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warning - Gardner Inc.

1. 16 BRAKING inss ccsccicsecccevien 21 TURNING A inse e a 22 SKIDDING OR 23 CLIMBING 24 DESCENDING A 26 TRAVERSING 27 RIDING OVER 27 RIDING THROUGH WATER 28 RIDING IN COLD 29 ACCESSORY USE AND VEHICLE 32 INSPECTION AND 33 35 BATTERY INSTALLATION 36 ADJUSTMENT OF THROTTLE LEVER 41 IDLE SPEED ADJUSTMENT 42 PUEL HOSE isc 42 ENGINE OIL 43 45 48 DRIVE CHAIN CLEANING AND OILING 49 TIRES orci 50 BRAKES 51 FRONT BRAKE 52 REAR DISC BRAKE 53 EXHAUS E E T 54 GENERAL LUBRICATION 0 0 eee
2. A WARNING Operation of this ATV by children under age 16 can be hazardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 16 to ride this ATV A WARNING Operating this ATV after consuming alcohol or drugs can be hazardous Alcohol and drugs could seriously affect your judgment and cause you to react more slowly They can also affect your balance and perception Operating this ATV after consuming alcohol or drugs can result in an accident Never consume alcohol or drugs before or while riding this ATV A 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 before riding and make sure it is in a safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this manual A WARNING Operating this ATV 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 specified in this user s manual Always maintain proper tire air pressure as described in the I
3. Baja Extreme 150 Read this manual carefully Never allow anyone under 16 years old ride this ATV This ATV is recommended only for a highly experienced rider OWNER S MANUAL Minimum Age Requirement 16 Always wear a helmet It could save your Life Do not remove the owner s manual form this vehicle Please obtain review and follow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle Motorsports Congratulations on your purchase of the Baja Motorsports Extreme 150 ATV It is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days form the date of purchase During the warranty period BAJA MOTORSPORTS LLC will at its option repair provide replacement parts or replace your Baja Motorsports Extreme 150 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 If 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 LLC 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 Baja Motorsports 150cc ATV for r
4. P O Box 61150 Phoenix Az 85082 Tel 602 443 9180 Toll Free 888 863 2252
5. VEHICLE Place the vehicle on level ground and wash the entire vehicle FUEL Drain the fuel from the fuel tank by a hand pump Drain the fuel from the carburetor by releasing the carburetor drain screw A WARNING Draining the fuel could be hazardous Fuel could catch fire if you do not handle it properly When draining the fuel from the fuel tank be sure to shut the engine off Do not smoke and never drain fuel in an area where there are open flames or sparks Keep pets and children away from the fuel and dispose of the drained fuel properly TIRES Inflate tires to the normal 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 FOR RETURNING TO SERVICE Clean the entire vehicle N Make sure that the vehicle is properly lubricated Perform the INSPECTION BEFORE RIDING as listed in this manual Start the vehicle as outlined in this manual T gt O 60 SPECIFICATIONS SERIAL NUMBER 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 1 is stamped on the frame between the front wheels The engine number 2 is stamped on the left side of the engine case below the cylinder Write down the serial numbers here
6. eee eens eeeeeeeeeeeeeteeeeeeeeeaeees 55 TROUBLESHOOTING 56 TRANSPORTING 58 CLEANING PROCEDURE 59 5 61 SERIAL NUMBER LOCATION 0 cece 62 SPECIFICATIONS ra 63 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 A WARNING SEVER INJURY OR DEATH can result if you do not follow these instructions 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 fit
7. for your future reference 61 BAJA EXTREME 150CC ATV 2WD Drive BAJA EXTREME 150CC ENGINE Combustion Cycle Suspension Front Double Wishbone 7 1 Number of Cylinder Suspension Rear Swing arm 7 1 Bore x Stroke 62mm x 49 5mm Brakes Front Double Sealed Drum Brakes Rear Hydraulic Disc Piston 149 5 cc Displacement Tire Front AT21x7 10 Compression 9 2 1 Ratio Tire Rear 21 10 8 Starter System Electric Overall Dimensions 68 3 x 40 8 x 41 3 Type of carburetor TK BS34 L xW xH Seat Height 29 9 inches Lubrication Pumped Oil Ground Clearance 4 8 inches Cooling Air cooled Wheelbase 44 inches Ignition Type C D I Dry Weight 350lbs 159KG Generator Magneto Fuel Capacity 2 3 gal 9 2liter Clutch Wet multi plate type Color Blue Transmission 5 speed 62 Gear Ratios Final Ratio Low 2 7692 36 13 2nd 1 8823 32 17 3rd 1 4000 28 20 4th 1 1304 26 23 5th 0 9600 24 25 2 667 40 15 WVdSVId LINDYID 0S VHVE BAJA INC EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is de livered to the first purchaser other than an authorized dealer or the date it is first used as a dem onstrator lease or company vehicle whichever comes first and continues for 60 months after that
8. 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 a few minutes Continued exposure in the cold weather could lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms include numbness in the extremities hands feet arms and legs and shivering Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body s core We strongly recommend that if you do any cold weather riding that you familiarize yourself with the symptoms treatment and prevention 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 prepared for bad weather and ATV breakdowns Wear warm water resistant clothing such as thermal underwear snowmobile suits lined gloves and boots and wool socks A WARNING Wearing loose clothing when riding your ATV could be hazardous Loose clothing such as a long scarf or shawl could get caught in an ATV s moving parts Never wear loose clothing when riding your ATV 30 RIDING YOUR ATV ON SNOW AND ICE A WARNING Riding on snow covered terrain even with care could be hazardous The snow may be covering rocks holes ice or other hazards that can cause loss of control Severe injury or de
9. read you should get a replacement by contacting Baja Motorsports A WARNING A WARNING UNDER NEVER ride as a passenger 1 6 Passengers can cause a loss of control resulting in Operation of the ATV by children under SEVERE INJURY or DEATH the age of 16 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 16 to operate this ATV Tire Specified Front AT21 x 7 10 Rear AT21 x 10 8 Maximum tire pressure 4 7psi for operating condition A WARNING Improper ATV use can result in SEVERE INJURY or DEATH IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS 29 ig N OF CONTROL gt yas LOSS CONTROL CAN RESULT IN ALWAYS USE NEVER USE NEVER CARRY NEVER USE SEVER E NJ U RY O R D EATH AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL COLD TIRE PRESSURE NEVER Operate Recommended Front 7 psi Without proper training or instruction Rear 7 psi At speeds too fast for your skills or the condition On public roads a collision can occur with another Never set tire pressure below the vehicle recommended level It could cause the tire to With Passenger passengers affect balance and dislodge from the rim steering and increase risk of losing control ALWAYS gt Use proper riding techniques to avoid vehicle LOADING overturns on hills and rough terrain and in turns Maximum ve
