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Baja motorsports WD250 Owner's Manual - Troubleshooting

Manual is about: ATV

Summary of WD250

  • Page 1

    Always wear a helmet; it could save your life! Do not remove this operator’s manual from this vehicle. Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle. Minimum age requirement 16 read this manual carefull...

  • Page 2

    Ii congratulations on your purchase of the baja motorsports wd250ur / wd250u atv. Congratulations on your purchase of the wd250ur / wd250u atv. The period of warranty for the vehicle shall be 90 days from the date of purchase and the warranty covers the manufacturer’s faulty workmanship and material...

  • Page 3: The Vehicle.

    Iii 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. Wa...

  • Page 4: Table of Contents

    1 important ...................................................................................................................... 2 foreword ...................................................................................................................... 3 notice to the user .....................

  • Page 5: Table of Contents

    2 vehicle weight limits ................................................................................................ 41 inspection and maintenance ................................................................................. 42 tools .............................................................

  • Page 6

    3 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. Note: indicates special information which is to make maintenance easier or instructions ...

  • Page 7

    4 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. It could be hazard...

  • Page 8

    5 · 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...

  • Page 9

    6 · 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 pointe...

  • Page 10: Wd250Ur / Wd250U

    7 wd250ur / wd250u right left rear wheel manual pull start drive select lever taillight gear shift lever front wheel front rack rear rack mirrors seat gas cap control panel front shocks foot brake oill fill cap/dipstick rear shock.

  • Page 11: Fuel And Oil

    8 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. Engine oil your 250cc atv has a four-stroke engine. Please use oil as described in the chart below. By using the prescribed oil, you w...

  • Page 12: Location of Warning Labels

    9 location of warning 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 motorsports....

  • Page 13: Warning

    10 loading dislodge from the rim. Maximum vehicle capacity is: 165kg (364 lbs.) maximum capacity includes the weight of the operator, cargo, and accessories plus the veritcal weight on trailer hitch. Warning improper tire pressure or overloading can cause loss of control. Loss of control can result ...

  • Page 14

    11 1. Speedometer indicates speed of atv 2. Odometer indicates total mileage driven. 3. Reverse indicator illuminates when atv is in reverse. 4. Km/h indicator illuminates when speedometer is in km/h 5. High beam indicator illuminates when high beam is on. 6. Lights indicator illuminates when headli...

  • Page 15: And Parking Brake Lock

    12 1 - engine stop switch with the engine stop switch in the “off” position the engine cannot be started. With the engine stop in the “run” position the engine can be started. 2 - rear brake lever rear brake is applied by squeezing the rear brake lever towards the grip. 3 - electric start button dep...

  • Page 16: Thumb Throttle

    13 right handlebar: front brake lever and thumb throttle rear foot brake rear foot brake foot brake located on the right hand side of the atv. Foot brake stops the rear wheels. 2 1 4 3 5 1 - throttle lever controls engine and atv speed. Operate this lever with your thumb. Push it forward to increase...

  • Page 17: Fuel Valve

    14 fuel level filler neck fuel valve this vehicle has one manually operated fuel valve. There are 3 positions “on” “off” “reserve” “on” position in this position, fuel is allowed to flow into the carburetor when the engine is running or being started. “off” position in this position the fuel is shut...

  • Page 18: Seat Lock

    15 seat lock to remove the seat, move the seat lock lever 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 the seat down firmly. Warning overfilling the fuel tank could be hazardous. If you overfill the fuel tank, fuel may ...

  • Page 19: 12V Utility Socket

    16 12v utility socket caution using accessories with wattage requirements over 100 watts could damage atv using accessories with wattage requirements over 100 watts could cause wiring and electrical components to overheat causing failure. Check accessory wattage requirements before plugging in to 12...

  • Page 20: 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 21: 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 increases the chances of an accident or equipment damage always inspect your atv each time...

  • Page 22

    19 check the condition of the atv to make sure that the atv does not have mechanical problems or you could get stranded when you ride. Before riding the atv, be sure to check the above items. Be sure your atv is in good condition to ensure the safety of the rider. Warning overloading could be hazard...

  • Page 23: Safety Gear

    20 safety gear a dot approved motorcycle helmet is the most important part of you 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 properly. You should wea...

  • Page 24: Break-In

    21 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. Maximum throttle opening recommendat...

  • Page 25: Starting The Engine

    22 starting the engine before attempting to start the engine, make sure to follow these steps. 1. Turn the fuel valve to the “on” position 2. Turn the key switch to the “on” position. 3. Set the engine stop switch to the “run“ position. 4. Set the thumb lever choke to the “on” position 5. Apply the ...

  • Page 26

    23 warning operating this atv on paved surfaces, including sidewalks, paths, parking lots, driveways and streets could be hazardous. Atv tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the atv, and may cause the vehicle to lose control. Avoid operatin...

