Phoenix 250 Owner`s Manual
Contents
1. SEQ Els Sewer gn Es RE 1 ae g dg ___ Rng oeg 008 006 fueA3 1 4 TETE vee ze ose 26 ez v9 or 190001 aon vj 90 moo x SW9 poje as UOISSIW UON 30 Maintenance Records To ensure proper maintenance keep record If the motorcycle is sold be sure to include the maintenance records All scheduled mainte nance is considered normal operator cost if a service center per forms these tasks you will be charged Please use the tables below to keep track of all maintenance performed quw by mq _ ___ EE 8 000 42 000 42172 aoo o2 soose 2000032000 mr a4o0Q840 3200051200 _ 1 14221 20083200 _ J 160000860 J 31 Tool kit and Owner s manual storage Your tool kit is located in the tool kit compartment These tools may come in handy during minor roadside repairs and adjustments Tools in tool kit e 10mmx12mm open end wrench e Standard phillips screw driver e Screw driver handle e Spark plug wrench e Tool bag The tool kit compartment can be found under the seat assembly Yo2. or 18 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 emis sion 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 perfor mance 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 main tenance 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 Un
3. L 1 HT Assy Yous pono AM upon Hu Assy Yous Asse Aejay MS AZL H7 1461 uonisod 30024 meni MS LZ AZ L 3461 HEL Cm MLZ AZL 203221 auuMvenig wig M Y MOIISA A euUMPPDeIS W8 fe15 1D SHUM MOII2A M A nig 18 p y u 16 1u6r1 61 4 9 5 POH MOIISA H A eniqaubr 91 p y u 19 4 9 uaa1b 1461 61 elg 9 MSE MSE AZL Tat x 2 Asse BE q 1829 MLT ATL 103e21puI fejo1 eis uoniu i HT ASSe MS AZL HY 2461 uonisod 3u044 Emission Control System Warranty BAJA MOTORSPORTS 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 delivered to the first purchaser other than an authorized dealer or the date it is first used as a demonstrator lease or company vehicle whichever comes first and continues for 60 months after that date
4. battery Battery and related components contain lead and lead compounds Battery Storage We recommend that you remove the battery from your motorcycle if you are planning to store it for a long period of time In order to maintain the life of the battery while storing you should slow trickle charge the battery every 30 days If you do not remove the battery you should disconnect the battery wires negative wire first 58 Battery e To avoid possibility of explosion always connect bat tery cable in order specified Negative first Positive last An exploding battery can cause serious injury or death e Batteries contain sulfuric acid e Always shield eyes with protective eye wear when orking around battery acid e Battery acid is poisonous and can cause severe burns e DO NOT smoke around batteries and keep away from open flames The battery can be found in the battery box under the right side cover below the driver seat 1 Remove the right side cover 2 Remove the rubber strap holding the battery in place 3 Disconnect the Negative terminal lead first then the Positive terminal lead 4 Remove the battery from the battery box 5 Unless you have been riding on a regular basis charge the battery 6 Store the battery in an easily accessible neutral climate location off of the floor and out of reach of children T Clean battery box before storing 8 Use a slow trickle charger every 30 days t
5. engine and let it run for 3 5 minutes 3 Turn the engine off and wait for at least 3 minutes 37 Engine Oil Draining Engine Oil continued 4 Remove the oil fill plug dipstick engine oil drain bolt and washer to drain the oil into an oil pan NOTICE Improper disposal of oil can be hazardous to the environ ment 5 Dispose of oil in an appropriate manner 6 Make sure the sealing washer is in good condition if not replace it You should replace every other time you change the oil Engine drain bolt Adding Engine Oil Install the engine drain bolt and torque to 18lbs ft 25Nm 8 Fill crankcase with recommended oil 1 6 US qt 9 Reinstall the oil fill plug dipstick 10 Start engine and let idle for 3 5 minutes 11 Turn engine off and let stand for 2 3 minutes 12 Hold the motorcycle in an upright position and check the oil level 13 Make sure their are no leaks 38 Air Cleaner Be sure to clean the air cleaner more frequently if you are ridding in dusty or wet areas You local service center can help you determine the correct service interval for your riding conditions Use only the air cleaner specified for your motorcycle or one of equivalent quality NOTICE Using the correct air cleaner can prevent engine wear dam age repairs spark plug fouling and poor gas mileage If you use the incorrect air cleaner you may cause sever engine damage NOTICE Improper air cleaner maintenance can caus
6. idle 3 Keep warming the engine until it responds to the throttle when choke is closed NOTICE Extensive use of the choke can cause damage to the piston and cylinder wall Fast idling for more than 5 minutes at Normal Air Temperature can cause exhaust pipe discoloration Flooded Engine The engine may be flooded with extra gasoline if it does not start after several attempts Try the following to clear a flooded engine 1 Turn the engine stop switch to the OFF position 2 Close the choke lever 3 Open the throttle completely 4 Push and hold in the start button for 5 seconds 5 Wait 10 seconds and turn the engine stop switch to the RUN position Next follow the High Air Temperature starting procedures 20 Starting and Stopping the Engine Shifting Gears How to stop the engine Normal Engine Stop e Shift into neutral and turn the ignition switch OFF e Leave engine stop switch in the RUN positive even when engine id OFF DO NOT leave the ignition switch ON while the engine stop switch if OFF this will allow the lights to stay ON causing the battery to loose life Emergency Engine Stop If an emergency stop is necessary use the engine stop switch Sim ply move the emergency stop switch to OFF Shifting Gears You motorcycle is equipped with a cable operated clutch It has five forward gears one down and four up 1 Tips for learning how to shift for the inexper
