Baja WD400U Service Manual Download

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WD400U Service Manual

For any questions please contact Baja Motorsports at 888-863-2252

Summary of Contents for WD400U

Page 1: ...WD400U Service Manual For any questions please contact Baja Motorsports at 888 863 2252...

Page 2: ...on 2 Disassembly and assembly of cushion fender and fuel tank 26 I Cushion 26 II Rear fender 26 III Fuel tank 29 IV Front fender 30 Section 3 Maintenance and adjustment of vehicle body 32 I Wear inspe...

Page 3: ...el Rear brake Rear wheel axle 64 I Removal steps 66 II Inspection stepes 68 III Installation steps 70 Section 3 Rear shock absorber and rear wheel fork 74 I Disassembling steps 75 II Checking steps 77...

Page 4: ...ction 11 Inspection of signal system 120 I If the neutral indicated lamp is out work 120 II If the reverse indicated lamp is out work 121 III If the HB indicated lamp is out work 122 Chapter V Engine...

Page 5: ...t silencer 12 Cushion 13 Fuel tank cover 14 Rear brake pedal 15 Front luggage carrier 16 Left rear brake lever 17 Hand operated parking brake 18 Main switch lock 19 Throttle grip 20 Right front brake...

Page 6: ...e 5 Stop rotating meter for rotator used for removing and assembling rotator of kick starter 6 Puller for crank for disassembling crank from crankcase 7 Puller for rocker shaft used for the removing r...

Page 7: ...II Instruments and meters The following instruments and meters can be selected with reference to the same type of vehicle...

Page 8: ...ing or replacing these components they should be kept in pairs When disassembling the engine clean all components and place in a tray in the order of disassembly not only increasing the assembling spe...

Page 9: ...ace all locking washer shim and location pin a After bolt or nut is in the lock position bend and fix both ends of locking shim along head of bolt or direction of nut 6 Bearing and oil seal When assem...

Page 10: ...le of battery see figure 7 1 When tightening or loosening bolt on terminal of battery do not let the wrench contact the engine or other metal parts of the vehicle body to avoid electric shock When con...

Page 11: ...tor make sure there are no defects on the housing of the joints When inserting the joint after defects are fixed put plastic coating on In general multi head connectors are plastic and designed to loc...

Page 12: ...cm mm 06 214 0 6214 3 281 1 094 0 3937 0 03937 mph mi ft yd in in Volume capacity cc cm cc cm lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP lig cu in qt IMP lig gal IMP liq Others kg mm kg...

Page 13: ...mp Final gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 23L 0 24 US qt Differential gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 35L 0 37 US qt Air filter Wet element Fue...

Page 14: ...oil damper Coil spring oil damper Wheel travel Front Rear 160mm 6 30in 180mm 7 09in Electrical Ignition system Generator Battery type Battery capacity DC C D I A C magneto YTX14AH 12V 12Ah Headlight t...

Page 15: ...erial of rim Steel plate Sixe of tire AT22x10 10 Size of rim AT 10x8 0 Type Drum type Thickness of friction piece 4 0mm 0 16in 2 0mm Free length of back spring of brake shoe 71 0mm 2 77in Free play of...

Page 16: ...I Electric capacity contactless type No loading adjusting voltage 14 1 14 9V Voltage resisting value 200V Type A C magneto Rated output voltage At 2000r min 14 15V Coil resistence color At 20 C 68 F...

Page 17: ...r Bore size 70 97 71 02mm 2 768 2 77in Distance between measuring point and upper endface of cylinder is 40mm 80 50mm Cylinder head Flatness of lower endface Measure the surface warp of every portion...

Page 18: ...ake exhaust Outside diameters of valve stem exhaust intake Inside diameter of valve guide intake exhaust Clearance between valve stem and guide exhaust intake Roundness of valve seem 0 02 0 03mm 0 000...

Page 19: ...arance of connecting rod E 55 95 56 00mm 2 18in 0 8 1 0mm 0 031 039in 0 35 0 65mm 0 014 0 025in 0 01 0 025mm 0 0004 0 001in 0 03mm 0 06mm 2 0mm Automatic centrifugal clutch Clutch shoe quantity thickn...

Page 20: ...17 Timing gear Bolt M10x25 1 45 33 Tensioner plate bolt Bolt M6x16 2 10 7 Tensioner Bolt M6x25 2 10 7 Tensioner plug Bolt M10x12 1 45 33 Cylinder bolt Bolt M6x30 1 10 7 Balanced initiative gear Bolt M...

Page 21: ...Output shaft turning yoke Nut M14 1 136 101 Output shaft bearing seat Bolt M8x30 4 23 17 Pull starter Bolt M6x14 4 10 7 Oneway drive Bolt M8x16 6 23 17 Oil pump cover Bolt M6x12 3 10 7 Starter motor B...

Page 22: ...cket Bolt M6x12 2 10 7 Meter Screw M3 2x30 2 3 2 Meter comp Screw M3 2x30 4 3 2 Fuel tank cover Screw M6x12 2 10 7 Front and rear rack Bolt M8x12 8 23 17 Front bumper Bolt M8x12 23 17 Front bumper Scr...

