Baja motorsports WD250UR Owner'S Manual Download Page 53

Page: 53 / 82

HEADLIGHT AND TAILLIGHT REPLACEMENT

Headlight bulb replacement.

Turn off main key switch

Locate headlights under front fender and slide back rubber moisture

protector from headlight housing

Push in bulb holder and turn left (CCW) until tabs line up with groves .

Remove bulb.

•

FUSE REPLACEMENT

Fuse may be bad if there is no spark while trying to start the ATV.

The fuse box is located under the seat directly in front of the battery.

To check fuse follow the instructions

Turn off main key switch

Lift seat and locate fuse box

Remove fuse box cap

Remove fuse and check. If fuse is bad, replace with 15 Amp fuse.

•

Moisture protector

Bulb holder

Bulb

Taillight replacement

Turn off main key switch

Locate screw holes in rear lens

Remove lens

Remove bulb by pushing in and

turning left (CCW).

•

Fuse box

Fuse cap

Fuse

15A

Good

Bad

Screw holes

Bulb

Summary of Contents for WD250UR

Page 1: ...llow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle Minimum Age Requirement 16 Read this manual carefully It contains important safety information No one under the age of 16 should operate this ATV OWNER S MANUAL WD250UR WD250U ATV REV B 022108 WD250U CAMO WD250UR RED ...

Page 2: ...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 MOTORSPORTS INC is not liable for any damage claim or liability claim personal or otherwise resulting from the operation of this product in any wa...

Page 3: ...ed 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 WARNING ...

Page 4: ...RAKE 13 FUEL VALVE 14 FUEL TANK CAP 14 SEAT LOCK 15 12V UTILITY SOCKET 16 RIDING YOUR ATV 17 BEFORE RIDING 17 INSPECTION BEFORE RIDING 18 SAFETY GEAR 20 BREAK IN 21 STARTING THE ENGINE 22 STARTING OFF 26 SHIFTING 27 BRAKING 29 TURNING 30 SKIDDING OR SLIDING 31 OPERATION ON HILLS 31 RIDING OVER OBSTACLES 35 RIDING THROUGH WATER 36 RIDING IN COLD WEATHER 37 RIDING ON SNOW OR ICE 39 ACCESSORY USE AND...

Page 5: ...T 52 FUEL HOSE 52 ENGINE OIL OIL STRAINER OIL FILTER 53 AIR FILTER 55 CLUTCH ADJUSTMENT 57 REAR GEAR CASE LUBRICATION 58 TIRES 59 BRAKES 61 HYDRAULIC FRONT BRAKES 61 REAR DRUM BRAKE 62 MUFFLER SPARK ARRESTER 64 GENERAL LUBRICATION 66 TROUBLESHOOTING 67 TRANSPORTING 69 CLEANING PROCEDURE 70 STORAGE PROCEDURE 72 SERIAL NUMBER LOCATION 73 SPECIFICATIONS 74 EMISSION CONTROL CYCTEM WARRANTY 76 Table of...

Page 6: ...t 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 ...

Page 7: ...n 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 ope...

Page 8: ...cessive 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 op...

Page 9: ... 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 for several times to let friction linings dry out Always use the tires with proper size and type tires specified in this manual...

Page 10: ...0U RIGHT LEFT Rear wheel Manual pull start Drive select lever Taillight Gear shift lever Front wheel Front rack Rear rack Mirrors Seat Gas cap Control panel Front shocks Foot brake Oill fill cap dipstick Rear shock ...

Page 11: ...ngine Please use oil as described in the chart below By using the prescribed oil you will realize the best lubrication for the engine 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 for good starting and smooth operation SAE 10W 30 SAE 10W 40 10W 50 ENGINE TEMP C F 30 22 40 104 20 4 10 14 0 32 10 50 20 68...

Page 12: ... AND PROTECTIVE GEAR NEVER OPERATE another vehicle ALWAYS NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL Without proper training or instruction At speeds too fast for your skills or the condition On public roads a collision can occur with With passenger passengers affect balance and steering and increase risk of losing control Use proper riding techniques to avoid...

Page 13: ... level It could cause the tire to Minimum Rear 22kpa 3 2psi Maximum Rear 28kpa 4psi WARNING LOAD LIMIT 30kg 66lbs NEVER sit here WARNING LOAD LIMIT 45kg 99lbs NEVER sit here SHIFTING INTO OR FROM REVERSE CAN ONLY BE DONE IN FIRST GEAR YOU MUST COME TO A COMPLETE STOP BEFORE SHIFTING INTO OR FROM REVERSE WARNING CAUTION Accessories connected to utility socket should not exceed 100 watts Make sure a...

