Baja motorsports WD250 Owner'S Manual Download

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Always wear a helmet; It could save your Life!

Do not remove this operator’s manual from this vehicle.

Please obtain, review, and follow 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

Summary of Contents for WD250

Page 1: ...low 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 infor...

Page 2: ...r 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...

Page 3: ...d 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 c...

Page 4: ...AKE 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...

Page 5: ...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 AR...

Page 6: ...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 7: ...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...

Page 8: ...essive 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 f...

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 stoppi...

Page 10: ...U 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 dipsti...

Page 11: ...gine 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...

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...

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 REVER...

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...

Page 15: ...e 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...

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 throt...

Page 17: ...sition 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 us...

Page 18: ...eck 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...

Page 19: ...mponents 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 accesso...

Page 20: ...arn 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 go...

Page 21: ...mages 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 le...

Page 22: ...OADING 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 handl...

Page 23: ...ect 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...

Page 24: ...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 exce...

Page 25: ...NG 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 Runnin...

Page 26: ...ating 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 e...

Page 27: ...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...

Page 28: ...d 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 ca...

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...

Page 30: ...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 Rele...

Page 31: ...e 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...

Page 32: ...fore 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 sli...

Page 33: ...r 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 y...

Page 34: ...LLS 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...

Page 35: ...V 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...

Page 36: ...radually 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 pa...

Page 37: ...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...

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...

Page 39: ...NG 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 fa...

Page 40: ...ng 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...

Page 41: ...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 42: ...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 R...

Page 43: ...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 car...

Page 44: ...64 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 trai...

Page 45: ...lutch 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...

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 o...

Page 47: ...cates 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...

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 p...

Page 49: ...s 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 emp...

Page 50: ...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 51: ...omplete 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...

Page 52: ...n 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 d...

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 fu...

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...

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...

Page 56: ...rks 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...

Page 57: ...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...

Page 58: ...ccur 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 we...

Page 59: ...ns 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 C...

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...

Page 61: ...ear 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 Hypo...

Page 62: ...m 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...

Page 63: ...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 faci...

Page 64: ...n 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...

Page 65: ...lebar 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 lea...

Page 66: ...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 th...

Page 67: ...s 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 ma...

Page 68: ...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 a...

Page 69: ...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 th...

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 n...

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 c...

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 p...

Page 73: ...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 t...

Page 74: ...shes 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 AFTE...

Page 75: ...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 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...

Page 77: ...inders 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 Sp...

Page 78: ...unt 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...

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 o...

Page 80: ...r 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 Wa...

Page 81: ...l 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...

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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