Baja motorsports WD90 Owner'S Manual Download

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Read this manual carefully. It contains important safety information.

Children under the age of 16 should be supervised by a responsible adult.

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.

OWNER’S MANUAL

REV. B

012209

WD90

Minimum Age Requirement: 10

Model: 90cc

For More information on ATV Safety Contact

the Baja ATV Safety Hotline at: 866-260-8630

Summary of Contents for WD90

Page 1: ...lways 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 OWNER S MANUAL R...

Page 2: ...in 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 Mo...

Page 3: ...0 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...

Page 4: ...d to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle The engine exhaust from this product contains...

Page 5: ...IN 19 STARTING THE ENGINE 20 SAFETY GEAR 24 STARTING OFF 26 BRAKING 27 TURNING 28 OPERATION ON HILLS 29 CLIMBING HILLS 29 DESCENDING A HILL 30 RIDING OVER OBSTACLES 32 SKIDDING OR SLIDING 33 RIDING T...

Page 6: ...AND ADJUSTING 58 TIRES 59 BRAKING 62 FRONT DRUM BRAKES 62 REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE 63 GENERAL LUBRICATION 64 TROUBLESHOOTING 65 FUEL SUPPLY CHECK 65 IGNITION SYSTEM CHECK 66 TRANSPO...

Page 7: ...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 t...

Page 8: ...that 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 ca...

Page 9: ...chedules 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...

Page 10: ...r procedures 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 pr...

Page 11: ...g 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 220 lbs Do not tow a trailer This vehicle is n...

Page 12: ...8 ATV 90 Rear Tire Gas Cap Muffler Oil cap Head lights Gas Cap vent hose Rear shock Spark plug RIGHT Seat Carburetor Front Tire Tail Light Front shocks Thumb throttle Fuel valve LEFT...

Page 13: ...our stroke engine Please use oil as described in the chart below By using prescribe oil you will realize the best lubrication for engine Use the chart to select a viscosity rating based on the tempera...

Page 14: ...on If a label comes off or becomes difficult to read you should get a replacement by contacting BAJA INC LOCATION OF LABELS 1 Operation of the ATV by children under the age of 10 increases the risk of...

Page 15: ...public roads a collision can occur with another vehicle With passenger passengers affect balance and steering and increase risk of losing control ALWAYS Use proper riding techniques to avoid vehicle o...

Page 16: ...Improper tire pressure or overloading can cause loss of control Loss of control can result in SEVERE INJURY or DEATH WARNING Cold tire pressure Front 7 Psi 48 Kpa Rear 7 Psi 48 Kpa Maximum weight capa...

Page 17: ...ng Screw To limit the throttle screw in throttle limiter screw HANDLEBAR SWITCHES LEFT HANDLEBAR Front Brake lever Parking Brake Pin Thumb Throttle Lever Throttle limiter screw Lock Nut With the Engin...

Page 18: ...he carburetor RES position arrow on valve pointing up If fuel level in the fuel tank becomes too low for engine to stay running while fuel valve is at ON position turn fuel valve to RESERVE Turning fu...

Page 19: ...G 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 20: ...The adult supervisor should grasp the lanyard and follow behind the ATV while the beginner is learning to operate the ATV The adult supervisor should pull the lanyard to remove the remote stop pin wh...

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: ...Proper air pressure Enough tread depth No cracks rips or other damages Fuel Enough fuel for the intended trip Fuel hose connected securely No damage to fuel tank or cap Fuel tank cap closed securely...

Page 23: ...o 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...

Page 24: ...ar brake lever and make sure that the rear wheels are in locking condition 5 Press the yellow starter button START to start the engine 6 After engine has warmed up set choke to down off position ON OF...

Page 25: ...s run your ATV outdoors where there is fresh air WARNING Carrying a passenger on this ATV Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you...

Page 26: ...road use only not for use on pavement Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control Never operate the ATV on any paved surfaces in...

