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Baja WD400U User Manual

Baja WD400U
180 pages
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WD400U Service Manual
For any questions please contact Baja Motorsports at 888-863-2252

Table of Contents

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Baja WD400U Specifications

General IconGeneral
BrandBaja
ModelWD400U
CategoryOffroad Vehicle
LanguageEnglish

Summary

Chapter I General Description

Section 1 Special tools, instruments & meters

Lists necessary special tools, instruments, and meters for maintenance.

Section 2 Identification code, label of model and engine No.

Explains how to locate the model and engine identification codes on the vehicle.

Section 3 Points for attention in maintenance

Provides crucial safety and procedural points to observe during maintenance.

Section 4 Specification

Contains detailed technical specifications, including unit conversion tables.

Section 5 Requirements for torque fastening

Specifies the correct torque values for various fasteners used in the ATV.

Section 6 Lubrication point and type of lubricants

Identifies all lubrication points and the recommended types of lubricants for each.

Chapter II Maintenance and adjustment of vehicle

Section 1 Periodic Maintenance/Lubrication

Outlines a schedule for routine maintenance and lubrication tasks.

Section 2 Disassembly and assembly of Cushion, Fender and Fuel tank

Provides detailed steps for removing and reinstalling the cushion, fenders, and fuel tank.

Section 3 Maintenance and Adjustment of vehicle body

Covers maintenance and adjustment procedures for the vehicle's body components.

Section 4 Maintenanace and Adjustment of Electrical Appliance

Details maintenance and adjustments for the vehicle's electrical system, including battery and fuses.

Section 5 Maintenance and Adjustment of Engine

Explains essential maintenance and adjustment procedures for the engine.

Chapter III Repair and Maintenance of Vehicle Body

Section 1 Rear Differential

Details repair, maintenance, troubleshooting, disassembly, and inspection of the rear differential.

Section 2 Rear wheel, rear brake, rear wheel axle

Covers the removal, inspection, and installation of rear wheel, brake, and axle components.

Section 3 Rear shock absorber and Rear swing arm

Explains disassembly, checking, and mounting procedures for the rear shock absorber and swing arm.

Section 4 Steering Operation system

Details removal, adjustment, and installation of the steering system components.

Section 5 Front Wheel and Front brake

Provides disassembly and installation steps for the front wheel and brake systems.

Section 6 Front shock absorber and Front wheel fork and Front Differential

Covers disassembly and installation procedures for front suspension and differential components.

Chapter IV Electric Appliance

Section 1 Electric Assembly

Illustrates the assembly of various electrical components and wiring harness.

Section 2 Inspect switch

Provides guidance on how to inspect and test various switches.

Section 3 Check Lamp (headlight)

Explains the procedure for checking the headlight bulb and its circuit.

Section 4 Troubleshooting Ignition System failure

Guides users through diagnosing and resolving ignition system malfunctions.

Section 5 Running of Starting circuit

Details the operation and circuit of the vehicle's starting system.

Section 6 Troubleshooting electric starting system

Provides troubleshooting steps for issues with the electric starting system.

Section 7 Battery will not hold charge

Offers troubleshooting steps for diagnosing battery charging and capacity problems.

Section 8 Troubleshooting

General troubleshooting steps for lighting system failures.

Section 9 Inspection of Lighting System

Covers inspection procedures for headlights and taillights.

Section 10 Troubleshooting

Troubleshooting guide for indicator lamps that are not functioning correctly.

Section 11 Inspection of Signal System

Details inspection procedures for signal system lamps like neutral and reverse indicators.

Chapter V Engine

Section I Disassembly of Engine

Comprehensive steps for removing and disassembling the engine.

Section 2 Inspection and Maintenance of Engine

Details inspection and maintenance procedures for various engine components.

Chapter VI Vehicle Ordinary Trouble and it’s judgement

(I) Starting trouble/difficulty

Diagnoses common starting issues related to fuel, electrics, and engine systems.

(II) Poor idle speed performance

Identifies potential causes for the engine's poor performance at idle speed.

(III) Poor middle and high speed performance

Addresses issues affecting engine performance at mid-range and high speeds.

(IV) Driving system

Troubleshoots problems related to the driving system, including gears and clutches.

(V) Clutch slips

Diagnoses the causes of clutch slippage and related component wear.

(VI) Clutch is locked

Identifies reasons for the clutch mechanism becoming locked or stuck.

(VII) Engine is overheated

Lists potential causes and troubleshooting for engine overheating.

(VIII) Brake trouble

Details common brake system malfunctions and their probable causes.

(IX) Shock absorber failure/ improper operation

Covers diagnosis of shock absorber failures and improper operation issues.

(X) Lighting System

Provides troubleshooting steps for various lighting system malfunctions.

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