Baja motorsports CN90U-2 User manual

I
CN90U-2/WD90U-2/WD90UR-2 ATV
Read this manual carefully. It contains important safety information.
Children under the age of 16 should be supervised by a responsible adult.
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.
Minimum Age Requirement -12
CN90U-2
WD90U-2
OWNER’S MANUAL
WD90UR-2 REV B
052008

II
Congratulations on your purchase of the
CN90U/WD90U/WD90UR ATV.
It is warranted to be free of manufacturing defects in the material of
workmanship for a period of 90 days from the date of purchase. During the
warranty period BAJA, INC. will at its option, repair, provide replacement
parts or replace your BAJA INC. 90cc ATV at no charge. This warranty does
not cover normal wear items or damage caused by neglect or misuse of the
product.
Engine Warranty – 90 days
Frame Warranty – 90 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 liable for any damage claim or liability claim person or
otherwise resulting from the operation of this product in any way.
Should you experience a problem or need to return your 90cc ATV for repair, please
call the BAJA INC. customer service department TOLL FREE at 1-888-863-BAJA (2252)
between the hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm
PST. During DST hours change to MT. You will be instructed how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.

III
This manual should be considered a permanent part of the vehicle
and should remain with the vehicle when resold or otherwise
transferred to a new user or operator. The manual contains
important safety information and instructions which should be read
carefully before operating the vehicle.
!
The engine exhaust from this product contains chemi-
cals known to the State of California to cause cancer,
birth defects or other reproductive harm.
CALIFORNIA PROPOSITION 65
! WARNING
! WARNING

1
SAFETY ...............................................................................................................3
IMPORTANT ................................................................................................3
NOTICE TO THE USER...............................................................................4
ATV 90..................................................................................................................7
FUEL AND OIL.....................................................................................................8
LOCATION OF LABELS......................................................................................9
CONTROL FUNCTIONS......................................................................................12
LEFT HANDLEBAR.....................................................................................12
RIGHT HANDLEBAR...................................................................................12
FUEL VALVE................................................................................................13
FUEL TANK CAP.........................................................................................13
SEAT LOCK .................................................................................................14
RIDING YOUR ATV..............................................................................................15
WHAT YOU SHOULD KNOW BEFORE RIDING ........................................15
INSPECTION BEFORE RIDING ..................................................................16
SAFETY GEAR ............................................................................................18
BREAK-IN ....................................................................................................19
STARTING THE ENGINE.............................................................................20
STARTING OFF ...........................................................................................24
BRAKING.....................................................................................................25
TURNING .....................................................................................................26
SKIDDING OR SLIDING ..............................................................................27
OPERATION ON HILLS...............................................................................28
CLIMBING A HILL......................................................................... 29
DESCENDING A HILL................................................................... 30
TRAVERSING A SLOPE................................................................ 31
RIDING OVER OBSTACLES.......................................................................31
RIDING THROUGH WATER ........................................................................32
RIDING IN COLD WEATHER ......................................................................33
DRESSING FOR COLD WEATHER RIDING..................................34
RIDING YOU ATV ON SNOW AND ICE .........................................35
ACCESSORY USE AND VEHICLE LOADING....................................................36
WEIGHT LIMITS.............................................................................. 37
INSPECTION AND MAINTENANCE ...................................................................38
MAINTENANCE SCHEDULE.......................................................................38
TOOLS .........................................................................................................40
SPARK PLUG ..............................................................................................40
BATTERY INSTALLATION ..........................................................................42
ENGINE SPEED GOVERNOR.....................................................................46
THROTTLE LEVER ADJUSTMENT ............................................................48
IDLE SPEED ADJUSTMENT.......................................................................49
FUEL HOSE .................................................................................................49
TABLE OF CONTENTS