10. E OIL Your Extreme 150 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 SAE 10W 30 ENGINE SAE 20W 40 SAE 10W 50 C 30 20 10 0 10 20 30 40 TEMP 22 4 14 32 50 68 86 104 Use the chart to select viscosity rating based the temperature range your area NOTE very cold weather below 5 F 15 C use SAE 10W 50 for good starting and smooth operation CHECKING THE OIL PROPER LEVEL Check the oil by inspecting the Engine Oil indicator located at the bottom of the engine The engine oil should completely fill the view window as indicated in the picture Add oil if the window is not completely filled or is the oil is at the level marked with an L LOCATION OF LABELS AND SERIAL NUMBERS SERIAL NUMBERS 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 1 is stamped on the frame between the front wheels The engine number 2 is stamped on the left side of the engine case below the cylinder LABELS Read and follow all of the warning 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
11. ION Failing to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy conditions could damage your ATV The air cleaner element could become clogged under these conditions and engine damage may result Always check the air cleaner element after riding in severe conditions Clean or replace the elements as necessary If water gets in the air cleaner case immediately clean the element and the inside of the case 44 REMOVAL 2 Remove the air cleaner cap 3 Take out the air cleaner element holder and air cleaner element WASHING THE ELEMENT Keep clean If riding in wet and dusty area often the filter must be cleaned more frequently Remove the Air Filter Cleaner cover remove the filter Wash the filter element Soak the element in clean oil until soak through then squeeze the filter several times Until the filter dry then reinstall it ANH Air Filter Element Element Guide 45 A 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 engine if the element is torn Examine carefully the element for tears before and after cleaning it Replace the element with new if it is torn CAUTION Failing to position the a
12. MAINTENANCE SCHEDULE Front Brake Adjustment 1 Try to move the vehicle backward and forward when the brake is applied If the front wheels can turn adjust the brake to lock the wheels securely 2 Measure the amount of free play needed to lock the brake lever as shown in above if necessary The free play is about 4 6mm 0 16 0 24in 3 After any adjustment of the brake check again to make sure the front 4 6mm wheels cannot turn when the brake 0 16 0 24in is applied 51 Rear Disk Brake 1 Inspect the brake Inspect the disk brake for leakage If the brake fluid leaks the safety of riding could be affected hose for cracks and the joint for leakage A WARNING Failing to maintain the brake shoes or pads could be hazardous Riding with worn brake shoes pads or shoes that are seriously worn will increase your chance of having an accident If you need to replace brake shoe pads have your authorized service center do the work Inspecting and maintaining the brake shoe pads is recommended Replace the shoe pads in sets A WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harmful if it comes in contact with your skin or eyes Keep brake fluid away from children and pets Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact wit
13. Motorsports at 888 863 2252 for the location of an Authorized Service Center in your area 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 conditions include operating under frequent full throttle or in dusty wet sandy or muddy areas These conditions could cause the ATV to wear more quickly Perform maintenance more often than shown in the chart If you have any questions regarding maintenance intervals consult your authorized service center or call Baja Motorsports CAUTION Using poor quality replacement parts could damage your ATV Poorly made replacement parts could cause your ATV to wear more quickly and shorten its useful life When replacing parts on your vehicle use only genuine replacement parts or their equivalent 34 SPARK PLUG Your ATV is equipped with a DR8EA NGK spark plug To determine if the standard spark plug is in good condition check the color of the plug s center electrode insulator after vehicle operation A brown color indicates that the plug is correct A white or dark insulator indicates that the engine may need adjustment or another plug type may be needed Consult your authorized dealer or Baja Motorsports if your plug insulator is not a light brown color CAUTION Failing to use the proper spark plug could damage your ATV An improper spar
14. NSPECTION AND MAINTENANCE section A 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 A WARNING Operating this 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 accident Never modify this ATV through improper installation or use of accessories Refer to the ACCESSORY USE AND LOADING section in this manual 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 A WARNING Checking maintenance items when the engine is running could be 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 throttle SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good
15. T remove container from battery while it is draining Never cut or pierce electrolyte container After all the electrolyte has drained from the bottles into the battery pull plastic electrolyte bottles gently out of the battery Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life Figure 3 After 30 minutes the battery is ready for its initial charge Place cap strip loosely over the filling holes as shown in the picture See figure 4 _ Sealed Lead Acid Batters EL 6 MMA 6 5 12V 65An1OHR 9 Figure 4 37 How to Initially Charge the battery 1 2 Connect the red positive cable to the red positive pole of the battery See figure 5 Connect the black negative cable to the black negative pole of the battery See figure 6 Note The red positive cable has a larger diameter than the black negative y cable Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete press down firmly with both hands to seat the caps Do not pound or hammer The battery is now sealed See figure 7 Install battery in the ATV and make sure it is secured properly See figure 8 Once battery is firmly seated in gray tray with rubber
16. 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 ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medical attention KEEP OUT OF REACH OF CHILDREN 36 Note The following page is for vehicles with battery s containing separate electrolyte pack Most battery s will come with the electrolyte already sealed into the battery Preparing the battery Place battery on level surface Remove sealing tape from top See figure 1 Take the electrolyte container out of the plastic bag Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery See figure 2 Push the container down strongly enough to break the silver seals See figure 3 Figure 1 As electrolyte starts flowing into battery air bubbles will come up from the mouths of the plastic electrolyte bottles Leave bottles upside down in battery holes until electrolyte is completely drained Never leave children unattended around battery If air bubbles cease to float to the top of the electrolyte bottles tap lightly on top 7 igure DO NO
17. at slow speeds and avoid hills when carrying cargo Carrying loads would affect the stability and handling of your ATV Allow enough stopping distance Stopping distance increases if you carry loads Use engine braking as much as possible 32 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 MAINTENANCE SCHEDULE Initial Every ITEM 1 Month 3 Month 6 Month 6 Month 1 Year Fuel Line 3 3 3 Spark Plug 1 3 1 3 1 3 1 3 1 3 Carburetor 3 3 3 3 3 AirFiter Element Cosh and enee a e a Valves 3 3 3 3 Drive Chain 2 3 2 3 2 3 2 3 2 3 Battery 1 3 1 3 1 3 1 3 1 3 Nut Bolt Fasteners 3 3 3 3 3 Wheels 3 3 3 3 Steering System 3 3 3 3 3 Brake 3 3 3 3 3 Oil Strainer 1 3 1 3 1 3 Transmission Oil 3 3 3 3 Wheel Bearing 2 3 2 2 3 2 3 2 3 2 2 2 1 clean 2 lubricate 3 adjust inspect replace if necessary 33 A WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous If you perform improper maintenance or do not maintain your ATV you may have an accident Keep you ATV in good condition The items in the Maintenance Schedule should be performed by a qualified person or an Authorized Service Center Call Baja