Page 14: ... headlights or taillights are on 7 M h mph indicator Illuminates when speedometer is in M h 8 Neutral indicator Illuminates when ATV is in Neutral 9 Km h M h mph toggle button Depressing Button toggles between Km h and M h 10 Ignition key switch Turn right CW ON Turn left CCW OFF ATV will only start when ignition key is turned to the ON Position Make sure ignition key switch is in the OFF position...

Page 15: ...ne Stop Switch is in the RUN position 4 Light switch There are 3 positions on the light switch OFF Daytime running lights and Headlights 5 High beam low beam switch 6 Parking Brake Lock While starting the engine or parking the machine especially on a slope apply the parking brake by squeezing the rear brake lever and pushing down the Parking Brake Lock 7 Manual Choke Lever When engine is cold plac...

Page 16: ... decrease engine and ATV speed 2 Front brake lever Squeeze lever toward hand grip to apply front brakes 3 Speed limiter screw The speed limiter keeps the throttle from fully opening even when the throttle is pushed to the maximum Turning the speed limiter screw clockwise limits the maximum engine power available and decreases the maximum speed Adjust this limiter screw according to the rider s ski...

Page 17: ...osition If the fuel level in the fuel tank becomes to low for the engine to stay running while the fuel valve is in the ON position turn the fuel valve to RESERVE This will allow the engine to begin using the reserve fuel supply You will need to re fuel as soon as possible Once re fueled turn the valve back to the ON Position FUEL TANK CAP To open the fuel tank cap take the end of the vent tube ou...

Page 18: ...neck 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 a...

Page 19: ...omponents to overheat causing failure Check accessory wattage requirements before plugging in to 12V electrical socket 12V Utility socket Use 1 Remove 12V utility socket accessory cap 2 Plug in accessory making sure plug is pushed all the way in socket Note Do not use accessory more than 10 minutes without engine running doing so will drain battery 3 After use make sure cap is placed back on socke...

Page 20: ...earn 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 municipal and governmental acts and regulations pertaining to owning and operating an off road vehicle WARNING Operating this ATV without proper instruction could be hazardous The risk of riding could increase great...

Page 21: ...amages Fuel 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 of switch Engine oil Proper level Check oil by inspecting Engine Oil Dip Stick The engine oil should be between the Minimum and Maximum lines Throttle Proper free play of throttle lever smooth response quick return to idle positi...

Page 22: ...LOADING section in this manual 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 VEHICLE LOADING section in this manual W...

Page 23: ...tect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt 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 Oper...

Page 24: ...o 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 engi...

Page 25: ...ING The ATV could start moving as soon as you start the engine Unexpected movement could cause you to lose control of the ATV Be sure to set the parking brake before you start the engine 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 W...

Page 26: ...rating 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 WARNING Operating this ATV at excessive speeds could be hazardous Riding a...

Page 27: ...r 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 handlebar...

Page 28: ...ld 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 t...

Page 29: ... Opening the throttle suddenly could be hazardous The front wheels could leave off the ground and cause loss of control of the ATV Always open the throttle gradually when you want to accelerate Parking brake Throttle When you are sure that the engine is warm release parking brake Release brake lever and open the throttle gradually to move forward ...

Page 30: ...o a lower gear by depressing the gear shift lever Gear Shift Lever DRIVE SELECT LEVER The drive select lever shifts the ATV in either forward or reverse To shift ATV in either forward or reverse 1 Release throttle 2 Apply brakes until you come to a complete stop 3 Shift transmission into first gear 4 Lift up on lock button on drive select lever and pull back for reverse making sure lever is locked...

Page 31: ...he gear case and keep oil up to the prescribed level CAUTION Always release the throttle before shifting gears Failure to release the throttle before shifting gears could cause damage to the engine and drive train WARNING Not looking behind vehicle before and while going in reverse could be hazardous Failure to look behind while backing could cause the ATV to run into an obstacle or person resulti...

Page 32: ...efore you begin to turn BRAKING 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 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 brake only after you ...

Page 33: ...er toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside of 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 ...

Page 34: ...ILLS 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 WARNIN...

Page 35: ...TV 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 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 bo...

Page 36: ...Gradually back down the hill with body weight leaning forward while apply ing front brake Use extreme caution when backing down a hill 4 Or if you can stop the vehicle apply the rear brake 5 Set the parking brake and dismount to the left while still leaning uphill 6 To turn the vehicle around drag the rear end of the ATV until the vehicle points downhill Stay on the uphill side of the vehicle whil...

Page 37: ...l slowly with the throttle released 5 Apply the rear brake to control the speed 6 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 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...

