OWNER`S MANUAL - Baja Motorsports
Contents
1. 21 EMISSION CONTROL SYSTEM WARRANTY 22 Table of Contents 2 Please read this manual and follow all instructions carefully To emphasize the special information the symbol and the words WARNING or CAUTION have some special meanings Pay great attention to the messages NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All information illustrations photographs and 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 make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold WARNING or CAUTION The 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 des2. 8 ENGINE STARTING AND STOPPING 9 SWITCHES ON THE RIGHT HANDLEBAR 10 CHECk UPS ADJUSTMENT AND MAINTENANCE 11 CHANGING THE OIL 12 CHECk UP OF SPARk PLUG 12 CHECkING amp CLEANING THE AIR FILTER 13 ADJUSTING THE THROTTLE CABLE 14 ADJUSTING THE CARBURETOR 14 ADJUSTMENT OF REAR BRAkE 15 ADJUSTMENT OF CHAIN 16 GREASING PROCEDURES TO THE DRIvING CHAIN 16 vEHICLE WASHING 17 INSTRUCTIONS FOR STORAGE 18 RESUMPTION OF SERvICE AFTER STORAGE 19 TABLE AND TORQUE OF FASTENERS 19 MAINTENANCE ROUTINE DIAGRAM 20 TROUBLE SHOOTING
3. or improperly gapped Remove and inspect spark plug Clean gap or replace 6 Spark plug wet with fuel flooded engine Remove and inspect spark plug Dry and reinstall spark plug 7 Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Take the engine to a qualified mechanic Replace or repair faulty components as necessary 1 Filter element s clogged Check air filter Clean or replace 2 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor Refuel with fresh gasoline 3 Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Take engine to a qualified mechanic Replace or repair faulty components as necessary Engine Lacks Power Engine will not Start 22 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 deliv ered to the first purchaser other than an authorized dealer or the date it is first used as a demonstra tor lease or company vehicle whichever comes first and continues for 60 months after that 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
4. parts and labor If an emission related part on your vehicle is defec tive 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 records 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 modifications 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 United States Environmental Protection Agency and the California Air Resources Board and is free from defects in material and workmanship which cause such vehicle to fail to con firm with applicable regulations of the United States Envir
5. hours of 7am and 5pm Monday through Friday MST Mountain Standard Time MDT Mountain Daylight Time during the daylight saving time You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED iii This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 WARNING 1 SAFE OPERATION 3 SAFETY GEAR 4 MODIFICATION OF vEHICLE 4 MAIN DATA 5 PARTS amp SUBASSEMBLIES 6 OPERATION 8 FUEL vALvE
6. of the cloth properly DO NOT SMOkE OR REFUEL THE vEHICLE NEAR OPEN FLAMES OR NEAR HEATING UNITS ONLY REFUEL THE vEHICLE IN OPEN AREAS TO REDUCE THE LIkELIHOOD OF THE BUILD UP OF GASOLINE FUMES Operation of the fuel valve the valve under the fuel tank ON With the handle of the fuel valve to ON position the fuel supply will flow to the carburetor OFF With the handle of the fuel valve to OFF position the fuel supply is cut off to the carburetor OFF ON Fuel valve Handle Fuel level Filler neck 9 ENGINE STARTING AND STOPPING Starting Engine 1 Place fuel valve lever to ON Position 2 Place Choke lever to ON Position 3 Set the ignition switch to Position 4 Pull the Start Recoil cord until engine starts 5 After engine has sufficiently warmed up place Choke lever in OFF Position Procedures for stopping engine 1 Release throttle twist grip to slow down engine 2 Set the ignition switch to position 3 Set the fuel valve lever the fuel tank valve handle to OFF position CAUTION verify oil level prior to starting see page 11 Starting the engine with low or no oil will damage the engine CAUTION Unnecessarily increasing RPM s to a high level while the Mini Bike is warming up is harmful to the engine WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide C
7. of the emission control systems caused by abuse alteration accident misuse the use of leaded gasoline Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use and the first required replacement inter val for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts Replacements of parts and other services and adjustments for required maintenance Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined 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 Physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of the Distributor 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 liability 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 busi ness during customary business hours This warranty does not
