Baja WD400U-2 Owner's manual

MinimumAgeRequirement 16

For MoreinformationonATVSafety Contact

the BajaATVSafetyHotlineat: 866-260-8630

REV.B (US)

012809

Always weara helmet; itcouldsaveyour life!

Donot removethis operator'smanualfrom this vehicle,according to guide-

lines with the U.S.ConsumerProduct SafetyCommission.

Pleaseobtain,review and follow provincial/municipalgovernmentsactsand

regulations pertainingto owningand operatinganoff-roadvehicle.

"YOURATVCAN BEHAZARDOUSTO OPERATE.A

collisionor rollovercanoccur quickly,evenduring

routinemaneuverssuchas turningand drivingon hillsor

over obstacles,ifyou fail to takeproperprecautions.

Foryoursafety,understandandfollow allthe warnings

containedin this owner'smanualandthe labelsonyour

vehicle.Failureto follow thesewarningcan resultin

SEVERINJURYOR DEATH.

Keeptheowner'smanualwithyourvehicleatall times."

Failuretofollow theagerecommendationsfor thisATV.

Failuretosupervisechildrenunder16onATVmodelsintendedfor theiruse.

UsebychildrenofATVsthatarenotrecommendedfor theiragecanleadtosevere

injuryor deathofthechild.

Eventhougha childmaybewithintheagegroupfor whichanATVisrecommended

heorshemaynothavetheskills,abilities,orjudgementneededtooperatetheATV

safelyandmaybeinvolvedina seriousaccident.

CategoryY (YouthModel)ATV.AnATVof appropriatesizeintendedfor recreational

useunderadultsupervisionbyanoperatorunderage16.YouthmodelATVscan

further becategorizedasfollows:

CategoryY-6+ATV.ACategoryY-6+ATVisayouthmodelATVthatisintendedfor

usebychildrenage6or older

CategoryY-10+ATV.A CategoryY-10+ATVisa youthmodelATVthatisintendedfor

usebychildrenage10or older.

CategoryY-12+ATV.A CategoryY-12+ATVisa youthmodelATVthatisintendedfor

usebychildrenage12or older.

CategoryT(TransitionalModel)ATV.ACategoryTATVisanATVofappropriate

sizethatisintendedfor recreationalusebyanoperatorage14orolderunderadult

supervision,or byanoperatorage16orolder.

Motorsports

Congratulationson yourpurchaseoftheBajaInc.WD400U-2ATV.

ThisATVis guaranteedtobefreeof manufacturingdefects in

materialandworkmanshipfor a periodof90daysfrom thedateof

purchase.DuringthewarrantyperiodBAJAINC.willat itsoption,

repair,providereplacementpartsor replaceyourBajaInc.400cc

ATVat no charge.Thiswarrantydoesnot covernormalwearitems

or damagecausedbyneglectormisuseoftheproduct.

EngineWarranty- 90 days

FrameWarranty- 90days

Warrantyisvoidif:

Frameisbentor brokenduetoabuse

Thewheelsarebentor broken

Fenderbentorbrokenduetoabuse

Anysignof impact,accident,jumping,spin-outsor rollover.

BAJAMOTORSPORTSis notliablefor anydamageclaimor

liabilityclaimpersonalorotherwiseresultingfrom theoperationof

thisproductin anyway.

Shouldyouexperiencea problemwithyourvehicle,pleasecallBajaInc.

customerservicelinetollfreeat 1-888-863-2252betweenthehoursof

7amand5proMondaythroughFridayMST(MountainStandardTime).

MDT(MountainDaylightTime)duringthedaylightsavingtime.Youwillbe

instructedhowtoproceed.

A COPYOFTHESALESRECEIPTISREQUIRED.

III

Thismanualshould beconsideredasa permanent

partof thevehicle andshould remainwiththe

vehiclewhen resoldorotherwisetransferredto

a newowneror operator. The manualcontains

importantsafety informationand instructions

whichshouldbe readcarefullybeforeoperatingthe

vehicle.

The engineexhaustfrom this productcontains

chemicalsknownto the Stateof Californiato cause

cancer,birthdefectsorother reproductiveharm.