Page 23: ...l Light lithium base grease Dust proof ring of brake Light lithium base grease Joint of front brake cable Light lithium base grease Front brake lever axle rear brake lever axle Light lithium base grea...

Page 24: ...nit Shift gear shaft upper cam plate unit Lubricating oil Steel ball bracket unit Steel ball bracket unit upper lower cam plate Lubricating oil Surpassing clutch Surpassing clutch main clutch cover in...

Page 25: ...sket if necessary Spark surpressor Clean Oil circuit Check for cracks damage in oil tube Replace gasket if necessary Engine oil Replace preheat engine before draining oil Oil filter Clean Oil filter s...

Page 26: ...ehicle on level ground 2 Disassemble the cushion 1 Pull the cushion lock lever 2 up then raise the rear of cushion 1 2 1 II Rear fender Disassembly 1 Place vehicle on level ground 2 Disassemble the re...

Page 27: ...nect the negative wire 2 and positive wire 3 of battery 5 Remove battery clamp bracket 4 6 Remove battery 5 7 Remove protective bracket 6 disconnect all wires from main wire harness 7 and electrical p...

Page 28: ...arness 1 and electrical parts connecting to switch box 2 4 Install Protective bracket 3 5 Connect battery 4 A Connect the positive wire 5 to battery B Connect the negative wire 6 to battery Install ba...

Page 29: ...Remember to install the bushing on the con necting point of luggage carrier and frame Fuel tank disassembly CAUTION Seat rear fender and rear luggage carrier will need to be removed before fuel tank d...

Page 30: ...Place the vehicle on level ground 2 Disassemble the front luggage carrier 1 3 Disassemble the front plastic bumper 2 4 Remove front metal bumper 3 5 Remove front fender Fuel tank Installation Reverse...

Page 31: ...he fastening torque of bolt bumper and frame is 16N m 12ft lbs 4 Install the front luggage carrier 3 Bolt 2 front luggage carrier and frame The fastening torque is 34N m 25ft lbs Bolt 3 front luggage...

Page 32: ...replace the brake shoe assy Refer to Rear wheel and rear brake section in Chapter VII II Adjustment of front brake CAUTION Before adjusting check the degree of wear on the front brake according to th...

Page 33: ...Rotate the adjusting screw 2 clockwise or counterclocksiwe to gain proper free clear ance Clockwise wear free clearance Counterclockwise decrease free clearance Tighten the lock nut III Adjustment of...

Page 34: ...ance rear brake pedal 20 30mm 0 78 1 17in Rotate adjusting nut 3 of rear brake cable until correct clearance is met 0 1mm 5 Rear brake arm assy 6 Pin Screw out the adjusting screw 2 of rear brake cabl...

Page 35: ...the oil filling screw plug 1 and sealing washer Observe the oil level the correct amount should be on the bottom of oil filling hole If the oil level is too low refill the recommened engine oil to spe...

Page 36: ...ealing washer oil drain screw plug position If damaged replace it 5 Install Oil drain screw plug rear driving gear case Torsion of oil drain screw plug 23N m 17ft lbs 6 Oil fill screw plug CAUTION Avo...

Page 37: ...oint unit of steering tension rod Rotate the steering bar leftward and or rightward then rotate from left to right If the ball pin unit 1 of steering tension rod has too much vertical clearance replac...

Page 38: ...ot correct adjust 3 Adjustment Adjustment steps of toe in Mark determination marks at the end of the left right tension rod 1 Loosen the locking nuts at the end of left right tie rod 2 Left right tie...

Page 39: ...k and Rear shock absorber and rear wheel fork 3 Inspection Operation Move the front rear shock absorbers up and down If it is not operating correctly replacce the compo nent Refer to Chapter 3 section...

Page 40: ...r Dimension Front Wan Da AT25x8 12 Rear Wan Da AT25x10 12 Tire pressure 1 Recommended tire pressure Front 34 5Kpa 5Psi Rear 34 5 Kpa 5Psi 2 Low tire pressure will cause the tire to dislodge from the r...

Page 41: ...t safe and may cause the loss of control Keep the proper tire pressure Normal Temp Front Rear Tire Pressure Standard 34 5Kpa 5Psi 34 5Kpa 5Psi Min 34 5Kpa 5Psi 34 5Kpa 5Psi Max 103 5Kpa 15Psi 103 5Kpa...

Page 42: ...easures below a When changing the battery be in a well ventilated area b Keep away from flame or spark such as welding equipment burning cigarettes etc c Smoking is strictly prohibited when charging o...

Page 43: ...pection of fuse CAUTION Close the main switch when checking or replacing the fuse otherwise it will cause a short circuit 1 Inspection steps Remove the fuse 1 Connect the small size test instrument to...

Page 44: ...trical Appliance of chapter 4 3 Installment of fuse cover III Replacement of headlight bulb 1 Cut off engine Connecting wire terminal of headlight 1 2 Removal Headlight unit 2 3 Remove lens 1 4 Remove...

