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MinimumAgeRequirement:10
Model:90cc
For MoreinformationonATVSafetyContact
the BajaATVSafetyHotlineat: 866-260-8630
REV.B
012209
Alwayswear a helmet;Itcouldsaveyour Life!
Pleaseobtain,review,andfollowprovincial/ municipalgovernmentactsand
regulationspertainingtoowningandoperatinganoff-roadvehicle.
"YOURATVCAN BEHAZARDOUSTOOPERATE.A
collisionor rollovercanoccurquickly,evenduring
routinemaneuverssuchas turningand drivingon hillsor
over obstacles,ifyou fail to takeproperprecautions.
Foryoursafety,understandandfollow allthe warnings
containedinthis owner'smanualandthe labelson your
vehicle.Failureto follow thesewarningcan resultin
SEVERINJURYOR DEATH.
Keeptheowner'smanualwithyourvehicle at all times."
Failuretofollow theagerecommendationsfor thisATV.
Failuretosupervisechildrenunder16onATVmodelsintendedfor theiruse.
UsebychildrenofATVsthatarenotrecommendedfor theiragecanleadtosevere
injuryordeathofthechild.
Eventhougha childmaybewithintheagegroupfor whichanATVisrecommended
heor shemaynothavetheskills,abilities,orjudgementneededtooperatetheATV
safelyandmaybe involvedina seriousaccident.
CategoryY (YouthModel)ATV.AnATVofappropriatesize intendedfor recreational
useunderadultsupervisionbyanoperatorunderage16.YouthmodelATVscan
further becategorizedasfollows:
CategoryY-6+ATV.ACategoryY-6+ATVisa youthmodelATVthatis intendedfor
usebychildrenage6 orolder
CategoryY-10+ATV.ACategoryY-10+ATVisa youthmodelATVthatis intendedfor
usebychildrenage10or older.
CategoryY-12+ATV.ACategoryY-12+ATVisa youthmodelATVthatis intendedfor
usebychildrenage12or older.
CategoryT (TransitionalModel)ATV.ACategoryTATVisanATVofappropriate
sizethatisintendedfor recreationalusebyanoperatorage14or olderunderadult
supervision,orbyanoperatorage16or older.
Congratulationson yourpurchaseof the WD90ATV.
Itiswarrantedtobefree ofmanufacturingdefectsinthematerialand
workmanshipfor a periodof90 daysfrom thedateofpurchase.Duringthe
warrantyperiodBAJAINC.willat itsoption,repair,providereplacement
partsor replaceyourBAJAINC.90ccATVat nocharge. Thiswarrantydoes
notcovernormalwearitemsor damagecausedbyneglector misuseof the
product.
EngineWarranty- 90days
FrameWarranty- 90 days
Warrantyisvoidif:
Frameisbentor brokenduetoabuse
Wheelsarebentor broken
Fenderbentor brokenduetoabuse
Anysignofimpact,accident,jumping,spin-outsor rollover.
BAJA,INC.isnotliablefor anydamageclaimor liabilityclaimpersonor
otherwiseresultingfrom theoperationofthisproductinanyway.
Shouldyouexperiencea problemwithyourvehicle,pleasecallBajaInc.
customerservicelinetollfreeat 1-888-863-2252betweenthehoursof
7amand5proMondaythroughFridayMST(MountainStandardTime).
MDT(MountainDaylightTime)duringthedaylightsavingtime.Youwillbe
instructedhowtoproceed.
ACOPYOFTHESALESRECEIPTIS REQUIRED.
This manual should be consideredas a permanent part
of thevehicle and should remain with the vehicle when
resold or otherwisetransferredto a new useror operator.
The manual contains importantsafety informationand
instructionswhichshould be readcarefully before
operatingthe vehicle.
The engineexhaust from this productcontains chemicals
knownto the State of California to cause cancer,birth
defects or other reproductiveharm.
