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WD90UR-2 ATV Read this manual carefully. It contains important safety information. Children under the age of 16 should be supervised by a responsible adult. OWNER’S MANUAL Quebec Canada - 14 Minimum Age Requirement -12 REV B 052108 Always wear a helmet; It could save your Life! Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle.
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Congratulations on your purchase of the WD90UR-2 ATV. It is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days from the date of purchase. During the warranty period BAJA, INC. will at its option, repair, provide replacement parts or replace your BAJA INC.
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WARNING This manual should be considered a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator. The manual contains important safety information and instructions which should be read carefully before operating the vehicle.
TABLE OF CONTENTS SAFETY .......................3 IMPORTANT ....................3 NOTICE TO THE USER ................4 ATV 90 ........................7 FUEL AND OIL .....................8 LOCATION OF LABELS ..................9 CONTROL FUNCTIONS ..................12 SPEEDOMETER/REARVIEW MIRROR ............12 LEFT HANDLEBAR ..................13 RIGHT HANDLEBAR ...................13 FUEL VALVE ....................14 FUEL TANK CAP ..................14 SEAT LOCK ....................15 RIDING YOUR ATV ....................16 WHAT YOU SHOULD KNOW BEFORE RIDING ........16...
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TABLE OF CONTENTS ENGINE OIL ....................51 CHANGING ENGINE OIL...............52 AIR FILTER ....................53 REMOVAL..................54 WASHING..................54 DRIVE CHAIN/SPROCKETS ...............56 INSPECTING THE DRIVE CHAIN............56 INSPECTING THE SPROCKETS............56 DRIVE CHAIN CLEANING, OILING AND ADJUSTING ......57 TIRES ......................58 BRAKING .....................60 FRONT DRUM BRAKES ..............60 REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE ....61 GENERAL LUBRICATION ................62 TROUBLESHOOTING ..................63...
SAFETY Please read this manual and follow all instructions carefully. To emphasize the special information, the symbol and the words WARNING or CAUTION have some special meanings. Pay great attention to the messages. WARNING Indicates a potential hazard that could result in death or injury.
SAFETY We believe in conservation and protection of the earth’s natural resources. We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off-road recreational use. NOTICE TO USERS THIS ATV IS NOT A TOY.
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SAFETY · Never operate this ATV at excessive speeds. Always operate at a speed that is proper for the terrain, visibility, operating conditions, and the operator’s skill / experience. · Never attempt wheelies, jumps, or other stunts. · Always inspect the ATV each time before use to ensure it is in a safe operating condition.
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SAFETY · Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight to uphill.
ATV90 Left side rear view mirror Gas Cap vent hose Gas Cap Front Rack Rear Rack Seat Rear shock Front Tire Choke Rear Tire Fuel Shut off Valve [Left] Speedometer Head lights Tail Light Front shocks Muffler Oil cap Carburetor [Right]...
FUEL AND OIL FUEL Proper fuel is very important for the engine. Ensure there is no dust, dirt, or water which has mixed in the fuel. Use regular unleaded gasoline with an octane number 90 or higher. ENGINE OIL Your 90cc ATV has a four-stroke engine. Please use oil as described in the chart below.
LOCATION OF LABELS Read and follow all of the warnings labels on your ATV. Make sure you understand all the labels. Keep the labels on the ATV. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting BAJA INC..
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LOCATION OF LABELS WARNING/AVERTISSEMENT NEVER ride as a passenger. Passenger can cause a loss of control, resulting in SEVERE INJURY or DEATH. N’utilesez jamais ce véhicule comme passager. Le passager peut causer la perte de contrôle entraînant des BLESSURES GRAVES ou LA MORT.
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LOCATION OF LABELS WARNING/AVERTISSEMENT IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. UNE PRESSION DES PNEUS INADÉQUATE OU TROP DE PRESSION PEUT ENTRAÎNER UNE PERTE DE CONTRÔLE. LA PERTE DE CONTRÔLE PEUT ABOUTIR À...
CONTROL FUNCTIONS SPEEDOMETER AND REARVIEW MIRROR Speedometer The speedometer has been pre-set by the factory in km/h and does not need setting. After power is turned on, press A to change between time, trip mileage or cumulative mileage. Setting the Time When the time is displayed, press B to adjust the hour, then press A to change the hour from 0 to 23.
CONTROL FUNCTIONS Parking Rear Brake lever Brake Pin HANDLEBAR & SWITCHES Light Switch LEFT HANDLEBAR With the Engine stop switch in the “Stop” position Engine Stop The engine cannot be started. switch With the Engine stop with in the “Run” position Electric Start The engine can be started.
