Baja motorsports WD400U-2 User manual

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 the U.S. Consumer Product Safety Commission.
Please obtain, review and follow provincial/ municipal governments acts and
regulations pertaining to owning and operating an off-road vehicle.
WD400U-2
REV. B (US)
012809
For More information on ATV Safety Contact
the Baja ATV Safety Hotline at: 866-260-8630

“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 the labels on your
vehicle. Failure to follow these warning can result in
SEVER INJURY OR DEATH.
Keep the owner’s manual with your vehicle at all times.”
Failure to follow the age recommendations for this ATV.
Failure to supervise children under 16 on ATV models intended for their use.
Use by children of ATVs that are not recommended for their age can lead to severe
injury or death of the child.
Even though a child may be within 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 Model) ATV. An ATV of appropriate size intended for recreational
use under adult supervision by an operator under age 16. Youth model ATVs can
further be categorized as follows:
Category Y-6+ ATV. A Category Y-6+ ATV is a youth model ATV that is intended for
use by children age 6 or older
Category Y-10+ ATV. A Category Y-10+ ATV is a youth model ATV that is intended for
use by children age 10 or older.
Category Y-12+ ATV. A Category Y-12+ ATV is a youth model ATV that is intended for
use by children age 12 or older.
Category T (Transitional Model) ATV. A Category T ATV is an ATV of appropriate
size that is intended for recreational use by an operator age 14 or older under adult
supervision, or by an operator age 16 or older.
!WARNING

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 replace your Baja Inc. 400cc
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
The wheels are bent or broken
Fender bent or broken due to abuse
Any sign of impact, accident, jumping, spin-outs or roll over.
BAJA MOTORSPORTS is not liable for any damage claim or
liability claim personal or otherwise resulting from the operation of
this product in any way.
Should you experience a problem with your vehicle, please call Baja Inc.
customer service line toll free at 1-888-863-2252 between the hours of
7am and 5pm Monday through Friday MST (Mountain Standard Time).
MDT (Mountain Daylight Time) during the daylight saving time. You will be
instructed how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.

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.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
CALIFORNIA PROPOSITION 65
WARNING
!
!

1
Table of Contents
IMPORTANT ........................................................................................................ 3
FOREWORD ........................................................................................................ 3
NOTICE TO THE USER....................................................................................... 4
BAJA INC. WD400U-2 ATV ................................................................................. 8
FUEL AND OIL..................................................................................................... 9
LOCATION OF WARNING LABELS ................................................................... 10
INDICATOR LIGHTS............................................................................................ 12
HANDLEBAR & SWITCH.................................................................................... 13
LEFT HANDLEBAR..................................................................................... 13
RIGHT HANDLEBAR................................................................................... 14
REAR FOOT BRAKE .................................................................................. 14
FUEL VALVE................................................................................................ 15
FUEL TANK CAP ......................................................................................... 15
SEAT LOCK ................................................................................................. 16
RIDING YOUR ATV.............................................................................................. 17
BEFORE RIDING ......................................................................................... 17
INSPECTION BEFORE RIDING .................................................................. 18
SAFETY GEAR ............................................................................................ 20
BREAK-IN .................................................................................................... 21
STARTING THE ENGINE............................................................................. 25
STARTING OFF ........................................................................................... 26
MANUAL PULL START ............................................................................... 27
DRIVE SELECT............................................................................................. 28
2WD/4WD BUTTON..................................................................................... 29
BRAKING..................................................................................................... 30
TURNING ..................................................................................................... 31
OPERATION ON HILLS............................................................................... 32
RIDING OVER OBSTACLES....................................................................... 35
SKIDDING OR SLIDING .............................................................................. 36
RIDING THROUGH WATER ........................................................................ 37
RIDING IN COLD WEATHER ...................................................................... 38
DRESSING FOR COLD WEATHER RIDING............................................... 39
RIDING ON SNOW OR ICE ......................................................................... 40
ACCESSORY USE AND VEHICLE LOADING.................................................... 41
INSPECTION AND MAINTENANCE ................................................................... 43
TOOLS ......................................................................................................... 45
SPARK PLUG .............................................................................................. 45
VALVE INSPECTION.......................................................................................47
BATTERY INSTALLATION .......................................................................... 48
FUSE REPLACEMENT................................................................................ 52