CALIFORNIA PROPOSITION65
IV
SAFETY...............................................................................................................3
IMPORTANT........................................................................................................3
NOTICETOTHEUSER.......................................................................................4
ATV90..................................................................................................................8
FUELANDOIL.....................................................................................................9
LOCATIONOFLABELS......................................................................................10
CONTROLFUNCTIONS......................................................................................13
LEFTHANDLEBAR.....................................................................................13
RIGHTHANDLEBAR...................................................................................13
FUELVALVE................................................................................................14
FUELTANKCAP.........................................................................................14
SEATLOCK.................................................................................................15
REMOTESTOPLANYARD..........................................................................16
RIDINGYOURATV..............................................................................................17
WHATYOUSHOULDKNOWBEFORERIDING........................................17
INSPECTIONBEFORERIDING..................................................................18
BREAK-IN....................................................................................................19
STARTINGTHEENGINE.............................................................................20
SAFETYGEAR............................................................................................24
STARTINGOFF...........................................................................................26
BRAKING.....................................................................................................27
TURNING.....................................................................................................28
OPERATIONONHILLS...............................................................................29
CLIMBINGHILLS...........................................................................29
DESCENDINGA HILL ...................................................................30
RIDINGOVEROBSTACLES.......................................................................32
SKIDDINGORSLIDING..............................................................................33
RIDINGTHROUGHWATER........................................................................34
RIDINGIN COLDWEATHER......................................................................35
DRESSINGFORCOLDWEATHERRIDING..................................36
RIDINGYOUATVONSNOWANDICE.........................................37
ACCESSORYUSEANDVEHICLELOADING....................................................39
INSPECTIONANDMAINTENANCE...................................................................40
MAINTENANCESCHEDULE......................................................................40
TOOLS.........................................................................................................42
SPARKPLUG..............................................................................................42
VALVEINSPECTION....................................................................................43
BATTERYINSTALLATION..........................................................................44
ENGINESPEEDGOVERNOR.....................................................................48
THROTTLELEVERADJUSTMENT............................................................50
IDLESPEEDADJUSTMENT.......................................................................51
FUELHOSE.................................................................................................51
ENGINEOIL.................................................................................................52
CHANGINGENGINEOIL...............................................................53
AIR FILTER..................................................................................................54
REMOVAL.......................................................................................55
WASHINGTHEELEMENT.............................................................55
DRIVECHAIN/SPROCKETS.......................................................................57
DRIVECHAINCLEANING,OILINGANDADJUSTING..............................58
TIRES...........................................................................................................59
BRAKING.....................................................................................................62
FRONTDRUMBRAKES.....................................................................62
REARHYDRAULICDISCBRAKEAND PARKINGBRAKE..............63
GENERALLUBRICATION...........................................................................64
TROUBLESHOOTING.........................................................................................65
FUELSUPPLYCHECK...............................................................................65
IGNITIONSYSTEMCHECK........................................................................66
TRANSPORTING.................................................................................................67
CLEANINGPROCEDURE...................................................................................68
PREPARATIONFORCLEANING................................................................68
WASHINGYOURATV.................................................................................69
STORAGEPROCEDURE....................................................................................70
SERIALNUMBERLOCATION............................................................................71
SPECIFICATIONS................................................................................................72
WIREDIAGRAM...................................................................................................73
EMISSIONCONTROLSYSTEMWARRANTY.....................................................74
Pleasereadthismanualandfollow all instructionscarefully.Toemphasizethe
specialinformation,thesymbol-_ andthewordsWARNINGor CAUTIONhave
somespecialmeanings.Payattentiontothemessages.
Indicatesa potentialhazardthatcouldresultindeathor injury.
_& CAUTIONIndicatesa potentialhazardthatcouldresultinvehicledamage.
NOTE:Indicatingspecialinformationwhichistomakemaintenanceeasieror
instructionsclearer.
WARNINGandCAUTIONarearrangedlikethis:
Thefirst partwillidentifya POTENTIALHAZARD.
ThesecondpartwilldescribeWHATCOULDHAPPENifyou ignore
theWARNINGor CAUTION.