Page 45: ...ting value If there are some oils on it clean off with cloth mixed with alcohol 7 Connect Light seat 1 CAUTION Be sure that the projective part of the bulb is engaged with the convex groove on the lig...

Page 46: ...ce with compressed air 6 Clean the foam filter a Clean with water completely b Squeeze the excess water of the foam and let dry NOTE When squeezing the water from the foam filter do not twist 7 Instal...

Page 47: ...t brown is normal condition If the color is clearly different check the engine 4 Clean the spark plug Clean the spark plug with spark plug cleaner 5 Measure the spark plug clearance 1 Measure with fee...

Page 48: ...ttle grip is within 3 5mm otherwise readjust the idle speed IV Adjustment of free play of throttle grip CAUTION First adjust the engine idle speed when adjusting throttle grip 1 Rest the vehicle on le...

Page 49: ...b Adjust the adjusting screw 2 clockwise or counter clockwise to make a obtain the speci fied length of 12mm 47in c Lock the locking nut 1 WARNING a For the beginner driver pay extra attention to scr...

Page 50: ...n is at the end point posi tion of compress stroke 1 Removal 1 Rest the vehicle on level ground 3 Remove a Manual operation start mechanism 1 b Timing observation hole scsrew 2 4 Remove a Valve cap 1...

Page 51: ...ica tion Intake valve clearance 0 02 0 03 0 00078 0 00117in normal temp Exhaust valve clearancee 0 03 0 05mm 0 001170 00195in normal temp 2 Adjustment of valve clearance a Loosen lock nut 1 b Insert t...

Page 52: ...inlet door CAUTION i Valve cap 1 2 should be placed in the upright position 3 ii Check if the o ring 4 is damaged if so re place immediately Torque of valve cap 10N m 7 4ft lbs VII Adjustment of timin...

Page 53: ...k plug off 3 The following are steps for measuring compres sion force a Install compression gauge 1 with proper adjuster b Open throttle lever completely Start engine battery has been charged fully un...

Page 54: ...ound 2 Check engine oil level and fill if necessary Inspection steps a Warm up engine after several minutes Let engine cool for 10 minutes allowing oil to settle in engine Compression read Reason Read...

Page 55: ...M10x25 4 Needle bearing 5 Oil seal 6 Needle bearing 7 Ring gear set 8 Bearing 9 Coller 10 Bearing retainer 11 O ring 12 Oil seal 13 Drain plug 14 Gasket 15 Breather 16 Bearing housing 17 Oil seal 18 B...

Page 56: ...ar cracked WARNING You should stop driving immediately if there is any indication that the gear teeth are cracked This could mean that the transmitting components are jammed by gear fragments and it i...

Page 57: ...mbly check and confirm the oil leakage carefully III Trouble shooting table Check following points if there is basic trouble condition To check if the wheel bear ings are damaged lift the front end of...

Page 58: ...fender Refer to rear fender 3 Disassemble 1 Rear wheel left 2 Connecting plate of rear wheel 3 Rear wheel right 4 Rear brake and rear brake hub 5 Rear axle shaft Refer to Rear wheel rear brake rear w...

Page 59: ...le 1 Rear driving gear case body 1 2 Annular gear pad 3 Shift gear 4 Thrust plain pad c Disassemble Bearing gasket transmission shaft last grade CAUTION On the bearing there is left handed thread The...

Page 60: ...d do not reuse e Disassemble 1 Oil seal 1 2 Bearing 2 Properly support rear differential case and use proper pressure assemble tool 3 f Disassemble Bearing 1 main driving gear Procedures for disassemb...

Page 61: ...to adjust the main driving gear and or shift gear when replacing them Turn to Choice of Main Driving and Shift Gear Pad 5 If the transmission shaft 5 spline has any wear or damage replace it 6 If the...

Page 62: ...Nut M10 tire 10 Bearing 11 Dust cover 12 Oil seal 13 Bearing 14 Oil seal 15 Nut M10 tire 16 Brake plate 17 Brake camshaft 18 Brake shoe 19 Return spring 20 Indicator plate 21 Bolt M6x30 22 Self lock n...

Page 63: ...62...

Page 64: ...ich will cause danger during the removal process rest the vehicle firmly 2 Removal of left wheel 1 Nut of rear wheel 2 Left rear wheel 3 Cotter pin 4 Axle nut CAUTION Remove rear wheel axle nut from r...

Page 65: ...Bearing retainer 2 Rear brake hub 11 Removal Tension spring Rear brake arm Brake indicating plate Rear brake shoe cam 12 Removal 1 Sealed bearing 13 Removal 2 Rear wheel axle Push the left side of the...

Page 66: ...Inspection 1 If there are any cracks bends or damage on the brake cover replace it 2 If the dust proof seal is worn or damaged replace it 10 Inspection 1 If cam shaft of rear brake is worn scraped or...

Page 67: ...placement steps of bearing and oil seal a Clean around the bearing of gear case end b Remove the oil seal 1 with plain screw driver CAUTION In order to protect the oil seal out edge from damage during...

Page 68: ...lment Installment of rear wheel axle 1 CAUTION Before installing the rear wheel axle loosen all bolts on the rear differential 2 hold the rear wheel axle with hand to help guide the gear groove of gea...