18. ath 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 A WARNING Riding on a frozen lake or river could be hazardous Serious injury or death could occur if the ice breaks and you could fall into the cold water Check with local authorities to verify the thickness of the ice and areas to avoid A WARNING Failing to use extra care when operating on slippery surfaces such as hard packed snow and ice could be hazardous Failing to use extra care could cause loss of traction or loss of vehicle control This could result in an accident including an overturn Do not operate on slippery surfaces until you have learned and practiced the skills necessary to control the ATV on such terrain Always use extra care on slippery surfaces Avoid riding on the snow or ice covered hills whenever possible Practice riding your ATV in an open snow or ice covered area at slow speeds before handling out on snow or ice covered trails Learn how your ATV responds to steering and braking on the type of terrain you will encounter on your ride Your eyes may be sensitive to sunlight when you ride over snow or ice on a bright sunny day Snow and ice reflects more light into your eyes than dirt or grass Tinted eye protection will reduce the amount of light reaching your eyes On overcast days you may find it helpful to use yellow tinted eye prote
19. azardous Carrying a passenger could greatly reduce your ability to keep balance If you carry a passenger you could lose control and both you and the passenger could be severely injured Never carry a passenger The ATV has a long seat so you can change positions to handle the ATV It is not for carrying passengers STARTING THE ENGINE Before attempting to start the engine make sure to follow these steps Insert the ignition key and turn it to the ON position Turn the fuel valve to ON Place the engine stop switch in the RUN position Pull the clutch lever on the left handlebar all the way in Push the START button Push the throttle lever lightly Step down on the shift lever to put the ATV in first gear See Basic Movement and Shifting on page 20 for to learn how to properly shift gears DO A WARNING The ATV could start moving as soon as you start the engine Unexpected movement could cause you to lose control of the ATV Be sure to set the parking brake before you start the engine A WARNING Running your ATV indoors where there is little or no ventilation could be hazardous Breathing in exhaust gases from the ATV could cause severe injury Always run your ATV outdoors where there is fresh air A 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 ve
20. azardous The ATV may have unusual handling if the tires are installed incorrectly The tires are intended to rotate in a specific direction as indicated by the arrows on the sidewall of each tire Install tires correctly so they rotate in the proper direction Tubeless Tire Repair If a leak or flat tire occurs due to a puncture the tire may be repaired using a plug type 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 readily available it is strongly recommended that you bring a plug type repair kit and a tire air pump with you 50 BRAKING The ATV has two front drum brakes and a rear disk brake A WARNING Failing to inspect and maintain your ATV s brake system properly could be hazardous Improper maintenance of the brake increases your chance of having an accident Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE A WARNING Operating the ATV in harsh conditions could be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions 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
21. bility of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The Distributor is not liable to any person for incidental consequential or spe cial damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth herein Any emission control system warranty implied by law including any warranty of mer chantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law No dealer is authorized to modify this Emission Control System Warranty If you have any ques tions regarding your warranty rights and responsibilities you should contact BAJA INC 888 863 2252 Motorsports Baja Inc
22. bing a hill could be hazardous The ATV could overturn if you do not climb a hill properly Maintain a steady speed when climbing the hill Always follow the proper procedures for climbing hills as described in this section If you start to climb a hill but are unable to make it to the top follow these instructions If you still have forward movement and enough space to turn around safely follow these instructions 1 Turn around on the hill before you lose forward speed As you turn on the side of the hill lean your body weight uphill 2 Once you have turned around ride down the hill as described in the DESCENDING A HILL section If you lose forward movement or begin to roll backwards follow these instructions 1 Lean farther forward uphill Never apply the rear brake if the vehicle has begun to roll backwards After the vehicle has stopped apply the rear brake Set the parking brake and dismount to the left while still leaning uphill ar DY If you are able drag the rear end of the ATV around until the vehicle points downhill Stay on the uphill side of the vehicle while dragging it around 6 Remount the vehicle once it is facing downhill apply the rear brake and ride down the hill as instructed in the DESCENDING A HILL section 25 DESCENDING A HILL A WARNING Going down a hill improperly could be hazardous Going down a hill improperly could cause loss of control or cause the ATV to o
23. ction 31 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 make the ATV less safe to ride Be cautious when choosing and installing accessories to your vehicle Your retailer may be able to help you choose accessories and install them correctly The guidelines below should help you to decide how to equip your ATV and how to use it correctly when you use accessories Accessory Use and Vehicle Loading Guidelines 1 The combined weight of the rider tools and any accessories or cargo must never exceed the vehicle s load capacity of 220 Ibs Check accessory mounting brackets and other attachments to make sure they provide a rigid non movable mount Accessories added to the handlebar of the ATV should be as light as possible The extra weight would cause the vehicle to be harder to steer Do not add accessories or cargo which interferes with controls or other equipment Do not carry heavy or bulky cargo Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle Locate cargo weight as close to the center of the vehicle if possible Secure your load well Shifting weight can affect your ability to handle the vehicle safely Ride