ThethirdpartwilldescribeHOWTOAVOIDTHEHAZARD.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.Read
itcarefullybeforeriding.Failingtofollow thewarningscontainedinthismanual
couldresultinINJURYor DEATH.
Itis importantthatthis manualremainwiththevehiclewhenyoutransferitto
anotheruserorowner.
Allinformation,illustrations,photographsandspecificationscontainedin
thismanualarebasedonthe latestproductinformationavailableatthetime
ofpublication.Dueto improvementsorotherchanges,therewillbesome
discrepanciesinthismanual.Wereservetherighttomakeproductchangesat
anytime,withoutnoticeandwithoutincurringanyobligationto makethesameor
similarchangestothevehiclepreviouslybuiltorsold.
Webelieveinconservationandprotectionoftheearth'snaturalresources.We
encourageeveryvehicleownerandoperatortodothesamebyobeyingposted
signsandridingonlyinareasdesignatedandapprovedforoff-roadrecreational
use.
NOTICETO PARENTS
ThisATVisbuiltfor usebychildrenage10andolder,buttheusersmanualis
writtenfor adultswhowill besupervisingthechildren,we stronglyrecommend,
therefore,thatyou reviewthisentiremanualwithyourchildandcarefullyexplain
theinstructions,requirements,andwarningsitcontainssothatyourchildcan
understandthem.
Childrendifferinskills,physicalabilities,andjudgement.Somechildrenmaynot
beabletooperateanATVsafely. Parentsshouldsupervisetheirchild'suseofthe
ATVat alltimes. Parentsshouldpermitcontinueduseonlyiftheydeterminethat
thechildhastheabilitytooperatetheATVsafely.
ItisveryimportantthateverychildwhoridestheATVshouldcompleteatraining
course.
THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE. An ATV
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, ifyou fail to take proper precautions.
SEVEREINJURYORDEATHcanresultifyoudo notfollow theseinstructions:
Readthismanualandall labelscarefullyandfollow theoperatingprocedures
described.
NeveroperateanATVwithoutproperinstruction.Takea traininqcourse.
Beginnershouldreceivetrainingfrom a certifiedinstructor.Contactan
authorizedATVdealeror callSVIAat 1-800-887-2887tofind outaboutthe
trainingcoursesnearestyou.
Alwaysfollow theseagerecommendations:
CategoryY (YouthModel)ATV.AnATVofappropriatesize intendedfor recreational
useunderadultsupervisionbyanoperatorunderage16.YouthmodelATVscan
further becategorizedasfollows:
CategoryY-6+ATV.ACategoryY-6+ATVisa youthmodelATVthatis intendedfor
usebychildrenage6 orolder
CategoryY-10+ATV.ACategoryY-10+ATVisayouthmodelATVthatisintended
for usebychildrenage10orolder.
CategoryY-12+ATV.ACategoryY-12+ATVisa youthmodelATVthatisintended
for usebychildrenage12orolder.
CategoryT (TransitionalModel)ATV.A CategoryTATVisanATVofappropriate
sizethatisintendedfor recreationalusebyanoperatorage14orolderunderadult
supervision,or byanoperatorage16orolder.
Neverallowa childunderage16to operateanATVwithoutadultsupervision,
andneverallowcontinueduseofanATVbya childif heor shedoesnothave
theabilitiestooperateitsafely.
Nevercarrya passengeronanATV.
NeveroperateanATVonanypavedsurfaces,includingsidewalks,driveways,
parkinglotsandstreets.
NeveroperateanATVonanypublicstreet,roador highway,evena dirtor
gravelone.
NeveroperateanATVwithoutwearinganapprovedmotorcyclehelmetthat
fits properly.Youshouldalsoweareyeprotection(gogglesor face shield)
goves,boots, ong-seevedshrt orjacket,and ongpants.
NeverconsumealcoholordrugsbeforeorwhileoperatingthisATV.
