Baja WD400U User Manual

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WD400U Service Manual

For any questions please contact Baja Motorsports at 888-863-2252

Table of Contents

Table of Contents2
Chapter I General Description5
Section Special Tools, Instruments & Meters6
- (I) Special Tools6
Section 2 Identification Code, Label of Model and Engine no8
Section 3 Points for Attention in Maintenance8
Section 4 Specification12
- How to Use Conversion Table of Unit12
- How to Use Conversion Table12
- Definition of Unit12
- II. Basic Specification13
- III. ATV Body15
- IV. Electric System16
- V. Maintenance Specification Of Engine17
Section 6 Lubrication Point and Type of Lubricants23
Content25
Chapter II Maintenance and Adjustment of Vehicle25
Section 1 Periodic Maintenance/Lubrication25
Section 2 Disassembly and Assembly of Cushion, Fender and Fuel Tank26
- (II) Rear Fender26
- (III) Fuel Tank29
- (IV) Front Fender31
Section 3 Maintenance and Adjustment of Vehicle Body32
- (I) Wear Inspection of Front and Rear Brake32
- (II) Adjustment of Front Brake32
- (III) Adjustment of Free Clearance of Left Lever and Rear Brake Pedal33
- (V) Lubricating Oil Level Inspection of Rear Driving Gearcase35
- (VII) Rubber Sleeve Inspection of Rear Wheel Fork37
- (VIII) Inspection of Steering System37
- (X) Inspection of Front/Rear Shock Absorber39
- (XII) Inspection of Tire40
- (XIII) Inspection of Rim41
Section 4 Maintenance and Adjustment of Electrical Appliance42
- (I) Inspection of Battery42
- (II) Inspection of Fuse43
Section 5 Maintenance and Adjustment of Engine46
- (II) Inspection of Spark Plug47
- (III) Adjustment of Idle Speed48
- (V) Adjustment of Speed Limiter49
- (VI) Adjustment of Valve Clearance50
- (VII) Adjustment of Timing Chain Tension52
Chapter III Repair and Maintenance of Vehicle Body55
- (II) Inspection56
- (III) Troubleshooting Table57
- (IV) Disassembly58
- (V) Inspection61
Section 2 Rear Wheel/Rear Brake/Rear Wheel Axle62
- (I) Removal Steps64
- (I) Disassembling Steps73
- (II) Checking Steps74
- (III) Mounting Steps77
Section 4 Steering Operation System80
- (II) Removal Steps of Steering Vertical Column Welding82
- (III) Inspection Content83
Section 5 Front Wheel and Front Brake88
- (II) Installation91
- (I) Disassembly95
Chapter IV Electric Appliance100
Section 1 Electric Assembly100
Section 2 Inspect Switch102
Section 4 Troubleshooting the Ignition System Failure104
Section 5 Running Starting Circuit106
Section 6 Troubleshooting Electric Starting System107
Section 7 Battery will Not Hold Charge110
Section 8 Troubleshooting112
Section 9 Inspection of Lighting System114
Section 10 Troubleshooting116
Section 11 Inspection of Signal System118
Chapter V Engine121
- (II) Disassembly of Engine123
Section 2 Inspection and Maintenance of Engine133
Section 3 Assembly and Adjustment of Engine152
- (I) Installation160
- (I) Starting Trouble/Difficulty177

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Baja WD400U Specifications

General

Brand	Baja
Model	WD400U
Category	Offroad Vehicle
Language	English

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