24. d movement could cause you to lose control of the ATV Make sure to apply the rear brake before you release the parking brake A WARNING While learning always practice in open level areas Ensure that the engine is warm release the front brake With the rear brake and clutch still engaged push down on the shift pedal to place the ATV in first gear Slowly let out the clutch lever and gently push the throttle lever to make the ATV move forward When you are sure that the engine is warm release SHIFT PATTERN the front brake and apply the rear brake Release the rear brake lever and gradually open the throttle while slowly releasing the clutch When the ATV s speed has increased pull the clutch back in quickly and release the throttle then toe up the gearshift lever to put the vehicle in 2nd gear Repeat this procedure to use the rest of the gears 1 through 5 Zea 4 gt gt 20 BRAKING To stop the ATV first release Then smoothly apply the rear and front brakes the throttle lever and pull in the clutch A 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 A 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 o
25. date or 5 000km whichever comes first provided there has been no abuse neglect or improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or replaced by the Distributor This is your emission control defects warranty OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance You should maintain a record of all maintenance performed on 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 or lack of maintenance re cords or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifica tions WARRANTY COVERAGE The Distributor warrants that each new 2009 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the U
26. dures 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 avoid going out of control when skidding or sliding Never operate an ATV in fast flowing water or in water deeper than that specified in this manual Remember that wet brakes can reduce stopping ability Test your brakes after leaving water If necessary apply them for several times to let friction linings dry out Always use the tires with proper size and type tires specified 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 breaking The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 220 Ibs Do not tow a trailer This vehicle is not designed for such use FUEL AND OIL FUEL The proper fuel is very important for the engine Ensure that there is no dust or dirt or water which has mixed in the fuel Please use the regular unleaded gasoline with an octane of 87 ENGIN
27. epair please call the BAJA MOTORSPORTS customer service department TOLL FREE at 1 888 863 2252 between the house 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 California Proposition 65 Warning A WARNING Engine exhaust some of its constituents and certain product components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A WARNING Operation of this ATV by children under age 16 can be hazardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 16 to ride this ATV A WARNING Operating this ATV after consuming alcohol or drugs can be hazardous Alcohol and drugs could seriously affect your judgment and cause you to react more slowly They can also affect your balance and perception Operating this ATV after consuming alcohol or drugs can result in an accident Never consume alcohol or drugs before or while riding this ATV Baja Extreme 150 Left A WARNING 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 c
28. er If necessary apply the brakes several times to let friction dry out the linings CAUTION Operating the ATV in water sand or mud causes rapid brake wear Excessive brake wear could cause the brakes to be less effective After repeated operation of the ATV in these conditions bring it to your authorized service center to have the brakes inspected and cleaned 28 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 or the brakes may be frozen to the wheels If the tires are frozen to the ground pour warm water around them to melt the ice If the brakes are frozen bring the ATV to a warmer area to thaw out the brakes After the engine has warmed up check the brakes Do this inspection on level ground and do not exceed the walking speed Be sure to check the operation of both front and rear brakes If the brakes do not work adequately stop riding the ATV CAUTION Using engine power to free up frozen wheels could damage your ATV Severe damage to the drive train may occur if you use engine power to free frozen wheels Before riding manually move the ATV forward and backward to make certain that all wheels roll freely Bring the ATV to a warmer area to allow the brakes to
29. f you do not handle it properly When draining 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 the fuel or you may create a fire hazard Dispose of drained fuel properly a Loosen the drain screw which is located under the carburetor Drain the fuel from the carburetor into a container Tighten the drain screw Run the engine for a few seconds Shut off engine Loosen the drain screw and check that the carburetor is filled back up with fuel If fuel is reaching the carburetor the ignition system should be checked next 55 Ignition System Check 1 Remove the spark plug and reattach it to the spark plug lead 2 Push the electric button START Apply the rear brake lever to make sure the rear wheels are locked If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is no spark take your machine to your service center A WARNING Performing the spark test improperly could be hazardous You could get a high voltage electrical shock if you are not familiar with this procedure Do not perform this check if you are not familiar with the procedure Do not point the spark plug near the spark plug hole during this test Do not do this test if you have a heart condition or wear a pacemaker Do not perform this test is any near any open fuel containers for near fuel wh
30. feet from the footrests during operation could be hazardous If you remove even one hand or foot from the ATV you could reduce your ability to control the ATV This could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your foot or leg may come in contact with the rear wheels This could injure you or cause an accident Always keep both hands on the handlebars and both feet on the foot rests of your ATV during operation 18 A WARNING Failing to use extra care when operating on excessively rough slippery or loose terrain could be hazardous Failing to use extra care could cause loss of traction This could result in an accident including an overturn Do not operate under these conditions until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on this kind of terrain A WARNING Failing to use extra care when operating this ATV on unfamiliar terrain could be hazardous You could come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV When you are sure that the engine is warm release the rear brake 19 A WARNING The ATV may start moving as soon as you release the parking brake Unexpecte
31. 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 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 follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle 11 INSPECTION BEFORE RIDING 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 fill the view window as indicated in the picture Add oil if the window is not completely filled 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
32. g 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 space to practice the new skills A 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 certified 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 WWww svia org WWW CpSC gZ0V www mmic ca CAT V 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