CONTROL FUNCTIONS Use the throttle adjusting screw to restrict maximum speed of the ATV. Adjust this limiter according to the rider’s skill and experience. Adjusting procedures: Loosen the Lock nut Turn the throttle adjusting screw clockwise to restrict maximum speed of the ATV.
CONTROL FUNCTIONS WARNING Overfilling the fuel tank could be hazardous. If you overfill the fuel tank, fuel may overflow when it expands. Expanding is due to heat from engine or sun. Overheated fuel could easily catch fire. WARNING Improper fueling of the ATV could be hazardous. Failing to follow safety precautions when refueling could result in a fire or let you to breathe toxic fumes.
RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING Before riding, you should read all the following information carefully. If you are properly prepared, you will have a more enjoyable ride. Before riding, you should find a good place to practice the skills. Find a flat, open area with enough space to practice the new skills.
RIDING YOUR ATV INSPECTION BEFORE RIDING WARNING Failing to inspect the ATV before operating could be hazardous. Failing to perform proper maintenance could also be hazardous. Failing to inspect and maintain your ATV could increase the chances of an accident or equipment damage Always inspect your ATV each time before riding, and make sure it is in a safe operating condition.
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RIDING YOUR ATV WARNING Overloading could be hazardous. Overloading could cause changes in vehicle handling and could lead to an accident. Never exceed the stated load capacity for this ATV. Refer to the ACCESSORY USE AND VEHICLE LOADING section in this manual. WARNING Operating this ATV with improper modifications could be hazardous.
RIDING YOUR ATV WARNING Checking maintenance items when the engine is running could be hazardous. You could be severely injured if your hands or clothing get caught in moving ATV parts. Shut the engine off when performing maintenance checks, except checking the engine stop switch and throttle.
RIDING YOUR ATV BREAK-IN The first month is the most important in the life of your vehicle. Proper operation during this break-in period will be helpful for assuring maximum life and performance of your new vehicle. The following guidelines explain proper break-in procedures.
RIDING YOUR ATV STARTING THE ENGINE Before attempting to start the engine, make sure to follow these steps. Turn the key switch to the “ON” (Middle) position. Set the engine stop switch to the “RUN“ position. If engine is cold, set choke lever to the down position.
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RIDING YOUR ATV WARNING Carrying a passenger on this ATV could be hazardous. Carrying a passenger could greatly reduce your ability to keep balance. If you carry a passenger, you could lose control, and both you and the passenger could be severely injured. Never carry a passenger.
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RIDING YOUR ATV WARNING Never operate this ATV at night. Night is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise. You may collide with another vehicle, a stationary object, or hazard found in the terrain.
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RIDING YOUR ATV WARNING Removing your hands from the handlebar or feet from the footrests during operation could be hazardous. If you remove even one hand or foot from the ATV, you could reduce your ability to control the ATV. This could cause you to lose your balance and fall off the ATV.
RIDING YOUR ATV WARNING The ATV may start moving as soon as you release the parking brake. Unexpected movement could cause you to lose control of the ATV. Make sure to apply the rear brake before you release the parking brake. STARTING OFF Release the rear brake lever When you are sure that the engine is...
RIDING YOUR ATV BRAKING Front Brake Rear Brake To stop the ATV, first release the Throttle Lever throttle lever, then apply the rear and front brakes smoothly. WARNING Braking while turning the ATV could be hazardous. Use of the brake when turning could cause the ATV to slide or roll over. Use the brake to slow down before you begin to turn.
RIDING YOUR ATV TURNING WARNING Turning the ATV improperly could be hazardous. If you turn the ATV improperly, it may cause a collision or overturn. Always follow proper procedures for turning as described in this section. Practice turning at low speeds before attempting to turn at faster speeds. Never turn at excessive speeds.
RIDING YOUR ATV SKIDDING OR SLIDING WARNING Skidding or sliding improperly could be hazardous. You may lose control of your ATV when you regain traction unexpectedly. This may cause the ATV to overturn. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.
RIDING YOUR ATV OPERATION ON HILLS WARNING Climbing hills improperly could be hazardous. Climbing hills improperly could cause loss of control or cause the ATV to overturn. Always follow the proper procedures for climbing hills as described in this section. Always check the terrain carefully before you start up any hill.
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RIDING YOUR ATV WARNING Stalling, rolling backwards or improperly dismounting the ATV while climbing a hill could be hazardous. The ATV could overturn if you do not climb a hill properly. Maintain a steady speed when climbing the hill. Always follow the proper procedures for climbing hills as described in this section.
RIDING YOUR ATV If you still have forward movement and the hill is not steep and there is enough space to turn around safely, follow these instructions. Turn around on hill before you lose forward momentum. As you turn on side of hill, lean your body weight uphill.