NeveroperatethisATVat excessivespeeds.Alwaysgoat a speedthatis
properfor theterrain,visibilityandoperatingconditions,andyourexperience.
Neverattemptwheelies,jumps,orotherstunts.
AlwaysinspectyourATVeachtimeyouuseitto makesureitisinsafe
operatingcondition.Alwaysfollow theinspectionandmaintenance
proceduresandschedulesdescribedinth=smanual.
Alwayskeepbothhandson thehandlebarsandbothfeet onthefootrests of
theATVduringoperation.
Alwaysgoslowlyandbeextracarefulwhenoperatingon unfamiliarterrain.
Alwaysbe alertto changingterrainconditionswhenoperatingtheATV.
Neveroperateon excessivelyrough,slipperyor looseterrainuntilyou have
learnedandpracticedtheskillsnecessaryto controltheATVonsuchterrain.
Alwaysbeespeciallycautiouson thesekindsofterrain.
Alwaysfollow properproceduresfor turningasdescribedinthismanual.
Practiceturningatlow speedsbeforeattemptingtoturnatfaster speeds.Do
notturnatexcessivespeeds.
NeveroperatethatATVon hillstoosteepfor theATVorfor yourabilities.
Practiceonsmallerhillsbeforeattemptinglargerhills.
Alwaysfollow properproceduresfor climbinghillsas describedinthis
manual.Checktheterraincarefullybeforeyoustartupanyhill.Neverclimb
hillswithexcessivelyslipperor loosesurfaces.Shiftyouweightforward.
Neveropenthethrottlesuddenlyor makesuddengearchanges.Nevergo
overthetopofanyhillathighspeed.
Alwaysfollow properproceduresfor goingdownhillsandfor brakingonhills
asdescribedinthismanual.Checktheterraincarefullybeforeyoustartdown
anyhill.Shiftyourweightbackward.Nevergodowna hillat highspeed.Avoid
goingdowna hillatananglethatwouldcausethevehicletoleansharplyto
oneside.Gostraightdownthehillwherepossible.
Alwaysfollow properproceduresfor crossingthesideofa hillas described
inthismanual.Avoidhillswithexcessivelyslipperyor loosesurfaces.Shift
yourweighttotheuphillsideof theATV.NeverattempttoturntheATVaround
onanyhilluntilyouhavemasteredtheturningtechniquedescribedin this
manualonlevelground.Avoidcrossingthesideofasteephill ifpossible.
Alwaysuseproperproceduresifyoustallorroll backwardswhenclimbing
a hill. Toavoidstalling,usepropergearandmaintaina steadyspeedwhen
climbinga hill.Ifyoustallor rollbackwards,follow thespecialprocedurefor
brakingdescribedinthismanual.Dismountontheuphillsideor toa side
ifpointedstraightuphill.TurntheATVaroundandremount,following the
proceduredescribedinthismanual.
Alwayscheckfor obstaclesbeforeoperatingina newarea.Neverattempt
tooperateoverlargeobstacles,suchas largerocksor fallen trees.Always
follow properprocedureswhenoperatingoverobstaclesas describedin this
manual.
Alwaysbecarefulwhenskiddingorsliding. Learntosafelycontrolskidding
orslidingbypracticingat lowspeedsandon level,smoothterrain. On
extremelyslipperysurfaces,suchasice,go slowlyandbeverycautiousin
ordertoreducethechanceofskiddingor slidingout ofcontrol.
NeveroperateanATVinfast flowing waterorinwaterdeeperthanthat
specifiedinthismanual. Rememberthatwet brakesmayhavereduced
stoppingability.Testyourbrakesafterleavingwater. Ifnecessary,apply
themseveraltimestoletfriction dryoutthelinings.
Alwaysusethesizeandtypetiresspecifiedinthismanual.Alwaysmaintain
propertirepressureasdescribedinthismanual.
NevermodifyanATVthroughimproperinstallationoruseofaccessories.
Neverexceedthestatedloadcapacityfor anATV.Cargoshouldbeproperly
distributedandsecurelyattached.Reducespeedandfollow instructionsin
thismanualfor carryingcargo.Allowgreaterdistancefor braking.
