1. DL manuals
  2. Baja motorsports
  3. Offroad Vehicle
  4. AP90
  5. Owner's Manual

Baja motorsports AP90 Owner's Manual

Manual is about: 90cc

Summary of AP90

  • Page 1

    Read this manual carefully. It contains important safety information. Children under the age of 16 should be supervised by a responsible adult. Always wear a helmet; it could save your life! Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning...

  • Page 2: Sever Injury Or Death.

    Ii “your atv can be hazardous to operate. 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. For your safety, understand and follow all the warnings contained in this owner’s manual ...

  • Page 3

    Iii congratulations on your purchase of the wd90 atv. It is warranted to be free of manufacturing defects in the material and 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...

  • Page 4: Operating The Vehicle.

    Iv this manual should be considered as 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. The...

  • Page 5: Table of Contents

    1 table of contents safety ...............................................................................................................3 important ........................................................................................................3 notice to the user ............................

  • Page 6: Table of Contents

    2 table of contents idle speed adjustment .......................................................................51 fuel hose .................................................................................................51 engine oil ..................................................................

  • Page 7: Safety

    3 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 attention to the messages. Note: indicating special information which is to make maintenance easier or instruction...

  • Page 8: Safety

    4 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 parents this atv is built for use by chi...

  • Page 9: Safety

    5 safety · never allow a child under age 16 to operate an atv without adult supervision, and never allow continued use of an atv by a child if he or she does not have the abilities to operate it safely. Never carry a passenger on an atv. · never operate an atv on any paved surfaces, including sidewa...

  • Page 10: Safety

    6 safety · always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slipper or loose surfaces. Shift you weight forward. Never open the throttle suddenly or make sudden gear changes. N...

  • Page 11: Safety

    7 · never modify an atv through improper installation or use of accessories. · never exceed the stated load capacity for an atv. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. · t...

  • Page 12: Atv 90

    8 atv 90 rear tire gas cap muffler oil cap head lights gas cap vent hose rear shock spark plug right seat carburetor front tire tail light front shocks thumb throttle fuel valve left.

  • Page 13: Fuel

    9 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. By using pres...

  • Page 14: Location of Labels

    10 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. Location of labels 1 operation of...

  • Page 15: Location of Labels

    11 location of labels 3 warning improper atv use can result in severe injury or death never use on public roads always use an approved helmet and protective gear never carry passengers never use with drugs or alcohol never operate: • without proper training or instruction. • at speeds too fast for y...

  • Page 16: Location of Labels

    12 location of labels improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Warning cold tire pressure: front: 7 psi (48 kpa) rear : 7 psi (48 kpa) maximum weight capacity; 220 lbs. (100 kg) 4.

  • Page 17: Control Functions

    13 control functions right handlebar throttle lever control the engine and atv speed with the throttle lever. Operate this lever with your thumb. Push it forward to increase engine and atv speed. Release it to decrease engine and atv speed. To set parking brake, squeeze front brake lever then depres...

  • Page 18: Fuel Valve

    14 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: 1. Loosen the lock nut 2. Turn the throttle adjusting screw clockwise to restrict maximum speed of the atv. 3. Turn the throttle adjustin...

  • Page 19: Seat Lock

    15 seat lock to remove the seat, move the seat lock lever (located under seat) backward. Raise the rear end of the seat and slide it back. To lock the seat, slide the seat lever into its retainer and push down firmly. Warning overfilling the fuel tank could be hazardous. If you overfill the fuel tan...

  • Page 20: Remote Stop Lanyard

    16 remote stop lanyard stop lanyard your atv is equipped with a remote stop lanyard. This lanyard should be used when training beginner operators. The adult supervisor should grasp the lanyard and follow behind the atv while the beginner is learning to operate the atv. The adult supervisor should pu...

  • Page 21: Riding Your Atv

    17 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 spac...

  • Page 22: Inspection Before Riding

    18 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 ...

  • Page 23: Riding Your Atv

    19 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. Br...

  • Page 24: Starting The Engine

    20 starting the engine before attempting to start the engine, make sure to follow these steps. 1. Turn the key switch to the “on” position. 2. Set the engine stop switch to the “run“ position. 3. If engine is cold, set choke lever to the up (on) position. 4. Apply the rear brake lever and make sure ...

  • Page 25: Riding Your Atv

    21 riding your atv warning running your atv indoors where there is little or no ventilation. Breathing in exhaust gases from the atv could cause severe injury. Always run your atv outdoors where there is fresh air. Warning carrying a passenger on this atv. Greatly reduces your ability to balance and...

  • Page 26: Warning

    22 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. Riding your atv warning operating this atv on paved surfaces. The atv’s ...

  • Page 27: Riding Your Atv

    23 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. Wa...

  • Page 28: Riding Your Atv

    24 riding your atv safety gear a dot approved motorcycle helmet is the most important part of your safety gear. A dot approved motorcycle helmet can help prevent a serious head injury. Choose a helmet that fits snugly. Motorcycle dealers can help in selecting a good quality helmet which fits properl...