RIDING YOUR ATV TRAVERSING A SLOPE WARNING Crossing hills or turning on hills improperly could be hazardous. Crossing hills or turning on hills improperly could cause loss of control or overturn. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the CLIMBING A HILL section.
RIDING YOUR ATV RIDING THROUGH WATER WARNING Operating this ATV through deep or fast flowing water could be hazardous. The ATV tires may float losing traction and then loss of control. This could lead to an accident. Never operate this ATV in fast flowing water or in water deeper than described in this section.
RIDING YOUR ATV RIDING IN COLD WEATHER WARNING Operating the ATV without a properly functioning brake system could be hazardous. Wet or frozen brakes will increase stopping distance. This will increase your chance of having an accident. Be sure to inspect the brakes before riding the vehicle in cold weather as described.
RIDING YOUR ATV DRESSING FOR COLD WEATHER RIDING WARNING Operating your ATV in cold weather without proper clothing could be hazardous. Continued exposure in the cold weather could lead to hypothermia. Hypothermia is a condition where your body’s inner temperature drops low enough to cause injury or death.
RIDING YOUR ATV RIDING YOUR ATV ON SNOW AND ICE WARNING Riding on snow-covered terrain, even with care, could be hazardous. The snow may be covering rocks, holes, ice or other hazards that can cause loss of control. Severe injury or death could occur if you lose control of the ATV.
ACCESORY USE AND VEHICLE LOADING WARNING Operating this ATV with improper modifications could be hazardous. Improper installation of accessories or modifications of the vehicle may cause changes in handling which could lead to an accident. Never modify the ATV with improper installation or use of improper accessories.
ACCESORY USE AND VEHICLE LOADING Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle. Locate cargo weight as close to the center of the vehicle if possible. Secure your load well. Shifting weight can affect your ability to handle the vehicle safely.
INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE It is very important to inspect and maintain your ATV regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed. Interval Initial 1 month Every 3 months...
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INSPECTION AND MAINTENANCE WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your ATV you may have an accident. Keep your ATV in good condition. Ask your authorized service center or a qualified mechanic to do the maintenance items marked with an asterisk (*).
INSPECTION AND MAINTENANCE TOOLS A tool kit is provided with your ATV. SPARK PLUG Your ATV is equipped with a T1136 spark plug. To determine if the standard spark plug is in good condition, check the color of the plug’s center electrode insulator after vehicle operation.
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INSPECTION AND MAINTENANCE NOTE: This ATV uses resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interference with your ATVs ignition system, resulting in the vehicle performance problems. Use recommended spark plugs. To install a spark plug turn it in as far as possible with your fingers, then tighten it with a wrench.
INSPECTION AND MAINTENANCE BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: Eye Protection Rubber Gloves WARNING The following procedure is very dangerous and should be performed with the utmost care and attention. Wear protective eyewear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes. KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
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INSPECTION AND MAINTENANCE Note: The following page is for vehicles with battery’s containing separate electrolyte pack. Most battery’s will come with the electrolyte already sealed into the battery. Preparing the battery: · Place battery on level surface. Remove Vent cap from battery vent located on top side portion of battery.
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INSPECTION AND MAINTENANCE How to Initially Charge the battery: Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 23) Connect the black negative (-) cable Figure 23 to the black negative (-) pole of the battery.
INSPECTION AND MAINTENANCE Battery Replacement: WARNING · DO NOT open sealed caps to add water to battery. · Always wear safety glasses and charge in a ventilated area. · If battery gets hot to the touch, discontinue charging and allow battery to cool down.
INSPECTION AND MAINTENANCE ENGINE SPEED GOVERNOR The ATV governor is set by the factory to limit speed of ATV to 15mph (24km/h) directly out of crate. The governor can be adjusted to allow the ATV to travel up to 30mph (48km/h). Any adjustment to governor should be performed by a responsible adult.
INSPECTION AND MAINTENANCE THE ADJUSTMENT OF THROTTLE LEVER WARNING Operating the vehicle with an inadequate throttle lever free distance could be hazardous. Inadequate throttle lever free distance could cause engine speed to rise suddenly when you turn the handlebars. This can lead the rider to lose control.
INSPECTION AND MAINTENANCE IDLE SPEED ADJUSTMENT WARNING Improper adjustment of the idle speed could be hazardous. An idle speed that is too high could cause the ATV to launch forward when you start the engine. This may cause an accident. Excessive engine wear may also result if idle speed is adjusted improperly or when the engine is not fully warmed up.
INSPECTION AND MAINTENANCE ENGINE OIL WARNING New and used oil could be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used oil can cause skin cancer in laboratory animals. Brief contact with the used oil may irritate the skin. Keep new and used oil away from children and pets.