7. 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 call the Baja INC customer service line toll free at 1 888 863 2252 between the hours of and 5pm Monday through Friday MST Mountain Standard Time Mountain Daylight Time during daylight saving time You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED Safety Information This user s manual contains important safety and maintenance information Read it carefully before riding Failure to follow the warnings contained in this manual could result in INJURY or DEATH ALWAYS WEAR A HELMET The operator and passenger if any of this vehicle should always wear a helmet approved by agencies such as the Department of Transportation DOT Safety Helmet Council of America SHCA or Snell Memorial Foundation SNELL Most motorcycle accident fatalities are due to head injuries The operator should also wear face shields or goggles boots or closed toe shoes gloves and other appropriate protective clothing TAKE TIME TO LEARN AND PRACTICE Take time to get to know this vehicle The operator s ability to operate this motorcycle safely is largely dependent upon the oper ator s ability to exercise proper judgement The operator must be of sufficient age understanding mental capacity and physical capability to sa
8. load that you are carrying Operating this motorcycle with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure ou may lose control of the motorcycle Always use the size and type tires specified Always maintain proper tire air pressure as described in this section Air Pressure Check the air pressure in both tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort We suggest you visually check the tire pressure before each ride and check the pressure each month by using an air pressure gauge Be sure that the tires are inflated to the pressures shown below Tire pressure should only be measured or adjusted when the tires are cold Front Tire Pressure 44 psi 303kpa 33 psi 227kpa 51 Tires Inspection Always look for the following when checking tire pressure e Bumps or bulges on the tire if there are any replace the tire e Cuts or cracks replace tire if any fabric is visible e Any foreign objects such as nails embedded in the tire e Excessive wear Pull to the side of the road if you drive over a pothole or any hard objects to inspect the tire for possible damage You should replace the tires if the thread wear reaches the following limits Front from center of tread 0 06 inch 1 5mm Rear from center of tread 0 08 inch 2 0mm Wear indicator loc
9. of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied If an emergency situation exists when a warranted part or a dealer is not reason ably available to the owner repairs may be performed at any available service establishment or by the owner using any replacement part The Distributor shall reimburse the owner for the expenses including diagnostic charges not to exceed the Distributor s suggested retail price for all warranted parts replaced and labor charges based on the Distributor s recommend time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may reasonably be required to keep receipts and failed parts in order to receive compensation This Emission Control System Warranty is in addition to the standard Limited War ranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following Failures or malfunctions 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 interval for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubri cants gaskets hoses and belts 68 Emission Control System Warranty Replace
10. re lease the clutch lever and open the throttle your motorcycle should accelerate gradually and move smoothly Lower lock nut Lower adjusting nut If you cannot accomplish the correct free play using both adjust ments contact your local service center 42 Engine Idle Speed For the best servicing you should visit your local service center Adjusting the idle speed will not cure all problems in the engine fuel delivery system Idle Speed Adjustment 1 If the engine is cold start it and run for 10 minutes of stop and go riding Turn the engine off 2 Park the motorcycle on a level surface using the side stand 3 Connect tachometer to the engine 4 Shift into neutral and start engine 5 Adjust the idle speed with throttle stop screw Idle Speed in neutral 1 400 100 rpm Throttle stop screw Decrease Increase 43 Spark Plug Spark Plug Recommendation Do not use any spark plug other than the one recommended in the heat recommended NOTICE If you use a spark plug in the improper heat range you can cause engine damage Spark Plug Replacement 1 Clean any all dirt around the spark plug base 2 Disconnect the spark plug caps and make certain you do not damage the wires 3 Remove the spark plug using the spark plug wrench provided in the tool kit 4 Inspect the electrodes on the spark plug for corrosion and depos its if it has great corrosion replace the plug 5 Using a wire type feeler c
11. this task 7 Lightly tighten the adjusting nuts and tighten the lock nuts while holding the adjusting nuts with a wrench Lubrication Lubricate the chain every 500 miles and more often if it appears to be dry Only use SAE 80 or 90 gear oil for lubrication other chain lubricants may contain solvents that can damage the rubber o rings 56 Drive Chain Removal Cleaning and Replacement Your motorcycle has a riveted master link and should only be re moved or replace by your local service center Do not use a steam cleaner high pressure washer or certain sol vents These product can damage the o rings 1 Use a dry cloth to clean the side surface of the chain Use a high flash point solvent not gasoline Do not use a solvent or brush to clean the o rings 2 Check to make sure the chain is not damaged or worn If needed replace the chain Replacement Chain 520 57 Battery Your motorcycle is equipped with a maintenance free battery You do not have to check the electrolyte level or add distilled water NOTICE If you remove the cap strip you can permanently damage the battery Any electrical accessory will use currents from the battery If you have electrical accessories on your motorcycle and you ride often be sure to charge the battery frequently You should remove the battery or disconnect the battery cables if you do not plan to ride for two weeks or more Immediately wash hands after handling
12. to the rear wheel sprockets To keep moisture and dirt out the O ring chain uses rubber rings between the side plates of the pin and roller links to seal in the lubricating grease Proper lubrication and adjustment will help extend the life of the chain You should always perform the pre ride inspection to check the adjustment and lubrication before riding If you are riding in dusty or muddy conditions remember to maintain and service the chain more often than usual Before any servicing to the chain occurs be sure the engine id off and in neutral You do not need to remove the chain to perform service in the main tenance schedule Inspection 1 Check the slack of the lower drive chain right between the two sprockets 2 The slack should remain consistent along the entire chain if not check to make sure their are no kinks or binds You can sometimes eliminate kinks or binds by lubricating the chain 3 Inspect chain for Damaged rollers Kinks or binds Dry or rusty links Improper adjustment Excessive wear Damaged or missing o rings 54 Drive Chain The chain should be replaced if there is damage to the rollers or if there are loose pins Lubricate any kinks or binds to work them out If the chain appears too dry or rusty lubricate 4 Check both the front and rear sprocket teeth for excessive wear or damage If needed replace the sprocket NOTICE The use of a new chain with a worn sprock