  • Page 29: Riding Your Atv

    25 riding your atv warning failure to inspect the atv before operating. Failure to properly maintain the atv. Increases the possibility of an accident or equipment damage. Always inspect your atv each time you us it to make sure the atv is in safe operating condition. Always follow the inspection an...

  • Page 30: Starting Off

    26 starting off release the rear brake lever and open the throttle gradually to move forward. Warning opening the throttle suddenly could be hazardous. The front wheels could leave the ground and cause loss of control of the atv. Always open the throttle gradually when you want to accelerate. Riding...

  • Page 31: Warning

    27 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. Braking warning braking hard on slippery surfaces could be hazardous. The atv could skid and go out of control if...

  • Page 32: Riding Your Atv

    28 riding your atv turning to turn the atv, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to move straight ahead. This is becaus...

  • Page 33: Riding Your Atv

    29 riding your atv operation on hills warning operating on excessively steep hills. The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the atv on hills too steep for the atv or for your abilities. Practice on smaller hills before attemp...

  • Page 34: Riding Your Atv

    30 riding your atv to climb a hill with the atv, follow the directions below. 1. Speed up and maintain a steady speed before reaching the top of the hill. Remember that you must ride at a steady speed all the way to the top of the hill. 2. Shift your body forward by sliding forward on the seat. Lean...

  • Page 35: Riding Your Atv

    31 riding your atv to ride down a hill with the atv, follow the instructions below. 1. Check the terrain carefully for any obstacles before you go down the hill. 2. Point the atv straight down the hill. 3. Transfer your body to the rear by sliding back on the seat. 4. Ride down the hill slowly with ...

  • Page 36: Riding Your Atv

    32 when traversing a slope, you should: 1. Lean your body uphill. 2. Steer slightly uphill, if necessary, to maintain a straight course. Riding your atv warning stalling, rolling backwards or improperly dismounting while climbing a hill. Could result in atv overturning. Use proper gear and maintain ...

  • Page 37: Riding Your Atv

    33 riding your atv if you come to an obstacle that you cannot avoid, you may be able to cross over it by using the following procedure. 1. If the obstacle is in front of you, approach at walking speed. 2. Rise up slightly on the footrests. 3. Pull up on the handlebar and apply a little throttle as t...

  • Page 38: Riding Your Atv

    34 riding your atv riding through water you can ride the atv through shallow water. Make sure it is not more than 10cm (4 inches) deep and is not moving fast. Choose a good place to cross before you ride through the water. Look for a spot where the banks are gently sloped on both sides and the botto...

  • Page 39: Riding Your Atv

    35 riding your atv riding in cold weather pre-ride inspection check that the throttle and all control levers move freely. Make sure that the footrests are free of ice or snow. Move the atv forward and backward to check that the wheels roll freely. If you cannot move the atv, the tires may be frozen ...

  • Page 40: Riding Your Atv

    36 riding your atv dressing for cold weather riding riding in cold weather can be hazardous. At a temperature of 10°f (-12°c), the wind chill created by going just 10 mph (16km/h) makes you as cold as if you were standing still at a temperature of -9°f (-23°c). At this temperature, exposed flesh wil...

  • Page 41: Riding Your Atv

    37 practice riding your atv in an open snow- or ice-covered area, at slow speeds, before handling out on snow- or ice-covered trails. Learn how your atv responds to steering and braking on the type of terrain you will encounter on your ride. Your eyes may be sensitive to sunlight when you ride over ...

  • Page 42: Warning

    38 accesory use and vehicle loading accessory use and vehicle loading there are many types of accessories for sale. However, we cannot have direct control over their quality or suitability. We cannot test each accessory that is available. If you add the wrong accessories or misuse the vehicle with s...

  • Page 43: Weight Limits

    39 weight limits never exceed the weight limits shown 1. Total weight limit is 100 kg (220 lbs), this limit includes rider and accessories 6. 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 t...

  • Page 44: Inspection And Maintenance

    40 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. Initial 1 month/...

  • Page 45: Inspection And Maintenance

    41 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 me...

  • Page 46: Tools

    42 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. A brown color indicates that the plug is correct. A ...

  • Page 47: Caution

    43 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 ...

  • Page 48: Battery Installation

    44 battery installation initial service and installation of battery: 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. Ke...

  • Page 49: Inspection And Maintenance

    45 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 sealing tape from top. (see figur...

  • Page 50: Inspection And Maintenance

    46 inspection and maintenance how to initially charge the battery: 1. Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 23) 2. Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure 24) note: the red positive (+) cabl...

  • Page 51: Battery Replacement:

    47 battery replacement: · remove old battery. Mark which cable is connected to the positive terminal (+) and which cable is connected to the negative (-) terminal. · clean cable connectors with wire brush or sandpaper to remove oxidation. · after charging, install new battery. Put dielectric grease ...

  • Page 52: Engine Speed Governor

    48 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. Changing top speed of at...

  • Page 53: Inspection And Maintenance

    49 low speed limit regulator 5-15mph (8-24km/h) 1. Remove low speed adjustment screw cover (d) from cdi governor box 2. Adjust low speed adjustment screw (e) to desired setting: cw (clockwise) faster, ccw (counter clockwise) slower. Re-install adjustment screw cover (d) . Note: low speed adjustment ...