8. the vehicle The following parts should be cleaned using low pressure water Wheel hub Exhaust pipe Fuel tank and lower portion of cushion Carburetor Head lock and ignition switch Meters 18 INSTRUCTIONS FOR STORAGE If the vehicle is not going to be used for a long period of time for example in winter time some steps should be taken to prevent malfunction of and damage to its components which might be caused by long storage Before storing the vehicle for a long period proper maintenance has to be carried in case maintenance is not completed when the vehicle is put back into use after storage 1 Change engine oil 2 Drain off fuel from the fuel tank and carburetor spray atomized anti rust oil onto the inside wall of the tank and then close the tank Dispose of any drained fuel properly so as not to adversely affect the environment Attention If the storage will last for more than one month fuel in the carburetor must be fully drained This will help ensure that the carburetor maintains its normal performance after the storage 3 Take out the spark plug pour about 15 20ml 5 68 oz of clean engine oil into the cylinder step down on the kick lever repetitively several times so as to have machine oil distributed all over the engine and finally fit the spark plug back on 4 Wash the vehicle clean wipe it dry and apply an even coat of wax to the painted surface and a coat of anti ru
9. throttle twist grip has the required free operating movement The required free operating movement 2 6mm 078 24in If the grip cannot be moved freely turn the adjusting nut to ensure proper operating movement After adjustment start the engine and check for the operating movement again Repeat the adjustment if necessary until the desired operating movement is obtained ADJUSTING THE CARBURETOR Adjusting procedures of idling speed 1 Support the vehicle by a stand 2 Adjust the idle speed by the throttle stop screw to 1400 200 RPM 150 CAUTION Do not try to correct a malfunctioning carburetor by adjusting the idling speed If the carburetor is not functioning properly it should be repaired by a service center Adjust idling speed only when the engine is warmed up or 10 minutes after operation Throttle cable adjust nut 15 ADJUSTMENT OF REAR BRAkE 1 The front brake hand grip should have free operating movement of 5 7mm 2 3in 2 To make adjustment turn rear adjusting nut clockwise to reduce and counterclockwise to increase the free operating movement of the hand brake 3 Brake shoes should be replaced by a qualified service technician once brake shoes are worn Brake cable Rear brake arm Rear brake adjusting nut 5 7mm free play 2 3in 16 GREASING PROCEDURES TO THE DRIvING CHAIN 1 Shut off the engine 2 Add light amounts of machine oil or chain grease to the driving c
10. when there is insufficient lubricating oil Otherwise it will cause harm to the engine Oil dip stick MACHINE OIL TEMP C F 30 22 40 104 20 4 10 14 0 32 10 50 20 68 30 86 20W 50 15W 40 10W 30 12 CHANGING THE OIL 1 Remove the Screw Plug located at the bottom of the engine and let the oil drain into an approved collection container DO NOT PERFORM THIS PROCEDURE WHILE THE ENGINE IS HOT SERIOUS BURNS COULD RESULT FROM CONTACT WITH HOT OIL 2 Dispose of the used oil properly For proper disposal procedures contact your local oil recycling center 3 Clean and replace the Screw Plug tightly Torque to 18 ft lb 4 Refill the engine with 0 53 qt 0 5L of recommended oil and recheck the amount of oil in the engine by using the oil gauge plug CHECk UP OF SPARk PLUG 1 Remove the cap of spark plug and screw off the spark plug using the plug wrench 2 Clean the spark plug all around or replace it if it is corroded or there is too much deposit on it 3 Regulate the gap of the spark plug to 7mm 79mm 028 031 3 The spark plug of the designated type should be used The applicable type of spark plug Meiya F7RTC Champion RN9YC NGk BPR6ES 7mm 79mm 028 031 Screw plug for oil draining 13 CHECkING amp CLEANING THE AIR FILTER 1 Remove seat to access air filter Seat is removed by remov
11. 00 rpm Wheelbase 1162mm 45 75 inches Torque max 9 76 ft lbs at 2500 rpm Dead weight 64 46 kg 142 1lbs Idling speed 1400 200 150 Payload 91kg 200 lbs Displacement of cylinder 197cc Front wheel 19 X 7 8 10psi Spark plug MEIYA F7RTC NGk BPR6ES Champion RN9YC Rear wheel 19 X 7 8 10psi Spark plug gap 0 7mm 0 79mm 028 031 Brake Type Drum Gap of air valve IN 0 15 02mm cold Capacity of gasoline tank 4 2L 95 gal Gap of air valve EX 0 20 02mm cold Capacity of oil tank 5L 53 qt Ground clearance 139 mm 5 5 Drive Centrifugal clutch Ignition means Magneto 6 PARTS amp SUBASSEMBLIES Rear brake lever Throttle twist grip 7 Front Wheel Front Shock Absorber EPA Sticker Side Stand Rear Wheel Seat Cushion Pull Start Cord Hand brake Air Filter Headlight Clutch cover Gas Tank Foot pegs Decorative tank Drive Chain Vehicle Identification Number Brake Drum 8 OPERATION FUEL vALvE Fuel filling The capacity of the fuel tank is 4 2L 95 gal Unscrew the gas cap by turning it counter clockwise and carefully fill the tank with unleaded gasoline through the opening DO NOT MIX GAS AND OIL TOGETHER THIS IS A 4 STROkE ENGINE Replace the gas cap by carefully aligning the threads on the cap and the tank and turning the cap clock wise Wipe any spilled fuel from the dirt bike using a cloth and dispose