Page 69: ...ake cam shaft 1 At the same time align the punch mark c on the rear brake cam shaft with that d of the rear brake arm assy 3 The torque of rear arm assy 9Nm 6 Application Sealing agent Be suitable for...

Page 70: ...on oil is not allowed to be used for splint on the right end of rear wheel axle other wise during the work the surplus lubri cation oil will leave on the brake shoe affect ing the brake performance 10...

Page 71: ...ed The torque of the lug nut of rear wheels is 55Nm WARNING When installing the core nut to the rear wheel be sure to face its core edge to the wheel 18 Installment Connecting plate of rear wheel 1 Wa...

Page 72: ...levis pin 5 Cover 6 Washer 7 Cotter pin 8 Rear swing arm 9 Rear axle housing 10 Bolt M10x20 11 Lock nut M10 12 Bushing 13 Bolt M12x1 25x80 14 Lock nut M12x1 25 15 Rubber boot 16 Tension spring 17 Hose...

Page 73: ...ection in this chapter 2 Take off lower cap of gear case 3 Take off the rear driving gear case sub assembly 1 Refer to Dischargment of rear driving gear case sub assembly and driving shaft section of...

Page 74: ...ut of rear wheel fork right side Attached Torque of rear arm joint bolt and nut is 130N m Torque of rear arm joint nut is 6N m 4ft lbs b Move the rear wheel fork across to check the side clearance A I...

Page 75: ...rear arm joint bolt 11 Remove rear swing arm 1 II Checking steps 1 Check a If rear shock absorber is leakage if any replace it b If rear shock absorber is bent or damaged if any replace it c Pull the...

Page 76: ...int bolt 1 rear arm joint bolt 2 and bush 3 If one of these parts are worn or damaged replace it 5 Check the bearing of rear wheel fork assy if there is free play during the bearing match with the rea...

Page 77: ...oil sealing WARNING Don t strike the bearing inner race 5 and roller III Mounting steps The reverse step of disassembly is the mounting step but the following points must be paid attention to during t...

Page 78: ...tact with the bushing 3 Attached Bolt torque value 6Nm 4ft lbs c Fix right rear arm nut 4 by standard torque Attached Rear arm nut torque 130Nm 96ft lbs 4 Check rear wheel fork free play Refer to step...

Page 79: ...of rear driving gear case sub assembly and driving shaft section of this chapter 9 Mount the rear wheel axle rear brake hub right rear wheel rear wheel joint plate and left rear wheel Refer to Instal...

Page 80: ...arm 3 Upper handle holder 4 Bolt M8x35 5 Cotter pin 6 Steering bearing 7 Oil seal Section 4 Steering Operation system 8 Bracket 9 Bolt M8x60 10 Lock washer 11 Collar 12 Washer 13 Nut M14 14 Cotter pi...

Page 81: ...n 2 2 Removal Ignition switch Neutral indicating light wire Reverse indicating light wire High beam indicating light wire Clutch switch wire 3 Removal 1 Brake cable from rear brake drum 4 Removal 2 Th...

Page 82: ...1 25 Tie rod 1 CAUTION When removing the tie rod end and steering ball pin from the steering vertical column welding assy and front seat assy of front brake with com mon bearing tension tool and other...

Page 83: ...do not straighten it forcefully if it is bent 3 Inspection Check the steering vertical column holder 1 and seal ring 2 If they are worn or damaged replace them 4 Inspection If the tie rod 1 is bent or...

Page 84: ...y the front brake CAUTION The connection nut A B can be tightened up only when the revealed thread length b of two ends of tension rod are the same Attached Lock nut torque of tie rod 30Nm 22ft lbs 7...

Page 85: ...CAUTION Never damage the seal ring when installing 4 Installment When installing the steering vertical column holder and steering vertical column welding take them as a unit WARNING In order to ensur...

Page 86: ...Mount the washer and nut on steering vertical column Nut torque 30Nm After you torque the nut use the cotter pin 9 Install Clip 1 locking washer 2 bolt 3 Attached bolt torque 23Nm 17ft lbs WARNING Alw...

Page 87: ...grip as sembly must correspond with the sunken part 2 on the right lever seat when installed WARNING Correct installation of cable and wire is very important to ensure the safe operation of ve hicle R...

Page 88: ...87 Section 5 Front Wheel and Front brake...

Page 89: ...uckle assembly 18 Bearing 19 Outer seal 20 Inner seal 21 Sleeve 22 Ball joint 23 Axle spring circlip 24 Front wheel hub 25 Front wheel shaft setting bolt 26 Front wheel seal 27 Washer 28 Castle nut M1...

Page 90: ...heel 3 Place a stand under the frame to support the vehicle 4 Remove Cotter pin 1 Castle nut 2 Washer 3 Hub and rotor 4 Item Parameter Tire specification 25x8 12 Rim dimension 12x8 Tire air pressure n...

Page 91: ...brake rotor for any damage and replace if necessary Check brake caliper for any leaks Check the brake pads for wear or damage and replace if necessary 6 Remove Brake protective plate 1 Installation 1...