Thecombinedweightoftheriderandanyaccessoriesor cargomustnever
exceedthevehicle'sloadcapacityof220 Ibs.
Donottowa trailer.Thisvehicleisnotdesignedfor suchuse.
FORMOREINFORMATIONABOUTATVSAFETY,calltheConsumerProductSafety
Commissionat 1-800-638-2772,SVIA1-800-887-2877,or BajaSafetyHotlineat
1-866-260-8630
Helmet
Gloves
Pants
Goggles
Longsleeveshirt
Boots
Muffler
RearTire
Gas Cap vent
hose
Gas Ca
Spark plug
Head lights
Rearshock Oilcap
RIGHT
Thumb
Fuel valve
Seat
TailLight
FrontTire
_uretor
LEFT
FUEL
Properfuel isveryimportantfor theengine. Ensurethereisnodust,dirt,or
waterwhichhasmixedinthefuel. Useregularunleadedgasolinewithan
octanenumber90or higher.
ENGINEOIL
Your90ccATVhasafour-stroke engine. Pleaseuseoilasdescribedinthe
chartbelow. Byusingprescribeoil,youwillrealizethebestlubricationfor
engine.
ENGINE
I
TEMP.
°C -30 -20 -10 0 10 20 30 40
oF
-22 -4 14 32 50 68 86 104
Usethecharttoselectaviscosityratingbasedonthetemperaturerangein
yourarea.
NOTE: Inverycoldweather(below5°F(-15°C),useSAE10W-50for good
startingandsmoothoperation.
Readandfollow allofthewarningslabels onyourATV. Makesureyou
understandallthelabels. KeepthelabelsontheATV.Donotremovethem
for anyreason.Ifa labelcomesoffor becomesdifficultto read,youshould
geta replacementbycontactingBAJAINC.
OperationoftheATVbychildrenunderthe age
of 10increasestheriskofsevereinjuryordeath.
Adultsupervisionrequiresfor childrenunder
age16.
NEVERpermitchildrenunderage10tooperate
thisATV.
10
NEVERrideasa passenger,
Passengercancausea loss
of control,resultingin
SEVEREINJURYor DEATH,
3
ImproperATVusecan resultinSEVERE INJURYor DEATH
ALWAYS USE AN NEVER USE NEVER CARRY NEVER USE
APPROVED HELMET ON PUBLIC PASSENGERS WITH DRUGS
AND PROTECTIVE ROADS OR ALCOHOL
GEAR
NEVEROperate:
• Withoutpropertraining orinstruction.
• At speedstoofast for yourskills orthe condition.
• Onpublicroads,a collisioncanoccurwith anothervehicle.
• Withpassenger-passengersaffectbalanceandsteeringand
increaserisk of losingcontrol.
ALWAYS:
• Useproperridingtechniquesto avoidvehicleoverturnson
hillsand roughterrain and inturns.
• Avoidpavedsurfaces-pavementmayseriouslyaffect
handlingandcontrol.
LOCATE AND READ OWNER'S MANUAL CAREFULLY BEFORE OPERATING.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
11
4
impropertire pressureor overloadingcan
cause lossof control,
Loss of control can result in SEVEREiNJURY
or DEATH.
®Cold tire pressure:
Front: 7 Psi (48Kpa)
Rear: 7 Psi (48 Kpa)
®Maximum weightcapacity; 220 Ibs. (100 kg)
12
HANDLEBAR&
SWITCHES
RearBrakelever
LightSwitch
LEFT HANDLEBAR
With theEnginestopswitchin the"Stop" position
Theenginecannotbestarted.
With theEnginestopin the"Run" position
Theenginecanbestarted.
Rearbrakelever
EngineStop
ElectricStart switch
Button
Applytherearbrakebysqueezingtherearbrakelevertowardsthegrip.
Electricstartingbutton
Pushelectricstartbuttontostartengine.