33. g procedures 1 Loosen the 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 finished tighten the lock nut Front Brake Lever Squeeze the Front Brake Lever to engage the brakes on the front tires Parking Brake The parking brake is made up of the pair of buttons labeled in the picture below Depress button 1 completely then pull in the brake lever until you can push button 2 and lock the lever in place Button 2 Button 1 SHIFT PATTERN LEFT SIDE SHIFT PEDAL The Shift Pedal is located on the left side of the ATV and used to change gears See the shifting diagram above for the gear layout FUEL VALVE This valve is located beneath the fuel tank and has three positions OFF position ON position RES position The fuel valve set to OFF The fuel valve set to The fuel valve set to fuel cannot flow Use this ON fuel can flow to RES fuel can flow to the position when the engine the engine The normal engine from the reserve is not running operating position supply Use this position if the vehicle runs out of fuel Once in this position it is critical to refill the tank RIGHT SIDE REAR BRAKE PEDAL Push the rear brake pedal to engage the rear brakes FUEL TANK CAP To open the fuel tank remove the vent t
34. h skin A WARNING Failure to use proper brake fluid can be hazardous The use of any fluid except DOT4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT4 brake fluid from a sealed container Never use or mix with different types of brake fluid 52 EXHAUST A WARNING The hot exhaust muffler could burn you The muffler will be hot enough to burn you after stopping the engine Wait until the exhaust muffler cools to remove it 1 Remove the nuts 2 Start the engine and rev it to blow out the accumulated carbon particles 3 Stop the engine Wait until the muffler cools enough then replace the nuts and tighten it securely A 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 A WARNING Blowing out the accumulated hot carbon particles where there is flammable material could cause a fire Exhausted hot carbon particles could catch fire 53 A WARNING Riding an ATV with improperly tightened drain nuts could be hazardous Running the engine with a loose drain nut or without a drain nut will let hot carbon particles to escape This can cause a fire Tighten the drain nuts securely GENERAL LUBRICATION Proper lubrication is important for safe smooth opera
35. he parts to load and then unload allowing the parts to 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 at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding the maximum throttle limit Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting This allows the lubricating oil to reach all critical engine components Observe Your Initial and Most Critical Service The initial service break in maintenance is the most important service that your vehicle will receive Observing a proper break in operation will help engine components seal properly Maintenance required as part of the initial service includes proper adjustments tightening of all bolts amp nuts and replacement of dirty oil Timely performance of this service will help you get the best service life and performance of the engine CAUTION Failure to follow Break In procedures can significantly shorten the life of your vehicle By not following Break In procedure you risk causing excessive wear and damaging the engine Be careful to correctly follow Break in Procedure 15 BASIC MOVEMENT AND SHIFTING A WARNING Carrying a passenger on this ATV could be h
36. hicle a stationary object or hazard found in the terrain A WARNING Operating this ATV on paved surfaces including sidewalks paths parking lots driveways and streets could be hazardous ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to lose control Avoid operating the ATV on paved surfaces if possible If you must ride on a paved surface go slowly and do not make sudden turns or stops A WARNING Operating this ATV 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 gravel street roads or highway In many states is it illegal to operate ATVs on public streets roads and highways A WARNING Operating this ATV at excessive speeds could be hazardous Riding at excessive speeds increases your chances of losing control of the ATV which could result in an accident Always go at a speed that is proper for the terrain visibility operating conditions operator skills and operator experience A WARNING Attempting wheelies jumps and other stunts could be hazardous Stunt riding increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off A WARNING Removing your hands from the handlebar or
37. hicle capacity is 220 Ibs gt Avoid paved surfaces pavement may seriously affect handling and control Maximum capacity includes the weight of the LOCATE AND READ OWNER S MANUAL CAREFULLY BEFORE OPERATING operator cargo and accessories FOLLOW ALL INSTRUCTIONS AND WARNINGS HANDLEBAR amp CONTROL LAYOUT LEFT HANDLEBAR Engine Stop Switch With this switch in the RUN position the engine can be started The engine will not start with this switch in the OFF position Start Button When the ignition key is in and turned to the On position the Engine Stop Switch is in the RUN position and the clutch is pulled in this Button will start the engine Clutch Lever The clutch lever is used to disengage the engine and while shifting gears Pull the lever to disengage the clutch and release it to engage it again Generally speaking for smooth shifting pull the clutch quickly and release it slowly The clutch must be disengaged to start the engine Headlight Switch This switch controls the operation of the headlights Available positions are HI LO and OFF RIGHT HANDLEBAR Throttle Lever This lever is controlled by the right hand thumb The Throttle Lever controls the speed of the engine pushing the lever will increase the speed Throttle Adjusting Screw Use the throttle adjusting screw to restrict maximum speed of the ATV Adjust this limiter according to the rider s skill and experience Adjustin
38. hills could be hazardous The ATV could overturn more easily on extremely steep hills than on level surfaces or small hills Never operate the ATV on hills which are too steep for the ATV or for your abilities Practice on smaller hills before trying larger hills 23 CLIMBING A HILL A WARNING Climbing hills improperly could be hazardous Climbing hills improperly could cause loss of control or cause the ATV to overturn Always follow the proper procedures for climbing hills as described in this section Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your body forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill ata high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill To climb a hill with the ATV follow the directions below 1 Speed 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 Shift your body forward by sliding forward on the seat Lean slightly forward For steep hills stand on the footrests and lean forward Maintain a steady speed while climbing the hill Slow down gradually when you reach the top of the hill 24 A WARNING Stalling rolling backwards or improperly dismounting the ATV while clim
39. ich has spilled on the ground on the engine or any part of the ATV COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the spark plug and clean it Replace 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 1250 125 RPM min 56 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 screw A WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire if you 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 the fuel or you may create a fire hazard Dispose of the drained fuel properly CAUTION Failing to secure the ATV properly could be hazardous Failing to secure the vehicle properly may result in an accident or damage to the vehicle When transporting the ATV lock the parking brake lever and tie down the vehicle securely with straps rope or some other suitable mea