13. 0 SAE 10W 40 SAE 10W 30 p 0 20 40 60 80 100 F 20 10 0 10 20 30 40 C e Use the recommended oil the oil does not need additives e Do not use graphite oil or oil with molybdenum additives e Do not use castor based racing oil vegetable oil or non detergent oil Checking and Adding Oil Cil fill plug dipstick Upper level mark ARAL Lower level mark 36 Engine Oil Checking and Adding Oil 1 Park your motorcycle on level ground and use the side stand for support 2 Start the engine and let it run for 3 5 minutes 3 Turn the engine off and wait for at least 3 minutes 4 Remove the oil fill plug dipstick and wipe clean 5 Hold the motorcycle in an upright position 6 Insert the dipstick in the oil fill until it rests on the metal do not screw it in 7T Remove the dipstick and check the oil level e If the oil is at or near the upper level mark there is no need to add oil e If the oil is at or near the lower level mark add the recommended oil until it reaches the upper level mark and do not overfill 8 Screw in the oil fill plug dipstick 9 Check for any leaks Changing Engine Oil This procedure will require some mechanical skill and special tools such as a torque wrench If you are not capable of performing this procedure contact your local service center Draining Engine Oil 1 Park your motorcycle on level ground and use the side stand for support 2 Start the
14. Motorsports Phoenix 250 Owner s Manual Minimum age requirement 16 REV B 030909 Always wear a helmet It could save your Life 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 Introduction Congratulations on your purchase of the Baja INC Phoenix 250 Motorcycle Take time to understand how your motorcycle works before riding Scheduled service is a must and it is important to follow the break in guidelines and pre ride instructions Make certain that you read the warranty coverage information provided and understand your responsibilities If you have any questions comment or concerns contact Baja INC at 888 863 2252 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 Safety The most important thing to remember is your safety and the safety of others We have included procedures an
15. aiton mark Wear indicator Replace tire immediately if the wear indicators are visible Tires Tires and Tube Repair If your tire in punctured or damaged replace the tire do not repair A repaired tube may fail while riding and is not as reliable as a new one temporary repair can be made in an emergency situation but will not perform at it s best Ride at slow speeds and do not carry a passenger with a repaired tire Have the tire and tube replaced as soon as possible If you replace only the tube and not the tire do not exceed 50mph for the first 24hrs and 80mph anytime after Tire Replacement When tire replacement is needed always replace them with the same size load range and speed rating Only use the tire size and type recommended Using improper tires can affect stability and handling hich may cause an accident resulting in injury or death Recommended Tire Size Front 110 90 16 Rear 130 90 15 When replacing a tire e Have the wheel balanced after installation e If possible have tire replaced by your local service center e Replace the tube Safety Reminders e Do not replace tire with a Radial tire Using a different type of tire may affect stability and handling e Do not replace with Car tires The tire may forcefully separate from the rim during installing causing serious injury or death 53 Drive Chain There is a riveted master link on the chain which connects the counter shaft
16. ake pedal and hold in brake lever to ensure that the brakes are operating correctly THROTTLE Rotate the throttle handle to ensure it moves smoothly LEAKS and LOOSE ENDS Check all hoses for leaks and cables that may be loose LIGHTS Be sure that your headlight tail light brake light and turn signals are working properly CHAIN Check the condition Adjust the slack if any and lubricate if needed TIRES Use an air pressure gauge to check the pressure If needed add air Look for excessive wear or damage If you are riding with a passenger or carrying cargo check LOAD LIMIT Do not exceed the load limit CARGO Secure all cargo REAR SUSPENSION Adjust the suspension according to the weight of the load you are carrying Make certain that you keep with the Periodic maintenance see peri odic maintenance section Loading guidelines and load limits Your motorcycle has been designed to carry you and one passenger When a passenger is riding with you there will be a difference in the acceleration and braking Load Limits Maximum weight capacity including rider passenger accessories and cargo 331 Ibs 150kg Maximum cargo weight 25lbs 10kg Loading guidelines Improper loading or overloading can be hazardous and may cause an accident resulting in serious injury or death Follow all load limits Improper loading of your motorcycle may affect your stability With the motorcycle properly loaded al
17. cements Failure to follow these safety precautions may increase your risk of injury Wear a helmet eye protection and bright protec tive clothing Do not ride after consuming alcohol or otherdrugs Slow down when road is slippery or visibility is reduced Read owner s manual carefully IMPORTANT DESCRIPTION DRIVE CHAIN COLD TIRE PRESSURES ADJUST DRIVE CHAIN AND APPLY CHAIN OIL DRIVER AND PASSENGER CHAIN FREE PLAY SHOULD BE 375 inches 10mm FRONT 200kpa 2 00kgf cm REAR 250kpa 2 50kgf cm 750 inches 20mm DRIVER ONLY FRONT 200kpa 2 00kgf cm REAR 225kpa 2 25kgf cm 029 TIRE SIZE LR FRONT 110 90 16 REAR 130 90 15 375 inches 750 inches Components Locations Steering lock Tail light Oil cap dipstick Rear brake pedal Rear shock preload adjuster Headlight Fuel valve Air cleaner Shift lever Passenger footrest Kick stand footrest Safety Labels Rear view mirror Brake fluid reservoir Speedometer Ignition switch Indicator lights Clutch lever Brake lever Headlight dimmer Throttle grip switch Engine stop switch Turn signal switch Fuel fill cap Indicators The indicators on your motorcycle help make you aware of possible issues refer to them often Speedometer Odometer Trip meter reset knob Lamp check Tripmeter high beam and neutral indicators
