Bajaj Electricals HT65/MB165 User's Manual
Contents
1. JIULUJJUIEJW JO SWH 20 TROUBLESHOOTING Engine will not Start 1 Fuel Valve OFF Move Fuel valve lever to ON 2 Choke OPEN Move Chock Lever to CLOSED 3 Out of fuel 4 Bad fuel engine stored Drain fuel and carburetor Refuel with without treating or draining fresh gasoline gasoline or refuled with bad gasoline 5 Spark plug faulty fouled Remove and inspect spark plug Clean or improperly gapped gap or replace 6 Spark plug wet with fuel Remove and inspect spark plug Dry and flooded engine reinstall spark plug 7 Fuel filter clogged Take the engine to a qualified mechanic carburetor malfunction Replace or repair faulty components as ignition malfunction valves necessary stuck etc Engine Lacks Power 1 Filter 5 clogged Check air filter Cean or replace 2 Bad fuel engine stored Drain fuel tank and carburetor Refuel with without treating or draining fresh gasoline gasoline or refueled with bad gasoline 3 Fuel filter clogged Take engine to a qualified mechanic carburetor malfunction Replace or repair faulty components as ignition malfunction valves necessary stuck etc 21 Motorsports Baja Motorsports LLC 2910 South Hardy Drive Suite 103 Tempe AZ 85282 Tel 480 222 8280 Toll Free 888 863 22522. 13 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 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 Throttle cable adjust nut 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 14 ADJUSTMENT OF REAR BRAKE 5 7mm free play 1 The front brake hand grip should have free operating 2 3in movement of 5 7mm 2 3in 2 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 technition once brake shoes are worn Rear brak
3. 41cm stroke 2 68 2 13 Overall width 737mm 29 PTO shaft rotation Counter clockwise Overall height 914mm 36 Output max 6 5hp at 3600 rpm Wheelbase 1162mm Torque max 9 76 ft lbs at 2500 rpm 45 75 Dead weight 75kg 165 Ibs Idling speed 1400 200 150 Payload 91kg 200 Ibs Displacement of 197cc cylinder Front wheel 19X7 8 Spark plug MEIYA F7RTC NGK 10psi BPR6ES Champion RN9YC Rear wheel 19X7 8 Spark plug gap 0 7mm 0 79mm 10psi 028 031 Drum Gap of air valve IN 0 15 02mm cold Capacity of gasoline 4 2L 95 gal Gap of air EX 0 20 02mm cold tank Capacity of oil tank 5L 53 qt Ground clearance 139 mm 5 5 Drive Cintrifugal Ignition means Magnito cutch PARTS amp SUBASSEMBLIES Rear brake lever Throttle twist grip Headlight Hand brake Front Shock Absorber Front Wheel N Rear Wheel Clutch cover Drive Chain Gi oe Side Stand Foot pegs Decorative tank Vehicle Identifictaion Number Seat Cushion Nir Filter Brake Drum Pull Start Cord EPA Sticker 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 careful
4. Monday thru Friday PST and Saturday 8am to 4pm PST During DST hours change to MT You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED li A WARNING 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 All operators should obtain review and follow provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle Children under the age of 16 should never operate this vehicle ill Table of Contents SAFE OPERATION SAFETY MODIFICATION OF VEHICLE MAIN DATA itse neren nnen dant inne PARTS amp SUBASSEMBLIES csc OPERATION E 8 FUEL COCK aantreden a R sd 8 ENGINE STARTING en sites e Sa KA u iri 9 SWITCHES ON THE RIGHT HANDLEBAR enen 10 CHECK UPS ADJUSTMENT AND MAINTENANCE seen 11 CHANGING THE OUD 12 CHECK UP OF SPARK PLUG 12 CHECKING amp CLEANING THE AIR 13 ADJUSTING THE THROTTLE CABLE ADJUSTING THE CARBURETOR ADJUSTMENT OF REAR ADJUSTMENT 2 6 GR
5. 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 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 17 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 gm Attention Carburetor Drain screw 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 A WARNING Gasoline is flammable and may cause fire and even an explosion under certain conditions Therefore do not smoke make a fire or have a
6. EASING PROCEDURES TO THE DRIVING CHAIN 16 17 INSTRUCTIONS FOR 18 RESUMPTION OF SERVICE AFTER 5 19 TABLE AND TORQUE OF FASTNERS 19 MAINTENANCE REOUTINE 20 TROUBLESHOOTING il ger e 21 Please read this manual and follow all instructions carefully To emphasize the special information the symbol A and the words WARNING or CAUTION have some special meanings Pay great attention to the messages A WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this WARNING or CAUTION The first part will identify a POTENTIAL HAZARD The second part will describe WHAT COULD HAPPEN if you ignore the WARNING or CAUTION The third part will describe HOW TO AVOID THE HAZARD This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All informati
7. Motorsports HT65 MB165 Mini Bike Read this manual carefully It contains important safety information No one under the age of 16 should operate this Mini Bike 5 MANUAL Minimum Age Requirement 16 Rev B 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 Motorsports Congratulations on your purchase of the Baja Motorsports Mini Bike Your Mini bike is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days form the date of purchase During the warranty period BAJA MOTORSPORTS LLC will at its option repair provide replacement parts or replace your Baja Motorsports 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 If wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over Should you experience a problem or need to return your Baja Motorsports Mini Bike for repair please call the BAJA MOTORSPORTS customer service department TOLL FREE at 1 888 863 BAJA 2252 between the house of 7am and 5pm
