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Baja motorsports WD400U-2, Owner'S Manual

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Baja motorsports WD400U-2 Owner'S Manual Download Page 6

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Table of Contents

HEADLIGHT/TAILLIGHT REPLACEMENT .................................................   52

THROTTLE LEVER ADJUSTMENT ............................................................   53                  

IDLE SPEED ADJUSTMENT .......................................................................   54

FUEL HOSE .................................................................................................   54

ENGINE OIL/OIL FILTER .............................................................................   55

AIR FILTER ..................................................................................................   57

FRONT/REAR GEAR CASE LUBRICATION ..............................................   60

TIRES ...........................................................................................................   61

FRONT DISK BRAKES ...............................................................................   64

REAR DRUM BRAKE  .................................................................................   64

MUFFLER/ SPARK ARRESTER..................................................................   66

OIL COOLER CLEANING PROCEDURE ....................................................   68

GENERAL LUBRICATION ...........................................................................   70

TROUBLESHOOTING .........................................................................................   71

TRANSPORTING .................................................................................................   74

CLEANING PROCEDURE ...................................................................................   75

STORAGE PROCEDURE ....................................................................................   77

SERIAL NUMBER LOCATION ............................................................................   78

SPECIFICATIONS ................................................................................................   79

EMISSION SYSTEM CONTROL WARRANTY....................................................       

Summary of Contents for WD400U-2

Page 1: ...ve your life Do not remove this operator s manual from this vehicle according to guide lines with the U S Consumer Product Safety Commission Please obtain review and follow provincial municipal govern...

Page 2: ...n the age group for which an ATV is recommended he or she may not have the skills abilities or judgement needed to operate the ATV safely and may be involved in a serious accident Category Y Youth Mod...

Page 3: ...90 days Warranty is void if Frame is bent or broken due to abuse The wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA MOTORS...

Page 4: ...to a new owner 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 c...

Page 5: ...7 INSPECTION BEFORE RIDING 18 SAFETY GEAR 20 BREAK IN 21 STARTING THE ENGINE 25 STARTING OFF 26 MANUAL PULL START 27 DRIVE SELECT 28 2WD 4WD BUTTON 29 BRAKING 30 TURNING 31 OPERATION ON HILLS 32 RIDIN...

Page 6: ...ER 55 AIR FILTER 57 FRONT REAR GEAR CASE LUBRICATION 60 TIRES 61 FRONT DISK BRAKES 64 REAR DRUM BRAKE 64 MUFFLER SPARK ARRESTER 66 OIL COOLER CLEANING PROCEDURE 68 GENERAL LUBRICATION 70 TROUBLESHOOTI...

Page 7: ...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...

Page 8: ...t every child who rides the ATV should complete a training course THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars...

Page 9: ...dules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar te...

Page 10: ...rocedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special proce...

Page 11: ...in this manual for carrying cargo Allow greater distance for braking The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 463 lbs 210 kg Do no...

Page 12: ...r Front luggage carrier Exhaust silencer Seat cushion Fuel cap Brake pedal Front shocks Rear tire Front bumper Left Fuel valve Manual pull start Headlight Taillight Two Four wheel transforming button...

Page 13: ...gasoline ENGINE OIL Your 400cc ATV has a four stroke engine Please use oil as described in the chart below By using the prescribe oil you will realize the best lubrication for the engine Use the chart...

Page 14: ...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 If a label comes off or becomes difficult to read you should get a rep...

Page 15: ...PRESSURE Recommended Front 5psi Rear 5psi Never set tire pressure below the recommended level It could cause the tire to Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HE...

Page 16: ...when oil temperature is too hot Stop the engine as soon as possible and allow engine to cool for at least 10 minutes Fan Light will illuminate when fan is ON Headlight Light will illuminate when head...

Page 17: ...taillight and meter light will NOT come on On Off switch On When the switch is placed in this position the engine is on Off When the switch is placed in this position the engine is off Start Button De...

Page 18: ...o apply front brakes 2WD 4WD button When this button is depressed the ATV is in Four wheel drive When button is pressed again button out the ATV is Two wheel drive Only press this button when the ATV...