Page 38: ... if possible TRAVERSING A SLOPE WARNING Operating this ATV over obstacles improperly could be hazardous Improperly crossing obstacles could cause loss of control or a collision It could 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 1 If the obstacle is in front of you approach at walking speed 2 Ris...

Page 39: ...ING 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 seve...

Page 40: ...ing 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 app...

Page 41: ...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 WARNING Operating your ATV in c...

Page 42: ...e 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 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...

Page 43: ...e 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 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 Secureyourloadwell Shiftingweig...

Page 44: ...364 lbs this limit includes rider accessories vertical weight on trailer hitch and cargo 2 Front rack 30 Kg 66 lbs 3 Rear rack 45 Kg 99 lbs 4 Tool kit compartment 2 Kg 4 5 lbs 5 Vertical weight on trailer hitch 15 Kg 33 lbs 6 Pulling load total weight of trailer cargo and rider 330Kg 728 lbs 2 5 4 3 1 ...

Page 45: ...Clutch I I I Wheels I I Wheel bearings I I Brake caliper linings and Brake pads I I I Front and rear suspension I Steering system I I I Bottom fitting of steering shaft lubricate with lithium Li based grease L Fittings and Fasteners T T T I Inspect and clean adjust lubricate or replace if necessary C Clean R Replace T Tighten L Lubricate INSPECTION AND MAINTENANCE It is very important to inspect a...

Page 46: ... 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 to wear more quickly Perform maintenance more often than shown in the chart If you have...

Page 47: ...icates that the engine may need adjustment or another plug type may be needed Consult your authorized dealer or Baja Motorsports 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 voids the warranty Use only the s...

Page 48: ... head Carefully install spark plug by hand If the spark plug is new tighten it with a wrench about 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 o...

Page 49: ...es 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 or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush...

Page 50: ...s upside down in battery holes until electrolyte is completely drained Never leave children unattended around battery If air bubbles cease to float to the top of the electrolyte bottles tap lightly on top DO NOT remove container from battery while it is draining Never cut or pierce electrolyte container After all the electrolyte has drained from the bottles into the battery pull plastic electrolyt...

Page 51: ...complete press down firmly with both hands to seat the caps Do not pound or hammer see figure 25 The battery is now sealed Locate battery compartment on ATV The battery compartment is located under the seat Battery terminals should be facing the front see figure 26 Once battery is firmly seated in battery compartment attach red positive cable to positive terminal on battery Then attach black negat...

Page 52: ...ten battery to the vehicle using metal battery strap 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 spar...

Page 53: ... is no spark while trying to start the ATV The fuse box is located under the seat directly in front of the battery To check fuse follow the instructions Turn off main key switch Lift seat and locate fuse box Remove fuse box cap Remove fuse and check If fuse is bad replace with 15 Amp fuse Moisture protector Bulb holder Bulb Taillight replacement Turn off main key switch Locate screw holes in rear ...

Page 54: ... not within the correct limits WARNING Operating the vehicle with an inadequate throttle lever free play 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 3 0 5 0mm ...

Page 55: ... 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 I...

Page 56: ...arks on the dipstick 5 Add oil if oil is below minimum mark on dipstick Do Not fill above maximum mark Refer to page 8 for correct engine oil type Engine oil replacement and oil filter element cleaning The engine oil should be changed every 20 to 40 hours of operation It should be changed more often in dirty and dusty areas 1 Park vehicle on level ground 2 Remove oil dipstick Dipstick Minimum Maxi...

Page 57: ...f 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 rags if wet with oil Recycle or properly dispose of used oil CAUTION Failure to...

Page 58: ...occur if the dirt entered the running engine Never run the engine without the air filter element in place CAUTION Failing to inspect the air filter element frequently if the vehicle is used in dusty wet or muddy conditions could damage your ATV The air filter element could become clogged under these conditions and engine damage may result Always check the air filter element after riding in severe ...

Page 59: ...ons below 6 Reinstall foam cover to the air filter element 7 Reinstall air filter and close cover Make sure that the element is securely in position and the air filter is properly sealed Washing Foam Cover OF AIR FILTER ELEMENT To wash the foam cover 1 Remove foam cover from air filter element 2 Wash foam cover gently in water or a mild non flammable solvent 3 Squeeze water out of foam cover and l...

Page 60: ... before and after cleaning it Replace the element with a new one if it is torn CLUTCH ADJUSTMENT 1 Loosen lock nut 2 Slowly rotate adjusting bolt left CCW until resistance is felt then rotate 1 8 turn 45 deg right CW 3 Tighten the lock nut to the specified value 15Nm 10 8 ft lb Lock nut Adjusting bolt CAUTION Failing to position the air cleaner element properly could damage your ATV Air will bypas...