CALIFORNIAPROPOSITION65

IV

TableofContents

IMPORTANT........................................................................................................3

FOREWORD........................................................................................................3

NOTICETOTHEUSER.......................................................................................4

BAJAINC.WD400U-2ATV.................................................................................8

FUELANDOIL.....................................................................................................9

LOCATIONOFWARNINGLABELS...................................................................10

INDICATORLIGHTS............................................................................................12

HANDLEBAR&SWITCH....................................................................................13

LEFTHANDLEBAR.....................................................................................13

RIGHTHANDLEBAR...................................................................................14

REARFOOTBRAKE..................................................................................14

FUELVALVE................................................................................................15

FUELTANKCAP.........................................................................................15

SEATLOCK.................................................................................................16

RIDINGYOURATV..............................................................................................17

BEFORERIDING.........................................................................................17

INSPECTIONBEFORERIDING..................................................................18

SAFETYGEAR............................................................................................20

BREAK-IN....................................................................................................21

STARTINGTHEENGINE.............................................................................25

STARTINGOFF...........................................................................................26

MANUALPULLSTART...............................................................................27

DRIVESELECT.............................................................................................28

2WD/4WDBUTTON.....................................................................................29

BRAKING.....................................................................................................30

TURNING.....................................................................................................31

OPERATIONONHILLS...............................................................................32

RIDINGOVEROBSTACLES.......................................................................35

SKIDDINGORSLIDING..............................................................................36

RIDINGTHROUGHWATER........................................................................37

RIDINGIN COLDWEATHER......................................................................38

DRESSINGFORCOLDWEATHERRIDING...............................................39

RIDINGONSNOWORICE.........................................................................40

ACCESSORYUSEANDVEHICLELOADING....................................................41

INSPECTIONAND MAINTENANCE...................................................................43

TOOLS.........................................................................................................45

SPARKPLUG..............................................................................................45

VALVEINSPECTION.......................................................................................47

BATTERYINSTALLATION..........................................................................48

FUSEREPLACEMENT................................................................................52

TableofContents

HEADLIGHT/TAILLIGHTREPLACEMENT.................................................52

THROTTLELEVERADJUSTMENT............................................................53

IDLESPEEDADJUSTMENT.......................................................................54

FUELHOSE.................................................................................................54

ENGINEOIL/OILFILTER.............................................................................55

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

FRONT/REARGEARCASELUBRICATION..............................................60

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

FRONTDISKBRAKES...............................................................................64

REARDRUMBRAKE.................................................................................64

MUFFLER/SPARKARRESTER..................................................................66

OILCOOLERCLEANINGPROCEDURE....................................................68

GENERALLUBRICATION...........................................................................70

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

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

CLEANINGPROCEDURE...................................................................................75

STORAGEPROCEDURE....................................................................................77

SERIALNUMBERLOCATION............................................................................78

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

EMISSIONSYSTEMCONTROLWARRANTY....................................................

Pleasereadthismanualandfollow all instructionscarefully.Toemphasize

thespecialinformation,thesymbolAandthewordsWARNINGor CAUTION

havesomespecialmeanings.Paygreatattentiontothemessages.

Indicatesa potentialhazardthatcouldresultindeathor injury.

-& CAUTION

Indicatesa potentialhazardthatcouldresultinvehicledamage.

NOTE:Indicatingspecialinformationwhichistomakemaintenanceeasieror

instructionsclearer.

WARNINGandCAUTIONarearrangedlikethis:

Thefirst partwillidentify a POTENTIALHAZARD.

ThesecondpartwilldescribeWHATCOULDHAPPENifyou ignore

theWARNINGor CAUTION.

ThethirdpartwilldescribeHOWTOAVOIDTHEHAZARD.

Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.

Readitcarefullybeforeriding. Failingtofollow thewarningscontainedin this

manualcouldresultinINJURYor DEATH.

Itis importantthatthis manualremainwiththevehiclewhenyoutransferitto

anotheruserorowner.