Page 19: ...ition arrow pointing up 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 e...

Page 20: ...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...

Page 21: ...ew 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...

Page 22: ...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 Fuel Enough fuel for the inte...

Page 23: ...se 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 thi...

Page 24: ...ankle long pants and a long sleeve shirt WARNING Operating this ATV without wearing an approved motorcycle helmet eye protection and protective clothing Operating without an approved motorcycle helmet...

Page 25: ...ze 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 a few minutes of idling time after war...

Page 26: ...te the ATV on any paved surfaces including sidewalks driveways parking lots and streets WARNING Operating this ATV on public streets roads or highways You may collide with another vehicle Never operat...

Page 27: ...RNING Attempting wheelies jumps and other stunts Increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off WARNING Operating this A...

Page 28: ...or equipment damage Always inspect your ATV each time you us it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in...

Page 29: ...els are in locking condition 5 Press the starter button START to start the engine WARNING The ATV could start moving as soon as you start the engine Unexpected movement could cause you to lose control...

Page 30: ...e you release the parking brake 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...

Page 31: ...until engagement can be felt Then pull forcefully being careful not to pull the rope all the way out CAUTION Don t start the engine in non neutral or without setting the parking brake system Put the...

Page 32: ...ive select lever to R reverse Note When in reverse the re verse indicator light should illuminate on the console if light does not come on check to see if vehicle is in first gear 5 Check for people o...

Page 33: ...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 resulting...

Page 34: ...us 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 hazard...

Page 35: ...body weight farther 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 incr...

Page 36: ...roperly Could cause loss of control or cause ATV to overturn Always follow the proper procedures for climbing hills as described in this owner s manual Always check the terrain carefully before you st...

Page 37: ...he hill 4 Slow down gradually when you reach the top of the hill WARNING Going down a hill improperly Could cause loss of control or cause ATV to overturn Always follow proper procedures for going dow...

Page 38: ...ean sharply to one side Go straight down the hill if possible WARNING Improperly crossing hills or turning on hills Could cause loss of control or cause ATV to overturn Never attempt to turn the ATV a...

Page 39: ...ds or improperly dismounting while climbing a hill Could result in ATV overturning Use proper gear and maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply...

Page 40: ...of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extrem...

Page 41: ...ing WARNING Operating this ATV through deep or fast flowing water Tires may float causing loss of traction and loss of control which could lead to an accident Never operate this ATV in fast flowing wa...

Page 42: ...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 Th...

Page 43: ...nd 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 encou...

Page 44: ...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 of changing terrain conditions WARNING...

Page 45: ...t 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...

Page 46: ...des rider accessories vertical weight on trailer hitch and all gear carried on front and rear racks 2 Front rack 40 kg 88 18 lbs 3 Rear rack 80 kg 176 37 lbs 4 Storage box 2 0kg 4 4lbs 5 Trailer hitch...

Page 47: ...mechanical experience If you are not sure how to do the maintenance ask your authorized service center or call BAJA INC CAUTION Using poor quality replacement parts could damage your ATV Poorly made...

Page 48: ...Engine Oil filter C C Engine Oil strainer C C Final Gear Oil R R Brake Fluid level I I I Brake Hose and joints I I Liquid cooling device hose and joints I I Speed sensor I I Radiator assembly C I Bra...

Page 49: ...or indicates that the engine may need adjustment or a new plug is needed Consult your authorized dealer or Baja Motorsports if your plug insulator is not a light brown color CAUTION Failing to use the...

Page 50: ...he gap to 0 6 0 7mm 024 028 in for good ignition Use a thickness gauge to check the gap CAUTION Improper installation of the spark plug could damage your ATV An overly tight or cross threaded spark pl...

Page 51: ...noise if the gap is too large in air valve If gap is too small valve operation will be hindered which could result in valve malfunction and failure Therefore air valve gap must be checked periodicall...

Page 52: ...yes 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 e...

Page 53: ...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...

Page 54: ...ds to seat the caps Do not pound or hammer The battery is now sealed see figure 26 Install battery into battery compartment The battery terminals should be facing the front see figure 27 Once battery...

Page 55: ...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...

