon snow-coveredterrain. Alwaysbealert to changingterrain conditions. Ridingon a frozen lakeor rivercouldbe hazardous. Seriousinjuryor death couldoccurif theice breaksand you couldfall intothe coldwater.
ACCESSORY USE AND VEHICLE LOADING OperatingthisATVwith impropermodificationscouldbe hazardous. Improperinstallationof accessoriesor modificationsofthe vehiclemay causechangesin handlingwhichcouldleadto an accident. NevermodifytheATVwith improperinstallationor useof improper accessories.All partsand accessoriesaddedto theATVshouldbe genuinepartsor theirequivalentdesignedfor useon this ATV. Install and usethemaccordingto their instructions.Ifyou haveany questions, contactyourdealer.
. Distributecargoweightevenlybetweenthefront and rearof the vehicleas well as bothsides of thevehicle. Locatecargoweightas closeto the centerof the vehicleif possible. . . . Secureyourloadwell.Shiftingweightcanaffectyourabilitytohandlethe vehiclesafely. Rideat slow speedsand avoidhillswhen carryingcargo. Carrying loadswouldaffect thestabilityand handlingof yourATV. Allowenoughstoppingdistance. Stoppingdistanceincreasesif you carry loads. Useenginebrakingas muchas possible.
MAINTENANCESCHEDULE It is very importantto inspectand maintainyourATVregularly. Followthe guidelinesin the chart. The intervalsbetweenperiodicservicesin monthsare shown. At the end of eachintervalbe sure to lerform the maintenancelisted.
Improper maintenance orfailing to performrecommended maintenancecouldbe hazardous. If you performimpropermaintenanceor do not maintainyourATVyou may havean accident. KeepyourATV in good condition.Askyourauthorizedservicecenter or a qualified mechanicto do the maintenanceitemsmarkedwith an asterisk(*). Youmay performthe unmarkedmaintenanceitemsby referringto the instructionsin this sectionif you havemechanical experience.If you are not sure howto do the maintenanceask your authorizedserviceor call Baja Inc.
TOOLS A tool kit is provided with your ATV. SPARK PLUG YourATV is equippedwith a Tl136 sparkplug. To determineif thestandard spark plug isin goodcondition,checkthe colorof the plug'scenterelectrode insulatoraftervehicleoperation.A browncolor indicatesthatthe plug is correct. Awhite or dark insulatorindicatesthatthe enginemayneed adjustment,or anotherplugtypemay be needed. Consultyourauthorized dealeror BAJAINC. ifyour plug insulatorisnot a light browncolor.
NOTE: ThisATV usesresistor-typesparkplugto avoidjammingelectronic parts. Impropersparkplugselectionmay causeelectronicinterferencewith yourATVsignitionsystem,resultingin the vehicleperformanceproblems. Use recommendedspark plugs. To installa spark plugturn it in as far as possiblewith yourfingers, thentighten it witha wrench. ,_, CAUTION Improperinstallationof the sparkplugcoulddamageyourATV. An overlytightor crossthreadedsparkplugwill damagethe aluminumthreads ofthe cylinderhead.
BATTERYINSTALLATION INITIAL SERVICE AND INSTALLATIONOF BATTERY: EyeProtection RubberGloves Thefollowing procedureisvery dangerousand shouldbe performedwith the utmostcareand attention.Wear protectiveeyewear,rubbergloves,ant havewateravailableshouldelectrolytecomein contactwith skin or eyes. KEEPALLCHILDRENAWAYFROMTHE AREAWHILETHISPROCEDURE IS BEINGPERFORMED. POISON- CAUSESSEVEREBURNS Containssulfuricacid. Avoidcontactwith skin,eyes,or clothing To preventaccidents,rinseemptycontainerwith water.
Note:The following page isfor vehicleswith battery'scontainingseparate electrolytepack. Mostbattery'swill comewith theelectrolytealreadysealed intothe battery. Preparinqthe battery: Placebatteryon level surface.Removesealingtape from top.(see figure 20) Taketheelectrolytecontainerout of the plasticbag. Placeelectrolytecontainerupsidedownwith the sealedsilvermouthsof theelectrolytebottlesin line with the sixfiller holesofthe battery.(seefigure 21) Pushthecontainerdownstronglyenoughto break the silverseals.