40. ir cleaner element properly could damage your ATV Air will bypass the air cleaner element if the element is not positioned properly This will cause the engine parts to wear more rapidly Be sure to position the air cleaner element properly 46 DRIVE CHAIN The condition and adjustment of the drive chain should be checked before riding Always follow the guidelines below for inspecting and servicing the chain A WARNING Failing to maintain the chain properly before each riding could be hazardous Riding with the chain in poor condition could lead to an accident Be sure to inspect and maintain the chain before riding according to these guidelines Inspecting the Drive Chain When inspecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear If you find anything wrong with the drive chain solve the problem if you can If necessary consult your authorized service center The drive chain is damaged means that the sprockets may also be damaged Inspect the sprockets as specified below Good Worn Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nut s If you find any of these problems with your sprocket consult Baja Motorsports or your local service center 47 DRIVE CHAIN CLEANING AND OILING Clean and oil the chain as the following 1 Wash the chain with water 2 Dry the chain and then oil the link
41. k plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which may not be covered under warranty Use only spark plug recommended for this engine Call Baja Motorsports if you are not sure which spark plus is correct for you vehicle 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 cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight CAUTION Dirt could damage your ATV if it entered an open spark plug hole of cylinder head Dirt could damage engine parts that move Cover the spark plug hole while the spark plug is out of the hole To maintain a proper functioning spark plug keep the plug free of carbon Remove carbon from the plug with a wire or pin and adjust the gap to 0 6 0 7mm for good ignition Use a thickness gauge to check the gap 35 BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY A WARNING The following procedure is very dangerous and should be performed with utmost care and attention Wear protective eyewear rubber gloves and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE
42. 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 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 Vi Table of Contents FUEL AND Ol Drenice ited theives 3 4 HANDLEBAR amp CONTROL 6 LEFT HANDLEBAR 6 7 SHIFT PEDAL 8 FUEL VALVE 8 REAR BRAKE PEDAL 9 REVERSE 2 2 9 FUEL TANK CAP ea er etaa EEN ETE 9 S EOLO AE TET T 10 RIDING YOUR ATV vise 11 WHAT YOU SHOULD KNOW BEFORE RIDING a sann dorer 11 INSPECTION BEFORE RIDING 12 SAFETY GEAR i TN 14 BREAKIN oeenn ana a e Ar 15 BASIC MOVEMENT AND 16 STARTING THE
43. mat under it attach the red positive wire to the red positive terminal on the battery See figure 9 Then attach the black negative wire to the black negative terminal on the battery See figure 10 A WARNING NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE Figure 10 38 Figure 6 Figure 7 Figure 9 Battery Replacement Remove old battery 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 remove oxidation After charging install new battery Put dielectric grease on the battery terminals to avoid corrosion Connect cables to the proper terminals Positive cable to positive terminal A and negative cable to negative terminal y Positive cable is red and larger in diameter Negative y cable is black and smaller of the two in diameter CONNECT NEGATIVE CABLE LAST Torque terminal bolts to 40 in Ibs Place rubber pad in bottom of battery tray Securely fasten battery to the vehicle using cover and strap A WARNING DO NOT open sealed caps to add water to battery Always wear safety glasses 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 charging turn off the charger first in order to prevent electric spark and explosio
44. n Charge in a well ventilated area DO NOT smoke around batteries and keep away from open flame A WARNING To avoid possibility of explosion always connect battery cable in the order specified RED first BLACK last An exploding battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with protective eyewear when working around battery acid Battery acid is poisonous and can cause severe burns DO NOT smoke around batteries and keep away from open flame 39 THE ADJUSTMENT OF THROTTLE LEVER 3 0 5 0mm Measure the throttle level play 0 12 0 20in 2 0 4 0mm as shown To adjust the throttle lever free distance 1 Remove the cover Loosen the nut 2 Turn the adjuster in or out to obtain the correct play 4 Recheck the throttle lever free distance Tighten the nut Readjust it if it is not within the correct limits A 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 suddenly when you turn the handlebars This can lead the rider to lose control Adjust the throttle lever free distance so that engine idle speed does not rise due to handlebar movement 40 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 T
45. n slippery surfaces A WARNING Operating the parking brake when the ATV is moving could be hazardous The front wheels could lock and it will cause a skid and an accident Use the parking brake only after you stop the ATV A WARNING Braking suddenly without disengaging the engine using the clutch can cause the engine to stop suddenly and the rear wheels to lock Use the clutch with the brake 21 TURNING To turn the ATV the rider must use proper technique Because the 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 in a straight line To turn one wheel must get more traction and let the other wheel slide This is accomplished by leaning in to turns as described below A WARNING Turning the ATV improperly could be hazardous If you turn the ATV improperly it may cause a collision or overturn Always follow proper procedures for turning as described in this section Practice turning at low speeds before attempting to turn at faster speeds Never turn at excessive speeds To turn the ATV using the following technique Move your body weight forward and to the inside of the turn Turn the handlebar while looking in the direction of the turn FOR HIGHER SPEEDS OR SHARPER TURNS Use the same technique that you use when you move your body weight farther toward the inside of the tur
46. n 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 increases This means you must lean your body farther into the turn as you go faster or turn more sharply This prevents the vehicle from tipping over to the outside of the turn If your ATV starts to tip while turning lean your body farther into the turn while gradually reducing the throttle and making the turn wider if possible 22 SKIDDING OR SLIDING You may experience skidding or sliding when you are braking You may be able to overcome it by using the techniques listed below If your front wheel skids Gain front wheel traction by reducing the throttle opening and leaning your body slightly forward If your rear wheel skids If space permits steer in the direction of the skid Shift your body away from the skid slightly Avoid using the throttle or brakes until you regain directional control of the vehicle A WARNING Skidding or sliding could be hazardous You may lose control of your ATV when you regain traction unexpectedly This may cause the ATV to overturn 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 OPERATION ON HILLS A WARNING Operating this ATV on excessively steep