Page 56: ...adlight bulb replacement Turn off main key switch Locate lights under front fenders remove screws and headlight housing Slide back moisture protector from headlight Push in bulb holder and turn left C...

Page 57: ...distance Readjust it if it is not within the correct limits WARNING Operating the vehicle with an inadequate throttle lever free distance could be hazardous Inadequate throttle lever free distance co...

Page 58: ...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...

Page 59: ...f 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 chang...

Page 60: ...sed 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 was...

Page 61: ...place could be hazardous If the air filter element did not filter dirt severe engine damage would occur if the dirt entered the running engine Never run the engine without the air filter element in pl...

Page 62: ...nt is damaged replace it 5 Wash the foam cover per instructions below 6 Reinstall foam cover to the air filter element 7 Reinstall air filter and close cover Wash the foam cover as the following 1 Rem...

Page 63: ...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...

Page 64: ...ve fill cap 5 Remove oil plug 6 Let oil drain out completely 7 Install the drain plug and tighten to 23Nm 12 6 ft lb 8 Install gear cover and tighten bolts 9 Add gear oil SAE 80 API G 4 Hypoid Gear oi...

Page 65: ...are cold Maximum pressure Front 34 47kpa 5psi Rear 34 47kpa 5psi WARNING Operating this ATV with improper tires or even improper tire air pressure could be hazardous If you use improper tires or impro...

Page 66: ...for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking Always follow the instructions in your owner s manual for c...

Page 67: ...e 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 where transportati...

Page 68: ...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 bra...

Page 69: ...nd 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 3 Measure the a...

Page 70: ...pressure 4 Stop the engine and let the exhaust pipe cool 5 Install the drain bolt back into the exhaust pipe and tighten WARNING Failing to maintain the brake shoes or pads could be hazardous Riding...

Page 71: ...is 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 it WARNING Riding an AT...

Page 72: ...ensure the oil cooler is in proper working order CLEANING AND INSPECTION OF OIL COOLER 1 Locate oil cooler under front fender assembly Oil Cooler Cooler Guard Screen 2 Remove Cooler Guard Screen loca...

Page 73: ...If sensor wires are loose squeeze connectors gently with a pair of pliers to provide a tight connection Note The fan sensor is the top sensor located on the oil cooler 1 purple wire and 1 Black wire...

Page 74: ...e Increase intervals when you use your ATV in severe conditions Your authorized service center should do general lubrication as shown in the MAINTENANCE CHART The authorized service center will lubric...

Page 75: ...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 WA...

Page 76: ...s not fouled Remove the 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...

Page 77: ...th Attach spark plug cap and ground to chassis Use the electric starter Turn the fuel valve to OFF Turn the fuel valve to RES Supply fuel Remove the fuel hose from the fuel valve Restart engine Check...

Page 78: ...ng 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...

Page 79: ...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 th...

Page 80: ...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 CLE...

Page 81: ...e 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 R...

Page 82: ...so need these numbers to help your authorized service center or Baja Motorsports order parts The Frame number is stamped on front of ATV frame The engine number is located on the right side of the eng...

Page 83: ...adius 3000mm 118 1 in Seat height 827mm 32 6 in Dry weight 259 9kg 573lbs ENGINE Type Four stroke air cooled Number of cylinders 1 Bore X Stroke 83 0x71 6 Displacement 387 4cm3 Corrected Compression r...

Page 84: ...Oil change with oil filter replacement 2 5 QT Total amount of gear oil 3 ounces per differential Fuel Main fuel tank capacity 11 8 QT Reserve fuel tank capacity 2 64 QT Brakes Front brake type Hydraul...

Page 85: ...Br W1 Headlight 1 12V 18W 18W Front side light 1 12V 15W Headlight 2 12V 18W 18W B B B B Front side light 2 12V 15W Y1 DG DG Y1 Y1 Y1 Y2 Bl Lb R W Ngear indicator light Lb G W W R G W R2 W G Y W G Bl...

Page 86: ...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 perfor mance of all scheduled maintena...

Page 87: ...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 LIMITATIO...

Page 88: ...ontract 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 impli...

Page 89: ...85 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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