  • Page 27

    24 warning attempting wheelies, jumps, and other stunts could be hazardous. Stunt riding increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. Warning removing your hands from the handlebar or feet from the footrests durin...

  • Page 28

    25 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. Warning failing to use extra care when operating on excessively rough, s...

  • Page 29

    26 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. Warning opening the throttle suddenly could be hazardous. The front wheels could leave off the ground and cause loss of control of the atv. Always open the th...

  • Page 30: Shifting:

    27 shifting: this atv has a 5 speed transmission with a centrifugal automatic clutch. To shift vehicle in neutral while driving, repeatedly depress the gear shift lever. The green indicator light will illuminate when in neutral. To shift the vehicle through gears 1-5 1. Release the throttle lever. 2...

  • Page 31

    28 caution do not coast for long periods of time with the engine not running, and do not tow the machine a long distance. Even when the machine is in neutral, the gears are not properly lubricated unless the engine is running. Towing the machine with the engine not running could cause damage to the ...

  • Page 32: Braking

    29 to stop the atv, first release the throttle lever. And 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. Braking war...

  • Page 33: Turning

    30 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 because the rear wheel...

  • Page 34: Skidding Or Sliding

    31 skidding or sliding you may experience skidding or sliding when you are not braking. You may be able to overcome it by using the techniques listed below. If your front wheel skids: gain front wheel traction by reducing the throttle opening and leaning your body slightly forward. If your rear whee...

  • Page 35: Climbing A Hill

    32 climbing a hill 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...

  • Page 36

    33 if climbing a hill and are unable to make it to the top, use the correct procedure described below to turn around to get down the hill. If you still have forward movement and enough space to turn around safely, follow these instructions. 1. Turn around on the hill before you lose forward speed. A...

  • Page 37: Descending A Hill

    34 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 body to the rear by sliding back on the seat. 4. Ride down the hill slowly with the throttle released...

  • Page 38: Riding Over Obstacles

    35 when traversing a slope, you should: 1. Lean your body uphill. 2. Steer slightly uphill, if necessary, to maintain a straight course. Riding over obstacles warning crossing hills or turning on hills improperly could be hazardous. Crossing hills or turning on hills improperly could cause loss of c...

  • Page 39: Riding Through Water

    36 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 bottom of the stream ...

  • Page 40: Riding In Cold Weather

    37 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 to the ground, o...

  • Page 41

    38 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 will freeze in just...

  • Page 42

    39 riding your atv on snow and ice 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...

  • Page 43

    40 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 some accessories installed, it can...

  • Page 44

    41 wd250ur / wd250u weight limits never exceed the weight limits shown 1. Total weight limit is 165 kg (364 lbs); this limit includes rider, accessories, vertical weight on trailer hitch and cargo. 2. Front rack - 30 kg (66 lbs.) 3. Rear rack - 45 kg (99 lbs.) 4. Tool kit compartment - 2 kg (4.5 lbs...

  • Page 45: Inspection And Maintenance

    42 item initial 1 months initial 3 months every 3 months every 6 months valves i i spark plug c c r air filter i every 20 - 40 hours (more often in dusty areas) carburetor i i cylinder head and breather hose i exhaust system i spark arrester i fuel hose i i engine oil r r engine oil filter c c engin...

  • Page 46

    43 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 maintenanc...

  • Page 47: Tools

    44 tools a tool kit is provided with your atv. Spark plug your atv is equipped with a d8rtc 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 48

    45 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 49: Battery Installation

    46 battery installation initial service and installation of battery: warning the following procedure is very dangerous and should be performed with utmost care and attention. Wear protective eye wear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes. Keep ...

  • Page 50: Preparing The Battery:

    47 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 figure 20) · take the electrolyt...

  • Page 51: Warning

    48 figure 26 red + black - battery bracket 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 posi...

  • Page 52: Battery Replacement:

    49 battery replacement: · remove old battery from under seat. The battery bracket will need to be removed (see figure 28). 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 re...

  • Page 53: Fuse Replacement

    50 headlight and taillight replacement headlight bulb replacement. Turn off main key switch locate headlights under front fender and slide back rubber moisture protector from headlight housing push in bulb holder and turn left (ccw) until tabs line up with groves . Remove bulb. • • • • fuse replacem...

  • Page 54

    51 the adjustment of throttle lever to adjust the throttle lever play: 1. Remove the adjuster cover (slide back on cable). 2. Loosen the throttle lever lock nut. 3. Turn the large adjustment nut in or out to obtain the correct play. 4. Tighten the throttle lever lock nut. 5. Recheck the throttle lev...

  • Page 55: Idle Speed Adjustment

    52 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 engine idle screw in or out so that the engine idle spee...

  • Page 56: Engine Oil

    53 engine oil to check oil level: 1. Park vehicle on level ground. 2. Remove dip stick and wipe off with a clean rag. Insert the dipstick in the filler hole. 3. Remove the dipstick and inspect the oil level. 4. Oil level should be in between the minimum and maximum marks on the dipstick. 5. Add oil ...