2
ENGINE OIL.................................................................................................50
CHANGING ENGINE OIL...............................................................51
AIR FILTER ..................................................................................................52
REMOVAL...................................................................................... 53
WASHING.......................................................................................53
DRIVE CHAIN/SPROCKETS.......................................................................55
INSPECTING THE DRIVE CHAIN........................................................55
INSPECTING THE SPROCKETS.........................................................55
DRIVE CHAIN CLEANING, OILING AND ADJUSTING......................56
TIRES ...........................................................................................................57
BRAKING.....................................................................................................59
FRONT DRUM BRAKES .....................................................................59
REAR HYDRAULIC DISC BRAKE AND PARKING BRAKE ..............60
GENERAL LUBRICATION...........................................................................61
TROUBLESHOOTING.........................................................................................62
FUEL SUPPLY CHECK................................................................................62
IGNITION SYSTEM CHECK ........................................................................63
TRANSPORTING.................................................................................................64
CLEANING PROCEDURE...................................................................................65
PREPARATION FOR CLEANING................................................................65
WASHING YOUR ATV .................................................................................66
INSPECTION AFTER CLEANING...............................................................66
STORAGE PROCEDURE....................................................................................67
SERIAL NUMBER LOCATION ............................................................................68
SPECIFICATIONS................................................................................................69
WIRE DIAGRAM...................................................................................................70
EMISSION CONTROL SYSTEM WARRANTY.....................................................71
TABLE OF CONTENTS

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 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 follow the warnings contained in this manual
could result in INJURY or DEATH.
It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
All information, illustrations, photographs and specications contained in
this manual are based on the latest product information available at the time
of publication. Due to improvements or other changes, there will be some
discrepancies in this manual. We reserve the right to make product changes at
any time, without notice and without incurring any obligation to make the same
or similar changes to the vehicle previously built or sold.
WARNING
Indicates a potential hazard that could result in
death or injury.
CAUTION
Indicates a potential hazard that could result in
vehicle damage.
WARNING-or-CAUTION
The rst part will identify a POTENTIAL HAZARD.
The second part will describe WHAT COULD HAPPEN if
you ignore the WARNING or CAUTION.
The third part will describe HOW TO AVOID THE
HAZARD.
SAFETY

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 HAZARDOUS TO THE OPERATOR. An
ATV is different from other vehicles including motorcycles and cars. A collision
or rollover could occur quickly, even during routine maneuvers such as turning
and driving on hills or over obstacles if you fail to take proper precautions.
· Read this manual and labels on the ATV carefully and follow the operations
procedures as described.
· Never operate the ATV without proper instruction. Take a training course.
Beginners should be trained by a licensed instructor. Always follow the
age recommendations
· Never carry a passenger on an ATV.
· Always avoid operating an ATV on paved surfaces, including: sidewalks,
paths, parking lots, driveways, streets, roads, and highways. Never
operate this or any ATV on a public street, road or highway where motor
vehicles are in operation.
· Never operate an ATV without wearing a DOT approved motorcycle helmet
which ts properly. Operators should also wear eye protection (goggles or
face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
WARNING
SEVERE INJURY OR DEATH can result if you
do not follow these instructions.
SAFETY

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
operating condition. Always follow the inspection and maintenance
procedures and schedule described in this manual.
· Always keep both hands on the handlebar and both feet on the footrests of
the ATV during operation.
· Always go slow and be extremely careful when operating on unfamiliar
terrain. Always be alert to the changing terrain conditions when operating
the ATV.
· Never operate on excessively rough, slippery or loose terrain until you
have learned and practiced the necessary skills to control the ATV on such
terrain.
· Always follow proper procedures for turning as described in this manual.
Practice turning at low speeds before attempting to turn at faster speeds.
Do not turn at excessive speeds.
· Never operate the ATV on hills that are too steep for the ATV or for the
operator’s ability. Practice on smaller hills before attempting larger hills.
· Always follow the 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 slippery or loose surfaces. Shift your weight forward.
Never open the throttle suddenly. Never go over the top of a hill at high
speeds.
· Always follow proper procedures for going down hills as described in this
manual. Check the terrain carefully before starting to go down any hill.
Shift your weight backward. Never go down a hill at an angle that would
cause the vehicle to lean sharply to one side. Go straight down the hill if
possible.
· Always follow proper procedures for crossing the side of a hill as described
in this manual. Avoid operation on hills with excessively slippery or loose
surfaces. Shift your weight to the uphill side of the ATV. Never attempt
to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side
of a steep hill if possible.
SAFETY