12. Always wear a helmet It could save your Life Do not remove this operator s manual from this vehicle Please obtain review and follow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle OWNER S MANUAL Minimum Age Requirement 16 Rev F US 012209 HT65 WR65 MB165 MB165 BC Mini Bike Read this manual carefully It contains important safety information No one under the age of 16 should operate this Mini Bike ii Congratulations on your purchase of the BAJA INC Mini Bike Your Mini bike is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days from the date of purchase During the warranty period BAJA INC will at its option repair provide replacement parts or replace your BAJA INC Mini Bike at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the product Engine Warranty 90 days Frame Warranty 90 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem with your vehicle please contact Baja Inc customer service line toll free at 1 888 863 2252 between the
13. 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 special 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 merchantability or fitness for a particular purpose is limited to the express emission con trol 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 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252
14. cribe HOW TO AVOID THE HAZARD CAUTION Indicates a potential hazard that could result in vehicle damage WARNING Indicates a potential hazard that could result in death or injury 3 SAFE OPERATION Rules for Safe Operation A pre operation check must be conducted before starting the engine insure safety prevent mishaps and damage to components It is strongly suggested that all operators take a certified motorcycle rider s course prior to operating the vehicle Full attention is required during driving paying close attention to the following points to avoid any injury to you by other motorized vehicles Do not drive too close to other vehicles Never carry a passenger This mini bike is for one operator only Never operate this mini bike at night Night is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise Driving at high speeds is the cause of many accidents do not drive at a speed that the actual situation does not permit 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 inf
15. hain Too much machine oil or chain grease may cause splattering to occur Attention The chain should be replaced when the adjusting limit has reached it s maximum ADJUSTMENT OF CHAIN 1 When chain adjustment is needed loosen rear axle bolt 2 Turn the chain adjusting nuts on the left and right sides to adjust the tension of the chain and to align the marking of the chain adjuster with the engraved lines in the similar position on both sides 3 Tighten rear axle bolt by a torque of 50 60Nm 37 44 ft lb 4 Repetitively check the tension of the chain 15 20mm 1 2 3 4 Chain adjusting nut Both Sides Rear axle bolt 17 vEHICLE WASHING Cleaning the vehicle regularly can slow down the color fading of its body and make it easier to check if there is any damage and any oil leakage 1 After pre wiping the vehicle should be washed with clean water to remove dirty residues so as to prevent corrosion Plastic subassemblies should be cleaned by wiping with a cloth or foam soaked in neutral detergent solution followed by washing with clean water 2 After the cleaned vehicle is air dried grease the chain and run the engine at idling speed for a few minutes 3 Prior to driving carefully check the braking system repeatedly and repair or adjust it if necessary CAUTION Washing the Mini Bike with over pressurized water may cause damage to some of its components Therefore do use a pressure washer to clean
16. hoke Lever ON OFF Fuel valve lever ON OFF 10 SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is provided on the right handlebar When the switch is turned to off position the engine will not start or stops the engine When the switch is turned to on position the engine can start and the vehicle can be driven ON button OFF button 11 CHECk UPS ADJUSTMENT AND MAINTENANCE Checking the Oil Check the engine oil each time prior to operating the mini bike The oil level should be between the upper and lower lines of the oil gauge 1 Set the Mini Bike on level ground screw off the oil gage plug wipe the oil gage rod clean and then insert the gage plug into the crankcase again to check the oil level There is no need to screw the oil gage plug into its hole in the crankcase 2 Add lubricating oil up to the edge of the fill plug 3 Finally screw in the oil gage plug tightly Lubricating Oil Recommended The lubricating oil is an important factor affecting the performance and service life of the engine Please refer to the chart for the correct grade of engine oil based on the environmental conditions in your area Do not use any other type of oil other than what is recommended in the chart DO NOT MIX OIL WITH THE GASOLINE Lubricating oils of different viscosity shall be employed in different regions and at different temperatures CAUTION Never start the engine
