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OWNER`S MANUAL - Baja Motorsports

1. 63 FUEL SUPPLY CHEC Kinnitati ta akas 63 IGNITION SYSTEM CHECK nine 64 aaaea eaaa 65 CLEANING 4 66 PREPARATION FOR 66 WASHING YOUR ATV 67 INSPECTION AFTER 67 STORAGE 68 SERIAL NUMBER 69 5 70 WIRE DIAGRAM 11 EMISSION CONTROL SYSTEM 72 SAFETY Please read this manual and follow all instructions carefully To emphasize the special information the symbol A and the words WARNING or CAUTION have some special meanings Pay great attention to the messages A WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged
2. E 41 555 41 BATTERY 43 ENGINE SPEED 47 THROTTLE LEVER ADJUSTMENT in 49 IDLE SPEED 50 FUEL HOSE a eaaa aaeain aea idvstateasscitandseinsedusatassvaiesesuacsksonsnis 50 TABLE CONTENTS ENGINE tn ce tertiaire nee 51 CHANGING ENGINE OIL rire 52 AIR FILTER 53 REMOVAL 54 WASHING wis cists cacuccadsnsancstincusvaiiuthcsesencasuussctnieannicsauisahansutiedinta ersta 54 DRIVE 5 56 INSPECTING THE DRIVE 56 INSPECTING THE 56 DRIVE CHAIN CLEANING OILING AND 57 TURES 58 BRAKING Sn 60 FRONT DRUM BRAKES rennes 60 REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE 61 GENERAL 0 0 62 5 0 4000
3. 14 14 15 RIDING YOUR ATV 16 WHAT YOU SHOULD KNOW BEFORE 16 INSPECTION BEFORE RIDING ns 17 SAFETY GEAR 18 BREAKIN antenne i 20 STARTING THE 0 41 21 STARTING OFF sieste gratuits 25 22 26 TURNING 27 SKIDDING OR SLIDING nn rrrrnnnnnnnnne 28 OPERATION HILLS 29 CLIMBING A HILL 30 DESCENDING A HILL 31 TRAVERSING 32 RIDING OVER 32 RIDING THROUGH WATER rires 33 RIDING COLD WEATHER rimes 34 DRESSING FOR COLD WEATHER 35 RIDING YOU ATV ON SNOW AND ICE 36 ACCESSORY USE AND VEHICLE 37 WEIGHT LIMITS iiini 38 INSPECTION AND MAINTENANCE rires 39 MAINTENANCE SCHEDULE 39 TOOLS
4. screws together Loosen both phillip head screws G and remove metal jumper F Re tighten phillip head screws after metal jumper is removed NOTE Metal jumper F needs to be permanently removed in the higher speed mode 15 30mph Place metal jumper F in a safe place in case it is needed in future to slow ATV back to 15mph or under Adjust high speed adjustment screw H located under screw cap I to desired setting CW clockwise allows unit to go faster CCW Counter clockwise slows unit down Re install CDI Governor box A in ATV 48 INSPECTION AND MAINTENANCE THE ADJUSTMENT OF THROTTLE LEVER A WARNING Operating the vehicle with an inadequate throttle lever free distance could be hazardous Inadequate throttle lever free distance could cause engine speed to rise suddenly when you turn the handlebars This can lead the rider to lose control Adjust the throttle lever free distance so that engine idle speed does not rise due to handlebar movement Throttle lever adjustment nut oat Measure the throttle lever play To adjust the throttle lever free distance Loosen the throttle lever adjustment nut Turn the large adjustment nut in or out to obtain the correct play Tighten the throttle lever adjustment nut Recheck the throttle lever free distance Readjust it if it is not within the correct limits 49 INSPECTION AND MAINTENANCE IDLE SPEE
5. Overloading could cause changes in vehicle handling and could lead to an accident Never exceed the stated load capacity for this ATV Refer to the ACCESSORY USE AND VEHICLE LOADING section in this manual A WARNING Operating this ATV with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may cause changes in handling In some situations this could lead to an accident Never modify this ATV through improper installation or use of accessories Refer to the ACCESSORY USE AND LOADING section in this manual A WARNING Operating this ATV with improper tires or improper tire air pressure could be hazardous If you use improper tires or improper air pressure you may lose control of the ATV This will cause an accident Always use the tires with size and type tires specified in this user s manual Always maintain proper tire air pressure as described in the INSPECTION AND MAINTENANCE section Check the condition of the ATV to make sure that the ATV does not have mechanical problems or you could get stranded when you ride Before riding the ATV be sure to check the above items Be sure your ATV is in good condition to ensure the safety of the rider RIDING YOUR ATV A WARNING Checking maintenance items when the engine is running could be hazardous You could be severely injured if your hands or clothing get caught in moving ATV parts Shut the engine
6. Failing to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy conditions could damage your ATV The air cleaner element could become clogged under these conditions and engine damage may result Always check the air cleaner element after riding in severe conditions Clean or replace the elements as necessary If water gets in the air cleaner case immediately clean the element and the inside of the case The air cleaner element must be kept clean to provide good engine power If you use your vehicle under normal low tension conditions you should service the air cleaner at the intervals specified If you ride in dusty wet or muddy conditions you will need to inspect the air cleaner element much more frequently Use the following procedures to remove the element and inspect it 53 INSPECTION AND MAINTENANCE REMOVAL Air filter cover Air cleaner element 2 Remove air cleaner element WASHING THE ELEMENT Wash the element as the following 1 Filla washing pan large enough to hold the element with nonflammable cleaning solvent Immerse the element in the solvent and wash it 2 Squeeze the element by pressing it between the palms of both hands to remove excess solvent A Do not twist or wring the element or it will develop cracks a immerse the element in another pan t filled with Air filter oil B Squeeze the element to remo
7. ATV during operation Always go slow and be extremely careful when operating on unfamiliar terrain Always be alert to the changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and practiced the necessary skills to control the ATV on such terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Never operate the ATV on hills that are too steep for the ATV or for the operator s ability Practice on smaller hills before attempting larger hills Always follow the proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speeds Always follow proper procedures for going down hills as described in this manual Check the terrain carefully before starting to go down any hill Shift your weight backward Never go down hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill if possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid operation on hills with excessively slippery or loose surfaces Shift your weigh
8. INSPECTION BEFORE RIDING A WARNING Failing to inspect the ATV before operating could be hazardous Failing to perform proper maintenance could also be hazardous Failing to inspect and maintain your ATV could increase the chances of an accident or equipment damage Always inspect your ATV each time before riding and make sure it is in a safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this manual ITEM TO CHECK CONTENT Smoothness No restriction of movement No play or looseness Brakes Proper brake lever free play enough brake force Parking brake effectiveness Tires Proper air pressure Enough tread depth No cracks rips or other damages Enough fuel for the intended trip Fuel hose connected securely No damage to fuel tank or cap Fuel tank cap closed securely Engine stop switch Proper operation Proper level Check the oil by inspecting the Engine Oil indicator located at the bottom of the engine The engine oil should completely fill the view window as indicated in the picture Add oil if the window is not completely filled Throttle Proper free play of throttle lever Smooth response Quick return to idle position Drive chain Proper tension adequate lubrication No excessive wear or damage General condition Bolts and nuts are tight No rattle from any parts of the engine when running No visible evidence of Damage RIDING YOUR ATV A WARNING Overloading could be hazardous
9. and should be performed with the utmost care and attention Wear protective eyewear rubber gloves and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medical attention KEEP OUT OF REACH OF CHILDREN 43 INSPECTION AND MAINTENANCE Note The following page is for vehicles with battery s containing separate electrolyte pack Most battery s will come with the electrolyte already sealed into the battery Preparing the battery Place battery on level surface Remove Vent cap from battery vent located on top side portion of battery see figure 20 Remove cell caps using a pair of pliers see figure 21 Wear eye protection and rubber gloves for this step Cut off tip of electrolyte bottle and Figure 20 attach tube Place other end of tube in battery and allow the electrolyte to drain in battery cell Fill battery to upper level mark located on front of battery Repeat step for each of the 6 cells see figure 22 Discard empty e