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
pointed straight to uphill. Turn the ATV around and remount, following the
procedure described in this manual.
· Always check for obstacles before operating in a new area. Never attempt
to operate over large obstacles, such as large rocks or fallen trees. Always
follow proper procedures when operating over obstacles as described in
this manual.
· Always be careful when skidding or sliding. Learn to safely control
skidding or sliding by practicing at low speeds and on level, smooth terrain.
On extremely slippery surfaces, such as ice, go slow and be very cautious
in order to avoid going out of control when skidding or sliding.
· Never operate an ATV in fast owing water or in water deeper than that
specied in this manual. Remember that wet brakes can reduce stopping
ability. Test your brakes after leaving water. If necessary, apply them
several times to let friction linings dry out.
· Always use the tires with proper size and type tires specied in this manual.
Always maintain proper tire pressure as described in this manual.
· Never modify an ATV through improper installation of accessories.
· Never exceed the stated load capacity for an ATV. Cargo should be
distributed properly and attached securely. Reduce speed and follow
instructions in this manual for carrying cargo. Allow longer distance for
braking.
· The combined weight of the rider and any accessories or cargo must never
exceed the vehicle’s load capacity of 100 Kg (220 lbs.)
· Do not tow a trailer. This vehicle is not designed for such use.
SAFETY

7
[Right]
[Left]
6
6
ATV90
Rear Tire
Gas Cap
Seat
Front Rack
Rear Rack
Carburetor
Mufer
Front Tire
Oil cap
Front shocks
Rear shock
Choke
Tail Light
Head lights
Fuel Shut off
Valve
Gas Cap vent
hose

8
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 prescribe oil, you will realize the best lubrication for
engine.
Use the chart to select a viscosity rating based on the temperature range in
your area.
NOTE: In very cold weather (below 5°F (-15°C), use SAE10W-50 for good
starting and smooth operation.
SAE 10W-30
SAE 20W-40
SAE 10W-50
ENGINE
TEMP.
°C
°F
-30
-22
40
104
-20
-4
-10
14
0
32
10
50
20
68
30
86
FUEL AND OIL

9
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 difcult to read, you should
get a replacement by contacting BAJA INC..
LOCATION OF LABELS
1
Operation of the ATV by children under the
age of 12 increases the risk of severe injury
or death.
Adult supervision requires for children
under age 16.
NEVER permit children under age 12 to
operate this ATV.
WARNING
UNDER
12
NEVER ride as a passenger.
Passenger can cause a loss
of control, resulting in
SEVERE INJURY or DEATH.
WARNING
1
324
56
2

10
3
LOCATION OF LABELS
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 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.
ALWAYS:
Use proper riding techniques to avoid vehicle overturns
on hills and rough terrain and in turns.
Avoid paved surfaces-pavement may seriously affect
handling and control.
LOCATE AND READ OWNER’S MANUAL CAREFULLY BEFORE OPERATING.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

11
LOCATION OF LABELS
5
6WARNING
LOAD LIMIT
4.5kg (10 lbs) NEVER sit here
WARNING
LOAD LIMIT
9.1kg (20 lbs) NEVER sit here
4

12
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 depress parking brake pin, set the parking
brake lever.
Throttle 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 stop with in the “Run” position
The engine can be started.
Rear brake lever
Apply the rear brake by squeezing the rear brake lever towards the grip.
Parking Brake
To set the parking brake, squeeze the rear brake lever, and depress the parking
brake pin.
Electric starting button
Engine Stop
switch
Electric Start
Button
Rear Brake lever Parking
Brake Pin
Front Brake
lever
Parking
Brake Lever
Throttle
Lever
Throttle
limiter
screw
Lock Nut
Light Switch
Parking
Brake Pin

13
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 adjusting screw counterclockwise to increase the
maximum speed of the ATV.
4. After nished, tighten the lock nut
FUEL VALVE
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 body; turn the fuel tank
cap counterclockwise. To close the fuel tank cap,
turn it clockwise and tighten it securely. Be sure
that the vent tube securely connects to the cap
as shown.
Fuel level
Filler neck
“ON” position
In this position, fuel will ow to
the carburetor when the engine is
running
or being started.
“OFF” position
No fuel will ow into the
carburetor.
Fuel tank
cap
CONTROL FUNCTIONS