Howto InitiallyCharqethe battery: 1. Connectthe red positive(+) cableto thered positive(+) poleof the battery. (seefigure 23) 2. Connectthe blacknegative(-) cableto the blacknegative(-) poleof the battery.(see figure 24) Note:The red positive(+) cablehasa larger diameterthan the blacknegative(-) cable. . Figure23 Chargingrate:Chargebattery@ 0.7Ampsfor 5 ~ 10 hours. • Afterchargingiscomplete,pressdown firmly with bothhandstoseat the caps. (Do not poundor hammer.)The batteryis nowsealed.
Battery Replacement: DO NOTopensealedcapsto addwaterto battery. Alwayswearsafety glassesand chargein a ventilatedarea. If batterygetshot to the touch,discontinuechargingandallow batteryto cooldown. Do not usefast chargingunlessit is an emergency. Atthe beginningor end of charging,turn offthe chargerfirst, in orderto preventelectricsparkand explosion. Chargein a well ventilatedarea. DO NOTsmokearoundbatteriesand keepawayfrom openflame.
ENGINESPEEDGOVERNOR TheATV governorisset bythe factory to limitspeedofATVto 15mph (24kin/h)directlyout of crate. Thegovernorcanbe adjustedto allowthe ATVto travelup to 30mph(48kin/h). Any adjustmentto governorshouldbe performedbya responsibleadult. Changingtop speedof ATVshouldmatch ridersability. The enginespeed governorispart of the CDI (A)locatedunderthe gastank of theATV. The governorshouldonlybe adjustedby a responsibleadultor qualified servicetechnicianworkingunderthe directionof the adultowner.
A D G I H Faster CW Adjustment Slower CCW screws (E) (H) Low Speed Limit Regulator 5-15mph (8-24kin/h) 1. RemoveLowspeedadjustmentscrewcover(D)from CDIgovernor box 2. AdjustLowspeedadjustmentscrew(E) to desiredsetting: CW (clockwise)faster, CGW(Counterclockwise)slower. Re-install adjustmentscrewcover(D). Note: Low speedadjustment(5-15mph) canonly be performedwith metaljumper(F) in place. TheATV is shippedwith metaljumper(F) in place. 3. Re-installCDI Governorbox (A) inATV.
THEADJUSTMENTOF THROTTLELEVER Operatingthe vehiclewith an inadequatethrottleleverfree distancecould be hazardous. Inadequatethrottleleverfree distancecouldcauseenginespeedto rise suddenlywhenyou turnthe handlebars.This canlead therider to lose control. Adjustthe throttleleverfree distanceso thatengineidlespeeddoes not risedue to handlebarmovement. Throttleleveradjustmentnut Measurethethrottlelever play. 3.0~5.0ram (0.12-0.20inches) Toadjustthethrottleleverfree distance: 1.
IDLESPEEDADJUSTMENT Improperadjustmentof the idlespeedcouldbe hazardous. An idle speedthat is too high couldcausetheATVto launchforward when you starttheengine. This may causean accident. Excessiveenginewear mayalso resultif idlespeed isadjustedimproperlyor when the engineis not fully warmedup. Adjustthe idleto the correctspeed. Makesurethe engineisfully warmbeforeadjustingtheengineidlespeed. To adjustthe idle speedproperly,you need a tachometer.
ENGINEOIL Newand usedoil couldbe hazardous. Children and pets maybe harmedby swallowingnewor usedoil. Continuouscontactwith usedoil can causeskin cancerin laboratory animals. Briefcontactwith the usedoil may irritatetheskin. Keep newand used oil awayfrom childrenand pets. To minimizeyour exposureto usedoil, weara long-sleeveshirtand moisture-proofgloves (suchas dishwashinggloves)when changingoil. If oil contactsyour skin,wash thoroughlywith soap andwater. Launderany clothingor rags ifwet with oil.
Changing engine oil The engineoil shouldbe changedevery20 to 40 hoursof operation.It should be changedmoreoften in dirtyand dustyareas. To chanqeoil: 1. Parkthevehicleon level ground. 2. Removethe oil cap. 3. Removethe drainboltand drain oil intopropercontainer. 4. Reinstallthe drainbolt 5. Pourfresh oil of the specifiedtypethroughtheoil fill hole. Oil Cap NOTE: Approximately900ml(1 Qt) of oil is required. 6. Tightentheoil cap, and checkoil levelthrough sightgauge. .
AIR CLEANER Operatingtheenginewithoutthe air cleanerelementin placecouldbe hazardous. If the air cleanerelementdid not filter dirt, severeenginedamagewould occurif thedirt enteredthe runningengine. Neverrunthe enginewithoutthe air cleanerelementin place. _&,CAUTION Failingto inspectthe air cleanerelementfrequently if thevehicleis used in dusty,wet,or muddyconditionscoulddamageyourATV. The air cleanerelementcould becomecloggedundertheseconditions, and enginedamagemay result.