10. for assuring maximum life and performance of your new vehicle The following guidelines explain proper break in procedures Maximum Throttle Opening Recommendation During the first 10 hours of operation you should always use less than 7 throttle opening Vary the Engine Rotating Speed Vary the engine rotating speed during the break in period This allows the parts to load and then unload allowing the parts to cool Although it is essential to place some stress on the engine components during break in you must be careful not to load the engine too much Avoid Constant Low Rotating Speed Operating the engine at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding the maximum throttle limit Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting This allows the lubricating oil to reach all critical engine components Observe Your Initial and Most Critical Service The initial service break in maintenance is the most important service that your vehicle will receive Observing a proper break in operation will help engine components seal properly Maintenance required as part of the initial service includes proper adjustments tightening of all bolts amp nuts and replacement of dirty oil Timely performance of this service will help you get the best service life and performance o
11. hazardous Loose clothing such as a long scarf or shawl could get caught in an ATV s moving parts Never wear loose clothing when riding your ATV Riding in cold weather can be hazardous At a temperature of 10 F 12 C the wind chill created by going just 10 mph 16km h makes you as cold as if you were standing still at a temperature of 9 F 23 C At this temperature exposed flesh will freeze in just a few minutes Continued exposure in the cold weather could lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms include numbness in the extremities hands feet arms and legs and shivering Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body s core We strongly recommend that if you do any cold weather riding that you familiarize yourself with the symptoms treatment and prevention of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be prepared for bad weather and ATV breakdowns Wear warm water resistant clothing such as thermal underwear snowmobile suits lined gloves and boots and wool socks 35 RIDING YOUR ATV RIDING YOUR ATV ON SNOW AND ICE A WARNING Riding on snow covered terrain even with care could be hazardous The snow may be covering rocks holes ice or o
12. hills than on level surfaces or small hills Never operate the ATV on hills which are too steep for the ATV or for your abilities Practice on smaller hills before trying larger hills 28 RIDING YOUR ATV OPERATION ON HILLS WARNING Climbing hills improperly could be hazardous Climbing hills improperly could cause loss of control or cause the ATV to overturn Always follow the proper procedures for climbing hills as described in this section Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your body forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at a high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill CLIMBING A HILL To climb a hill with the ATV follow the directions below 1 Speed up and maintain a steady speed before reaching the top of the hill Remember that you must ride at a steady speed all the way to the top of the hill 2 Shift your body forward by sliding forward on the seat Lean slightly forward For steep hills stand on the footrests and lean forward 3 Maintain a steady speed while climbing the hill 4 Slow down gradually when you reach the top of the hill 29 RIDING YOUR ATV A WARNING Stalling rolling backwards or improperly dismounting the ATV while c
13. like this A WARNING or CAUTION The first part will identify POTENTIAL HAZARD The second part will describe WHAT COULD HAPPEN if you ignore the WARNING or CAUTION The third part will describe HOW TO AVOID THE HAZARD This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold 3 SAFETY We believe in conservation and protection of the earth s natural resources We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off road recreational use NOTICE TO USERS THIS ATV IS NOT A TOY COULD BE HAZARDOUS TO THE OPERATOR An ATV is different from other vehicles including motorcycles and cars A collision or rollover could occur quickly even during routine m
14. off when performing maintenance checks except checking the engine stop switch and throttle SAFETY GEAR A WARNING Operating this ATV without wearing an approved DOT motorcycle helmet eye protection and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident Always wear an approved DOT motorcycle helmet which fits properly Always wear eye protection goggles or face shield You should also wear gloves boots long sleeve shirt or jacket and long pants ADOT approved motorcycle helmet is the most important part of you safety gear ADOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good quality helmet which fits properly You should wear eye protection when you ride If a rock or a branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride The proper clothes can protect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt RIDING YOUR ATV BREAK IN The first month is the most important in the life of your vehicle Proper operation during this break in period will be helpful
15. the fuel tank a Loosen the drain screw which is located under the carburetor Drain the fuel from the carburetor into a container b Tighten the drain screw the engine for a few seconds Shut off engine d Loosen the drain screw and check that the carburetor is filled back up with fuel e If fuel is reaching the carburetor the ignition system should be checked next 63 TROUBLESHOOTING Ignition System Check A WARNING Performing the spark test improperly could be hazardous You could get a high voltage electrical shock if you are not familiar with this procedure Do not perform this check if you are not familiar with the procedure Do not point the spark plug near the spark plug hole during this test Do not do this test if you have a heart condition or wear a pacemaker Do not perform this test near any open fuel containers for near fuel which has spilled on the ground on engine or any part of the ATV 1 Remove the spark plug and reattach it to the spark plug lead 2 Push the electric button START yellow button Apply the rear brake lever to make sure the rear wheels are locked If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is no spark take your machine to your service center COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove th
16. ANCE BRAKING The ATV has two front drum brakes and one rear disk brake A WARNING Failing to inspect and maintain your ATV s brake system properly could be hazardous Improper maintenance of the brake increases your chance of having an accident Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE A WARNING Operating the ATV in harsh conditions could be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brake must be inspected more often than recommended in the MAINTENANCE SCHEDULE FRONT DRUM BRAKES 1 Try to move the vehicle backward and forward when the front brake is applied If the front wheels can turn adjust the front brake to lock the wheels securely Front Brake Adjustment 2 Measure the amount of free play in the brake lever needed to begin applying the brakes as shown The free play should be about 4 6mm 0 16 0 24 inches 3 Adjust the brakes by turning the adjustment nut located on right and left front brake drum assemblies Front brake hub Front Brake adjustment nut 4 After any adjustment of the brake check again to make sure front wheels cannot turn when the brake is applied 60 INSPEC
17. C Air Cleaner tExhaust pipe bolt and muffler bolt Cylinder head cylinder and muffler Throttle cable Inspect every month Drive Chain Clean lubricate and inspect each time the ATV is ridden Steering tChassis bolts Flexible tube Brake fluid 5 5 n Replace every 2 years l Inspect and clean adjust lubricate or replace if necessary C Clean R Replace T Tighten L Lubricate every 2 years Replace every 4 years 39 INSPECTION AND MAINTENANCE A WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous If you perform improper maintenance or do not maintain your ATV you may have an accident Keep your ATV in good condition Ask your authorized service center or a qualified mechanic to do the maintenance items marked with an asterisk You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do the maintenance ask your authorized service center or call BAJA INC CAUTION If you use your ATV under severe conditions it will need maintenance more often than shown in the chart Operating your ATV under severe conditions causes more wear on your ATV Severe conditions include operating under frequent full throttle or in dusty wet sandy or muddy areas These conditions could cause the ATV t
18. D ADJUSTMENT A WARNING Improper adjustment of the idle speed could be hazardous An idle speed that is too high could cause the ATV to launch forward when you start the engine This may cause an accident Excessive engine wear may also result if idle speed is adjusted improperly or when the engine is not fully warmed up Adjust the idle to the correct speed Make sure the engine is fully warm before adjusting the engine idle speed To adjust the idle speed properly you need a tachometer If you do not have one ask your authorized service center to perform this adjustment Idle Screw adjustment To adjust the idle speed 1 Start the engine and warm it up 2 the throttle stop screw in or out so that the engine idle speed is at 1400 1600r min FUEL HOSE Inspect the fuel hose for damage and 4 fuel leakage If any defects are found Fuel Hose 50 INSPECTION AND MAINTENANCE ENGINE OIL A WARNING New and used oil could be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used oil can cause skin cancer in laboratory animals Brief contact with the used oil may irritate the skin Keep new and used oil away from children and pets To minimize your exposure to used oil wear a long sleeve shirt and moisture proof gloves such as dish washing gloves when changing oil If oil contacts your skin wash thoroughly with soap and water Launder any clothing or