Page 92: ...91 2 Attach brake caliper 1 3 Attach Hub and rotor 4 Washer 3 Castle nut 2 Cotter pin 1 4 Attach Front wheel 1 secure with lug nuts 2 Dust proof cover 3 1 1 2 3 4 2 3 1...

Page 93: ...astle nut Section 6 Front shock absorber and Front wheel fork and Front Differential 8 Cotter pin 9 Left lower A arm 10 Right lower A arm 11 A arm bushing 12 Bolt M10x1 25x70 13 Lock nut M10x1 25 14 F...

Page 94: ...r gasket 15 Rank 16 Bearing 17 Rolled needle bearing 18 Transducer 19 Washer 20 Seal o ring 21 Spout 22 Seal o ring 23 Seal 24 Bolt M10x16 25 Washer 26 Clip spring 27 Clutch gear wheel 28 Clip spring...

Page 95: ...1 Place container under drain bolt 1 and let drain completely 2 Remove front luggage rack bumper and front fender Refer to the second section of chapter 2 Disassemble the front wheel front brake hub b...

Page 96: ...95 5 Remove Upper A arm 1 from frame Lower A arm 2 from frame 6 Remove Front differential case 1 1 2 1...

Page 97: ...96 Remove M6 bolts 2 and electric motor comp 1 Use force on the end bearing to dislodge the drive assembly 3 1 2 3...

Page 98: ...tial axle Front differential II Installation of front shock absorber and front wheel fork These directions are as sembly for one side on the unit only 1 Reverse Disassembly steps 2 Install the front d...

Page 99: ...differential 7 Attach the steering knuckle 1 to the lower 2 and upper 3 A arms secure with castle nut and cotter pin a 8 Attach the steering tie rod 4 the steering knuckle 1 secure with castle nut and...

Page 100: ...nition coil 8 Bolt M6x20 9 Stop lamp switch assembly 10 Battery 11 Rectifier 12 Bolt M6x25 13 Negative cable 14 Battery press plate stand 15 Rubber washer 16 Main cable protection plate 17 Bolt M6x20...

Page 101: ...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 102: ...circuit Turn the switch on and off many times while inspecting The left figure indicates the wire position of switch The vertical line indicates switch posi tion The first row indicates color of wire...

Page 103: ...al in on Adjust the choice knob of the pocket multime ter to x1 Connect the multimeter pen to correspond ing lamp wire end First connect the multimeter pen to wire end 1 and pen to wire end 2 to check...

Page 104: ...sistance of ignition coil and wire 4 Engine stop switch Check and repair 1 Spark plug Check the spark plug condition Check the spark plug type Check the spark plug gap Refer to chapter 3 Check the spa...

Page 105: ...Press the starting switch to start the engine Increase the spark clearance until the engine can not be started Min spark clearance 6 0mm 0 24in No spark 3 Resistance of spark plug cap Remove the spark...

Page 106: ...switch is closed OR Rear brake switch rear switch is closed When the vehicle is in drive or reverse and the rear brake is in idle then the cut off relay will prevent starting device from running In t...

Page 107: ...ore trouble shooting 1 Cushion 2 Front frame 3 Front fender 1 Safety Refer to Check of switch PASS 2 Battery Check the condition of the battery Refer to Check battery chapter 3 Voltage of open circuit...

Page 108: ...s on The circuit is on 5 Starting relay Remove the connector of the starting relay from cable Connect the multimeter x1 and battery 12V to end of wire on relay Battery end blue white wire end 1 Batter...

Page 109: ...ystem PASS 9 Starting switch Refer to Check system PASS 10 Circuit connection Check the circuit connection of entire start ing system Refer to Electric diagram FAIL Replace main switch FAIL Replace ne...

Page 110: ...ttery Refer to Inspection of battery in chapter 3 Voltage 12 8V or more under load PASS 3 Charging voltage Connect engine tachometer to the wire to spark plug Connect pocket tester DC 20V to the batte...

Page 111: ...stator coil x1 Pocket multimeter white terminal 1 Pocket multimeter white terminal 2 Pocket multimeter white terminal 3 Measure the resistance value of stator coil At 20 C 68 F 0 7 1 80 Specification...

Page 112: ...carrier 3 Front covering parts Use special tools for troubleshooting 1 Safety Refer to Inspection of switch PASS 2 Battery Check the condition of battery Refer to Inspection of battery in chapter 3 Vo...

Page 113: ...the wire coupling for entire lighting system Refer to Diagram PASS Check the returning condition of each lighting system Refer to Inspection of lighting system FAIL If the lamp switch fails replace t...

Page 114: ...or yel low terminal 2 Multimeter black terminal 3 A When switch is in LOW position B When switch is in HI position Turn main switch to ON position Turn lamp switch to LOW or HI position Check the vol...

Page 115: ...ltimeter blue terminal 1 Multimeter black terminal 2 Turn main switch to ON position Turn lamp switch to LOW or HI position Check the voltage of blue wire in coupler of bulb socket 12V PASS No failure...

Page 116: ...e shooting 1 Seat 2 Front frame 3 Front pedal Use specific tools for troubleshooting 1 Safety Refer to Inspection of switch PASS 2 Battery Check the condition of the battery Refer to Inspection of bat...

Page 117: ...h PASS 4 Coupling of wires Check the coupling of whole signal system wires Refer to Diagram of wires PASS Check the condition of each signal system Refer to Inspection of signal system FAIL Replace ma...

Page 118: ...Connect pocket tester DC 20V to the tail lamp terminal Pocket tester blue terminal 2 Pocket tester black terminal 1 Adjust main switch to ON position Check voltage 12V Meet specification No failure o...

Page 119: ...imeter DC 20V to the taillight terminal Multimeter blue terminal 2 Multimeter black blue terminal 1 Adjust main switch ON position Check the volts 12V Meet specification No failure on this circuit No...

Page 120: ...er DC 20V to the tail lamp terminal Pocket tester blue terminal 1 Pocket tester black terminal 2 Adjust main switch to ON position Check voltage 12V Meet specification No failure on this circuit No el...

Page 121: ...ve Exhaust pipe 1 2 Remove Silencer 2 4 Carburetor and air intake pipe Place the throttle cock grip on OFF position and remove Throttle cable 1 Fuel line 2 Clip 3 Carburetor carburetor seat and hook h...

Page 122: ...neto wire 1 Reverse switch wire 2 Neutral switch wire 3 Air pipe 4 7 Disassembly of engine 1 Remove Bolt 1 top supporting of engine Bolt 2 bottom supporting of engine Bolt 3 rear upper supporting of e...

Page 123: ...ntying the knot 3 pull out the rope long enough to tie a knot to avoid to be pulled into the cap 46 Remove Screw pin 1 Guide plate 1 Compressing spring 3 Circlip 4 Driving jaw 5 Torsion spring 6 47 Re...

Page 124: ...123 1 2 3 2 Remove Shifter linkage rod 1 Pay attention not to lose washer 3 Remove Cam sprocket cover 1 4 Remove Spark plug 1 Upper valve cap intake 2 Lower valve cap exhaust 3 1...

Page 125: ...ratchet 4 Use a wire to hold chain so the timing chain does not drop into crankcase 7 Remove All the bolts and nut on the cylinder cover CAUTION Loosen every bolt and nut by circle then disas semble...

Page 126: ...assembling the piston pin circlip cover the crankcase with a clean cloth to avoid the circlip suddenly dropping into the case Before disassembling the piston pin remove the burr of circlip groove and...

Page 127: ...Internal yoke for tension spring 3 Tension spring 4 13 Remove Starting ratchet 1 CAUTION Fix the starting ratchet with special tool and loosen the bolt on the starting ratchet 14 Remove Left crankcase...

Page 128: ...se cover 1 Dowel pin Intermediate gear shaft 3 key way Washer Duplex intermediate gear 5 Oil pump protective plate 6 Counter balance gear 7 18 Remove Oil pump 19 Remove Upper timing chain guide 1 Timi...

Page 129: ...utput shaft 1 Drive chain 2 Washer Input shaft drive 3 Slider 4 Forward gear 5 Needle bearing 6 Washer 23 Remove Main drive gear 1 Bearing retainer 2 Bearing 3 Bearing housing 4 snap ring Output drive...

Page 130: ...129 25 Remove CVT cover 1 Clutch support bracket 2 Secondary clutch 3 Primary clutch 4 Primary clutch sleeve 5 V belt 6 CVT rear cover 7 1 2 3 3 4 4 6 4 7...

Page 131: ...emove Seal 1 Snap ring 2 Output Shaft 3 28 Remove Lock nut 1 One way clutch bearing 2 Clutch 3 40 Remove Stop plate 2 Pressing plate 3 CAUTION Knock the locking part 1 of stop plate flat 1 before remo...

Page 132: ...t then pull out the rocker 43 Remove Valve lock clip 1 CAUTION Disassemble the valve lock clip with valve spring compressing device 44 Remove Valve outer spring 1 Valve inner spring 2 Valve 3 Valve lo...

Page 133: ...ace or replace if unqualified 2 Intake and exhaust valve 1 Check Valve surface Valve rod end Replace it if it is worn exfoliation corroded or unqualified 2 Check Valve rod end 1 Replace the valve valv...

Page 134: ...nner diameter gauge 1 CAUTION When replacing the valve replace the valve guide pipe and valve rod oil seal together 3 Valve guide pipe 1 Check Valve guide pipe Replace it if it is worn or the oil leak...

Page 135: ...Regrind the valve race after installing valve guide pipe 4 Valve race 1 Clean Carbon deposit valve race and valve face 2 Check Valve seat ring Regrind the valve race if it is exfoliation corroded 3 M...

Page 136: ...e too narrow or not in the middle it is necessary to correct valve race 4 Correct Valve race Use reamers of 30 45 and 60 CAUTION Rotate the reamer with even force to avoid cutting mark And remove surp...

Page 137: ...amer 45 contacting width 1 0mm 0 04in D The contacting part is too narrow and on bottom of valve Reamer assy of valve rale Result USE Use reamer of 60 first Make the contracting part in Reamer of 45 t...