18. d labels to help you make safe informed decisions This information is provided to make you aware of potential hazards that could hurt you and or others It is impossible to warn you of ALL potential hazards so you must use your own best judgement The following are different kinds of safety information you will find in this manual Safety Labels On your motorcycle Safety Messages Warning Caution and Danger The meaning of Warning Caution and Danger Safety Messages Death or serious injury CAN occur if proper instructions are not followed Death or serious injury WILL occur if proper instructions are not followed yN CAUTION You CAN be hurt if proper instructions are not followed The engine exhaust from the product contains chemicals known to the state of California to cause caner birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 Contents er sr nn d etia tieu Pg 6 Safety Information Pg 7 Safety Labels Pg 9 Component Locations Pg 10 Indicator S si a en rue Pg 12 CORlFols ceret nn Pg 13 Before Riding eerte ttt hee eds Pg 16 Pre ride Inspection Pg 17 Loading guidelines and Load limits Pg 18 Starting Procedures ees Pg 19 Starting and Stopping Engine Pg 19 Shifting g ars rre Pg 21 23 nes Pg 24 Maintenance Safety Pg 26 en et n
19. e early engine wear or poor performance Replacing Air Cleaner 1 You will need to remove the seat in order to access the bolt that needs to be removed in order to take the side cover off Remove seat by inserting ignition key into key slot on side cover Turn key clockwise and seat will unlatch 2 Remove bolt 3 Remove left side cover and unscrew 3 screws holding air cleaner cover on 4 Discard air cleaner 5 Install new air cleaner 6 Replace air cleaner cover using screws 7 Replace left side cover using bolt to secure Bolt Key slot Screws 7 Left side cover 39 Crankcase Breather and Throttle Crankcase Breather You should service the crankcase breather more often if you are rid ding at full throttle or in rain Be sure to service if there are deposits in the transparent section of the drain tube Draining 1 Place a drain oil pan under the crankcase breather tube plug 2 Remove the plug so that the rube drains into the pan 3 Reinstall the crankcase breather tube plug THROTTLE Inspection Check the free play at the throttle grip Free play 1 16 1 4 inch 2 6mm If needed adjust to specified free play Adjustment 1 Loosen lock nut 2 Turn adjuster 3 After the adjustment has been made check the full rotation of throttle grip from all steering positions Lock nut Adjuster Throttle Inspection D 1 Make sure that all nuts and bolts are securely fastened and the thrott
20. ents We suggest you use regular unleaded fuel Be sure to only use an octane number of 86 or higher Using a lower octane gasoline can cause severe damage to the engine Never use stale or contaminated gasoline or an oil gasoline mixture Fuel Capacity Fuel tank capacity including reserve 3 12 US gal Reserve capacity 0 47 US gal After using the reserve tank you should refill the gas tank immedi ately Then turn the fuel valve to the ON position so you do not run out fuel in the reserve tank 34 Fuel and Engine Oil Refueling 1 Insert ignition key in the fuel fill cap and turn clockwise 2 Open cap 3 Add fuel to the bottom of the filler neck Do not overfill Filler neck Gasoline is extremely flammable and explosive You can be burned or seriously injured 4 After refueling push cap into the filler neck until it snaps and locks 5 Turn the fuel valve back to the ON position if it was in the RESERVE position By using checking adding and changing the recommended engine oil you can prolong the life of your engine Changing your engine oil helps get rid of dirt or debris that can damage the engine Always be sure to keep the right amount of oil in the engine or serious damage can occur If you are driving in dusty areas you should change the oil more frequently 35 Engine Oil Recommended Oil API classification SEorSG Viscosity weight SAE15W 40 Eo SAE 20W 50 SAE 20W 4
21. et will cause quick wear to the chain 5 Replace A Good Replace Adjustment Every 500 miles you should check and adjust if needed the slack of the drive chain If you are riding at high speeds the chain may need adjusting more often Index mark Axle nut Rear edge of adjusting slot Drive chain adjusting nut 95 Drive Chain 1 Place the motorcycle on level ground using the side stand Make sure the transmission is in neutral and the ignition switch if in the OFF position 2 Loosen the axle nut 3 Loosen the lock nuts on both sides of swing arm 4 Turn both adjusting nuts the same amount of turns until you have reached the correct slack To tighten the chain turn the adjusting nuts clockwise To loosen the chain provide slack turn the adjusting nuts counter clockwise Adjust the slack in between the drive sprocket and the rear wheel sprocket Move the motorcycle forward stop and park it on the side stand Recheck the slack it should allow vertical movement by hand 9 16 inch 15 30mm 5 You can check the rear axle alignment by making sure the index marks align with the rear edge of the adjusting slots Both marks should be at some point If they do not match up turn the left or right adjusting nut until the marks correspond and recheck the chain slack 6 Torque the rear axle nut to 65ft Ibs 88Nm If you do not have a torque wrench available make sure to have your local service center perform
22. fely operate this vehicle This vehicle should only be operated after sufficient practice in a decongested area Safe operation includes responsibility for the safety of a passenger if any We recommend that any inexperienced driver should take a certified course approved by the Motorcycle Safety Foundation MSF RIDE DEFENSIVELY common accident happens when a car suddenly moves into your lane Most motorcycle collisions happen when a car turns left in front of a motorcycle Pay extra attention to other vehicles around you never expect that they can see you Safety Information MAKE YOURSELF VISIBLE Make yourself more visible by wearing bright reflective clothing Use your horn when it helps others see you and before turning use your turn signal RIDE WITHIN YOUR LIMITS You should not ride beyond your abilities and never faster than the posted speed limit NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATION OF ANY KIND SUCH OPERATION COULD BE DANGEROUS TO YOURSELF AND OR OTHERS KEEP YOUR VEHICLE IN A SAFE CONDITION Proper maintenance will ensure a safe ride Perform all recommended maintenance and inspect your vehicle before each ride Never modify your vehicle in any way to make it unsafe Safety Labels The safety labels on your motorcycle provide you with important information do not remove them If a label becomes too difficult to read or comes off contact Baja INC for repla