REMOVAL 1. Removeair filter. Loosenclamps Air filter cover Clamp 2. Removeair filter cover. 3. Removefoam air filter element. Foamair filter element WASHINGTHE ELEMENT Washthe elementas the followinq: 1. Filla washingpan largeenoughto hold the elementwith a nonflammable cleaningsolvent. Immersethe element in thesolventand washit. @ 2. Squeezetheelementby pressingit betweenthe palmsof bothhandsto removeexcesssolvent(A). Do nottwist or wring theelementor itwill develop cracks. 3.
_k CAUTION A tornair filter coulddamageyourATV. Dirtand dust may getinside of theengine if the elementis torn. Examinecarefullytheelementfor tearsbeforeand aftercleaningit. Replacethe elementwith a newone if it is torn. Oil and solventcouldbe hazardous. Childrenand pets couldbe harmedfrom the oil and solvent. Be sureto keepoil and solventawayfrom childrenand pets. Disposeof usedoil and solventproperly. 3. Reinstallthe cleanedelementin reverseorderof removal.
DRIVECHAIN/SPROCKETS The conditionand adjustmentof thedrivechainshouldbe checkedbefore riding. Alwaysfollow theguidelinesbelowfor inspectingand servicingthe chain. Failingto maintainthe chainproperlybeforeeachridingcouldbe hazardous. Ridingwith the chainin poor conditioncouldleadto anaccident. Besureto inspectand maintainthe chainbeforeriding,accordingtothese guidelines.
DRIVECHAINCLEANING,OILINGANDADJUSTING Clean and oil the chain as the following: 1. Washthe chainwithwater. 2. Dry the chain,and then oilthe linkswith Chainlubeor equivalent. Failingto inspectthedrivechainslackbeforeeachuseof theATV could be hazardous. Toomuchchainslackcould causethe chainto comeoff thesprockets, resultingin an accidentor seriousdamageto theATV. Inspectthedrive chainslackbeforeeachuse. Adjusting the Drive Chain 20-30 mm (0.8-1.
TIRES OperatingthisATVwith impropertires,or with improperor uneventire pressure. Useof impropertires on thisATV,or operationof this ATVwith improperor uneventire pressure,may causelossof control,increasingyourrisk of an accident. Alwaysusethesize and typeof tires specified.Alwaysmaintainpropertire air pressureas describedin this section. OperatingthisATVwith impropermodifications.
Usingworntires couldbe hazardous. Thetractionofthevehiclewillbedecreased. Thisincreases yourriskofhaving anaccident. Replace thefront andreartireswhenthedepthonthetreadis4.0mm (0.16inches) or less. TheATV is equippedwith low pressuretubelesstires of the sizeand type listedbelow: Front Rear Size AT 16X8-7 AT16X8-7 TireTreadCondition _. 4.0 mm (0.16inches) TireAir Pressure Checktheair pressurein all tires beforeriding.
Overfillingtheair to thetires couldbe hazardous. If you put too muchair intothetire, the tire mayburstcausingsevere injury. Checkthe air pressurefrom timeto timewhilegraduallyinflatingthe tire, untilthe specifiedair pressureisobtained. Usingtiresthat havebeen installedincorrectlycouldbe hazardous. TheATV mayhaveunusualhandlingif thetires are installedincorrectly. The tiresare intendedto rotatein a specificdirection,as indicatedbythe arrowson the sidewallof eachtire.
BRAKING TheATV hastwofront drumbrakesand one reardisk brake. Failingto inspectand maintainyourATV'sbrakesystemproperlycould be hazardous. Impropermaintenanceof the brake increasesyour chanceof havingan accident. Besure to inspectthebrakebeforeridingaccordingto the INSPECTION BEFORERIDINGsection. Alwaysmaintainyour brakesaccordingto the MAINTENANCESCHEDULE. OperatingtheATVin harshconditionscouldbe hazardousif you do not inspectbrakewear often.
Rear Hydraulic Disk Brake Failingto maintainthe brakeshoesor padscouldbe hazardous. Ridingwith wornbrakeshoes,pads,or shoesthatare seriouslyworn,will increaseyour chanceof havingan accident. If you needto replacebrakeshoe pads,haveyour authorizedservice centerdo thework. Inspectingand maintainingthe brakeshoepads is recommended.Replacethe shoe padsin sets. Brakefluid reservoir Brakefluid cap Brakefluid Level Brakefluid hose .
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 ...............