17. ing nut located under seat see photo 2 Locate Air Filter Box under seat and remove cover 3 Remove air filter 4 Remove foam cover from Air filter element 5 Tap the Air filter element gently to remove most of the dust and dirt Blow out remaining dust with compressed air If the element is damaged replace it 6 Wash the foam element cover per instructions below then allow to dry thoroughly 7 Reinstall foam cover to the air filter element 8 Reinstall air filter and close cover CAUTION The air filter element must be intact or the engine will suck in dust and dirt resulting in a shorter service life of the engine Water should be prevented from entering into the filter when washing the vehicle The filter element shall be cleaned gently without twisting to prevent it from cracking Never wash it with gasoline or any acid alkaline or organic volatile oil to avoid its aging which will result in reducing the effect of the air filter oil to catch particles before they enter the engine Replace the filter element with a new one if it is broken or cracked Air Filter box Removal of filter Removal of cover Rinse with fresh water then squeeze out excess Wash with mild soap and water Air filter element Foam cover Air Filter Seat nut 14 ADJUSTING THE THROTTLE CABLE Make sure the throttle cable is adjusted properly To adjust throttle cable rotate adjustment nut located at the hand throttle Check if the
18. onmental Protection Agency or the California Air Resources Board for the periods specified above Your emission control system warranty covers components whose failure would increase an engine s emission including electronic controls fuel injection system carburetor the ignition system catalytic converter or any other system utilized in this vehicle to control emission if it is originally equipped Also included may be hoses connectors and other emission related assemblies Replacing or repair ing 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 compliance with applicable standards may be denied This Emission Control System Warranty is in addition to the standard Limited Warranty 23 EXCLUSIONS AND LIMITATIONS This warranty does not cover the following Failures or malfunctions
19. ools and authorized spare parts are used The user must also be capable of completing the procedure means This item can only be carried out by an authorized service center in order to ensure safety Notes 1 Maintenance should be conducted more frequently when Mini Bike is driven in dusty areas 2 When Mini bike has exceeded the maximum figures specified in the table maintenance should be still cycled according to the intervals of time or hours stated herein ITEM OF MAINTENANCE EA USE 1ST MO 20 HRS EvERY 3 MO 50 HRS EvERY 6 MO 100 HRS EvERY YR 300 HRS Engine oil Check X Engine oil Change X X Air filter Check X Air filter Clean X X Air filter Change X Carburetor sediment cup Clean X Spark plug Check Adjust X Spark plug Replace X Idle speed Check Adjust X valve clearance Check Adjust X Fuel tank and filter Clean X Fuel tube Check X Front shock bolts Tighten to spec X All nuts and bolts Check for tightness X Chain tension Check X Brakes Check X Throttle Check X Throttle cable Check X MAINTENANCE SCHEDULE 21 TROUBLESHOOTING 1 Fuel valve OFF Move Fuel valve lever to ON 2 Choke OPEN Move Chock Lever to CLOSED 3 Out of fuel Refuel 4 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel and carburetor Refuel with fresh gasoline 5 Spark plug faulty fouled
20. ormation available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold Always avoid operating this mini bike on paved surfaces including sidewalks paths parking lots driveways streets roads and highways Never operated this or any Off Road vehicle on a public street road or highway where motor vehicles are in operation 4 SAFETY GEAR 1 Never operate this mini bike without wearing a DOT approved motorcycle helmet which fits properly Operators should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 2 Loose clothes are not suitable for motorcycle driving or riding as they may get caught on footrest or wheel resulting in danger MODIFICATION OF THE vEHICLE CAUTION Never perform any unauthorized modifications to this vehicle Only use original replacement part which can be obtained through BAJA INC 888 863 2252 5 MAIN DATA Description Data Description Data Overall length 1680mm 66 14 inches Cylinder bore x stroke 6 8cm X 15 41cm 2 68 X 2 13 Overall width 800 1mm 31 5 inches PTO shaft rotation Counter clockwise Overall height 979 9mm 38 58 inches Output max 6 5hp at 36
21. st oil on the chrome plated surfaces 5 Inflate the tires as required and put the vehicle up on wooden blocks with the two wheels clearing the ground 6 Put the vehicle in a shady and cool place free from humidity and direct sunlight and cover it properly not with plastic or other painted materials If there is a garage store it within WARNING Gasoline is flammable and may cause fire and even an explosion under certain conditions Therefore do not smoke make a fire or have any fire around while draining off fuel Carburetor drain screw 19 RESUMPTION OF SERvICE AFTER STORAGE 1 Remove the covering and remove the wooden blocks used in storing the vehicle Change the engine oil if the vehicle has been out of service for over 4 months 2 Drain off the remaining atomized anti rust oil from the fuel tank followed by filling it with fresh gasoline therein 3 Prior to driving all the required check ups must be made It is better to drive it at a low speed in an open area to test its performance before normal operation TABLE AND TORQUE OF FASTENERS Ser No Fastener Torque Newton m Foot lb 1 Front wheel axle nut 35 45Nm 26 33 ft lb 2 Rear wheel axle nut 50 60Nm 37 44 ft lb 3 Front Fork Bolts 45 47 5Nm 33 35 ft lb 1 2 3 20 means This item of maintenance should be carried out at a service center It may be also done by the user with reference to this manual provided special t
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