8. arily increasing RPM s to a high level while the Mini Bike is warming up is harmful to the engine Procedures for stopping the engine 1 Release the throttle twist grip to slow down the engine 2 Set the ignition switch to position 3 Set the fuel valve lever the fuel tank valve handle to OFF position SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is provided on the right handlebar When the switch is turned to AS 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 be driven ON button OFF button 10 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 fuel plug 3 Finally screw in the oil gage plug tightly CAUTION Never start the engine when there is insufficient lubricating oil Otherwise it will cause harm to the engine Oil dip stick Lubricating Oil Recommended The lubricating oil is an important factor affecting
9. e arm Brake cable Rear brake adjusting nut 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 Ib 4 Repetitively check the tension of the chain Rear axle bolt 15 20mm 1 2 3 4 Chain adjusting nut Both Sides GREASING PROCEDURES TO THE DRIVING CHAIN 1 Shut off the engine 2 Add light amounts of machine oil or chain grease to the driving chain 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 16 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 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 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 1 After pre wiping the vehicle should be washed with clean water to remove
10. ly 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 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 Filler neck Fuel level 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 caburetor Fuel Valve Handle 8 ENGINE STARTING CAUTION Verify oil level prior to starting see page 11 Starting the engine with low or no oil will damage the engine A WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide 1 2 3 To start a cold engine Set the ignition switch to position Ensure that there is fuel in the tank Set the fuel valve lever to ON position Choke Lever Closed FF ON Place the choke lever in the closed position Fuel valve lever 1 2 Start the engine with the pull start cord 3 4 Turn the carburetor choke lever to the ON position when the engine has sufficiently Allow the engine to idle until the engine is warm warmed up CAUTION Unnecess
11. ny fire around while draining off fuel 3 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 apply an even coat of wax to the painted surface and a coat of anti rust 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 18 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 Front wheel axle nut 35 45Nm 26 33 ft lb Rear wheel axle nut 50 60Nm 37 44 ft lb 3 Front Fork Bolts 45 47 5Nm 33 35 f
12. of spark plug Meiya F7RTC Champion RN9YC BPR6ES 12 CHECKING amp CLEANING THE AIR FILTER 1 Remove seat to access air filter Seat is removed by removing nut located under seat see photo Locate Air Filter Box under seat and remove cover Remove air filter Remove foam cover from Air filter element 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 thouroghly 7 Reinstall foam cover to the air filter element 8 Reinstall air filter and close cover Seat nut Air Filter Removal of filter Air Filter box Removal of cover Air filter element Wash with mild soap and water Rinse with fresh water then queeze out excess 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
13. on 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 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
14. 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 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 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 Never perform any unauthorized modifications to this vehicle Only use original replacement part which can be obtained through Baja Motorsports 888 863 2252 MAIN DATA Description Overall length Data 1624mm 64 Description Cylinder bore x Data 6 8cm X 15
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16. 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 C C 30 20 10 0 10 20 30 40 TEMP 11 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 Dispose of the used oil properly For proper disposal procedures contact your local oil recycling center Clean and replace the Screw Plug tighly Refill the engine with the proper amount of oil and recheck the amount of oil in the engine by using the oil gauge plug Screw plug for oil draining CHECK UP OF SPARK PLUG A 1 Remove the cap of spark plug and screw off the spark plug using the plug wrench Clean the spark plug all around or replace it if it is corroded or there is too much deposit on it Ta Regulate the gap of the spark plug to 7mm 79mm 028 031 7mm 79mm The spark plug of the designated type should be used i 9 028 031 The applicable type
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