Ak CAUTION Failingtotroubleshoota problemcorrectlywould damageyourATV. Improper repairsor adjustmentsmay damagethe vehicle. Suchdamage may not be coveredunderwarranty. If you are notsure aboutthe proper action,consultyourauthorizedservicecenteror BAJAINC. aboutthe problem. Drainingfuel from thecarburetorcouldbe hazardous. Fuelcouldcatchfire if you do not handleit properly. Whendrainingthe carburetor,be sureto shut theengineoff.
IgnitionSystemCheck Performingthesparktest improperlycouldbe hazardous. Youcouldgeta highvoltageelectricalshockifyouarenotfamiliar withthis procedure. Do not performthis checkifyou arenot familiar with the procedure.Do not pointthespark plug nearthespark plugholeduringthis test. Do not do this test if you havea heartconditionor wear a pacemaker.Do not performthis test nearany openfuel containersfor nearfuel whichhas spilledon the ground,on engine,or any part of theATV. . 2.
Drainingfuel from thecarburetorcouldbe hazardous. Fuelcouldcatchfire if you do not handleit properly. Whendrainingfuel from the carburetor, besuretoshuttheengineoff. Donot smoke,andneverdrainor refuelin anareawherethereareopenflamesor sparks.Donotspillthefuel or youmaycreatea fire hazard.Disposeofthe drainedfuel properly. -& CAUTION Failingto securetheATV properlycouldbe hazardous. Failingto securethevehicleproperlymay resultin an accidentor damage to thevehicle.
-& CAUTION High pressure washers coulddamage your ATV. High pressure washers such as those found at coin-operatedcarwashes have enough pressure to damagethe parts of your ATV. It may cause rust, corrosionand increase wear. Do not use high pressure washers to cleanyour ATV. Athoroughcleaningof yourATVis a necessarypartof maintenance.It will help keepyourATVlookingandperforming best. Propercleaningcanalsoextendthe lifeofyourATV.
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.
If you do notuseyourATVfor an extendedperiod,itwill needspecialservice requiringappropriatematerials,equipmentand skill. Forthis reason,we recommendthatyou trustthis maintenancework to yourauthorizedservice center. If you wishto servicethe machinefor storageyourself,follow the general guidelinesbelow: VEHICLE Placethevehicleon levelgroundandwashthe entirevehicle. FUEL Drainingthe fuel couldbe hazardous. Fuelcouldcatchfire if you do not handleit properly.
Youneedto knowtheframe and engineserialnumbersto get title documentsfor yourATV.You also needthesenumbersto helpyour authorizedservicecenteror BAJAINC.order parts. Theframe/vin number is stampedon the front of theframe as shownin the photograph.The engineserialnumberis stampedon the leftside of the crankcase. Frame/kinnumber Engineserialnumber Writedownthe serialnumbersherefor yourfuture reference FrameNo.: EngineNo.
DIMENSIONSAND DRYMASS Overalllength................................................................................. 1400ram(51.2in) Overallwidth....................................................................................... 0mm (37.4in) Overallheight................................................................................... 930ram(36.6in) Wheelbase........................................................................................ 930mm(36.6 in) Fronttread...............................
BAJAINC. - EMISSIONCONTROLSYSTEMWARRANTY YOURWARRANTYRIGHTSAND OBLIGATIONS The emissioncontrolsystemwarrantyperiodfor this vehiclebeginson the datethevehicleis deliveredto thefirst purchaserotherthan anauthorized dealer,or thedate it is first usedas a demonstrator,lease,or company vehicle,whichevercomesfirst and continuesfor 60 monthsafterthatdate, or 5,000kin,whichevercomesfirst, providedthere hasbeen no abuse,neglector impropermaintenanceof yourvehicle.
Youremissioncontrolsystemwarrantycoverscomponentswhosefailure wouldincreasean engine'semission,includingelectroniccontrols,fuel injectionsystem,carburetor,the ignitionsystem,catalyticconverter,or any other systemutilizedin this vehicleto controlemissionif it is originallyequipped. Alsoincludedmay be hoses,connectorsand otheremission-related assemblies.
• Useof replacementpartsor accessoriesnot conformingto the original specificationswhichadverselyaffect performance • Physicaldamage,corrosion,or defectscausedby fire, explosionsor similarcausesbeyondthe controlof theDistributor. • Failuresnot causedby a defectin materialor workmanship. Useof thevehiclein any typeof competitiveracingor relatedeventsimmediatelyand completelyvoidsthis and all otherwarranties.
Motorsports _ Baja, IN(3. RO. Box 61150 Phoenix, AZ.
