Baja motorsports BA90-2, Owner'S Manual

Page 1: ...dult 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 OWNER S MA...

Page 2: ...in the age group for which an ATV is recommended he or she may not have the skills abilities or judgement needed to operate the ATV safely and may be involved in a serious accident Category Y Youth Mo...

Page 3: ...0 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not...

Page 4: ...to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle The engine exhaust from this product contains ch...

Page 5: ...G 18 INSPECTION BEFORE RIDING 19 BREAK IN 21 STARTING THE ENGINE 22 SAFETY GEAR 25 STARTING OFF 27 BRAKING 28 TURNING 29 OPERATION ON HILLS 30 CLIMBING HILLS 30 DESCENDING A HILL 31 RIDING OVER OBSTAC...

Page 6: ...SPROCKETS 59 DRIVE CHAIN CLEANING OILING AND ADJUSTING 60 TIRES 61 BRAKING 64 FRONT DRUM BRAKES 64 REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE 65 GENERAL LUBRICATION 66 TROUBLESHOOTING 67 FUEL SUPPLY...

Page 7: ...intenance easier or instructions clearer WARNING and CAUTION are arranged like this This user s manual contains important safety and maintenance information Read it carefully before riding Failing to...

Page 8: ...that every child who rides the ATV should complete a training course THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and ca...

Page 9: ...chedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar...

Page 10: ...r procedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pr...

Page 11: ...in this manual for carrying cargo Allow greater distance for braking The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 220 lbs Do not tow a...

Page 12: ...8 Right Left 6 ATV 90 Rear Tire Gas Cap Seat Carburetor Muffler Front Tire Oil cap Front shocks Choke Tail Light Head lights Fuel Shut off Valve Gas Cap vent hose Shift Lever...

Page 13: ...our stroke engine Please use oil as described in the chart below By using prescribe oil you will realize the best lubrication for engine Use the chart to select a viscosity rating based on the tempera...

Page 14: ...u should get a replacement by contacting BAJA INC LOCATION OF LABELS 1 Operation of the ATV by children under the age of 10 increases the risk of severe injury or death Adult supervision requires for...

Page 15: ...At speeds too fast for your skills or the condition On public roads a collision can occur with another vehicle With passenger passengers affect balance and steering and increase risk of losing control...

Page 16: ...12 4 LOCATION OF LABELS...

Page 17: ...crease throttle while shifting gears Do not place your foot on gear shift lever except to shift gears while operating vehicle doing so could cause the ATV to shift unexpectedly NOTE Only shift to low...

Page 18: ...Adjusting Screw To limit the throttle screw in throttle limiter screw HANDLEBAR SWITCHES LEFT HANDLEBAR With the Engine stop switch in the Stop position The engine cannot be started With the Engine s...

Page 19: ...There are two positions ON and OFF See the picture below for the correct operation of these two fuel valves FUEL TANK CAP To open the fuel tank cap take the end of the vent tube out from the vehicle...

Page 20: ...r 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 Refuel in a well ventilated area Make sure the engi...

Page 21: ...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 pull the lanyard to remove the remote stop pin wh...

Page 22: ...ystem on your ATV before riding Learn to find these controls without looking for them because you will not have time to look for them when you are riding Canadian residents must obtain review and foll...

Page 23: ...Proper air pressure Enough tread depth No cracks rips or other damages Fuel Enough fuel for the intended trip Fuel hose connected securely No damage to fuel tank or cap Fuel tank cap closed securely...

Page 24: ...s ATV with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may cause changes in handling In some situations this could lead to an accide...

Page 25: ...o cool Although it is essential to place some stress on the engine components during break in you must be careful not to load the engine too much Avoid Constant Low Rotating Speed Operating the engine...

Page 26: ...TART to start the engine 6 After engine has warmed up set choke to up position WARNING Running your ATV indoors where there is little or no ventilation could be hazardous Breathing in exhaust gases fr...

Page 27: ...on public streets roads or highways could be hazardous You may collide with another vehicle if you ride on the public roads Never operate this ATV on any public street road or highway even dirt or gr...

Page 28: ...kills and operator experience 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...

Page 29: ...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 throt...

Page 30: ...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 c...

Page 31: ...ure to apply the rear brake before you release the parking brake Release front parking brake pin and front brake lever open throttle gradually to move forward WARNING Opening the throttle suddenly cou...

Page 32: ...you begin to turn BRAKING WARNING Braking hard on slippery surfaces could be hazardous The ATV could skid and go out of control if you brake too hard Apply the brakes lightly and carefully on slippery...

Page 33: ...your body weight farther toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside of the turn increase as the speed or the turn sharpness...

Page 34: ...hrottle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at a high speed An obstacle a sharp drop or another vehicle or person could be on the o...

Page 35: ...TE a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Av...

Page 36: ...cle to lean sharply to one side Go straight down the hill if possible WARNING Improperly crossing hills or turning on hills Could cause loss of control or cause ATV to overturn Never attempt to turn t...

Page 37: ...hill Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to a side if pointe...

Page 38: ...control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain O...

Page 39: ...en crossing WARNING Operating this ATV through deep or fast flowing water Tires may float causing loss of traction and loss of control which could lead to an accident Never operate this ATV in fast fl...

Page 40: ...ore riding If the brakes do not regain full stopping power ask your authorized service center to check them before you continue riding your ATV Water that enters the brakes may freeze after you park y...

Page 41: ...ntion of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be...