19. ECTING THE DRIVE CHAIN When inspecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear If you find anything wrong with the drive chain solve the problem by repairing or replacing the chain If necessary consult your authorized service center INSPECTING THE SPROCKETS If it is determined the drive chain is damaged check the sprocket also for damage A worn chain an adverse affect on the front and rear sprockets When inspecting sprockets look for the following Gc Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts Sprocket If you find any of these problems with your sprocket consult BAJA INC or your local service center 56 INSPECTION AND MAINTENANCE DRIVE CHAIN CLEANING OILING AND ADJUSTING Clean and oil the chain as the following 1 Wash the chain with water 2 Dry the chain and then oil the links with Chain lube or equivalent A WARNING Failing to inspect the drive chain slack before each use of the ATV could be hazardous Too much chain slack could cause the chain to come off the sprockets resulting in an accident or serious damage to the ATV Inspect the drive chain slack before each use Adjusting the Drive Chain 20 30 mm 0 8 1 2 inches The drive chain should be adjusted and make sure there is 20 30 mm 0 8 1 2 inches of slack as shown above To a
20. ES LES INSTRUCTIONS ET AVERTISSEMENTS 10 LOCATION OF LABELS WARNING AVERTISSEMENT IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH UNE PRESSION DES PNEUS INADEQUATE OU TROP DE PRESSION PEUT ENTRAINER UNE PERTE DE CONTROLE LA PERTE DE CONTROLE PEUT ABOUTIR A DES BLESSURES GRAVES OU LA MORT COLD TIRE PRESSURE PRESSION DES PNES FROIDS Recommended Front 5 psi Recommand Avant 5 psi Rear 5 psi Arri re 5 psi Never set tire pressure below the Ne jamais gonfler les pneus avec recommended level It could cause the Une pression en dessous du niveau tire to dislodge from the rim recommand Cela pourrait le pneu de la jante LOADING Maximum vehicle capacity is 220 Ibs CHARGEMENT Capacit maximale du v hicule est de 220 165 113 kg LOAD LIMIT POIDS LIMITE WARNING AVERTISSMENT 9 1kg 20 Ibs NEVER sit here Ne vous asseyez pas ici LOAD LIMIT POIDS LIMITE WARNING AVERTISSMENT 4 5kg 10 Ibs NEVER sit here Ne vous asseyez pas ici 11 CONTROL FUNCTIONS SPEEDOMETER AND REARVIEW MIRROR Speedometer The speedometer has been pre set by the factory in km h and does not need setting After power is turned on press A to change between time trip mileage or cumulative mileage Setting the Time When the time is displayed press B to adjust the hour then press A to change the hour from 0 to 23 After the hour is
21. Motorsports WD90UR 2 ATV Read this manual carefully It contains important safety information Children under the age of 16 should be supervised by a responsible adult OWNER S MANUAL Minimum Age Requirement 12 Quebec Canada 14 REV 052108 Always wear a helmet It could save your Life Please obtain review and follow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle Motorsports Congratulations on your purchase of the WD90UR 2 ATV It is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days from the date of purchase During the warranty period BAJA INC will at its option repair provide replacement parts or replace your BAJA INC 90cc ATV at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the product Engine Warranty 90 days Frame Warranty 90 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem or need to return your 90cc ATV for repair please call the BAJA INC customer service department TOLL FREE at 1 888 863 BAJA 2252 be
22. N AND MAINTENANCE ENGINE SPEED GOVERNOR The ATV governor is set by the factory to limit speed of ATV to 15mph 24km h directly out of crate The governor can be adjusted to allow the ATV to travel up to 30mph 48km h Any adjustment to governor should be performed by a responsible adult Changing top speed of ATV should match riders ability The engine speed governor is part of the CDI A located under the gas tank of the ATV The governor should only be adjusted by a responsible adult or qualified service technician working under the direction of the adult owner Adjusting Speed Governor to increase or decrease speed 1 Remove CDI Governor box A located under seat by sliding out of rubber CDI mount B 2 Unplug the 2 electrical plugs C and remove CDI governor box A from ATV 47 INSPECTION AND MAINTENANCE Adjustment screws E H Speed Limit Regulator 5 15mph 8 24km h Remove Low speed adjustment screw cover D from CDI governor 3 box Adjust Low speed adjustment screw E to desired setting CW clockwise faster CCW Counter clockwise slower Re install adjustment screw cover D Note Low speed adjustment 5 15mph can only be performed with metal jumper F in place The ATV is shipped with metal jumper F in place Re install CDI Governor box A in ATV High Speed Limit Regulator 15 30mph 24 48km h Locate the two phillip head screws G with metal jumper F connecting
23. ROTECTIVE ROADS PASSENGERS OR ALCOHOL GEAR N ALLEZ PAS SUR LES NE TRANSPORTEZ JAMAIS NE CONDUISEZ JAMAIS UTILISEZ TOUJOURS UN VOIES PUBLIQUES DE PASSAGER SOUS L INFLUENCE DE CASQUE QUI CONVIENT M DICAMENTS OU AU CONDUCTEUR ET UNE DE L ALCOOL VISI RE PROTECTRICE NEVER OPERATE NE JAMAIS op rer Without proper training or instruction e entra nement ou instruction At speeds too fast for your skills or the e une trop grande vitesse pour vos habilet s ou condition pour les conditions On public roads a collision can occur Sur les routes publiques une collision peut with another vehicle survenir avec un autre v hicule With passenger Passengers affect Avec un passager l quilibre et la direction balance and steering and increase risk of seront affect s et augmente les risques de la losing control perte de contr le ALWAYS TOUJOURS Use proper riding techniques to avoid e Utilisez des techniques de conduits ad quates vehicle overturns on hills and rough pour viter que le v hicule ne se renverse sur terrain and in turns une colline ou sur un terrain cahoteux ainsi que Avoid paved surfaces pavement may dans les virages seriously affect handling and control vitez les surfaces pav es car celles ci augmentent les risques de perte de contr le LOCATE AND READ OWNER S MANUAL CAREFULLY BEFORE OPERATING FOLLOW ALL INSTRUCTIONS AND WARNINGS LISEZ ATTENTIVEMENT LE MANUEL DE L UTILISATEUR SUIVEZ TOUT
24. TION AND MAINTENANCE REAR HYDRAULIC DISK BRAKE AND PARKING BRAKE A WARNING Failing to maintain the brake shoes or pads could be hazardous Riding with worn brake shoes pads or shoes that are seriously worn will increase your chance of having an accident If you need to replace brake shoe pads have your authorized service center do the work Inspecting and maintaining the brake shoe pads is recommended Replace the shoe pads in sets Brake fluid cap Brake fluid Level Brake fluid hose Brake fluid reservoir 2 Brake caliper Brake fluid hose Parking Brake adjustment nut 1 Inspect the rear disk brake caliper and brake fluid reservoir for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joint for leakage 3 Check the brake fluid level in the brake fluid reservoir if level is at or below the LOWER mark inspect brake pads for wear and hydraulic system for leaks 4 To add brake fluid unscrew the 4 screws on top of the bake fluid container Add DOT3 or DOT4 brake fluid Do not mix brake fluid types 61 INSPECTION AND MAINTENANCE GENERAL LUBRICATION Proper lubrication is important for safe smooth operation and long life of your vehicle Be sure that all lubrication is performed during periodic maintenance on the vehicle Increase intervals when you use your ATV in severe conditions Your authorized service center should do general lu
25. WNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance You should maintain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications WARRANTY COVERAGE The Distributor warrants that each new 2009 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and e is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above Your emission control system warranty covers components whose failure would increase
26. an engine s emission including electronic controls fuel injection system carburetor the ignition system catalytic converter or any other system utilized in this vehicle to control emission if it is originally equipped Also included may be hoses connectors and other emission related assemblies Replacing or repairing other components including parts labor and other costs not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility The Distributor will not cover repairs performed outside of an authorized dealer or repair facility The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following 1 Failures or malfunctions of the emission control systems caused by abuse alteration accident misuse the use of leaded gasoline 2 Replacement of expendable maintenance items unless they are original equipme
27. aneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions A WARNING SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and labels on the ATV carefully and follow the operations procedures as described Never operate the ATV without proper instruction Take a training course Beginners should be trained by a licensed instructor Always follow the age recommendations Never carry a passenger on an ATV Always avoid operating an ATV on paved surfaces including sidewalks paths parking lots driveways streets roads and highways Never operate this or any ATV on a public street road or highway where motor vehicles are in operation Never operate an ATV without wearing a DOT approved motorcycle helmet which fits properly Operators should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Never operate this ATV at excessive speeds Always operate at a speed that is proper for the terrain visibility operating conditions and the operator s skill experience Never attempt wheelies jumps or other stunts Always inspect the ATV each time before use to ensure it is in a safe operating condition Always follow the inspection and maintenance procedures and schedule described in this manual Always keep both hands on the handlebar and both feet on the footrests of the
28. brication as shown in the MAINTENANCE CHART The authorized service center will lubricate the vehicle such as wheel bearings swing arm bearings steering shaft holder cables etc Brake cable Drive chain Throttle cable Throttle lever a FF N gt a Steering bushing 62 TROUBLESHOOTING Failing to troubleshoot a problem correctly would damage your ATV Improper repairs or adjustments may damage the vehicle Such damage may not be covered under warranty If you are not sure about the proper action consult your authorized service center or BAJA INC about the problem A WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire if you do not handle it properly When draining the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of drained fuel properly This troubleshooting guide is provided to help you find the cause of some common complaints COMPLAINT Engine is hard to start or does not start at all Something is probably wrong with the fuel system or ignition system FUEL SUPPLY CHECK Make sure there is adequate fuel in the fuel tank Check that the engine stop switch is in the RUN position Check that the fuel valve is in the ON position Make sure there is enough fuel reaching the carburetor from
29. djust chain 1 Loosen 4 nuts 1 Adjust slack in drive chain by loosening cinch nut 3 and then turning chain adjusting bolt 2 3 When proper adjustment is obtained tighten nuts 1 and cinch nut 3 57 INSPECTION AND MAINTENANCE TIRES A WARNING Operating this ATV with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the ATV Always use the size and type tires specified Always maintain proper tire A WARNING Using worn tires could be hazardous The traction of the vehicle will be decreased This increases your risk of having an accident Replace the front and rear tires when the depth on the tread is 4 0 mm 0 16 19 7 8 AT19X 9 5 8 Tire Tread Condition 5 4 0 mm 0 16 inches Tire Air Pressure Check the air pressure in all tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort Be sure that the Cold Tire Air Pressure tires are inflated to the pressures shown Tire pressure should only be measured or 5 psi adjusted when the tires are cold 58 INSPECTION AND MAINTENANCE A WARNING Overfilling the air to the tires could be hazardous If you put too much air into the tire the tire may burst causing severe injury Check the air pressure from time to time while gradually inflating the tire unti
30. e only after you stop the ATV 26 RIDING YOUR TURNING A WARNING Turning the ATV improperly could be hazardous If you turn the ATV improperly it may cause a collision or overturn Always follow proper procedures for turning as described in this section Practice turning at low speeds before attempting to turn at faster speeds Never turn at excessive speeds To turn the ATV the rider must use the proper technique Because this vehicle has a solid rear axle both rear wheels always turn at the same speed This means that if the rear wheels are getting equal traction the vehicle will tend to move straight ahead This is because the rear wheels will travel the same distance For the vehicle to turn the outside rear wheel must travel a longer distance that the inside rear wheel To make this happen the rider must create less traction for the inside wheel allowing it to skid This allows it to travel a shorter distance than the outside wheel This happens even though both wheels are still turning at the same speed To turn ATV use the following technique Move your body weight forward and to the inside of the turn Turn the handlebar while looking in the direction of the turn FOR HIGHER SPEEDS OR SHARPER TURNS Use the same technique that you use when you move your body weight farther toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside o
31. e spark plug and clean it Replace it if necessary 3 Make sure the fuel valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min 64 TRANSPORTING A WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire if you do not handle it properly When draining fuel from the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of the drained fuel properly CAUTION Failing to secure the ATV properly could be hazardous Failing to secure the vehicle properly may result in an accident or damage to the vehicle When transporting the ATV lock the parking brake lever and tie down the vehicle securely with straps rope or some other suitable means It is best to transport the ATV in the normal upright position Carburetor Drain screw located at bottom of carburetor Before transporting the ATV make sure the fuel valve is turned to the off osition then drain fuel from the carburetor as follows 1 Drain fuel from carburetor into an empty container by loosening the carburetor drain screw 2 When fuel has been drained retighten the drain screw 65 CLEANING PROCEDURE CAUTION High pressure washers could damage your ATV High pr
32. effective After repeated operation of the ATV in these conditions bring it to your authorized service center to have the brakes inspected and cleaned You can ride the ATV through shallow water Make sure it is not more than 10cm 4 inches deep and is not moving fast Choose a good place to cross before you ride through the water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfamiliar with the area park the ATV and inspect the stream first to find a suitable spot for crossing When crossing operate the ATV at a slow steady speed Be careful not to damage banks when crossing 33 RIDING YOUR ATV RIDING IN COLD WEATHER A WARNING Operating the ATV without a properly functioning brake system could be hazardous Wet or frozen brakes will increase stopping distance This will increase your chance of having an accident Be sure to inspect the brakes before riding the vehicle in cold weather as described Pre ride Inspection Check that the throttle and all control levers move freely Make sure that the footrests are free of ice or snow Move the ATV forward and backward to check that the wheels roll freely If you cannot move the the tires may be frozen to the ground or the brakes may be frozen to the wheels If the tires are frozen to the ground pour warm water around them to melt the ice If the brakes are frozen bring the ATV to a warmer a
33. el could catch fire if you do not handle it properly When draining the fuel from the fuel tank be sure to shut the engine off Do not smoke and never drain fuel in an area where there are open flames or sparks Keep pets and children away from the fuel and dispose of the drained fuel properly Drain fuel from the fuel tank by a hand pump Drain the fuel from the carburetor by releasing the carburetor drain screw TIRES Inflate tires to the normal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire vehicle 2 Make sure that the vehicle is properly lubricated 3 Perform the INSPECTION BEFORE RIDING as listed in this manual 4 Start the vehicle as outlined in this manual 68 SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your ATV You also need these numbers to help your authorized service center or BAJA INC order parts The frame vin number is stamped on the front of the frame as shown in the photograph The engine serial number is stamped on the left side of the crankcase Frame Vin number Engine serial number Write down the serial numbers here for your future reference Frame No Engine 69 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall lengt
34. errain Always be alert to changing terrain conditions when operating the 24 RIDING YOUR A WARNING The ATV may start moving as soon as you release the parking brake Unexpected movement could cause you to lose control of the ATV Make sure to apply the rear brake before you release the parking brake STARTING OFF When you are sure that the engine is Release the rear brake lever warm release the rear brake and open the throttle gradually to move forward A WARNING Opening the throttle suddenly could be hazardous The front wheels could leave the ground and cause loss of control of the ATV Always open the throttle gradually when you want to accelerate 25 RIDING YOUR BRAKING Rear Brake Front Brake To stop the ATV first release the throttle lever then apply the rear Throttle Lever and front brakes smoothly A WARNING Braking while turning the ATV could be hazardous Use of the brake when turning could cause the ATV to slide or roll over Use the brake to slow down before you begin to turn A WARNING Braking hard on slippery surfaces could be hazardous The ATV could skid and go out of control if you brake too hard Apply the brakes lightly and carefully on slippery surfaces A WARNING Operating the parking brake when the ATV is moving could be hazardous The front wheels could lock and it will cause a skid and an accident Use the parking brak