23. heck the gap on every new spark plug If an adjustment is needed bend the electrode carefully the gap should be 0 024 0 028 inch 0 60 0 70mm 6 Thread spark plug in by hand so there is no cross threading 7 Tighten old but still good spark plug 1 8 1 4 turn after it seat Tighten new spark plug 1 2 turn after i seats 8 Reinstall the spark plug caps ib Electrode Spark plug gap NOTICE Incorrect tightening of the spark plug can cause severe damage to the engine Too loose can damage piston too tight can damage the threads 44 Suspension The front and rear suspension systems consists of springs and hy draulic damping devices The rear suspension system has a spring pre load which adjusts the force needed to begin compression of the spring Traction and comfort are acquired by the oil damper system It hydraulically controls the compression and rebound of the sus pension Whenever you change the load on your motorcycle add passenger or cargo or when riding conditions change be sure to adjust the rear suspension pre load If you set the spring pre load to a lower setting would accomplish a softer ride This setting should be used with a light load and smooth roads For a more firm ride set the spring pre load to a higher set ting used for heavy loads rough roads and a more challenging ride Rear Suspension Adjustment Adjustment to the spring pre load on the rear suspension should be done for the
24. ienced rider e Shift while moving a straight line e Let loose on the throttle and pull in clutch lever completely before shifting improper shifting may cause damage to the engine e Recognize the engaging point when you release the clutch lever 21 Shifting Gears Tips for learning how to shift for the inexperienced rider continued e Reduce the throttle or shift to a higher gear before engine RPM s get too high e Shift to a lower gear before the engine RPM s get too low e When the engine RPM s are too high do not downshift to slow your motorcycle this could cause damage e Do not coast or tow your motorcycle for a long period of time while the engine is off e If your speed drops below 9mph 15km h pull in clutch lever and shift down to 1st gear or stalling can occur Recommended shift point To get the best fuel economy possible ride in the highest gear that allows the engine to run and accelerate the smoothest Shifting up from 1st to 2nd 12mph 20km h 2nd to 3rd 19mph 30km h 3rd to 4th 25mph 40km h 4th to 5th 31mph 50km h Shifting down from 5th to 4th 22mph 35km h 4th to 3rd 16mph 25km h 22 Braking Your motorcycle is equipped with a hand operated front hydraulic disc brake and a foot operated rear drum brake Your front brake provides 70 of your braking power By using both front and rear brakes you will achieve faster more stable and effective braking To slow down or
25. ification Serial Numbers The frame VIN and engine serial numbers will be required when you register your motorcycle You may also need this information when ordering parts make sure to keep these numbers in a safe spot Frame number VIN Vehicle Identification Number can be found on the left side of the front forks stamped into a metal plate Frame serial number Engine number can be found stamped into the left side of the crankcase Engine serial number 62 Specifications Overall length 86 2 inch 2 190mm Overall width 31 5 inch 800mm Overall height 46 1 inch 1 170mm Fuel tank capacity 1312058 Engine oil recommendation service classification SF or SG SAE 15W 40 Engine oil capacity 16054 Drive chain lubricant SAE 80 or 90 gear oil Operator and one passenger Maximum weight 3311bs 150kg Includes rider passenger cargo and accessories Wheelbase 57 5 inch 1 460mm 63 Specifications Compression ratio 921 exhaust 0 002in 0 05mm 1 400 100rpm Primary reduction 3651 Gear ratio 3rg 4 333 Gear ratioath 10083 Gear ratio sth 10138 Final drive chain O 130 90 15 Rear tire pressure COLD 33psi 227kpa Battery 12V 9Ah 64 Specifications Main fuse 65 Wire Diagram Hy Asse ups yeds reds v v pojuonw6 _ 61 H1
26. illuminate when Hibeam you turn the ignition switch indicator and will remain on until you select low beam or shift out of neutral Neutral indicator Turn signal indicator Speedometer Shows the speed you are traveling miles per hour Odometer Tracks the total miles driven Trip meter Tracks the total miles driven on your trip Hi beam indicator llluminates when hi beam lights are on Turn signal indicator Flashes when left right turn signal is on Neutral indicator llluminates when transmission is in neutral Trip meter reset know Turn this knob to reset the trip meter Controls FUEL VALVE Fuel valve Used to control the flow of gasoline from the fuel tank to the carburetor OFF ON gasoline can flow to the carburetor OFF gasoline cannot flow to the carburetor RES gasoline can flow to the carburetor when you have run out of gas in the gas tank Make sure to refuel as soon as possible CHOKE LEVER Choke lever May be used when starting engine See starting procedures using choke lever on page 17 Controls IGNITION SWITCH iW Ignition switch Used for PW starting and stopping the engine The key is used to lock the steering preventing theft ON All electrical components are ON OFF All electrical components are OFF START BUTTON AND ENGINE STOP SWITCH Engine stop switch Start button 4 Pushing the start button will start the engine When button is
27. ited 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 confirm with applicable regulations of the United States Environ mental Protection Agency or the California Air Resources Board for the periods specified above 67 Emission Control System Warranty 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 except in an emer gency situation 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