Allinformation,illustrations,photographsandspecificationscontainedin

thismanualarebasedonthe latestproductinformationavailableatthetime

ofpublication.Dueto improvementsorotherchanges,therewillbesome

discrepanciesinthismanual.Wereservetherighttomakeproductchanges

atanytime,withoutnoticeandwithoutincurringanyobligationtomakethe

sameorsimilarchangestothevehiclepreviouslybuiltor sold.

Webelieveinconservationandprotectionoftheearth'snaturalresources.We

encourageeveryvehicleownerandoperatortodothesamebyobeyingposted

signsandridingonlyinareasdesignatedandapprovedforoff-roadrecreational

use.

NOTICETO PARENTS

ThisATVisbuiltfor usebychildrenage16andolder,buttheusersmanualis

writtenfor adultswhowillbesupervisingthechildren,we stronglyrecommend,

therefore,thatyoureviewthisentiremanualwithyourchildandcarefullyexplain

the instructions,requirements,andwarningsitcontainssothatyourchildcan

understandthem.

Childrendifferinskills,physicalabilities,andjudgement.Somechildrenmaynot

beabletooperateanATVsafely.Parentsshouldsupervisetheirchild'suseof the

ATVatalltimes. Parentsshouldpermitcontinueduseonlyiftheydeterminethat

thechildhastheabilitytooperatetheATVsafely.

ItisveryimportantthateverychildwhoridestheATVshouldcompletea training

course.

THIS ATV ISNOT A TOY AND COULD BE HAZARDOUS TO OPERATE. AnATV

handles differently from other vehicles including motorcycles and cars. A collision

or rollover can occur quickly, even during routine maneuvers such as turning and

driving on hills or over obstacles, if you fail to take proper precautions.

SEVEREINJURYORDEATHcanresultifyou donotfollow theseinstructions:

Readthismanualandalllabelscarefullyandfollow theoperatingprocedures

described.

NeveroperateanATVwithoutproperinstruction.Takea traininqcourse.

Beginnershouldreceivetrainingfrom a certifiedinstructor.Contactan

authorizedATVdealeror call SVIAat 1-800-887-2887to find outaboutthe

trainingcoursesnearestyou.

Alwaysfollow theseagerecommendations:

CategoryY (YouthModel)ATV.AnATVofappropriatesize intendedfor recreational

useunderadultsupervisionbyanoperatorunderage16.YouthmodelATVscan

further becategorizedasfollows:

CategoryY-6+ATV.A CategoryY-6+ATVisa youthmodelATVthatisintendedfor

usebychildrenage6or older

CategoryY-10+ATV.ACategoryY-10+ATVisayouthmodelATVthatisintended

for usebychildrenage10or older.

CategoryY-12+ATV.ACategoryY-12+ATVisayouthmodelATVthatisintended

for usebychildrenage12or older.

CategoryT(TransitionalModel)ATV.A CategoryTATVisanATVofappropriate

sizethatisintendedfor recreationalusebyanoperatorage14orolderunderadult

supervision,or byanoperatorage16orolder.

Neverallowa childunderage16tooperateanATVwithoutadultsupervision,

andneverallowcontinueduseofanATVbya childifheor shedoesnothave

theabilitiestooperateitsafely.

Nevercarrya passengeron anATV.

NeveroperateanATVon anypavedsurfaces,includingsidewalks,driveways,

parkinglotsandstreets.

NeveroperateanATVon anypublicstreet,roador highway,evena dirtor

gravelone.

NeveroperateanATVwithoutwearinganapprovedmotorcyclehelmetthat

fits properly.Youshouldalsoweareyeprotection(gogglesorface shield),

gloves,boots,long-sleevedshirtorjacket,andlongpants.

NeverconsumealcoholordrugsbeforeorwhileoperatingthisATV.

NeveroperatethisATVat excessivespeeds.Alwaysgo ata speedthatis

properfor theterrain,visibilityandoperatingconditions,andyourexperience.

Neverattemptwheelies,jumps,or otherstunts.

AlwaysinspectyourATVeachtimeyouuseittomakesureitisin safe

operatingcondition.Alwaysfollow theinspectionandmaintenance

proceduresandschedulesdescribedin thismanual.

Alwayskeepbothhandsonthehandlebarsandbothfeet on thefootrestsof

theATVduringoperation.