35. essure washers such as those found at coin operated car washes have enough pressure to damage the parts of your ATV It may cause rust corrosion and increase wear Do not use high pressure washers to clean your ATV A thorough cleaning of your ATV is a necessary part of maintenance It will help keep your ATV looking and performing best Proper cleaning can also extend the life of your ATV It is important to clean and inspect your ATV after every ride especially if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust system can reduce engine cooling ability conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries on the ATV Block or seal the end of the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering engine 66 CLEANING PROCEDURE WASHING YOUR ATV With some care your ATV can be washed in a similar manner to washing an automobile Note Avoid spraying or allowing water to flow over the following places Ignition switch Spark plug Fuel tank cap Carburetor Use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your ATV with mild soap or detergent and water Try to thoroughly remove all dirt and debris with
36. f the engine 20 RIDING YOUR STARTING THE ENGINE Before attempting to start the engine make sure to follow these steps 1 Turn the key switch to the ON Middle position Set the engine stop switch to the RUN position If engine is cold set choke lever to the down position Apply the rear brake lever and make sure that the rear wheels are in locking condition Press the yellow starter button START to start the engine Ignition key After engine has warmed up set choke to up switch position _ 1 Choke Lever Engine stop switch NY 4 4 al RUN A WARNING The ATV could start moving as soon as you start the engine Unexpected movement could cause you to loose control of the ATV Be sure to set the parking brake before you start the engine A WARNING Running your ATV indoors where there is little or no ventilation could be hazardous Breathing in exhaust gases from the ATV could cause severe injury Always run your ATV outdoors where there is fresh air 21 RIDING YOUR ATV A WARNING Carrying a passenger on this ATV could be hazardous Carrying a passenger could greatly reduce your ability to keep balance If you carry a passenger you could lose control and both you and the passenger could be severely injured Never carry a passenger The ATV has a long seat so you can change positions to handle the ATV It is
37. f the turn increase as the speed or the turn sharpness increases This means you must lean your body farther into the turn as you go faster or turn more sharply This prevents the vehicle from tipping over to the outside of the turn If your ATV starts to tip while turning lean your body farther into the turn while gradually reducing the throttle and making the turn wider if possible 27 RIDING YOUR ATV SKIDDING OR SLIDING A WARNING Skidding or sliding improperly could be hazardous You may lose control of your ATV when you regain traction unexpectedly This may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slow and be very cautious in order to reduce the chance of skidding or sliding You may experience skidding or sliding when you are not braking You may be able to overcome it by using the techniques listed below If your front wheel skids Gain front wheel traction by reducing the throttle opening and leaning your body slightly forward If your rear wheel skids If space permits steer in the direction of the skid Shift your body away from the skid slightly Avoid using the throttle or brakes until you regain directional control of the vehicle A WARNING Operating this ATV on excessively steep hills could be hazardous The ATV could overturn more easily on extremely steep
38. gnition type sn CDI DIU A 11136 11137 CAPACITIES 8 6L 2 272 gal Engine Oil nds dianid 1L 1qt 70 lt lt anun 26 45 4 93 4 2 4 cig iep tagus wet 7 Cr 91254171 9 fuming 8 grins 125 ROY Wang syng ia Fg UNS Wan 71 BAJA INC EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer or the date it is first used as a demonstrator lease or company vehicle whichever comes first and continues for 60 months after that date or 5 000km whichever comes first provided there has been no abuse neglect or improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or replaced by the Distributor This is your emission control defects warranty O
39. h 1650mm 64 96 inches Overall width ss 890mm 35 03 inches Overall height 1050mm 41 33 inches Wheelbas s 2 tes 1030mm 40 55 inches Ground clearance 120mm 4 72 inches Seat cscs NS 730mm 28 74 inches Diy weight cinean 130kg 286 Ibs ENGINE Sn Ann AN nt A four stroke air cooled Number of cylinders ss 1 Bore X Soke 47 X 49 5mm Displacement aaea 86 Corrected Compression ratio 8 6 1 CarDUretOr DZ19G 2 AA Polyurethane Foam element 22 4 6Kw 8500 Rated 4 2Kw 8000r min Max 6 0N m 6000r min TRANSMISSION Primary reduction 4 095 Final reduction 2 652 Driven chain ne Drum brake Rear brake tunes nes Disc brake Front tire 6126 19 7 8 Rear tife 612 044 19 9 5 8 ELECTRICAL I
40. l the specified air pressure is obtained A WARNING Using tires that have been installed incorrectly could be hazardous The ATV may have unusual handling if the tires are installed incorrectly The tires are intended to rotate in a specific direction as indicated by the arrows on the sidewall of each tire Install tires correctly so they rotate in the proper direction Tire Replacement Your ATV has low pressure tubeless tires Air is sealed by the contact surfaces of the inner wheel rim and the tire bead If the inner wheel rim or tire bead is damaged air may leak Be extremely careful not to damage these sections when replacing tires It is very important to use the proper tools when repairing or replacing tires in order to protect the tire bead or wheel rims Have this work done by your authorized service center or a qualified tire repair station When breaking the tire bead loose from the wheel be extremely careful not to damage the inner wheel rim surface or the tire bead Tubeless Tire Repair If a leak or flat tire occurs due to a puncture the tire may be repaired using a plug type patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your ATV in areas here transportation or service facilities are not readily available it is strongly recommended that you bring a plug type repair kit and a tire air pump with you 59 INSPECTION AND MAINTEN
41. ld be hazardous Stunt riding increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 23 RIDING YOUR A WARNING Removing your hands from the handlebar or feet from the footrests during operation could be hazardous If you remove even one hand or foot from the ATV you could reduce your ability to control the ATV This could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your foot or leg may come in contact with the rear wheels This could injure you or cause an accident Always keep both hands on the handlebars and both feet on the foot rests of your ATV during operation A WARNING Failing to use extra care when operating on excessively rough slippery or loose terrain could be hazardous Failing to use extra care could cause loss of traction This could result in an accident including an overturn Do not operate under these conditions until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on this kind of terrain WARNING Failing to use extra care when operating this ATV on unfamiliar terrain could be hazardous You could come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of control Go slow and be extra careful when operating on unfamiliar t
42. le limiter screw Throttle Adjusting Screw To limit the throttle screw in throttle limiter screw Parking Brake Pin Throttle Lock Nut Lever CONTROL FUNCTIONS Use the throttle adjusting screw to restrict maximum speed of the ATV Adjust this limiter according to the rider s skill and experience Adjusting procedures 1 Loosen the Lock nut 2 Turn the throttle adjusting screw clockwise to restrict maximum speed of the ATV 3 Turn the throttle adjusting screw counterclockwise to increase the maximum speed of the ATV 4 After finished tighten the lock nut FUEL VALVE There are two positions ON and OFF See the picture below for the correct operation of these two fuel valves ON position OFF position In this position fuel will flow to No fuel will flow into the the carburetor when the engine is carburetor running or being started FUEL TANK CAP To open the fuel tank cap take the end of the vent tube out from the vehicle body turn the fuel tank cap counterclockwise To close the fuel tank cap turn it clockwise and tighten it securely Be sure that the vent tube securely connects to the cap as shown Filler neck Fuel level Fuel tank cap CONTROL FUNCTIONS A WARNING Overfilling the fuel tank could be hazardous If you overfill the fuel tank fuel may overflow when it expands Expanding is due to heat from engine or su