28. ke pedal until it starts to engage to check the free play 0 78 1 2 inch 20 30mm If needed adjust to specified range Adjustment 1 Turn the rear brake adjusting nut clockwise to increase free play and counter clockwise to decrease the cut out should be seated on the brake arm pin 2 Depress and release the brake Spin the wheel and make sure that it rotates smoothly Repeat procedure several times Check free play If you are unable to adjust Brake arm pin free play correctly see your local service center Adjusting nut 49 Brakes Other Inspections e Make sure the brake pedal is positioned properly and the securing bolts are tight e Inspect the brake rod arm spring and fasteners make sure the are in good condition Brake Shoe Wear You are able to check brake show wear without having to disas semble the rear end There is an external brake wear indicator By depressing the brake pedal the brake arm arrow moves toward a reference mark on the brake pedal 1 Park your motorcycle and use the side stand for support 2 Depress the brake pedal and check the movement of the arrow on the brake arm If the arrow aligns with the reference mark on the brake pedal have your local service center replace the brake shoes Arrow Reference mark Brake panel Brake arm 50 Tires The tires on your motorcycle should be the proper type and size They should be in good condition and properly inflated for the
29. lace Turn the handlebars left Insert ignition key into lock and turn clockwise 90 remove key Turn fuel valve OFF Steering lock Theft Prevention tips e You should park your motorcycle in a garage if possible otherwise make certain to park in a well lit area e Never leave the ignition key with the motorcycle e Always use the steering lock even for a short period of time e You should invest in a good quality anti theft device that will secure your motorcycle to a stationary object e Keep the owner s manual registration and insurance with the motorcycle to help authorities find you if it has been stolen and recovered 24 Servicing your Motorcycle This section is provided to help you keep your motorcycle in good running condition The following table provides you with the three types of inspections recommended for your motorcycle Type of inspection Refer to When to perform Who performs service page Pre ride inspection before every ride Maintenance Interval on schedule Service Center schedule It is essential to your safety that you keep your motorcycle well maintained A properly maintained motorcycle will help protect your investment avoid break downs and have maximum performance The maintenance of your motorcycle id YOUR responsibility Follow all maintenance and inspection recommendations Improper maintenance can cause an accident resulting in injury or death I
30. le assembly is positioned correctly 2 Check the full rotation of the throttle grip from all steering positions 40 Clutch System The proper free play adjustment of the clutch allows for a gradual smooth engagement when shifting gears Early wear can occur if you do not properly adjust the free play Clutch Free Play Left handlebar inspection 1 Check free play if needed adjust to specified adjustment Free Play 3 8 13 16 inch 10 20mm Upper Adjustment Always adjust using the upper clutch cable adjuster before using the lower adjustment 1 Loosen upper lock nut 2 Rotate the upper clutch cable adjuster until the proper free play has been accomplished 3 Tighten the upper lock nut and check that the free play is correct Clutch cable adjuster Upper lock nut Clutch System Lower Adjustment If the upper clutch cable adjuster has reached it s limit or you cannot obtain the correct free play you may also use the lower clutch cable adjuster 1 Loosen the upper lock nut and rotate the upper clutch cable adjuster in to maximum free play 2 Tighten the upper lock nut Clutch cable adjuster Upper lock nut 3 Loosen lower lock nut 4 Rotate lower adjusting nut until the proper free play has been ac complished 5 Tighten lower lock nut and check adjustment 6 Start engine hold in clutch lever and shift into gear Make sure the engine does not stall and the motorcycle does not move Slowly
31. less you have proper tools and service information have your local service center perform these tasks For safety reason ONLY your local service center should perform these tasks NOTES 1 Repeat the frequency interval at higher odometer readings 2 Service more frequently if you are ridding in dusty or wet areas 3 Service more frequently if you are ridding at full throttle or in rain 4 Replace every 2 years or at indicated odometer reading which ever comes first 28 Maintenance Safety adjust lubricate or replace if necessary clean Inspect Replace Lubricate R L A Adjust C Clean uejs s 01 U09 UOISSILS peeds ajpi euibu3 E U9919S 5 9 9 CRE A NN HR A CR LE RES ER 14 rmos ERE LE p ese CE 9 0Ju L emm EE ER RENTE sula uoissiu3 29 Maintenance Schedule Inspect clean adjust lubricate or replace if necessary R Replace Lubricate L A Adjust Clean C ee p E RERO ER RE TE ANS syoq SINN _ Ex qug sw 22272
32. ments 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 0 Accident 0 Misuse 0 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 lim ited 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 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 co
33. n the event of an accident have a service center inspect ALL parts even if they appear to be undamaged 25 Maintenance Safety This section will instruct you on how to perform some important routine maintenance You can perform many of these tasks with the tools provided with the motorcycle The more difficult tasks such as wheel removal should be performed by a professional technician If you do not feel capable of performing any one task do not hesitate to contact your local service center for help WARNING Failing to follow these maintenance instructions can result in serious injury or death Important Safety Precautions e Always turn the engine off before performing any maintenance or repairs e Let the engine cool before touching any related parts e Do not touch any moving parts while engine is running e Make sure you have the tools and skills required before perform ing any maintenance repairs e Use the side stand or maintenance stand to prevent the motor cycle from falling over e Keep cigarettes sparks and flames away from all fuel related parts Use a non flammable solvent when cleaning parts Keep in mind that your local service center is equipped with the proper tools and knowledge to help service your motorcycle If nec essary please contact them to ensure greater quality and reliability 26 Maintenance Safety Including the regular maintenance and pre ride inspection perform the periodic check