Page 42: ...of control Severe injury or death could occur if you lose control of the ATV Go slowly and be careful when riding on snow covered terrain Always be alert to changing terrain conditions WARNING Riding...

Page 43: ...ity of 220 lbs 100 kg 2 Check accessory mounting brackets and other attachments to make sure they provide a rigid non movable mount 3 Accessories added to the handlebar of the ATV should be as light a...

Page 44: ...the vehicle Locate cargo weight as close to the center of the vehicle if possible 7 Secureyourloadwell Shiftingweightcanaffectyourabilitytohandlethe vehiclesafely 8 Ride at slow speeds and avoid hill...

Page 45: ...C Exhaust pipe bolt and muffler bolt T T T Cylinder head cylinder and muffler C C Spark plug C R Valve clearance Check Adjust I Idle Speed I I I Throttle cable I I I Fuel line I I I Brakes I I I Tire...

Page 46: ...nc CAUTION If you use your ATV under severe conditions it will need maintenance more often than shown in the chart Operating your ATV under severe conditions causes more wear on your ATV Severe condit...

Page 47: ...e engine may need adjustment or another plug type may be needed Consult your authorized dealer or BAJA INC if your plug insulator is not a light brown color CAUTION Failing to use the proper spark plu...

Page 48: ...se a thickness gauge to check the gap CAUTION Improper installation of the spark plug could damage your ATV An overly tight or cross threaded spark plug will damage the aluminum threads of the cylinde...

Page 49: ...ll make excess noise if the gap is too large in air valve If gap is too small valve operation will be hindered which could result in valve malfunction and failure Therefore air valve gap must be check...

Page 50: ...OM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANT...

Page 51: ...cell Fill battery to upper level mark located on front of battery Repeat step for each of the 6 cells see figure 22 Discard empty electrolyte bottles in a waste area that is inaccessible to children...

Page 52: ...the black negative y cable 3 Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete re install securely all six battery caps see figure 26 Install battery into battery tray l...

Page 53: ...sses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to cool down Do not use fast charging unless it is an emergency At the beginning or end of...

Page 54: ...atch riders ability The engine speed governor is part of the CDI A located under the gas tank of the ATV The governor should only be adjusted by a responsible adult or qualified service technician wor...

Page 55: ...ate the two phillip head screws G with metal jumper F connecting screws together 2 Loosen both phillip head screws G and remove metal jumper F Re tighten phillip head screws after metal jumper is remo...

Page 56: ...not within the correct limits 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...

Page 57: ...t 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 i...

Page 58: ...e proof gloves such as dish washing gloves when changing oil If oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil Recycle or properly dispose of u...

Page 59: ...2 Remove the oil cap 3 Remove the drain bolt and drain oil into proper container 4 Reinstall the drain bolt 5 Pour fresh oil of the specified type through the oil fill hole NOTE Approximately 900ml 1...

Page 60: ...e 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 CAUTION...

Page 61: ...t for tears before and after cleaning it Replace the element with a new one if it is torn CAUTION Failing to position the air cleaner element properly could damage your ATV Air will bypass the air cle...

Page 62: ...TION AND MAINTENANCE REMOVAL OF AIR FILTER 2 Remove Air Filter CLEANING THE AIR FILTER Tap the air filter on a firm surface to dislodge as much dirt and debris as possible If tapping the air filter do...

Page 63: ...authorized service center Inspecting the Sprocket Check sprocket for damage or wear A worn chain can have an adverse affect on the front and rear sprockets When inspecting the sprockets look for the...

Page 64: ...WARNING Failing to inspect the drive chain slack before each use of the ATV could be hazardous Too much chain slack could cause the chain to come off the sprockets resulting in an accident or serious...

Page 65: ...nts designed for use on this ATV and should be installed and used according to instructions If you have questions consult a Baja Inc authorized ATV dealer TIRES WARNING Overloading this ATV or carryin...

Page 66: ...ing 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 t...

Page 67: ...ype patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your ATV in areas here transportation or service facilities are not...

Page 68: ...ons can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brake must be inspected more often than recommended in the MAINTENANCE SCHEDU...

Page 69: ...ke fluid Level Brake fluid reservoir 1 Inspect the rear disk brake caliper and brake fluid reservoir for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose fo...

Page 70: ...rease intervals when you use your ATV in severe conditions Your authorized service center should do general lubrication as shown in the MAINTENANCE CHART The authorized service center will lubricate t...

Page 71: ...ew seconds Shut off engine d Loosen the drain screw and check that the carburetor is filled back up with fuel e If fuel is reaching the carburetor the ignition system should be checked next WARNING Dr...

Page 72: ...ace it if necessary 3 Make sure the fuel valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 16...

Page 73: ...u 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 Do not spill t...

Page 74: ...cooling ability conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries on the ATV Block or sea...

Page 75: ...d Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remo...

Page 76: ...rmal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVI...

Page 77: ...ized 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 stamped on the left side of the crankcase W...

Page 78: ...temperature Compression Ratio 9 1 1 Starting System Electric Spark plug NGK C7HSA AC S102F CHAMPION Z10YC BOSCH U4BC AUTOLIGHT 2795 Fuse 15Ah PARAMETER OF ATV Dimension 58 27 in x 33 in x 35 5 in L x...

Page 79: ...75...

Page 80: ...your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance o...

Page 81: ...ontrol system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance...

Page 82: ...liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise...

Page 83: ...Baja INC PO Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...