Page 61: ...gear case 4 Remove fill cap 5 Remove oil plug 6 Let oil drain out completely 7 Install the drain plug and tighten 24Nm 18 ft lb 8 Install gear cover and tighten bolts 9 Add gear oil SAE 80 API G 4 Hypoid Gear oil fill to brim of hole approx 9 oz 266ml 10 Install fill cap and tighten to 23Nm 17 ft lb Fill cap Drain plug Gear cover CAUTION Failing to have the proper amount of gear oil in the rear tr...

Page 62: ...um Maximum Front 20kpa 3psi 17kpa 2 5psi 23kpa 3 3psi Rear 24kpa 3 5psi 23kpa 3 3psi 28kpa 4 0psi 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 air pressure as described in this sectio...

Page 63: ...d 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 WARNING Overfilling the tires with air could be hazardous If you put too...

Page 64: ...en 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 hand brake adjustment 1 Try to move the vehicle backward and forward when the front hand brake is applied If the front wheels can turn a...

Page 65: ...dlebar 1 Inspect the front 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 sc...

Page 66: ...R HAND AND FOOT BRAKE ADJUSTMENT 1 Try to move the vehicle backward and forward when the rear hand brake is applied If the rear wheels can turn adjust the brake to lock the wheels securely 2 Measure the amount of free play in the rear hand brake lever The free play should be about 5 7mm 0 2 0 3in 3 Try to move the vehicle backward and forward when the rear foot brake is applied If the rear wheels ...

Page 67: ...es the brake pads and the calipers is recommended Replace the shoe and the pads in sets SPARK ARRESTER CLEANING Periodically the spark arrestor will need cleaning 1 Select a well ventilated area and make sure the exhaust pipe is cool 2 Remove the drain bolt 3 Start the engine block the end of the exhaust pipe with a dowel this will increase the speed of the engine because of back pressure 4 Stop t...

Page 68: ...s fresh air WARNING The hot exhaust muffler could burn you The muffler will be hot enough to burn you after stopping the engine Wait until the exhaust muffler cools to remove the dowel WARNING Riding an ATV with improperly tightened drain bolt could be hazardous Running the engine with a loose drain bolt or without a drain bolt will let hot carbon particles to escape This can cause a fire Tighten ...

Page 69: ...e your ATV in severe conditions Your authorized service center should do general lubrication as shown in the MAINTENANCE CHART The authorized service center will do general lubrication This includes the lubrication of wheel bearings swing arm bearings steering shaft holder cables etc O Oil G Grease 1 Bottom fitting of steering shaft lubricate with lithium Li based grease 2 Brake cable 3 Throttle c...

Page 70: ... 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 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 ne...

Page 71: ... 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 5 Make sure the air filter is clean WARNING Performing the spark test improperly could be hazardous You could get a high voltage electrical shock if you are not f...

Page 72: ... 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 parki...

Page 73: ...m 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 CAUTION High pressure washers could damage you...

Page 74: ...ushes 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 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 sec...

Page 75: ...te 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 t...

Page 76: ... help your authorized service center or Baja Motorsports order parts The frame VIN number is stamped on the front of the ATV frame as shown in the photograph The engine serial number is located on the right side of the engine housing Write down the serial numbers here for your future reference Frame No Engine No Engine serial number Frame number ...

Page 77: ...linders 1 Bore X Stroke 71mm x 58mm Displacement 229 6 cm3 Compression ratio 8 7 1 Carburetor Vacume film piece Air cleaner Paper with Polyurethane Foam Element TRANSMISSION Primary reduction system Spur Gear Primary reduction ratio 73 22 3 318 Secondary reduction system Shaft Drive Secondary reduction ratio 19 18 X 46 11 4 414 Transmission Type Constant Mesh 5 speed forward 1 speed reverse Operat...

Page 78: ...ount of engine oil 63 oz 1 8L Total amount of gear oil 9 oz 0 266L FUEL Main fuel tank capacity 2 64 gallons 9L Reserve fuel tank capacity 0 35 gallons 1 3L BRAKES Front brake type Hydraulic disc brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation SUSPENSION Front 2 Spring oil dampener shocks Rear 1 Spring oil dampener shock Front suspension travel 12 5mm...

Page 79: ... 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 in a reasonable ...

Page 80: ...er 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...

Page 81: ...al 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...

Page 82: ...78 Baja INC P O Box 61150 Phoenix AZ 85082 Toll Free 866 250 7155 Service Center Line 866 401 2252 ...

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