Baja motorsports WD90 Owner's manual

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

YourATVisequippedwitharemotestoplanyard.Thislanyardshould

beusedwhentrainingbeginneroperators.Theadultsupervisorshould

graspthelanyardandfollow behindtheATVwhilethebeginneris

learningtooperatetheATV.Theadultsupervisorshouldpullthe lanyard

toremovetheremotestoppinwhichwillstoptheengine.

NOTE:ThisATVwillnotstartor operatewithouttheremotestoppinand

lanyardinplace.

16

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Baja motorsports WD90 Owner's manual

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