47. nited States Environmental Protection Agency and the California Air Resources Board and e is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above Your emission control system warranty covers components whose failure would increase gine s emission including electronic controls fuel injection system carburetor the ignition sys tem catalytic converter or any other system utilized in this vehicle to control emission if it is origi nally equipped Also included may be hoses connectors and other emission related assemblies Replacing or repairing other components including parts labor and other costs not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility The Distributor will not cover repairs performed outside of an authorized dealer or repair facility The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control 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 com
48. ns Use extra tie downs when you transport the vehicle in the standing position 57 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 brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust system can reduce engine 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 seal the end of the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering engine CAUTION High pressure washers could damage your ATV High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your ATV It may cause rust corrosion and increase wear Do not use high pressure washers to clean your ATV 58 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 t
49. o adjust the idle speed 1 Start the engine and warm it up 2 Turn the throttle stop screw in or out so that the engine idle speed is at 1250 125 r min A WARNING Improper adjustment 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 if idle speed is adjusted improperly or when the engine is not fully warmed up Adjust the idle to the correct speed Make sure the engine is fully warm before adjusting the engine idle speed FUEL HOSE Inspect the fuel hose for damage and fuel leakage If ay defects are found the fuel hose must be replaced 41 ENGINE OIL The engine oil should be changed every 20 to 40 hours of operation It should be changed more often in dirty and dusty areas To change oil 1 Park the vehicle on level ground 3 Remove the drain bolt and drain the oil into a bucket 4 Reinstall the drain bolt 5 Pour fresh oil of the specified type through the oil litter hole see pg 3 fuel and oil NOTE Approximately 850 ml 31 67 ounces of oil is required 6 Tighten the oil cap 7 Dispose of used oil as per governmental regulations 42 A WARNING New and used oil could be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used oil can cause skin cancer in laboratory animals Brief contact wi
50. o remove the majority of dirt or other debris Hand wash your ATV with mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as between engine cooling fins linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used 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 Remove the rags or wrapping from the exhaust pipe For extended life of your ATV lubricate according to GENERAL LUBRICATION section Follow the procedures in the INSPECTION BEFORE RIDING section to check your ATV for any problems that may have occurred during your last ride A WARNING Operating the ATV with wet brakes could be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing the ATV riding at a slow speed If necessary apply brake several times to let the friction dry out the linings 59 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 yourself follow the general guidelines below
51. ontains important safety information and instructions which should be read carefully before operating the vehicle HOW TO READ THIS MANUAL Please read this manual and follow all instructions carefully To emphasize the special information the symbol A and the words WARNING or CAUTION have some special meanings Pay great attention to the messages A WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this A WARNING or CAUTION The first 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 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 specifications 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
52. pliance with applicable standards may be denied This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following 1 Failures or malfunctions of the emission control systems caused by abuse alteration accident misuse the use of leaded gasoline 2 Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use and the first required replace ment interval for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts 3 Replacements of parts and other services and adjustments for required maintenance 4 Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined 5 Repairs or replacements as a result of o Accident o Misuse o Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance 6 Physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of the Distributor 7 Failures not caused by a defect in material or workmanship Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties LIMITED LIABILITY The lia
53. quality helmet which fits properly A WARNING Operating this ATV without wearing an approved DOT motorcycle helmet eye protection and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident Always wear an approved DOT motorcycle helmet which fits properly Always wear eye protection goggles or face shield You should also wear gloves boots long sleeve shirt or jacket and long pants You should wear eye protection when you ride If a rock or a branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride The proper clothes can protect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt 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 Recommendation During the first 10 hours of operation you should always use less than 1 2 throttle opening Vary the Engine Rotating Speed Vary the engine rotating speed during the break in period This allows t
54. s properly Operators should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 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 the handlebar and both feet on the 5 of the ATV during operation Always go slowly 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 star
55. s with Chain lube or equivalent Adjusting the Drive Chain 30 40 MM 1 18 in 1 57 in The drive chain should be adjusted and make sure there is 30 40 mm 1 18 1 57 in of slack as shown above You can adjust the drive chain as the following 1 Loosen nuts 2 Adjust the slack in the drive chain by turning the chain adjust bolt equally to tighten or slacken the chain 3 When proper adjustment is obtained tighten the nut 4 Tighten the adjusting nuts and A 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 damage to the ATV Inspect the drive chain slack before each use 48 TIRES The ATV is equipped with low pressure tubeless tires of the size and type listed below AT21 X 7 10 AT21 X 10 8 A WARNING Operating 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 type tires specified Always maintain proper tire air pressure as described in this section Tire Tread Condition 4 0 mm 0 16 in FED A WARNING Using worn tires could be hazardous The traction of the vehicle will be decreased This increases your risk of having an accident Replace
56. t 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 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 proce