Alwaysgoslowlyandbeextracarefulwhenoperatingon unfamiliarterrain.

AlwaysbealerttochangingterrainconditionswhenoperatingtheATV.

Neveroperateonexcessivelyrough,slipperyor looseterrainuntilyouhave

learnedandpracticedtheskillsnecessarytocontroltheATVonsuchterrain.

Alwaysbeespeciallycautiousonthesekindsofterrain.

Alwaysfollow properproceduresfor turningas describedinthismanual.

Practiceturningat lowspeedsbeforeattemptingtoturnat fasterspeeds.Do

notturnat excessivespeeds.

NeveroperatethatATVonhillstoosteepfor theATVorfor yourabilities.

Practiceonsmallerhillsbeforeattemptinglargerhills.

Alwaysfollow properproceduresfor climbinghillsas describedinthis

manual.Checktheterraincarefullybeforeyoustartupanyhill.Neverclimb

hillswithexcessivelyslipperor loosesurfaces.Shiftyouweightforward.

Neveropenthethrottlesuddenlyor makesuddengearchanges.Nevergo

overthetopofanyhillat highspeed.

Alwaysfollow properproceduresfor goingdownhillsandfor brakingonhills

asdescribedinthismanual.Checktheterraincarefullybeforeyoustartdown

anyhill.Shiftyourweightbackward.Nevergodowna hillat highspeed.Avoid

goingdowna hillat ananglethatwouldcausethevehicletoleansharplyto

oneside.Gostraightdownthehillwherepossible.

Alwaysfollow properproceduresfor crossingthesideofa hillas described

inthismanual.Avoidhillswithexcessivelyslipperyor loosesurfaces.Shift

yourweighttotheuphillsideoftheATV.NeverattempttoturntheATVaround

onanyhilluntilyouhavemasteredtheturningtechniquedescribedinthis

manualon levelground.Avoidcrossingthesideof a steephillif possible.

Alwaysuseproperproceduresifyoustallorrollbackwardswhenclimbing

a hill. Toavoidstalling,usepropergearandmaintaina steadyspeedwhen

climbinga hill.Ifyoustallorroll backwards,follow thespecialprocedurefor

brakingdescribedinthismanual.Dismounton theuphillsideor toaside

ifpointedstraightuphill.TurntheATVaroundandremount,following the

proceduredescribedinthismanual.

Alwayscheckfor obstaclesbeforeoperatingina newarea.Neverattempt

tooperateoverlargeobstacles,suchas largerocksor fallentrees.Always

follow properprocedureswhenoperatingoverobstaclesasdescribedin this

manual.

Alwaysbecarefulwhenskiddingor sliding. Learntosafelycontrolskidding

orslidingbypracticingat lowspeedsandon level,smoothterrain. On

extremelyslipperysurfaces,suchasice,goslowlyandbeverycautiousin

ordertoreducethechanceofskiddingor slidingout ofcontrol.

NeveroperateanATVinfast flowing wateror inwaterdeeperthanthat

specifiedinthismanual. Rememberthatwet brakesmayhavereduced

stoppingability.Testyourbrakesafterleavingwater. Ifnecessary,apply

themseveraltimestoletfriction dryoutthelinings.

Alwaysusethesizeandtypetiresspecifiedinthismanual.Alwaysmaintain

propertirepressureasdescribedinthismanual.

NevermodifyanATVthroughimproperinstallationoruseofaccessories.

Neverexceedthestatedloadcapacityfor anATV.Cargoshouldbeproperly

distributedandsecurelyattached.Reducespeedandfollow instructionsin

thismanualfor carryingcargo.Allowgreaterdistancefor braking.

Thecombinedweightoftheriderandanyaccessoriesorcargomustnever

exceedthevehicle'sloadcapacityof463 Ibs(210kg).

Donottowa trailer.Thisvehicleisnotdesignedfor suchuse.