RIGHTHANDLEBAR
ThrottleLever
Control the engineandATVspeedwiththethrottlelever. Operatethisleverwith
yourthumb. Pushitforward toincreaseengineandATVspeed. Releaseitto
decreaseengineandATVspeed.
Parking
Toset parkingbrake,squeezefront brakelever BrakePin FrontBrakelever
thendepressparkingbrakepin,settheparking
brakelever.
ThrottleAdjustingScrew
Tolimitthethrottle,screwinthrottle
limiterscrew
/v, LockNut
ThumbThrottleLever
limiterscrew
13
UsethethrottleadjustingscrewtorestrictmaximumspeedoftheATV.Adjustthis
limiteraccordingtotherider'sskillandexperience.
Adjustinqprocedures:
1. LoosentheLocknut
2. Turnthethrottleadjustingscrew clockwisetorestrictmaximumspeedoftheATV.
3. Turnthethrottleadjustingscrew counterclockwiseto increasethemaximumspeed
oftheATV.
4. Afterfinished, tightenthelocknut
FUELVALVE
Therearethreepositions:"ON","OFF", and"RES".
"ON" position-Inthisposition,fuel willflow tothecarburetorwhentheengineis
runningor beingstarted.
"OFF" position-Nofuelwillflow intothecarburetor.
"RES" position(arrowonvalvepointingup)- Iffuel levelinthefuel tankbecomestoo
low for enginetostayrunningwhilefuel valveisat "ON" position,turnfuel valveto
"RESERVE". Turningfuelvalveto "RESERVE"willallowenginetobeginusingreserve
fuel supply. Youwill needtore-fuelassoon aspossible.Thereisapproximately1Lof
fuel leftin tankwhenfuel valveisplacedat "RESERVE". Oncere-fueled,turnfuel valve
backtothe"ON" Position
ON OFF RES
FUELTANKCAP
Toopenthefuel tankcap,taketheendofthevent
tubeoutfrom thevehiclebody;turnthefueltank
capcounterclockwise.Toclosethefuel tankcap,
turnitclockwiseandtightenitsecurely.Besure
thattheventtubesecurelyconnectstothecap
asshown.
Fueltank
14 cap
Overfilling thefueltankcouldbehazardous.
Ifyouoverfillthefuel tank,fuel mayoverflowwhenitexpands. Expanding
isduetoheatfrom engineor sun. Overheatedfuel couldeasilycatchfire.
Stopaddingfuel whenthefuel levelreachesthebottomofthefiller neck.
Improperfueling oftheATVcouldbehazardous.
Failingtofollow safetyprecautionswhenrefuelingcouldresultin a fireor
letyouto breathetoxicfumes.
Refuelin awellventilatedarea. Makesuretheengineisoffandavoid
spillingfuel ona hotengine. Donotsmoke,andmakesurethereareno
openflamesorsparksin thearea. Avoidbreathinggasolinevapors. Keep
childrenandpetsawaywhenyouare refuelingtheATV.
SEATLOCK
Toremovetheseat,movetheseatlocklever
(locatedunderseat)backward.Raisetherear
endoftheseatandslideitback.
Tolocktheseat,slidetheseatleverintoits
retainerandpushdownfirmly.
Improperlyinstallingtheseatcouldbehazardous.
Failingtoinstalltheseatproperlycouldallowtheseatto moveandcause
theridertolosecontrol.
Makesureyouarein properpositionandtheseatisattachedsecurely
whenyou installit.
15
REMOTESTOP LANYARD
StopLanyard
StopLanyard
YourATVisequippedwitharemotestoplanyard.Thislanyardshould
beusedwhentrainingbeginneroperators.Theadultsupervisorshould
graspthelanyardandfollow behindtheATVwhilethebeginneris
learningtooperatetheATV.Theadultsupervisorshouldpullthe lanyard
toremovetheremotestoppinwhichwillstoptheengine.
NOTE:ThisATVwillnotstartor operatewithouttheremotestoppinand
lanyardinplace.
16
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