14
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 down rmly.
WARNING
Overlling the fuel tank could be hazardous.
If you overll the fuel tank, fuel may overow when it expands. Expanding
is due to heat from engine or sun. Overheated fuel could easily catch re.
WARNING
Improper fueling of the ATV could be hazardous.
Failing to follow safety precautions when refueling could result in a re or
let you to breathe toxic fumes.
Refuel in a well ventilated area. Make sure the engine is off and avoid
spilling fuel on a hot engine. Do not smoke, and make sure there are no
open ames or sparks in the area. Avoid breathing gasoline vapors. Keep
children and pets away when you are refueling the ATV.
WARNING
Improperly installing the seat could be hazardous.
Failing to install the seat properly could allow the seat to move and cause
the rider to lose control.
Make sure you are in proper position and the seat is attached securely
when you install it.
CONTROL FUNCTIONS

15
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 nd a good place to practice the skills. Find a at, open
area with enough space to practice the new skills.
Make sure that it is legal to ride in the area you selected. Review the local laws and make
sure you are not trespassing. Call the police if you don’t know where you can ride.
Protect your riding areas. When you are riding, remember to keep the terrain in good
condition. Don’t destroy plants, trees or other vegetation. Don’t litter and don’t bother
wildlife. With your help, your riding area can remain open for use in the future.
After you have found a good place to practice, review the control system on your ATV
before riding. Learn to nd 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 follow all provincial and municipal
government acts and regulations pertaining to owning and operating an off-road vehicle.
WARNING
Operating this ATV without proper instruction could be hazardous.
The risk of riding could increase greatly if you do not know how to operate the ATV
properly under different situations and in different types of terrain.
Beginners and inexperienced operators should complete a certied training
course. You should regularly practice the skills learned in the course and the
operating techniques described in this user’s manual. For more information about
the training course, visit www.svia.org or call 800-887-2887.
For more information on ATV safety and other provincial and municipal
governmental acts and regulation pertaining to owning and operating an off-road
vehicle visit one of the following web-sites:
www.svia.org
www.cpsc.gov
www.mmic.ca/CATV/
RIDING YOUR ATV

16
INSPECTION BEFORE RIDING
WARNING
Failing to inspect the ATV before operating could be hazardous. Failing to
perform proper maintenance could also be hazardous.
Failing to inspect and maintain your ATV could increase the chances of an
accident or equipment damage
Always inspect your ATV each time before riding, and make sure it is in a safe operating
condition. Refer to the INSPECTION AND MAINTENANCE section in this manual.
ITEM TO CHECK CONTENT
Steering Smoothness; No restriction of movement; No
play or looseness
Brakes Proper brake lever free play; enough brake
force; Parking brake effectiveness
Tires 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
Engine stop switch Proper operation
Engine oil Proper level – Check the oil by inspecting the
Engine Oil indicator located at the bottom of
the engine. The engine oil should completely
ll the view window as indicated in the picture.
Add oil if the window is not completely lled.
Throttle Proper free play of throttle lever; Smooth
response; Quick return to idle position
Drive chain Proper tension; adequate lubrication; No excessive
wear or damage
General condition Bolts and nuts are tight; No rattle from any
parts of the engine when running; No visible
evidence of Damage
RIDING YOUR ATV

17
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 hazardous.
Overloading could cause changes in vehicle handling and could lead to an
accident.
Never exceed the stated load capacity for this ATV. Refer to the
ACCESSORY USE AND VEHICLE LOADING section in this manual.
WARNING
Operating this ATV with improper modications could be hazardous.
Improper installation of accessories or modications to this vehicle may
cause changes in handling. In some situations, this could lead to an
accident.
Never modify this ATV through improper installation or use of
accessories. Refer to the ACCESSORY USE AND LOADING section in
this manual.
WARNING
Operating thisATV with improper tires, or improper tire air pressure could be
hazardous.
If you use improper tires or improper air pressure, you may lose control of the
ATV. This will cause an accident.
Always use the tires with size and type tires specied in this user’s manual.
Always maintain proper tire air pressure as described in the INSPECTION
AND MAINTENANCE section.
RIDING YOUR ATV