43. lectrolyte bottles in a waste area that is inaccessible to children and animals After each cell is filled with electrolyte to upper level remove tube from battery and set electrolyte aside Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life After 30 minutes the battery is ready for its initial charge Place caps loosely over cell holes Figure 22 44 INSPECTION AND MAINTENANCE How to Initially Charge the battery 1 Connect the red positive cable to the red positive pole of the battery see figure 23 2 Connect the black negative cable to the black negative pole of the battery see figure 24 Note The red positive cable has a larger diameter than the black negative y cable 3 Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete re install securely all six battery caps see figure 25 e Install battery into battery tray located under seat see figure 26 battery is firmly seated tray attach red positive wire to positive terminal on battery then attach black negative wire to negative terminal on battery see figure 26 Figure 26 45 INSPECTION AND MAINTENANCE Ba
44. limbing a hill could be hazardous The ATV could overturn if you do not climb a hill properly Maintain a steady speed when climbing the hill Always follow the proper procedures for climbing hills as described in this section Never attempt climbing a hill if there is a possibility of not making it to the top A WARNING Attempting to turn an ATV around on a steep hill while climbing could cause the ATV to roll over which could result in severe injury or death The ATV could overturn if you try to turn around on a steep hill Follow proper procedures listed in this section for backing down a steep hill if stalled If you climb a hill and are unable to make it to the top use one of the correct procedures described below to get back down the hill Never attempt to turn an ATV around on a steep hill doing so could cause the ATV to overturn If you lose forward momentum or begin to roll backwards follow these instructions 1 Lean uphill 2 Never apply rear brake but use front brake 4 Gradually back down the hill with body weight leaning forward while applying front brake Use extreme caution when backing down a hill 30 RIDING YOUR ATV If you still have forward movement and the hill is not steep and there is enough space to turn around safely follow these instructions 1 around on hill before you lose forward momentum As you turn on side of hill lean your body weight uphill 2 Once you ha
45. n Overheated fuel could easily catch fire A WARNING Improper fueling of the ATV could be hazardous Failing to follow safety precautions when refueling could result in a fire or let you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid Spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area Avoid breathing gasoline vapors Keep children and pets away when you are refueling the ATV SEAT LOCK To remove the seat move the seat lock lever backward Raise the rear end of the seat and slide it back To lock the seat slide the seat lever into its retainer and push down firmly A WARNING Improperly installing the seat could be hazardous Failing to install the seat properly could allow the seat to move and cause the rider to lose control Make sure you are in proper position and the seat is attached securely when you install it RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING Before riding you should read all the following information carefully If you are properly prepared you will have a more enjoyable ride Before riding you should find a good place to practice the skills Find a flat open area with enough space to practice the new skills A WARNING Operating this ATV without proper instruction could be hazardous The risk of riding could increase greatly if you do not know how to operate the ATV pro
46. not for carrying passengers A WARNING Operating this ATV on paved surfaces including sidewalks paths parking lots driveways and streets could be hazardous ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to lose control Avoid operating the ATV on paved surfaces if possible If you must ride on a paved surface go slow and do not make sudden turns or stops A WARNING Operating this ATV on public streets roads or highways could be hazardous You may collide with another vehicle if you ride on the public roads Never operate this ATV on any public street road or highway even dirt or gravel street roads or highway In many states is it illegal to operate ATVs on public streets roads and highways 22 RIDING YOUR A WARNING Never operate this ATV at night Night is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise You may collide with another vehicle a stationary object or hazard found in the terrain A WARNING Operating this ATV at excessive speeds could be hazardous Riding at excessive speeds increases your chances of losing control of the ATV which could result in an accident Always go at a speed that is proper for the terrain visibility operating conditions operator skills and operator experience A WARNING Attempting wheelies jumps and other stunts cou
47. nt defective in material or workmanship under normal use and the first required replacement interval for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts 3 Replacements of parts and other services and adjustments for required maintenance 4 Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined 5 Repairs or replacements as a result of 0 Accident 0 Misuse 0 Use of replacement parts accessories not conforming to the original specifications which adversely affect performance 6 Physical damage corrosion defects caused by fire explosions or similar causes beyond the control of the Distributor 7 Failures not caused by a defect in material or workmanship Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The Distributor is not liable to any person for incidental consequential or
48. o wear more quickly Perform maintenance more often than shown in the chart If you have any questions regarding maintenance intervals consult your authorized service center or call BAJA INC CAUTION Using poor quality replacement parts could damage your ATV Poorly made replacement parts could cause your ATV to wear more quickly and shorten its useful life When replacing parts on your vehicle use only genuine replacement parts or their equivalent 40 INSPECTION AND MAINTENANCE A tool kit is provided with your ATV SPARK PLUG Your ATV is equipped with a T1136 spark plug To determine if the standard spark plug is in good condition check the color of the plug s center electrode insulator after vehicle operation A brown color indicates that the plug is correct A white or dark insulator indicates that the engine may need adjustment or another plug type may be needed Consult your authorized dealer or BAJA INC if your plug insulator is not a light brown color CAUTION Failing to use the proper spark plug could damage your ATV An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which may not be covered under warranty Use only the spark plug recommended for this engine Call BAJA INC if you are not sure which spark plug is correct for you vehicle 41 INSPECTION AND MAINTENANCE NOTE This ATV uses resistor type spark plug to av
49. oid jamming electronic parts Improper spark plug selection may cause electronic interference with your ATVs ignition system resulting in the vehicle performance problems Use recommended spark plugs To install a spark plug turn it in as far as possible with your fingers then tighten it with a wrench CAUTION Improper installation of the spark plug could damage your ATV An overly tight or cross threaded spark plug will damage the aluminum threads of the cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 7 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight CAUTION Dirt could damage your ATV if it entered an open spark plug hole of cylinder head Dirt could damage engine parts that move Cover the spark plug hole while the spark plug is out of the hole ALTERNATE SPARK PLUG TYPES C7HSA AC 51022 CHAMPION Z10YC BOSCH U4BC AUTOLIGHT 2795 To maintain a proper functioning spark plug keep the plug free of carbon Remove carbon from the plug with a wire or pin and adjust the gap to 0 24 0 28 inch 0 6 0 7mm for good ignition Use a thickness gauge to check the gap 42 INSPECTION AND MAINTENANCE BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY Eye Protection Rubber Gloves A WARNING The following procedure is very dangerous
50. out excessive water pressure even at remote areas such as between engine cooling fins linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING A WARNING Operating the ATV with wet brakes could be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing the ATV riding at a slow speed If necessary apply brake several times to let the friction dry out the linings Remove the rags or wrapping from the exhaust pipe For extended life of your ATV lubricate according to GENERAL LUBRICATION section Follow the procedures in the INSPECTION BEFORE RIDING section to check your ATV for any problems that may have occurred during your last ride 67 STORAGE PROCEDURE If you do not use your ATV for an extended period it will need special service requiring appropriate materials equipment and skill For this reason we recommend that you trust this maintenance work to your authorized service center If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE Place the vehicle on level ground and wash the entire vehicle FUEL A WARNING Draining the fuel could be hazardous Fu