Page 27: ...rottle 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...

Page 28: ...d motorcycle helmet eye protection and protective clothing Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating...

Page 29: ...our ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which...

Page 30: ...gh slipper or loose terrain Could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until...

Page 31: ...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 fro...

Page 32: ...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 of the turn increase as the speed or the turn sharpness...

Page 33: ...ills improperly 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 befor...

Page 34: ...TE a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Av...

Page 35: ...cle to lean 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 t...

Page 36: ...hill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointe...

Page 37: ...control 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 O...

Page 38: ...en crossing 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 fl...

Page 39: ...ore 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 y...

Page 40: ...atment 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 mig...

Page 41: ...an 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 W...

Page 42: ...s or cargo must never exceed the vehicle s load capacity of 220 lbs 2 Check accessory mounting brackets and other attachments to make sure they provide a rigid non movable mount 3 Accessories added to...

Page 43: ...vehicle Locate cargo weight as close to the center of the vehicle if possible 7 Secureyourloadwell Shiftingweightcanaffectyourabilitytohandlethe vehiclesafely 8 Ride at slow speeds and avoid hills wh...

Page 44: ...C Exhaust pipe bolt and muffler bolt T T T Cylinder head cylinder and muffler C C Spark plug C R Valve clearance Check Adjust I Idle Speed I I I Throttle cable I I I Fuel line I I I Brakes I I I Tire...

Page 45: ...nc 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 condit...

Page 46: ...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 en...

Page 47: ...spark plug by hand into the threads 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 f...

Page 48: ...OM 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 ANT...

Page 49: ...Leave bottles 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 ta...

Page 50: ...ps for 5 10 hours After charging is complete press down firmly with both hands to seat the caps Do not pound or hammer The battery is now sealed see figure 25 Locate battery compartment on ATV The bat...

Page 51: ...sses 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...

Page 52: ...atch 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 wor...

Page 53: ...ate the two phillip head screws G with metal jumper F connecting screws together 2 Loosen both phillip head screws G and remove metal jumper F Re tighten phillip head screws after metal jumper is remo...

Page 54: ...not within the correct limits 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...

Page 55: ...t 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 i...

Page 56: ...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 57: ...move the oil cap 3 Remove the drain bolt and drain oil into proper container 4 Reinstall the drain bolt 5 Pour fresh oil of the specified type through the oil fill hole NOTE Approximately 900ml 1 Qt o...

Page 58: ...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 CAUTIO...

Page 59: ...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 cra...

Page 60: ...lly the element for tears before and after cleaning it Replace the element with a new one if it is torn CAUTION Failing to position the air cleaner element properly could damage your ATV Air will bypa...

Page 61: ...thorized service center If it is determined the drive chain is damaged check the sprocket also for damage A worn chain can have an adverse affect on the front and rear sprockets When inspecting the sp...

Page 62: ...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 t...

Page 63: ...an accident Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Baja Inc or equivalent components designed for...

Page 64: ...type listed below Tire Tread Condition 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 co...

Page 65: ...ype 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...

Page 66: ...ould 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 vehi...

Page 67: ...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 bra...

Page 68: ...maintenance on the vehicle 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 s...

Page 69: ...ew 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 Dr...

Page 70: ...ace 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 16...

Page 71: ...u 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 t...

Page 72: ...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 sea...

Page 73: ...d 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 Remo...

Page 74: ...rmal 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 SERVI...

Page 75: ...ized 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 W...

Page 76: ...5mm Displacement 85 9cc Corrected Compression ratio 8 6 1 Carburetor PZIP Air cleaner Polyurethane Foam element Max power 4 6Kw 8500r min Rated power 4 2Kw 8000r min Max torque 6 0N m 6000r min TRANS...

Page 77: ...73 WIRE DIAGRAM...

Page 78: ...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 79: ...ontrol 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...

Page 80: ...liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise...

Page 81: ...77 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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