34. n tn qe Pg 32 Side cover removal Pg 33 i 34 Fuel and Engine oil Pg 35 Air Cleaner Pg 39 Crankcase breather and throttle Pg 40 ier Hee enone on esa ea ee Pg 41 Engine idle Pg 43 Spark oett Pg 44 Contents SUSPENSION ennemies Pg 45 Baker en Pg 47 TES eode eco erbe eat Pg 51 Drive Chalh nn in ne an Pg 54 Battery naii eee ete thee ue Pg 58 Appearance Pg 61 Vehicle Identification Pg 62 SDeCIfICallOris edet otra o Pg 63 Wire te tenente einn Pg 66 Emission Control System Warranty Pg 67 Warranty oss Congratulations on your purchase of the Baja Inc Phoenix 250 Motorcycle It is warranted to be free of manufacturing defects in the 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 Phoenix 250 Motorcycle 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
35. ntrol system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this war ranty 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 questions regarding your warranty rights and responsibilities you should contact BAJA INC 866 401 2252 or the California Air Resources Board 9528 Telstar Avenue El Monte CA 91731 for California registered vehicles only 69 4 BP Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252
36. o maintain life of the battery Negative terminal lead Positive terminal lead Battery Rubber strap 59 Battery Charging the Battery Charging the battery incorrectly may cause damage Always read the instructions that came with the battery charger and follow all directions on the battery For home charging we suggest you use a trickle charger A trickle charger can be left connects for a long period of time without causing damage to the battery Do not leave the battery connected to the charger longer than the recommended amount of time Do not use an automotive battery charger as this can cause permanent damage to your battery 60 Appearance Care You should always clean and polish your motorcycle on a regular basis to keep it looking newer longer General Recommendations e You may use the following to clean your motorcycle amild neutral detergent and water amild spray and cleaner polisher amild cleaner de greaser e Do not use products that contain chemical solvents or harsh deter gents e Before cleaning make sure the engine is cool e Wash your motorcycle in a shady area Direct sunlight can cause water spots and fading e Do not use a high pressure washer to clean we suggest you use a garden hose NOTICE High pressure washers can cause damage to certain parts of your motorcycle e When you are finished cleaning your motorcycle always check for wear or leaks 61 Vehicle Ident
37. ontainer of brake fluid never use an opened container that may be contaminated Brake Fluid Level Inspection 1 Park your motorcycle on level ground in an upright position 2 Check the fluid level It should be above the lower mark if not check for wear on the brakes If the pads are worn replace immedi ately Have your local service center do this 47 Brakes Other Inspections e Make sure there are no leaks in the fluid lines e Check for loose fittings or damage to the fluid lines NOTICE Brake fluid can damage painted surfaces and plastic handle with care Clean any spills immediately In case of contact with skin wash thoroughly Contact with eyes wash thoroughly and see a doctor immediately Brake Pads Wear Brake pad wear depends on how much you use the brakes the type of riding and road conditions Normally brake pads tend to wear quicker on wet and dirty roads Be sure to check the pads for wear during each maintenance interval You can inspect the wear on pad by using the wear indicator mark If the pads are worn replace immediately Have your local service center do this 48 Brakes Rear Brake Pedal Free Play Brake Pedal Height Adjustment The height of the brake pedal can be adjusted by using the stopper bolt 1 Loosen lock nut and turn stopper bolts to adjust 2 Tighten lock nut Stopper bolt Inspection 1 Park your motorcycle on the side stand for support 2 Depress the bra
38. pressed in the start motor will crank the engine headlights will turn off but the taillight will stay on See starting procedures Start button Engine stop switch In case of an emergency and a quick stop is necessary turn switch to the OFF position This switch must be in the RUN position in order to start the vehicle and should remain in this position even while the engine is off If you leave ignition switch on and engine stop switch off the lights will stay on causing the battery to lose life RUN P OFF Controls HEADLIGHT DIMMER SWITCH TURN SIGNAL SWITCH AND HORN Headlight dimmer switch Headlight dimmer switch This switch is used to change from to LO beam 40 40 Turn signal Horn switch Turn signal switch Use this switch to signal a lane change or tun lt Left gt Right Horn The horn is used to warn other motorist Trip meter reset knob By turning the knob counter clockwise you can reset the trip meter to zero 0 Tripmeter reset knob Before Riding Before your first ride on your new motorcycle we strongly recommend you e Read the owner s manual e Understand all safety labels e Know how to operate all controls Before you ride each time make sure e You are in good physical and mental health e You are wearing protective gear helmet clothing eye protection etc If you have a passenge
39. r be sure they also have protective gear on e You do not have ANY alcohol or drugs in your system Protective Clothing For your protection we urge you to ALWAYS wear protective cloth ing The proper clothes can protect you from injury Wear an ap proved motorcycle helmet goggles a good pair of gloves strong boots that cover the ankle long pants and a long sleeve shirt every time you ride Helmets and Eye protection A DOT approved motorcycle helmet is the most important part of your protective gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snug Motor cycle dealers can help in selecting a good quality helmet which fits properly Not wearing a helmet greatly increases your chances of serious head injuries or death in the event of an accident If you are riding with a passenger be sure they are also earing a helmet and eye protection Pre Ride Inspection Before each ride check the condition of your motorcycle to make sure that it does not have mechanical problems Your motorcycle should always be in good riding condition to ensure the safety of you your passenger if any and others around you Improper maintenance of this motorcycle or failure to correct any problems can result in serious injury or death ALWAYS perform a pre ride inspection before every ride Be sure to check the following items before each ride BRAKES Press on the br