  • Page 54: Warning

    50 the adjustment of throttle lever to adjust the throttle lever free distance: 1. Loosen the throttle lever adjustment nut 2. Turn the large adjustment nut in or out to obtain the correct play. 3. Tighten the throttle lever adjustment nut. 4. Recheck the throttle lever free distance. Readjust it if...

  • Page 55: Idle Speed Adjustment

    51 idle speed adjustment to adjust the idle speed properly, you need a tachometer. If you do not have one, ask your authorized service center to perform this adjustment. To adjust the idle speed: 1. Start the engine and warm it up. 2. Turn the throttle stop screw in or out so that the engine idle sp...

  • Page 56: Warning

    52 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. To mi...

  • Page 57: Changing Engine Oil

    53 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: 1. Park the vehicle on level ground. 2. Remove the oil cap. 3. Remove the drain bolt and drain oil into proper container. 4. Reinstall t...

  • Page 58: Air Cleaner

    54 air cleaner the air cleaner element must be kept clean to provide good engine power. If you use your vehicle under normal, low-tension conditions, you should service the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air cleane...

  • Page 59: Removal

    55 removal 1. Remove air filter. Loosen clamps 2. Remove air filter cover. 3. Remove foam air filter 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. Immerse the element in the solvent and was...

  • Page 60: Warning

    56 warning oil and solvent could be hazardous. Children and pets could be harmed from the oil and solvent. Be sure to keep oil and solvent away from children and pets. Dispose of used oil and solvent properly. Caution a torn air filter could damage your atv. Dirt and dust may get inside of the engin...

  • Page 61: Drive Chain/sprockets

    57 sprocket 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. Inspecting the drive chain when inspecting the chain, look for the following: · loose pins · damaged rollers ·...

  • Page 62: Adjusting The Drive Chain

    58 drive chain cleaning, oiling and adjusting clean and oil the chain as the following: 1. Wash the chain with water. 2. Dry the chain, and then oil the links with chain lube or equivalent. Adjusting the drive chain the drive chain should be adjusted and make sure there is 20~30 mm (0.8~1.2 inches) ...

  • Page 63: Warning

    59 warning operating this atv with improper tires, or with improper or uneven tire pressure. Use of improper tires on this atv, or operation of this atv with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. Always use the size and type of tires specif...

  • Page 64: Warning

    60 warning using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident. Replace the front and rear tires when the depth on the tread is 4.0 mm (0.16 inches) or less. The atv is equipped with low pressure tubeless tires of the siz...

  • Page 65: Tire Replacement:

    61 tire replacement: your atv has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires. It is very important to...

  • Page 66: Braking

    62 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. Be sure to inspect the brake before riding according to th...

  • Page 67: Rear Hydraulic Disk Brake

    63 rear hydraulic disk 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 t...

  • Page 68: Inspection And Maintenance

    64 inspection and maintenance 2 o o o 4 5 g 1 3 o 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 con...

  • Page 69: Fuel Supplying Check

    65 this troubleshooting guide is provided to help you find the cause of some common complaints. Complaint: engine is hard to start or does not start at all. Something is probably wrong with the fuel system or ignition system. Fuel supplying check 1. Make sure there is adequate fuel in the fuel tank....

  • Page 70: Ignition System Check

    66 ignition system check 1. Remove the spark plug and reattach it to the spark plug lead. 2. Push the electric button “start “(yellow button). Apply the rear brake lever to make sure the rear wheels are locked. If the ignition system is operating properly, a blue spark should jump across the spark p...

  • Page 71: Warning

    67 it is best to transport the atv in the normal upright position. Before transporting the atv make sure the fuel valve is turned to the off position then drain fuel from the carburetor as follows: 1. Drain fuel from carburetor into an empty container by loosening the carburetor drain screw. 2. When...

  • Page 72: Preparation For Cleaning

    68 a thorough cleaning of your atv is a necessary part of maintenance. It will help keep your atv looking and performing best. Proper cleaning can also extend the life of your atv. It is important to clean and inspect your atv after every ride, especially if it is used in mud, brush, grass, water, s...

  • Page 73: Washing Your Atv

    69 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 · carburetor use a garden hose at low pressure to remove the majority of d...

  • Page 74: Vehicle

    70 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, foll...

  • Page 75: Serial Number Location

    71 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. The engine serial number is ...

  • Page 76: Specifications

    72 dimensions and dry mass overall length.................................................................................1400mm (51.2 in) overall width....................................................................................... 0mm (37.4 in) overall height...................................

  • Page 77: Wire Diagram

    73 wire diagram.

  • Page 78

    74 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,...

  • Page 79

    75 your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injec- tion system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is origin...

  • Page 80

    76 • use of replacement parts or accessories not conforming to the origi- nal specifications which adversely affect performance • physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the distributor. • failures not caused by a defect in material o...

  • Page 81: Baja, Inc.

    77 baja, inc. P.O. Box 61150 phoenix, az. 85082 tel: 602-443-9180 toll free: 888-863-2252.