FORMOREINFORMATIONABOUTATVSAFETY,callthe ConsumerProductSafety

Commissionat 1-800-638-2772,SVIA1-800-887-2877,or BajaSafetyHotlineat

1-866-260-8630

WD400U-2

Two/Fourwheel

transforming button

Fuelvalve

Manual pull start

Headlight

Taillight

Front tire

Oil fill

plug

Rearshock

[Left]

Rear luggage

carrier

Seat cushion

Fuel

cap

Front luggage

carrier

Exhaust

silencer

bumper

Front

shocks

Reartire

Brake pedal

[Right]

FUELAND OIL

FUEL

Theproperfuel is very important for theengine. Ensurethatthere is no

dust,dirt,or waterwhichhasmixedinthefuel. Pleaseuseregularunleaded

gasoline

ENGINEOIL

Your400ccATVhasa four-stroke engine.Pleaseuseoilasdescribedin the

chartbelow. Byusingtheprescribeoil,youwillrealizethebestlubricationfor

theengine.

ENGINE

I

TEMP,

°C -30 -20 -10 0 10 20 30 40

°F -22 -4 14 32 50 68 86 104

Usethechartto selectaviscosityratingbasedonthetemperaturerangein

yourarea.

LOCATIONOF WARNINGLABELS

Readandfollow allofthewarnings labels onyourATV. Makesureyou

understandallthelabels. KeepthelabelsontheATV.Donotremovethem

for anyreason.Ifa labelcomesoffor becomesdifficultto read,youshould

geta replacementbycontactingBajaMotorsports.

10

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE AN NEVER USE NEVER CARRY NEVER USE

APPROVED HELMET ON PUBLIC PASSENGERS WITH DRUGS

AND PROTECTIVE ROADS OR ALCOHOL

GEAR

NEVER OPERATE :

• Without proper training or instruction.

• At speeds too fast for your skills or the condition.

• On 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

overturns on hills and rough terrain and in turns.

• Avoid paved surfaces-pavement may seriously affect

handling and control.

LOCATE AND READ OWNER'S MANUAL CAREFULLY BEFORE OPERATING.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

Operation of the ATV by children under

the age of 16 increases the risk of severe

injury or death.

NEVER permit children under age 16

-- to operate thisATV.

NEVER rideas a passenger.

Passenger can cause a loss

of control, resulting in

SEVERE INJURY or DEATH.

IMPROPER TIRE PRESSURE OR

OVERLOADING CAN CAUSE LOSS

OF CONTROL.

LOSS OF CONTROL CAN RESULT

IN SEVERE INJURY OR DEATH.

COLD TIRE PRESSURE:

Recommended: Front 5psi, Rear 5psi

Never set tire pressure below the

recommended level. It could cause the tire to

dislodge from the rim.

LOADING

Maximum vehicle capacity is: 210Kg (463 Ibs.)

Maximum capacity includes theweight of the

operator, cargo, and accessories plus theveritcal

weight on trailer hitch.

11

INDICATORLIGHTS

Headlight Fan

Kilometers/ Milesperhour

hour

FourWheelDrive

NeutralLight Indicator

Indicator

Km/htomphbutton OilTemperature

warning

ReverseLight

Indicator

Reverse light indicator-LightwillilluminatewhentheATVisin Reverse.

Neutral lightindicator-LightwillilluminatewhentheATVisin Neutral.

Fourwheel drive indicator-LightwillilluminatewhentheATVis infour

wheeldrive,2WD/4WDbuttonispressedIn.

OilTemperaturewarning- Lightwillilluminatewhenoiltemperatureistoo

hot.Stoptheengineassoonaspossibleandallowenginetocoolfor atleast

10minutes.

Fan-Lightwillilluminatewhenfan is"ON".

Headlight-Lightwillilluminatewhenheadlightsare"ON".

Kilometers/hour-Lightwillilluminatewhenodometerisreadingin kilome-

ters.

Miles per hour- Lightwillilluminatewhenodometerisreadinginmiles.

12

LEFTHANDLEBARSWITCHES

ANDPARKINGBRAKE

Parkit

Lig

On/Off

switch

StartButton

ManualChokelever

Closed Open

Light switch

Whenswitchisinthetop positiontheheadlight,taillightandmeterlightillu-

minates.Whenswitchisinthecenterthetaillightandmeterlightilluminates.