Page 138: ...lightly when rotating the valve forward and backward Be sure to clean all the dirt on the valve face and valve race after every grinding 6 Measure the contacting width again after correcting and grind...

Page 139: ...nd outer spring totally 6 Seal check of valve 1 Installation of valve Lubricate Valve rod part 1 Valve rod oil seal 2 Install Valve spring seat 1 lower part Oil seal of valve rod 2 Valve 3 Inner sprin...

Page 140: ...nd exhaust way respectively Check the valve seal There should be no leakage on valve race 2 3 Regrinding procedure Remove components of the cylinder cover again Grind repeatedly with fine grinding pow...

Page 141: ...tion cam If ever worn replace it 2 Check Rocker shaft surface Replace or check lubrication if there are dents scratches or discoloration 3 Measure Measure inner diameter of valve rocker hole Replace i...

Page 142: ...heck Timing chain Replace it if the chain is stretched or not flexible or broken 10 Timing sprocket and crankshaft sprocket Check Timing chain Crankshaft sprocket on crankshaft If there is wear and da...

Page 143: ...f the operation is inflexible replace chain tensioner 13 Valve cover and sprocket cabinet cover 1 Check Valve cover upper valve cover 1 and lower valve cover 2 Sprocket cabinet cover 3 O ring 4 Replac...

Page 144: ...cylinder C Piston lower part diameter P If out of specification hone or replace the cyl inder and replace the piston and piston ring as a set at the same time 15 Piston ring and piston pin Piston rin...

Page 145: ...0 8in then pull the pis ton ring with piston top to make it vertical with cylinder wall Use feeler gauge 1 If out of specification replace a set of ring Closed clearance Standard Limit Piston 0 15 0...

Page 146: ...r assy 3 Contact surface of overrunning clutch 4 Bimetallic bushing 5 If scraped worn or damaged replace duplex intermediate gear intermediate gear axle electric starting gear assy as a set 2 Inspecti...

Page 147: ...ection Clutch case assy 1 inner surface Abrasion wear or damaged replace it Single direction 2 inside the clutch case assy If scraped worn or damaged replace it 2 Inspection the operation of single di...

Page 148: ...Roll the fork shaft on a plane If bent replace it WARNING Never attempt to straighten a bent fork shaft 3 Inspection Movement of fork on the fork shaft 1 If not smooth in operation replace fork or fo...

Page 149: ...clip and washer Inspection Circlip Washer If damaged loose or bent replace it 29 Crankcase 1 Clean crankcase with soft agent completely 2 Clean all sealing surfaces and closing surfaces completely 3 I...

Page 150: ...3 Cracks damage replace it 31 Output Mechanism 1 Inspection All gears 1 If pressing mark abrasion wear is found replace it Connecting jaw 2 If pressing mark abrasion wear is found replace it Driving...

Page 151: ...bent shaft and reuse it 6 Inspection Flexibility of fork movement Install the reverse fork 1 to fork shaft if not active or smooth in operation replace fork and fork shaft 7 Inspection Reverse control...

Page 152: ...in 5 Initiative gear clamp plate 6 Circlip 7 Woodruff key 8 Washer 9 Bolt M10x40 10 Bearing Section 3 Assembly and Adjustment of Engine 11 Seal ring sheath 12 Seal ring 13 Nut M16 14 Balanced shaft 15...

Page 153: ...l seal 7 Seal o ring 8 Middle shaft 9 Bearing 10 Bearing 11 Chain with gear type 12 Output shaft 13 Circlip 14 Driven gear 15 Pin 16 Cirlcip 17 Rolled needle bearing 18 Gearshift arm comp 19 Fuel seal...

Page 154: ...Bearing 16010 5 Fuel seal SD32x66x8 6 Circlip 75 5 7 Circlip 49 8 Bearing seat seal cushion 9 Flange bolt mx 10 One way machine 11 Nut M22 12 Sliding sheath 13 Trigonometry belt 14 Drive plate 15 CVT...

Page 155: ...earing 18 Nut 19 Rear cover 20 O ring 21 Bolt M8x15 22 Reverse fork 23 Compressing spring 24 Steel ball 6 35G100b 25 Reverse fork shaft 26 Reverse control lever assy 27 Reverse operating shaft 28 Circ...

Page 156: ...le 4 Double wheel 5 Woodruff key 6 Washer 7 Electric starting gear assy 8 Electric starting clutch 9 Roller 10 Spring cover 11 Spring 12 Timing chain 13 Up guide plate assembly 14 Magneto rotor 15 Mag...

Page 157: ...1 5 Valve locking 6 Valve spring cover 7 Valve recoil sealing 8 Valve spring 9 Valve outer spring 10 Valve spring seal 11 Inlet valve 12 Bolt M6x12 13 Locking plate 14 Clamp plate 15 Rolling bearing 6...

Page 158: ...nut 12 Washer 25 O ring 26 Screw M6x18 06025 29 Chain tensioner 30 Tensioner washer 31 Upper guide plate assembly 32 Bolt 95026 06014 33 Bolt M10V1 25x25 34 Washer 35 Timing sprocket wheel 36 Lower g...

Page 159: ...d 2 1 Cylinder body assembly 2 Screw M6 x 25 10 9 3 Cylinder body gasket 4 Locating pin 99530 14016 5 O ring 6 Piston ring 1 7 Piston ring 2 8 Oil ring subassembly 9 Circlip 10 Piston 11 Piston Pin 12...

Page 160: ...159 Installation Attach gear and shaft to bracket using circlip 1 2 3...

Page 161: ...160 Mount bracket 4 to crankcase 5 using M8 bolts 3 Torque of bolt 23Nm 17ft lbs Install internal drive gear 1 Install reverse shaft 9 using circlip 6 seal 5 and washer 4 6 8 9 7 1 2 5 4 3...

Page 162: ...161 Install oil screen 1 using M6 bolts 2 Torque of bolts 10Nm 7ft lbs Mount balanced shaft 3 2 1 3 2 1...

Page 163: ...162 Attach shifting fork 1 to gear Install crank chain 2 Install crankshaft 1 Attach right crankcase 5 to left crankcase 4 using silicon as sealent 5 1 4 2 1...

Page 164: ...163 Outside of right crankcase Attach clutch plates to right crankcase using one way bearing 2 2...

Page 165: ...164 Use gasket 1 when installing cover 2 Use circlip 4 to hold in bearing Mount cover 2 using M8 bolts 3 Torque of bolts 23Nm 17ft lbs 3 2 2 1 4 5...

Page 166: ...sure pieces are used in this order Mount rear cover 1 using M10 bolts Torque of bolts 45Nm 33ft lbs Make sure to use all shims 2 four on each side Mount u joint using M12 nut Torque of nut 80Nm 59ft...

Page 167: ...universal joint 1 using circlips 2 Mount oil pump gear 3 using M6 bolts 4 Torque of bolts 10Nm 7ft lbs Install timing chain guard 5 Install timing chain 6 make sure to feed chain 6 onto sprocket 7 2...

Page 168: ...167 Mount gear 3 in crankcase Install pin 2 and spring 1 in gear 3 Install piston 6 using piston pin 5 and clips 7 Install piston rings 4 on piston 6 3 1 2 6 5 4 7...

Page 169: ...168 Install gearshift connector 1 assembly to crankcase Mount starter motor 2 using M8 bolts 3 Mount cylinder 5 using base gasket 4 2 3 5 4 1...

Page 170: ...169 Valve inner spring outer spring valve locking clips Install camshaft 1 using bracket 3 and M6 bolts 2 Torque of bolts 10Nm 7ft lbs 1 1 2 3...

Page 171: ...170 Install rocker arms 1 in cylinder head 2 Install cylinder head 2 using M10 bolts 3 Torque ob bolts 45Nm 33ft lbs Attach valve covers 5 using M6 bolts 4 Torque of bolts 10Nm 7ft lbs 1 2 2 3 4 5...

Page 172: ...ifold 1 using M6 bolts 2 Torque of bolts 10Nm 7ft lbs Mount timing sprocket 3 using bracket and M8 bolts 4 Torque of bolts 23Nm 17ft lbs Attach timing chain cover using M8 bolts Torque of bolts 23Nm 1...

Page 173: ...lts 10Nm 7ft lbs Install spring 2 using M10 bolt 1 Torque of bolts 45Nm 33ft lbs Install flywheel gear 5 on crankshaft Make sure to use a gasket 6 when installing left crankcas cover Attach flywheel 7...

Page 174: ...173 Mount left crankcase cover 1 using M10 bolts 2 Torque bolts 45Nm 33ft lbs Mount recoil ratchet 3 to crankcase cover 2 Attach pull starter 5 using M8 bolts 4 Torque of bolts 23Nm 17ft lbs 1 2 3 5 4...

Page 175: ...174 Install oil filter 1 below pullstarter Install inside right crankcase cover 2 1 2...

Page 176: ...175 Install drive 2 and driven pulleys 1 Install holding plate 4 using M8 bolts 3 Install right crankcase cover 5 using M8 bolts 6 Torque of bolts 10Nm 7ft lbs 1 2 3 4 5 6...

Page 177: ...ylinder head washer is damaged Cylinder body is worn or damaged Trouble CAUTION Please refer to relevant contents for the in spection adjustment and replacement of parts I Starting trouble difficulty...

Page 178: ...Fork is worn 3 Shifting cam Recess of shifting cam is worn 2 Piston and piston ring Improper piston ring installation Piston rings are worn and out of elasticity Piston rings are damaged Piston is dam...

Page 179: ...lebar is bent 2 Steering system Wrong toe in Steering pillar is bent 4 Driving system Claw of gear end is down V Clutch slips 1 Clutch Improper adjustment of clamp plate release rod clearance of clutc...

Page 180: ...big 5 Frame Bent Damaged frame 6 Rear wheel fork Bearing is damaged or worn Rear wheel fork is bent or damaged X Lighting System 1 Headlight malfunction Bulb is damaged Weight capacity exceeded Chargi...

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Baja WD400U, Service Manual

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Summary of Contents for WD400U

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