57. th the used oil may irritate the skin Keep new and used oil away from children and pets To minimize your exposure to used oil wear a long sleeve shirt and moisture 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 used oil CAUTION Failure to use the correct oil could harm your ATV Be sure to use the oil specified in the FUEL AND OIL RECOMMENDATION section CAUTION Running the engine without an adequate amount of engine oil could cause severe engine damage Running the engine without any engine oil could cause engine overheating Always check the amount of engine oil before starting the engine 43 AIR CLEANER The air cleaner element must be kept clean to provide good engine power If you use your vehicle under normal low tension conditions you should service the air cleaner at the intervals specified If you ride in dusty wet or muddy conditions you will need to inspect the air cleaner element much more frequently Use the following procedures to remove the element and inspect it A WARNING Operating the engine without the air cleaner element in place could be 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 CAUT
58. thaw out After the brakes thaw dry them by applying them several times before 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 your ATV The frozen water can prevent wheels from turning or the brakes from working After riding through water mud snow or slush it is important to dry the brakes before parking the ATV To dry the brakes apply them several times while riding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section A WARNING Operating the ATV without a properly functioning brake system could be hazardous Wet or frozen brakes will increase stopping distance This will increase your chance of having an accident Be sure to inspect the brakes before riding the vehicle in cold weather as described above 29 DRESSING FOR COLD WEATHER RIDING A WARNING Operating your ATV in cold weather without proper clothing could be hazardous Continued exposure in the cold weather could lead to hypothermia Hypothermia is a condition where your body s inner temperature drops low enough to cause injury or death Always dress for the worst weather conditions you might encounter Be prepared for bad weather and ATV breakdowns Riding in cold weather can be hazardous At a temperature of 10 F 12 C the wind chill created by going
59. the front and rear tires when the depth on the tread is 4 0 mm 0 16 in or less Tire Air Pressure Check the air pressure in all tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort Be sure that the tires are inflated to the 50 0 50 kgf cm2 7psi pressures shown below Tire pressure should only be measured or adjusted when the tires are cold Cold Tire Air Pressure 50 0 50 kgf cm2 7psi 49 A WARNING Overfilling the air to the tires could be hazardous If you put too much air into the tire may burst and causing severe injury Check the air pressure from time to time while inflating the tire gradually until the specified air pressure is obtained 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 use the proper tools when repairing or replacing tires in order to protect the tire bead or wheel rims Have this work done by your authorized service center or a qualified tire repair station When breaking the tire bead loose from the wheel be extremely careful not to damage the inner wheel rim surface or the tire bead A WARNING Using tires that have been installed incorrectly could be h
60. tion 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 service center should do general lubrication as shown in the MAINTENANCE CHART The authorized service center will lubricate the vehicle such as wheel bearings swing arm bearings steering shaft holder cables etc Grease Steering shaft holder Brake cable 3 Drive chain Throttle cable 5 Throttle lever 54 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 CAUTION Failing to troubleshoot a problem correctly would damage your ATV Improper repairs or adjustments may damage the vehicle Such damage may not be covered under warranty If you are not sure about the proper action consult your authorized service center or Baja Motorsports about the problem Fuel Supplying Check 1 Make sure there is adequate fuel in the fuel tank 2 Check that the engine stop switch is in the RUN position 3 Check that the fuel valve is in the ON position 4 Make sure there is enough fuel reaching the carburetor from the fuel tank A WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire i
61. u cannot avoid you may be able to cross over it by using the following procedure If the obstacle is in front of you approach at walking speed Rise up slightly on the footrests Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle RE DS eee Lean forward and release the throttle after the front wheels are over the obstacle Remember that some obstacles are too high for your ATV or for your abilities If you are not sure that you can safely cross over an obstacle back up and ride around the obstacle 27 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 is hard If you are unfamiliar with the area park the ATV and inspect the stream first to find a suitable spot for crossing When crossing operate the ATV at a slow steady speed Be careful not to damage banks when crossing A WARNING Operating this ATV through deep or fast flowing water could be hazardous The ATV tires may float losing traction and then loss of control This could lead to an accident Never operate this ATV in fast flowing water or in water deeper than described in this section Remember that wet brakes may reduce the stopping ability Test your brakes after leaving the wat
62. ube from the cap and rotate it counterclockwise To replace the cap turn it clockwise and tighten it securely Be sure to replace the vent tube as shown Filler neck Fuel level A WARNING Overfilling the fuel tank could be hazardous If you overfill the fuel tank fuel may overflow when it expands Expanding is due to heat from engine or sun Overheated fuel could easily catch fire Stop adding fuel when the fuel level reaches the bottom of the filler neck A WARNING Improper 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 engine is off and avoid spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area Avoid breathing gasoline vapors Keep children and pets away when you are refueling the ATV 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 firmly A 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 that the seat is attached securely when you ride RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING Before ridin
63. verturn Always follow the proper procedures for going down hills as described in this section To ride down a hill with the ATV follow the instructions below 1 Check the terrain carefully for any obstacles before you go down the hill 2 Point the ATV straight down the hill 3 Transfer body to the rear by sliding back on the seat 4 Ride down the hill slowly with the throttle released 5 Apply the rear brake to control the speed 6 Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill if possible 26 TRAVERSING A WARNING Crossing hills or turning on hills improperly could be hazardous Crossing hills or turning on hills improperly could cause loss of control or overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the CLIMBING AHILL section Practice this technique on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When traversing a slope you should 1 Lean your body uphill 2 Steer slightly uphill if necessary to maintain a straight course RIDING OVER OBSTACLES A WARNING Operating this ATV over obstacles improperly could be hazardous Improperly crossing obstacles could cause loss of control or a collision It could also cause the ATV to overturn If you come to an obstacle that yo

warning - Gardner Inc.

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