51. perly under different situations and in different types of terrain Beginners and inexperienced operators should complete a certified training course You should regularly practice the skills learned in the course and the operating techniques described in this user s manual For more information about the training course visit www svia org or call 800 887 2887 For more information on ATV safety and other provincial and municipal governmental acts and regulation pertaining to owning and operating an off road vehicle visit one of the following web sites www svia org www cpsc gov www mmic ca CATV Make sure that it is legal to ride in the area you selected Review the local laws and make sure you are not trespassing Call the police if you don t know where you can ride Protect your riding areas When you are riding remember to keep the terrain in good condition Don t destroy plants trees or other vegetation Don t litter and don t bother wildlife With your help your riding area can remain open for use in the future After you have found a good place to practice review the control system on your ATV before riding Learn to find these controls without looking for them because you will not have time to look for them when you are riding Canadian residents must obtain review and follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle RIDING YOUR ATV
52. r good starting and smooth operation LOCATION OF LABELS Read and follow all of the warnings labels on your ATV Make sure you understand all the labels Keep the labels on the ATV Do not remove them for any reason Ifa label comes off or becomes difficult to read you should get a replacement by contacting BAJA INC 1 WARNING AVERTISSEMENT NO ONE UNDER GER 14 1 2 Quebec Canada Operation of the ATV by children L op ration du VTT par des enfants under the age of 12 increases the risk moins de 12 ans augmente les of severe injury or death risques de BLESSURES GRAVES OU LA MORT Adult supervision required for children under age 16 Les personnes de moins de 16 ans ne doivent pas utiliser ce v hicule NEVER permit children under age 12 sans tre supervis es par un adulte to operate this ATV Ne jamais permettre un enfant de moins de 12 ans d utiliser ce VTT LOCATION OF LABELS WARNING AVERTISSEMENT NEVER ride as a passenger Passenger can cause a loss of control resulting in SEVERE INJURY or DEATH N utilesez jamais ce v hicule comme passager Le passager peut causer la perte de contr le entra nant des BLESSURES GRAVES ou LA MORT WARNING AVERTISSEMENT Improper ATV use can result in SEVERE INJURY or DEATH L usage inad quat du VTT peut entra ner des blessures graves ou la mort ALWAYS USE AN APPROVED NEVER USE ON PUBLIC NEVER CARRY NEVER USE WITH DRUGS HELMET AND P
53. rags if wet with oil Recycle or properly dispose of used oil CAUTION Failure to use the correct oil could harm your ATV Be sure to use the oil specified in the FUEL AND OIL RECOMMENDATION section CAUTION Running the engine without an adequate amount of engine oil could cause severe engine damage Running the engine without any engine oil could cause engine overheating Always check the amount of engine oil before starting the engine 51 INSPECTION AND MAINTENANCE Changing engine oil The engine oil should be changed every 20 to 40 hours of operation It should be changed more often in dirty and dusty areas To change oil 1 Park the vehicle on level ground 2 Remove the 3 Remove the drain bolt and drain into proper container Oil drain bolt 4 Reinstall the drain bolt 5 Pour fresh oil of the specified type through the oil fill hole NOTE Approximately 900ml 1 Qt of oil is required 6 Tighten the oil cap and check oil level through sight gauge 7 Dispose of used oil as per governmental regulations Oil sight gauge 52 INSPECTION AND MAINTENANCE AIR FILTER A WARNING Operating the engine without the air cleaner element in place could be hazardous If the air cleaner element did not filter dirt severe engine damage would occur if the dirt entered the running engine Never run the engine without the air cleaner element in place CAUTION
54. rea to thaw out the brakes After the engine has warmed up check the brakes Do this inspection on level ground and do not exceed walking speed Be sure to check the operation of both front and rear brakes If the brakes do not work adequately stop riding the ATV Bring the ATV to a warmer area to allow the brakes to thaw out After the brakes thaw dry them by applying them several times before riding If the brakes do not regain full stopping power ask your authorized service center to check them before you continue riding your ATV Water that enters the brakes may freeze after you park your ATV The frozen water can prevent wheels from turning or the brakes from working After riding through water mud snow or slush it is important to dry the brakes before parking the ATV To dry the brakes apply them several times while riding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section 34 RIDING YOUR ATV DRESSING FOR COLD WEATHER RIDING A WARNING Operating your ATV in cold weather without proper clothing could be hazardous Continued exposure in the cold weather could lead to hypothermia Hypothermia is a condition where your body s inner temperature drops low enough to cause injury or death Always dress for the worst weather conditions you might encounter Be prepared for bad weather and ATV breakdowns A WARNING Wearing loose clothing when riding your ATV could be
55. res specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation of accessories Never exceed the stated load capacity for an ATV Cargo should be distributed properly and attached securely Reduce speed and follow instructions in this manual for carrying cargo Allow longer distance for braking The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 100 Kg 220 165 Do not tow a trailer This vehicle is not designed for such use Left side rear view mirror Gas Cap vent hose Front Rack Gas Cap Rear Rack Front Tire 4 Fuel Shut off Rear Tire Valve Left Speedometer Head lights Tail Light Muffler FUEL AND OIL FUEL Proper fuel is very important for the engine Ensure there is no dust dirt or water which has mixed in the fuel Use regular unleaded gasoline with an octane number 90 or higher ENGINE OIL Your 90cc ATV has a four stroke engine Please use oil as described in the chart below By using prescribe oil you will realize the best lubrication for engine SAE 10W 30 ENGINE SAE 20W 40 C 30 20 10 0 10 20 30 40 TEMP Q F 22 4 14 32 50 68 86 104 Use the chart to select a viscosity rating based on the temperature range in your area NOTE In very cold weather below 5 F 15 C use SAE10W 50 fo
56. se RIDING OVER OBSTACLES A WARNING Operating this ATV over obstacles improperly could be hazardous Improperly crossing obstacles could cause loss of control or a collision It would also cause the ATV to overturn If you come to an obstacle that you cannot avoid you may be able to cross over it by using the following procedure If the obstacle is in front of you approach at walking speed 2 Rise up slightly on the footrests 3 Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle 4 Lean forward and release the throttle after the front wheels are over the obstacle Remember that some obstacles are too high for your ATV or for your abilities If you are not sure that you can safely cross over an obstacle back up and ride around the obstacle 32 RIDING YOUR ATV RIDING THROUGH WATER A WARNING Operating this ATV through deep or fast flowing water could be hazardous The ATV tires may float losing traction and then loss of control This could lead to an accident Never operate this ATV in fast flowing water or in water deeper than described in this section Remember that wet brakes may reduce the stopping ability Test your brakes after leaving the water If necessary apply the brakes several times to let friction dry out the linings CAUTION Operating the ATV in water sand or mud causes rapid brake wear Excessive brake wear could cause the brakes to be less
57. set press B once to adjust the minute press A to change the minute from 00 to 59 press B once when the correct time is displayed Pressing B will finish the time adjustment and exit Clearing the Trip Mileage Press A to display the trip mileage Press B once to clear trip mileage The accumulative total distance does not change Rearview Mirror Adjust the review mirror by grasping the outer edges and turning the mirror until it is adjusted to the ideal position for the person operating the ATV CONTROL FUNCTIONS Rear Brake lever HANDLEBAR amp SWITCH ES Light Switch LEFT HANDLEBAR With the Engine stop switch in the Stop position The engine cannot be started Engine Stop switch With the Engine stop with in the Run position The engine be started Electric Start Button Rear brake lever Apply the rear brake by squeezing the rear brake lever towards the grip Parking Brake To set the parking brake squeeze the rear brake lever and depress the parking brake pin Electric starting button RIGHT HANDLEBAR Throttle Lever Control the engine and ATV speed with the throttle lever Operate this lever with your thumb Push it forward to increase engine and ATV speed Release it to decrease engine and ATV speed Front Brake To set parking brake squeeze front brake lever Parking lever then depress parking brake pin set the parking Brake Lever brake lever Thrott