2
Table of Contents
HEADLIGHT/TAILLIGHT REPLACEMENT................................................. 52
THROTTLE LEVER ADJUSTMENT............................................................ 53
IDLE SPEED ADJUSTMENT....................................................................... 54
FUEL HOSE ................................................................................................. 54
ENGINE OIL/OIL FILTER............................................................................. 55
AIR FILTER .................................................................................................. 57
FRONT/REAR GEAR CASE LUBRICATION .............................................. 60
TIRES ........................................................................................................... 61
FRONT DISK BRAKES ............................................................................... 64
REAR DRUM BRAKE ................................................................................. 64
MUFFLER/ SPARK ARRESTER.................................................................. 66
OIL COOLER CLEANING PROCEDURE.................................................... 68
GENERAL LUBRICATION........................................................................... 70
TROUBLESHOOTING......................................................................................... 71
TRANSPORTING................................................................................................. 74
CLEANING PROCEDURE................................................................................... 75
STORAGE PROCEDURE.................................................................................... 77
SERIAL NUMBER LOCATION ............................................................................ 78
SPECIFICATIONS................................................................................................ 79
EMISSION SYSTEM CONTROL WARRANTY....................................................

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-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.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
WARNING
Indicates a potential hazard that could result in death or injury.

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 age 16 and older, but the users manual is
written for adults who will be supervising the children, we strongly recommend ,
therefore, that you review this entire manual with your child and carefully explain
the instructions, requirements, and warnings it contains so that your child can
understand them.
Children differ in skills, physical abilities, and judgement. Some children may not
be able to operate an ATV safely. Parents should supervise their child’s use of the
ATV at all times. Parents should permit continued use only if they determine that
the child has the ability to operate the ATV safely.
It is very important 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 cars. 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.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
· Read this manual and all labels carefully and follow the operating procedures
described.
· Never operate an ATV without proper instruction. Take a training course.
Beginner should receive training from a certied instructor. Contact an
authorized ATV dealer or call SVIA at 1-800-887-2887 to nd out about the
training courses nearest you.
· Always follow these age recommendations:
Category Y (Youth Model) ATV. An ATV of appropriate size intended for recreational
use under adult supervision by an operator under age 16. Youth model ATVs can
further be categorized as follows:
Category Y-6+ ATV. A Category Y-6+ ATV is a youth model ATV that is intended for
use by children age 6 or older

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, driveways,
parking lots and streets.
· Never operate an ATV on any public street, road or highway, even a dirt or
gravel one.
· Never operate an ATV without wearing an approved motorcycle helmet that
ts properly. You should also wear eye protection (goggles or face shield),
gloves, boots, long-sleeved shirt or jacket, and long pants.
· Never consume alcohol or drugs before or while operating this ATV.
· Never operate this ATV at excessive speeds. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
· Never attempt wheelies, jumps, or other stunts.
· Always inspect your ATV each time you use it to make sure it is in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules 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 terrain.
Always be alert to changing terrain conditions when operating the ATV.
· Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control the ATV on such terrain.
Always be especially cautious on these kinds of 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 that ATV on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
Category Y-10+ ATV. A Category Y-10+ ATV is a youth model ATV that is intended
for use by children age 10 or older.
Category Y-12+ ATV. A Category Y-12+ ATV is a youth model ATV that is intended
for use by children age 12 or older.
Category T (Transitional Model) ATV. A Category T ATV is an ATV of appropriate
size that is intended for recreational use by an operator age 14 or older under adult
supervision, or by an operator age 16 or older.

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
over the top of any hill at high speed.
· Always follow proper procedures for going down hills and for braking on hills
as described in this manual. Check the terrain carefully before you start down
any hill. Shift your weight backward. Never go down a hill at high speed. Avoid
going down a hill at an angle that would cause the vehicle to lean sharply to
one side. Go straight down the hill where possible.
· Always follow proper procedures for crossing the side of a hill as described
in this manual. Avoid 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.
· Always use proper 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 procedure for
braking described in this manual. Dismount on the uphill side or to a side
if pointed straight 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 slowly and be very cautious in
order to reduce the chance of skidding or sliding out of control.
· Never operate an ATV in fast owing water or in water deeper than that
specied in this manual. Remember that wet brakes may have reduced
stopping ability. Test your brakes after leaving water. If necessary, apply
them several times to let friction dry out the linings.
· Always use the size and type tires specied in this manual. Always maintain
proper tire pressure as described in this manual.