40. s once a month and once a week if you ride frequently Check the odometer and perform any scheduled maintenance necessary Tires Fluids Lights Free play Drive Chain Fuses e Check the air pressure and add air if needed e Check for any excessive wear on the tread e Check for any damage that may have occurred e Check the rims and spokes for any possible damage e Check the level of engine oil e Check the level of the brake fluid e Add the correct fluids if necessary e Check the headlight brake light tail light and turn signals Make certain they all work properly e Check the clutch lever rear brake pedal and throttle grip e Check the condition adjust the slack and lubricate if necessary e Always have spare fuses Nut and bolts e Check all nuts and bolts tighten if needed 27 Maintenance Schedule This portion of the manual will tell you how often to perform main tenance The maintenance schedule is based on average riding conditions If you ride more frequently than usual and in dusty or wet weather be sure to maintain your motorcycle more often We recommend that you have your local service center perform exten sive maintenance and repairs unless you have advanced mechanical skills If needed you can purchase a service manual from Baja INC Every maintenance item requires some mechanical knowledge some parts require more technical information and tools than others Un
41. stop your motorcycle apply front and rear brakes while down shifting Slowly increase braking as you feel your speed reduce In order to prevent stalling pull in clutch lever before stop ping completely If you apply you brakes too abruptly you may lock the wheels slide and loose control of your motorcycle If this should happen release the brakes and steer straight until you have completely regained control Before making a turn reduce your speed Try not to brake or close the throttle too quickly while turning or you may loose control of your motorcycle When traveling down a steep grade reduce your speed by down shifting rather than braking Applying your brakes for a long period of time can reduce their effectiveness You should never ride with your foot resting on the brake pedal or you hand on the brake lever This mat cause your brakes to overheat and indicate false braking to other motorist s 23 Parking Try when possible to park on level ground If you have no paved surface to park on make sure the ground is firm If it is necessary for you to park on a hill position your rear wheel against the curb at an angle and leave the transmission in gear While parked use the side stand for support Use your foot to guide the side stand down Put something solid under the side stand if you must park on a soft surface Always use the steering lock when your motorcycle is parked this will lock the handlebars in p
42. u must insert the ignition key into the key slot on the compartment cover Turn key clockwise and remove cover To re install align tabs and push Turn key counter clockwise Store the owner s manual under the see assembly along with the tool kit and any other important documents 32 Side Cover Removal Left Side Cover In order to clean and maintain the air cleaner you must remove the left side cover Removal 1 You will need to remove the seat in order to access the bolt that needs to be removed in order to take the side cover off Remove seat by inserting ignition key into key slot on side cover Turn key clockwise and seat will unlatch 2 Remove bolt Bolt 3 Remove cover Left side cover Installation Key slot 1 Align prongs 2 Reverse removal steps Right Side Cover In order to clean and maintain the battery and fuses you must remove the right side cover Removal 1 You will need to remove the seat in order to access the bolt that needs to be removed in order to take the side cover off Remove seat by inserting ignition key into key slot on left side side cover Turn key clockwise and seat will unlatch 2 Remove bolt 3 Remove cover Bolt Installation 1 Align prongs 2 Reverse removal steps Right side cover 33 Fuel Fuel Recommendation Type Unleaded Octane number 86 or higher Unleaded fuel procedures fewer engine deposits and will extend the life of the exhaust system compon
43. ways ride at a reduced speed If you have questions about carrying cargo contact Baja INC for advice Check the following when carrying a passenger or cargo e Both tires are properly inflated e Rear suspension may need adjusting e Secure all cargo e Balance cargo weight e Do not attach large or heavy items to the front of your motorcycle Starting and Stopping the Engine Always follow proper starting procedures y WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide Starting procedure e Insert key into ignition turn to ON position e Make sure the transmission is in the NEUTRAL position e Turn the engine stop switch to e Turn fuel valve to ON If you are restarting a warm engine follow procedure for High Air Temperature Normal Air Temperature 10 35 C 50 95 F 1 Open choke lever 2 Start the engine leaving throttle closed Do not open throttle while choke is open this will make it difficult to start 3 After engine has started close choke lever If idle is not stable open the throttle a little OFF Starting and Stopping the Engine High Air Temperature 35 C 95 F or above DO NOT OPEN CHOKE 1 Slightly open throttle 2 Start engine Low Air Temperature 10 C 50 F or below 1 Follow Normal Air Temperature procedures 1 2 2 After RPM s pick up open the choke to keep fast
44. weight of a rider and passenger if any and different riding conditions The adjustments in this manual are limited Do not disassemble or service the dampers have your local service center perform these tasks 45 Suspension Rear Suspension Spring Pre load There are 5 different spring pre load adjustments for all types of loads and riding conditions Spring pre load adjuster Position 1 Lightest load and smoothest ride Position 2 Standard position Positions 3 5 Heavier heaviest load and firmer ride Always adjust both shocks to the same position Adjust in sequence never go from position 1 to position 5 or you may cause damage to the shock 46 Brakes Your motorcycle uses a front hydraulic disc brake and rear drum brake Hydraulic Liquid Front Brake The brake fluid will drop as the brake pads wear or if there is a leak To ensure there are no leaks often check the brake system You should also check the brake pads for wear and the brake fluid level If you feel abnormal free play in the brake lever check for wear on the brake pads If you discover the brake pads to be worn you should replace them immediately If the pads are still in good condition there may be air in the brake system You will need to bleed the brakes visit your local service center for help Brake Fluid Recommendation We recommend that you use DOTS brake fluid or any brake fluid of the same quality Always use a fresh new c
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