58. special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law No dealer is authorized to modify this Emission Control System Warranty If you have any questions regarding your warranty rights and responsibilities you should contact BAJA INC 888 863 2252 Motorsports Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 866 250 7155
59. st days you may find it helpful to use yellow tinted eye tection protection 36 ACCESORY USE AND VEHICLE LOADING A WARNING Operating this ATV with improper modifications could be hazardous Improper installation of accessories or modifications of the vehicle may cause changes in handling which could lead to an accident Never modify the ATV with improper installation or use of improper accessories All parts and accessories added to the ATV should be genuine parts or their equivalent designed for use on this ATV Install and use them according to their instructions If you have any questions contact your dealer There are many types of accessories for sale However we cannot have direct control over their quality or suitability We cannot test each accessory that is available If you add the wrong accessories or misuse the vehicle with some accessories installed it can make the ATV less safe to ride Be cautious when choosing and installing accessories to your vehicle Your retailer may be able to help you choose accessories and install them correctly The guidelines below should help you to decide how to equip your ATV and how to use it correctly when you use accessories Accessory Use and Vehicle Loading Guidelines 1 The combined weight of the rider tools and any accessories or cargo must never exceed the vehicle s load capacity of 100 Kg 220 Ibs 2 Check accessory mounting brackets and other attachments to make s
60. t to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible SAFETY Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight to uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slow and be very cautious in order to avoid going out of control when skidding or sliding Never operate an ATV in fast flowing water or in water deeper than that specified in this manual Remember that wet brakes can reduce stopping ability Test your brakes after leaving water If necessary apply them several times to let friction linings dry out Always use the tires with proper size and type ti
61. ther hazards that can cause loss of control Severe injury or death could occur if you lose control of the ATV Go slowly and be careful when riding on snow covered terrain Always be alert to changing terrain conditions A WARNING Riding on a frozen lake or river could be hazardous Serious injury or death could occur if the ice breaks and you could fall into the cold water Check with local authorities to verify the thickness of the ice and areas to avoid A WARNING Failing to use extra care when operating on slippery surfaces such as hard packed snow and ice could be hazardous Failing to use extra care could cause loss of traction or loss of vehicle control This could result in an accident including an overturn Do not operate on slippery surfaces until you have learned and practiced the skills necessary to control the ATV on such terrain Always use extra care on slippery surfaces Avoid riding on snow or ice covered hills whenever possible Practice riding your ATV in an open snow or ice covered area at slow speeds before handling out on snow or ice covered trails Learn how your ATV responds to steering and braking on the type of terrain you will encounter on your ride Your eyes may be sensitive to sunlight when you ride over snow or ice on a bright sunny day Snow and ice reflects more light into your eyes than dirt or grass Tinted eye protection will reduce the amount of light reaching your eyes On overca
62. ttery Replacement A WARNING DO NOT open sealed caps to add water to battery Always wear safety glasses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to cool down Do not use fast charging unless it is an emergency At the beginning or end of charging turn off the charger first in order to prevent electric spark and explosion Charge in a well ventilated area DO NOT smoke around batteries and keep away from open flame A WARNING To avoid possibility of explosion always connect battery cable in the order specified RED first BLACK last An exploding battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with protective eyewear when working around battery acid Battery acid is poisonous and can cause severe burns DO NOT smoke around batteries and keep away from open flame Remove old battery Mark which cable is connected to the positive terminal and which cable is connected to the negative terminal Clean cable connectors with wire brush or sandpaper to remove oxidation After charging install new battery Put dielectric grease on the battery terminals to avoid corrosion Connect cables to the proper terminals Positive red cable to positive terminal and negative cable to negative terminal Positive cable is red Negative cable is black CONNECT NEGATIVE CABLE LAST 46 INSPECTIO
63. tween the hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm PST During DST hours change to MT You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED WARNING This manual should be considered a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 TABLE OF CONTENTS 3 3 NOTICE TO THE USER 4 5 chsniaisnsusdatbandacoatade 7 2 8 9 CONTROL FUNCTIONS iaiia 12 SPEEDOMETER REARVIEW MIRROR 12 LEFT HANDLEBAR isississsssscsscosseccucassnseavarsuctsseverdetsussassicsanoisussoressanesnecnsiacs 13 RIGHT 13 FUEL VALVE
64. ure they provide a rigid non movable mount 3 Accessories added to the handlebar of the ATV should be as light as possible The extra weight would cause the vehicle to be harder to steer 4 Do not add accessories or cargo which interferes with controls or other equipment 5 Do not carry heavy or bulky cargo 37 ACCESORY USE AND VEHICLE LOADING 6 Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle Locate cargo weight as close to the center of the vehicle if possible 7 Secure your load well Shifting weight can affect your ability to handle the vehicle safely 8 Ride at slow speeds and avoid hills when carrying cargo Carrying loads would affect the stability and handling of your ATV 9 Allow enough stopping distance Stopping distance increases if you carry loads Use engine braking as much as possible WILDERNESS TRAIL 90 WEIGHT LIMITS Never exceed the weight limits shown 1 Total weight limit is 100 Kg 220 Ibs this limit includes rider and accessories 2 Front rack 9 1 Kg 20 165 3 Rear rack 4 5 Kg 10 165 38 INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE It is very important to inspect and maintain your ATV regularly Follow the guidelines in the chart The intervals between periodic services in months are shown At the end of each interval be sure to perform the maintenance listed Every 3 months Every 6 months
65. ve excess oil Make sure that the element remains damp with oil but not soaked 54 INSPECTION AND MAINTENANCE A torn air filter could damage your ATV Dirt and dust may get inside of the engine if the element is torn Examine carefully the element for tears before and after cleaning it Replace the element with a new one if it is torn A WARNING Oil and solvent could be hazardous Children and pets could be harmed from the oil and solvent Be sure to keep oil and solvent away from children and pets Dispose of used oil and solvent properly 3 Reinstall the cleaned element in reverse order of removal Be sure that the element is securely in position and is properly sealed CAUTION Failing to position the air cleaner element properly could damage your ATV Air will bypass the air cleaner element if the element is not positioned properly This will cause the engine parts to wear more rapidly Be sure to position the air cleaner element properly 55 INSPECTION AND MAINTENANCE DRIVE CHAIN SPROCKETS The condition and adjustment of the drive chain should be checked before riding Always follow the guidelines below for inspecting and servicing the chain A WARNING Failing to maintain the chain properly before each riding could be hazardous Riding with the chain in poor condition could lead to an accident Be sure to inspect and maintain the chain before riding according to these guidelines INSP
66. ve turned around ride down hill as described in the DESCENDING A HILL section DESCENDING A HILL A WARNING Going down a hill improperly could be hazardous Going down a hill improperly could cause loss of control or cause the ATV to overturn Always follow the proper procedures for going down hills as described in this section To ride down a hill with the ATV follow the instructions below Check the terrain carefully for any obstacles before you go down the hill Point the ATV straight down the hill Transfer body to the rear by sliding back on the seat Ride down the hill slowly with the throttle released Apply the rear brake to control the speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill if possible 31 RIDING YOUR ATV TRAVERSING A SLOPE A WARNING Crossing hills or turning on hills improperly could be hazardous Crossing hills or turning on hills improperly could cause loss of control or overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the CLIMBING A HILL section Practice this technique on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When traversing a slope you should 1 Lean your body uphill 2 Steer slightly uphill if necessary to maintain a straight cour

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