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.
· The combined weight of the rider and any accessories or cargo must never
exceed the vehicle’s load capacity of 463 lbs (210 kg).
· Do not tow a trailer. This vehicle is not designed for such use.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
Commission at 1-800-638-2772, SVIA 1-800-887-2877, or Baja Safety Hotline at
1-866-260-8630

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 ll
plug

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 prescribe oil, you will realize the best lubrication for
the engine.
Use the chart to select a viscosity rating based on the temperature range in
your area.
SAE 10W-30
SAE 20W-40
ENGINE
TEMP.
°C
°F
-30
-22
40
104
-20
-4
-10
14
0
32
10
50
20
68
30
86
SAE 5W-30

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 difcult to read, you should
get a replacement by contacting Baja Motorsports.
1
2
3
4
5
6
7
8

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
to operate this ATV.
WARNING
NEVER ride as a passenger.
Passenger can cause a loss
of control, resulting in
SEVERE INJURY or DEATH.
LOADING
dislodge from the rim.
Maximum vehicle capacity is: 210Kg (463 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
IN SEVERE INJURY OR DEATH.
COLD TIRE PRESSURE:
Recommended: Front 5psi, Rear 5psi
Never set tire pressure below the
recommended level. It could cause the tire to
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN
APPROVED HELMET
AND PROTECTIVE
GEAR
NEVER OPERATE
:
another vehicle.
ALWAYS :
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
Without proper training or instruction.
At speeds too fast for your skills or the condition.
On public roads, a collision can occur with
With passenger-passengers affect balance and
steering and increase risk of losing control.
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.
WARNING
80kg (176lbs) NEVER sit here
WARNING
LOAD LIMIT
40kg (88lbs) NEVER sit here
WARNING
LOAD LIMIT
1
2
3
4
5
6
7
8

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 Temperature warning- Light will illuminate when oil temperature is too
hot. Stop the engine as soon as possible and allow engine to cool for at least
10 minutes.
Fan- Light will illuminate when fan is “ON”.
Headlight- Light will illuminate when headlights are “ON”.
Kilometers/hour- Light will illuminate when odometer is reading in kilome-
ters.
Miles per hour- Light will illuminate when odometer is reading in miles.
Reverse Light
Indicator
Neutral Light
Indicator
Four Wheel Drive
Indicator
Oil Temperature
warning
Miles per hour
Fan
Headlight
Kilometers/
hour
Km/h to mph button

13
Light switch
Start Button Manual Choke lever
Parking brake
OpenClosed
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 position the headlight, taillight and meter light
will NOT come on.
On/Off switch
On. When the switch is placed in this position the engine is on.
Off. When the switch is placed in this position the engine is off.
Start Button
Depress start button to start the engine.
Manual Choke switch
When switch is left, the choke is closed. When switch is right, the choke is
open.
Parking Brake
When the parking brake is set the ATV will not be able to move. To set: Hold
brake handle in and push parking brake down.
LEFT HANDLEBAR SWITCHES
AND PARKING 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 lever
Squeeze lever toward hand grip to apply front brakes.
2WD/4WD button
When this button is depressed the ATV is in Four wheel drive. When
button is pressed again (button out) , the ATV is Two wheel drive.
Only press this button when the ATV is stopped. Do not press this
button while the ATV is moving.
Throttle cable adjustment
Remove cover and rotate throttle cable adjusting screw to adjust the
slack of throttle cable.
RIGHT HANDLEBAR, FRONT BRAKE
LEVER AND THUMB THROTTLE
Throttle lever
2WD/4WD button
Brake uid reservoir Front brake
lever
Throttle cable
adjustment

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 ow into the carburetor when the
engine is running or being started.
“OFF” position (arrow pointing left)
In this position the fuel is shut off from the carburetor. The fuel
valve needs to be placed in this position when the ATV is not in use
“RESERVE” position (arrow pointing up)
If the fuel level in the fuel tank becomes to low for the engine to
stay running while the fuel valve is in the “ON” position, turn
the fuel valve to “RESERVE”. This will allow the engine to begin
using the reserve fuel supply. You will need to re-fuel as soon as
possible. Once re-fueled, turn the valve back to the “ON “ Position
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 close it
securely. Be sure that the vent tube securely
connects to the cap as shown
“ON” “OFF” “RESERVE”

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 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.
Stop adding fuel when the fuel level reaches the bottom of the ller
neck.
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 installed.