  • Page 57

    54 4. Remove oil filter cap 5. Remove oil filter 6. Clean oil strainer and oil filter with solvent. 7. Inspect rubber o-ring on the oil filter cap and replace if damaged. 8. Reinstall oil filter, o-ring and oil filter cover. 9. Reinstall oil strainer, spring and cap. 10. Torque drain plug to 18 ft.L...

  • Page 58: Air Filter

    55 air filter the air filter 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 filter at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air filter el...

  • Page 59

    56 air filter removal and cleaning 1. Locate air filter box under seat and remove cover. 2. Remove air filter. 3. Remove foam cover from air filter element. 4. Tap the air filter element gently to remove most of the dust and dirt. Blow out remaining dust with compressed air. If the element is damage...

  • Page 60: Clutch Adjustment

    57 warning oil and solvent could be hazardous. Children and pets could be harmed if they have access to oil or 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...

  • Page 61: Rear Gear Case Lubrication

    58 rear gear case lubrication to check rear gear case oil: 1. Place vehicle on level ground 2. Remove gear case fill cap. 3. Inspect oil level. Oil level should be up to the brim of the hole. 4. If oil is low, add specified oil (sae 80 api g- 4 hypoid gear oil). 5. Tighten fill cap to 23nm (17ft.Lb)...

  • Page 62: Tires

    59 tires the atv is equipped with low pressure tubeless tires of the size and type listed below: tire tread condition tire air pressure check the air pressure in all tires before riding. Improper air pressure would effect handling, steering response, traction, tire life and rider comfort. Be sure th...

  • Page 63

    60 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 64: Braking

    61 braking the atv has two front disk brakes and one rear drum brake. Hydraulic front brakes 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...

  • Page 65: Rear Brakes

    62 rear brakes rear foot brake located on right side of atv front hydraulic disk brake inspection brake fluid level brake fluid cap brake hose front disk brake caliper brake disk brake hose lower mark brake fluid reservoir 5~7mm free play (0.2~0.3in) adjusting nut rear hand brake located on left sid...

  • Page 66: Rear Brake Shoe Inspection

    63 rear brake shoe inspection 1. Locate brake wear indicator on outside of brake drum. 2. Check the position of the needle to see if it has reached the maximum wear limit. 3. If maximum wear limit has been reached (needle is at the end of the brake wear indicator), replace brake shoes as a set. Maxi...

  • Page 67: Spark Arrester Cleaning

    64 warning failing to maintain the brake shoes, the brake pads and the calipers could be hazardous. Riding with worn brake shoes or pads, will increase your chance of having an accident. If you need to replace brake shoe or pads, have your authorized service center do the work. Inspecting and mainta...

  • Page 68

    65 warning running the engine indoors or in a garage could be hazardous. Exhaust gas contains carbon monoxide that is colorless and odorless. It could cause serious injury or death. Only run the engine outdoors where there is fresh air. Warning the hot exhaust muffler could burn you. The muffler wil...

  • Page 69: General Lubrication

    66 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 number of intervals when you use your atv in severe conditions. Your authorized service cent...

  • Page 70: Troubleshooting

    67 troubleshooting this troubleshooting guide is provided to help you to 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 fue...

  • Page 71: Ignition System Check

    68 ignition system check 1. Remove the spark plug and reattach it to the spark plug lead. 2. Apply the rear brake lever to make sure the rear wheels are locked. Turn ignition key to the “on” position. Slide the engine stop switch to the “run” position. Push the electric button “start “(yellow button...

  • Page 72: Transporting

    69 transporting it is best to transport the atv in the normal position. Before transporting the atv drain the fuel from the carburetor as follows: 1. Drain fuel from carburetor into an empty container by loosening the carburetor drain screw. 2. When the fuel has been drained, retighten the drain scr...

  • Page 73: Cleaning Procedure

    70 cleaning procedure 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, bru...

  • Page 74: Washing Your Atv

    71 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 • air filter use a garden hose at low pressure to remove the ...

  • Page 75: Storage Procedure

    72 storage procedure if you do not use your atv for a long time, 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 you...

  • Page 76: Serial Number Location

    73 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 motorsports order parts. The frame/vin number is stamped on the front of the atv frame as shown in the photog...

  • Page 77

    74 specifications wd250ur / wd250u dimensions and dry mass overall length............................................................................1940mm (76.38 in) overall width.............................................................................1050mm (41.34 in) overall height..............

  • Page 78

    75 electrical ignition type................................................................................Cdi generator system.......................................................................A.C. Magneto battery type, voltage, capacity..................................................12n14-bs...

  • Page 79

    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...

  • Page 80

    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 ...

  • Page 81

    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 an...

  • Page 82: Baja Inc.

    78 baja inc. P.O. Box 61150 phoenix, az. 85082 toll free: 866-250-7155 service center line: 866-401-2252.