INSPECTION AND MAINTENANCE Changing engine oil The engine oil should be changed every 20 to 40 hours of operation. It should be changed more often in dirty and dusty areas. To change oil: Park the vehicle on level ground. Oil Cap Remove the oil cap.
INSPECTION AND MAINTENANCE AIR FILTER WARNING Operating the engine without the air cleaner element in place could be hazardous. If the air cleaner element did not filter dirt, severe engine damage would occur if the dirt entered the running engine. Never run the engine without the air cleaner element in place.
INSPECTION AND MAINTENANCE REMOVAL Air filter cover Remove air filter cover. Air cleaner element Remove air cleaner element. WASHING THE ELEMENT Wash the element as the following: 1. Fill a washing pan large enough to hold the element with a nonflammable cleaning solvent.
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INSPECTION AND MAINTENANCE CAUTION A torn air filter could damage your ATV. Dirt and dust may get inside of the engine if the element is torn. Examine carefully the element for tears before and after cleaning it. Replace the element with a new one if it is torn. WARNING Oil and solvent could be hazardous.
INSPECTION AND MAINTENANCE DRIVE CHAIN/SPROCKETS The condition and adjustment of the drive chain should be checked before riding. Always follow the guidelines below for inspecting and servicing the chain. WARNING Failing to maintain the chain properly before each riding could be hazardous.
INSPECTION AND MAINTENANCE DRIVE CHAIN CLEANING, OILING AND ADJUSTING Clean and oil the chain as the following: Wash the chain with water. Dry the chain, and then oil the links with Chain lube or equivalent. WARNING Failing to inspect the drive chain slack before each use of the ATV could be hazardous.
INSPECTION AND MAINTENANCE TIRES WARNING Operating this ATV with improper tires, or even improper tire air pressure could be hazardous. If you use improper tires or improper tire air pressure, you may lose control of the ATV. Always use the size and type tires specified. Always maintain proper tire WARNING Using worn tires could be hazardous.
INSPECTION AND MAINTENANCE WARNING Overfilling the air to the tires could be hazardous. If you put too much air into the tire, the tire may burst causing severe injury. Check the air pressure from time to time while gradually inflating the tire, until the specified air pressure is obtained.
INSPECTION AND MAINTENANCE BRAKING The ATV has two front drum brakes and one rear disk brake. WARNING Failing to inspect and maintain your ATV’s brake system properly could be hazardous. Improper maintenance of the brake increases your chance of having an accident.
INSPECTION AND MAINTENANCE REAR HYDRAULIC DISK BRAKE AND PARKING BRAKE WARNING Failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, or shoes that are seriously worn, will increase your chance of having an accident. If you need to replace brake shoe pads, have your authorized service center do the work.
INSPECTION AND MAINTENANCE GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and long life of your vehicle. Be sure that all lubrication is performed during periodic maintenance on the vehicle. Increase intervals when you use your ATV in severe conditions. Your authorized service center should do general lubrication as shown in the MAINTENANCE CHART.
TROUBLESHOOTING CAUTION Failing to troubleshoot a problem correctly would damage your ATV. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty. If you are not sure about the proper action, consult your authorized service center or BAJA INC. about the problem.
TROUBLESHOOTING Ignition System Check WARNING Performing the spark test improperly could be hazardous. You could get a high voltage electrical shock if you are not familiar with this procedure. Do not perform this check if you are not familiar with the procedure. Do not point the spark plug near the spark plug hole during this test.
TRANSPORTING WARNING Draining fuel from the carburetor could be hazardous. Fuel could catch fire if you do not handle it properly. When draining fuel from the carburetor, be sure to shut the engine off. Do not smoke, and never drain or refuel in an area where there are open flames or sparks.
CLEANING PROCEDURE CAUTION High pressure washers could damage your ATV. High pressure washers such as those found at coin-operated car washes have enough pressure to damage the parts of your ATV. It may cause rust, corrosion and increase wear. Do not use high pressure washers to clean your ATV. A thorough cleaning of your ATV is a necessary part of maintenance.
CLEANING PROCEDURE WASHING YOUR ATV With some care, your ATV can be washed in a similar manner to washing an automobile. Note: Avoid spraying or allowing water to flow over the following places: · Ignition switch · Spark plug · Fuel tank cap ·...
STORAGE PROCEDURE If you do not use your ATV for an extended period, it will need special service requiring appropriate materials, equipment and skill. For this reason, we recommend that you trust this maintenance work to your authorized service center. If you wish to service the machine for storage yourself, follow the general guidelines below: VEHICLE Place the vehicle on level ground and wash the entire vehicle.
SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your ATV. You also need these numbers to help your authorized service center or BAJA INC. order parts. The frame/vin number is stamped on the front of the frame as shown in the photograph.
BAJA INC. – EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
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Your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injection system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assemblies.
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6. Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. 7. Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties.