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Baja WD400U-2 Owner's Manual

Manual is about: ATV Motorsports

Summary of WD400U-2

  • Page 1

    Read this manual carefully. It contains important safety information. No one under the age of 16 should operate this atv. Owner’s manual minimum age requirement 16 always wear a helmet; it could save your life! Do not remove this operator’s manual from this vehicle, according to guide- lines with th...

  • Page 2: Sever Injury Or Death.

    “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 and...

  • Page 3

    Iii congratulations on your purchase of the baja inc. Wd400u-2 atv. This atv is guaranteed to be free of manufacturing defects in 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 ...

  • Page 4: 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 owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the vehicle. Wa...

  • Page 5: Table of Contents

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

  • Page 6: Table of Contents

    2 table of contents headlight/taillight replacement ................................................. 52 throttle lever adjustment ............................................................ 53 idle speed adjustment ....................................................................... 54 fuel hos...

  • Page 7

    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: indicating special information which is to make maintenance easier or instructions...

  • Page 8: Notice to Parents

    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 parents this atv is built for use by children a...

  • Page 9

    5 · 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 sidewalks, dr...

  • Page 10

    6 · 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. Never go...

  • Page 11

    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: Wd400U-2

    8 wd400u-2 [right] rear luggage carrier front luggage carrier exhaust silencer seat cushion fuel cap brake pedal front shocks rear tire front bumper [left] fuel valve manual pull start headlight taillight two/four wheel transforming button front tire rear shock oil fill plug.

  • Page 13: Fuel And Oil

    9 fuel and oil fuel the proper fuel is very important for the engine. Ensure that there is no dust, dirt, or water which has mixed in the fuel. Please use regular unleaded gasoline engine oil your 400cc atv has a four-stroke engine. Please use oil as described in the chart below. By using the prescr...

  • Page 14: Location of Warning Labels

    10 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 15: Warning

    11 ! Warning “must stop before changing to 2wd/4wd” warning ! This vehicle is an all-terrain vehicle and is not intended for use on public highways warning under 16 operation of the atv by children under the age of 16 increases the risk of severe injury or death. Never permit children under age 16 t...

  • Page 16: Indicator Lights

    12 indicator lights reverse light indicator - light will illuminate when the atv is in reverse. Neutral light indicator - light will illuminate when the atv is in neutral. Four wheel drive indicator - light will illuminate when the atv is in four wheel drive, 2wd/4wd button is pressed in. Oil temper...

  • Page 17: Light Switch

    13 light switch start button manual choke lever parking brake open closed on/off switch light switch when switch is in the top position the headlight, taillight and meter light illu- minates. When switch is in the center the taillight and meter light illuminates. When switch is in the bottom positio...

  • Page 18: Rear Foot Brake

    14 rear foot brake foot brake located on the right hand side of the atv. Foot brake stops the rear wheels. Throttle lever controls engine and atv speed. Operate this lever with your thumb. Push it forward to increase engine and atv speed. Release it to decrease engine and atv speed. Front brake leve...

  • Page 19: Fuel Valve

    15 fuel level filler neck fuel valve this vehicle has one manually operated fuel valve. There are 3 positions “on” position (arrow pointing down) in this position, fuel is allowed to flow into the carburetor when the engine is running or being started. “off” position (arrow pointing left) in this po...

  • Page 20: Seat Lock

    16 seat lock to remove the seat, pull the seat lock lever up. 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 tank, fuel may overflow when it...

  • Page 21

    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 increases the chances of an accident or equipment damage always inspect your atv each time...

  • Page 23

    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 24: Safety Gear

    20 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 properly. You should we...

  • Page 25: 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 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. Warning operating this atv on paved surfaces. The atv’s tires are design...

  • Page 27: Warning

    23 warning operating this atv at excessive speeds. Increases your chances of losing control of the atv, which can result in an accident. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Warning attempting wheelies, jumps, and other stunts...

  • Page 28: Warning

    24 warning failing to use extra care when operating this atv on unfamiliar terrain. You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the atv overturning or going out of control. Go slowly and be extra careful when operating on unfamiliar terrain. Always ...

  • Page 29: Starting The Engine

    25 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. Apply the rear brake lever and make sure that the rear wheels ...

  • Page 30

    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. Make sure to apply the rear brake before you release the parking brake. Warning opening the throttle suddenly could be hazardous. The front wheels could leave...

  • Page 31: Manual Pull Start

    27 manual pull start recoil starter firmly grasp handle and pull slightly up until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. Caution: don’t start the engine in non-neutral or without setting the parking brake system. Put the transmission in neu...

  • Page 32: Drive Select Lever

    28 drive select lever the drive select lever shifts the atv from forward to reverse or reverse to forward. To shift atv in reverse: 1. Release throttle 2. Apply brakes coming to a complete stop. 3. Shift transmission into neutral. 4. Shift drive select lever to “r” (reverse). Note: when in reverse, ...

  • Page 33

    29 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 34: Braking

    30 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 35: Turning

    31 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 36: Operation On Hills

    32 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 attempting larger hill...

  • Page 37: Warning

    33 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 slightly forwar...

  • Page 38: Warning

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

  • Page 39: Riding Over Obstacles

    35 riding over obstacles warning improperly operating over obstacles. Could cause loss of control or a collision. Could cause the atv to overturn. Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over ob...

  • Page 40: Warning

    36 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 the front wheels ...

  • Page 41: Riding Through Water

    37 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 42: Riding In Cold Weather

    38 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 43

    39 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 44

    40 riding your atv on snow and ice practice riding your atv in an open snow- or ice-covered area, at slow speeds, before heading 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 45

    41 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 46: Wd400U-2 Weight Limits

    42 wd400u-2 weight limits 1 2 3 never exceed the weight limits shown 1. Total weight limit is 210.01 kg (463 lbs), this limit includes rider, accessories, vertical weight on trailer hitch and all gear carried on front and rear racks. 2. Front rack - 40 kg (88.18 lbs.) 3. Rear rack - 80 kg (176.37 lb...

  • Page 47: Inspection And Maintenance

    43 inspection and maintenance 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. Warning improper maintenance or faili...

  • Page 48: Maintenance Schedule

    44 item initial 1 months/ 20 hrs initial 3 months/ 50 hrs every 3 months/ 50 hrs every 6 months/ 100 hrs valves i i spark plug i c r valve clearance-check-adjust i air filter i every 20 - 40 hours (more often in dusty areas) carburetor i i cylinder head breather hose i exhaust system i spark arreste...

  • Page 49: Tools

    45 tools a tool kit is provided with your atv. Spark plug your atv is equipped with a d8rea 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 light brown color indicates that the plug is in go...

  • Page 50

    46 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 51: Valve Inspection

    47 valve inspection refer to maintenance schedule in this owner’s manual for valve adjustment inspection intervals. Valve clearance should be: intake: 0.002 inch (0.05 mm) exhaust: 0.003 inch (0.0762 mm) the engine will make excess noise if the gap is too large in air valve. If gap is too small valv...

  • Page 52: Battery Installation

    48 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 your skin or eyes. ...

  • Page 53

    49 note: the following page is for vehicles with battery’s containing separate electrolyte pack. Most batteries 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 54

    50 how to initially charge the battery: 1. Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 24) 2. Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure 25) note: the red positive (+) cable has a larger diameter tha...

  • Page 55

    51 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 56: Fuse Replacement

    52 fuse replacement fuse may be bad if there is no spark while trying to start the atv. The fuse box is located under the seat directly in front of the battery. To check fuse follow the instructions • turn off main key switch • lift seat and locate fuse box • remove fuse box cap • remove fuse and ch...

  • Page 57

    53 the adjustment of throttle lever to adjust the throttle lever play: 1. Remove the adjuster cover (slide back on cable). 2. Loosen adjuster nut and move adjuster in or out to obtain the correct play. 3. Tighten adjuster nut 4. Recheck the throttle lever free distance. Readjust it if it is not with...

  • Page 58: Idle Speed Adjustment

    54 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 59: Engine Oil

    55 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 60

    56 4. Remove oil filter cover 5. Remove oil filter 6. Replace oil filter with new filter. 7. Reinstall oil filter and oil filter cover. 8. Tighten drain plug and oil filter cap to specified torque. 9. Fill crankcase with specified oil. Refer to pg. 9 for correct oil. Warning new and used oil could b...

  • Page 61: Air Filter

    57 air filter the air filter element must be kept clean to provide good engine power. If you use your vehicle under normal, low dust 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 eleme...

  • Page 62: Air Filter Removal

    58 air filter removal washing foam cover 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 ...

  • Page 63

    59 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 64

    60 front and rear gear case lubrication to check front and 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...

  • Page 65: Tires

    61 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 affect handling, steering response, traction, tire life and rider comfort. Be sure th...

  • Page 66: Warning

    62 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 67

    63 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 68: Rear Brakes

    64 rear brakes 1. Inspect the front disk brake caliper for leakage. If brake fluid leaks, the safety of riding could be affected. 2. Inspect the brake hose for cracks, and the joint for leakage. 3. Check the brake fluid level in the brake fluid reservoir, if level is at or below the lower mark, insp...

  • Page 69: Rear Brake Shoe Inspection

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

  • Page 70: Spark Arrester Cleaning

    66 spark arrester cleaning periodically the spark arrestor will need cleaning 1. Select a well ventilated area and make sure the exhaust pipe is cool 2. Remove the drain bolt 3. Start the engine, block the end of the exhaust pipe with a dowel, this will increase the speed of the engine because of ba...

  • Page 71

    67 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 72

    68 the oil cooler should be checked for mud and debris before each ride, the following steps should be taken to ensure the oil cooler is in proper working order. Cleaning and inspection of oil cooler 1. Locate oil cooler under front fender assembly. Oil cooler cooler guard screen 2. Remove “cooler g...

  • Page 73

    69 3. With screen still removed from oil cooler, remove sediment from oil cooler by allowing running water to flow through the cooler fins. 4. Re-install cooler guard screen. 5. Check to make sure wire connection on both heat light sensor and fan sensor are secure and are in place. If sensor wires a...

  • Page 74: General Lubrication

    70 1 o o o 2 3 4 g 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 servic...

  • Page 75: Troubleshooting

    71 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 76: Ignition System Check

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

  • Page 77: Troubleshooting

    73 1. F uel 2. C ompr esssion 3. Ignition 4. B att er y c heck if ther e is fuel in the fuel tank. U se the elec tr ic star ter t o see if ther e is compr ession. R emo ve the spar k plug and check the elec tr o des . U se the elec tr ic star ter . Ther e is fuel some fuel n o fuel ther e is c ompr ...

  • Page 78: Transporting

    74 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 79: Cleaning Procedure

    75 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 80: Washing Your Atv

    76 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 81: Storage Procedure

    77 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 82: Serial Number Location

    78 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 number is stamped on front of atv frame. The engine number is located on t...

  • Page 83: Specifications Wd400U-2

    79 specifications wd400u-2 dimensions and dry mass overall length......................................................................1968mm (77.5 in) overall width........................................................................1060mm (41.73 in) overall height..................................

  • Page 84

    80 electrical ignition type...................................................................................Cdi generator system..........................................................................A.C. Magneto battery type, voltage, capacity.......................................................

  • Page 85

    81 ignition c oil spar k plug b att er y 12v 12a h po w er lo ck m ast er fuse b ox m m b 15a m agnet o cdi c omp . R ec tifier 4w d shif t swit ch 4w d shif t mot or m m oil c o oling swit ch fan mot or fr on t br ak e swit ch r ear br ak e swit ch fgear ngear rgear r igh t swit ch assembly high&l ...

  • Page 86: Warranty

    82 baja motorsports – 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,...

  • Page 87

    83 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 original...

  • Page 88

    84 use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties. Limited liability the liability of the distributor under this emission control system warranty is lim- ited solely to the remedying of defects in material workman...

  • Page 89: Baja Inc.

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