Whenswitchisinthebottompositiontheheadlight,taillightandmeterlight

willNOTcomeon.

On/Offswitch

On.Whentheswitchisplacedinthispositiontheengineison.

Off.Whentheswitchisplacedinthispositiontheengineisoff.

Start Button

Depressstartbuttontostarttheengine.

Manual Choke switch

Whenswitchisleft,thechokeisclosed.Whenswitchisright,thechokeis

open.

Parking Brake

WhentheparkingbrakeissettheATVwillnotbeabletomove. Toset:Hold

brakehandleinandpushparkingbrakedown.

13

RIGHTHANDLEBAR,FRONTBRAKE

LEVERANDTHUMBTHROTTLE

Brakefluid reservoir Frontbrake

lever

Throttlecable

adjustment Throttlelever

2WD/4WDbutton

Throttle lever

ControlsengineandATVspeed.Operatethisleverwithyourthumb.

PushitforwardtoincreaseengineandATVspeed. Releaseitto

decreaseengineandATVspeed.

Front brake lever

Squeezelevertowardhandgriptoapplyfront brakes.

2WD/4WDbutton

WhenthisbuttonisdepressedtheATVisin Fourwheeldrive.When

buttonispressedagain(buttonout), theATVisTwowheeldrive.

OnlypressthisbuttonwhentheATVisstopped.Do notpressthis

buttonwhiletheATVismoving.

Throttlecable adjustment

Removecoverandrotatethrottlecableadjustingscrewtoadjustthe

slackof throttlecable.

REARFOOTBRAKE

Footbrakelocatedontherighthandsideofthe

ATV.Footbrakestopstherearwheels.

14

FUELVALVE

This vehicle hasone manually operatedfuel valve. Thereare3 positions

"ON.... OFF.... RESERVE"

"ON" position (arrowpointing down)

Inthis position,fuel is allowedtoflow into thecarburetorwhenthe

engineis running orbeingstarted.

"OFF" position(arrowpointingleft)

Inthis positionthefuel is shutofffrom the carburetor.Thefuel

valveneedstobeplacedinthis positionwhentheATVisnotin use

"RESERVE"position(arrowpointingup)

If thefuel levelin thefuel tank becomesto low for the engineto

stayrunningwhilethefuelvalveisinthe"ON" position,turn

thefuel valveto"RESERVE". Thiswillallowtheenginetobegin

usingthereservefuel supply.Youwillneedtore-fuelassoonas

possible.Oncere-fueled,turnthevalvebacktothe"ON "Position

FUELTANKCAP

Toopenthefueltank cap,taketheendofthe

vent tubeoutfromthevehiclebody;turnthe

fueltankcapcounterclockwise.Toclosethe

fueltankcap,turnitclockwiseandcloseit

securely.Besurethattheventtubesecurely

connectstothecapasshown

Fuellevel

15

Overfillingthefuel tankcouldbehazardous.

Ifyouoverfillthefuel tank,fuel mayoverflowwhenitexpands.

Expandingisduetoheatfrom engineor sun. Overheatedfuel could

easilycatchfire.

Stopaddingfuel whenthefuel levelreachesthebottomofthefiller

neck.

Improperfueling oftheATVcouldbehazardous.

Failingtofollow safetyprecautionswhenrefuelingcouldresultin a

fire or letyoutobreathetoxicfumes.

Refuelin awellventilatedarea. Makesuretheengineisoffand

avoidspillingfuel on a hotengine.Donotsmoke,andmakesure

therearenoopenflamesor sparksinthearea. Avoidbreathing

gasolinevapors. Keepchildrenandpetsawaywhenyouare

refuelingtheATV.

SEATLOCK

Toremovetheseat,pulltheseatlocklever

up. Raisetherearendoftheseatandslideit

back

Tolocktheseat,slidetheseatleverintoits

retainerandpushdownfirmly.

Improperlyinstallingtheseatcouldbehazardous.

Failingto installtheseatproperlycouldallowtheseattomoveand

causetheriderto losecontrol.

Makesureyouareinproperpositionandtheseatisattached

securelywheninstalled.

16

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