Baja motorsports DB30 Mini Bike Owner`s manual

DB30 Mini Bike
Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this Mini Bike without adult
supervision.
OWNER’S MANUAL
Weight capacity: 150 lbs.
REV-A
072607
Always wear a helmet; It could save your Life!
Do not return this product to the store. Contact Baja Motorsports at
1-800-863-2252 for parts and service.
If for any reason, you do return this product to the store, make sure all gas and oil
is drained from the unit. The store cannot accept any returns with gas and oil.
Please obtain, review, and follow provincial / municipal government acts and
regulations pertaining to owning and operating an off-road vehicle.
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
Wheels are bent or broken
Fender bent or broken due to abuse
Any sign of impact, accident, jumping, spin-outs or roll over.
BAJA MOTORSPORTS, LLC 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 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 hours of 7am and 5pm 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.
ii
!
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 without adult
supervision.
! WARNING
The engine from this exhaust contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
CALIFORNIA PROPOSITION 65
iii
table of contents
SAFETY -------------------------------------------------------
Safe Operation ------------------------------------ Safety Gear -----------------------------------------
Location of Labels -------------------------------
SPECIFICATIONS ------------------------------------------
LOCATION OF PARTS ----------------------------------- OPERATION ------------------------------------------------- Left and Right Hand Grip ----------------------
Engine ON/ OFF switch and Pull Cord ------ Fuel Fill ---------------------------------------------- Fuel Valve -------------------------------------------
INSPECTION BEFORE RIDING -------------------------
ENGINE STARTING AND STOPPING -----------------
INSPECTION AND MAINTENANCE ------------------
Checking Oil ----------------------------------------
Changing Oil ---------------------------------------
Check-up of Spark Plug-------------------------
Checking and cleaning Air Filter --------------
Adjusting Throttle Cable ------------------------
Adjusting Carburetor ----------------------------
Adjustment of Rear Brake ----------------------
Adjustment of Chain -----------------------------
Clutch cleaning and maintenance -----------
Vehicle Washing -----------------------------------
Instruction for Storage --------------------------
Resumption of Service after Storage --------
MAINTENANCE SCHEDULE ----------------------------
TROUBLE SHOOTING ------------------------------------
ELECTRICAL SCHEMATIC -------------------------------
EMISSIONS CONTROL SYSTEM WARRANTY-------
2
3
5
6
8
9
10
10
10
11
11
12
13
14
14
15
15
16
17
17
18
19
20
21
22
23
24
25
26
27
safety
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.
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 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
SAFE OPERATION
Rules for Safe Operation
·
A pre-operation check must be conducted before starting the engine to insure
safety, prevent mishaps and/or damage to components.
ITEM TO CHECK
CONTENT
Steering
Smoothness; No restriction of movement; No play or looseness
Brakes
Proper brake lever free play; enough brake force
Tires
Proper air pressure; Enough tread depth; No cracks, rips, or
other damages
Fuel
Enough fuel for the intended trip; Fuel hose connected securely;
No damage to fuel tank or cap; Fuel tank cap closed securely
Engine stop switch
Proper operation
Engine oil
Proper level – Check oil by inspecting Engine Oil Dip Stick.
The engine oil should be between the Minimum and Maximum
lines.
Throttle
Proper free play of throttle lever; smooth response; quick
return to idle position
General condition
Bolts and nuts are tight; no rattle from any parts of the engine
when running, no visible evidence of Damage
It is strongly suggested that all operators take a certified motorcycle rider’s
course prior to operating the vehicle.
Pay close attention to the following points while riding Mini-bike:
·
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.
safety
·
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
·
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
SAFETY GEAR
A DOT approved motorcycle helmet is the most important part of you safety
gear. A DOT approved motorcycle helmet can help prevent a serious head injury.
Choose a helmet that fits snugly. Motorcycle dealers can help in selecting a good
quality helmet which fits properly.
WARNING
Operating this Mini Bike without wearing an approved DOT motorcycle
helmet, eye protection, and protective clothing could be hazardous.
Operating without an approved DOT motorcycle helmet or eye protection
increases your chances of a severe head injury or death in an accident.
Operating without protective clothing also increases your chances of
severe injury in an accident.
Always wear an approved DOT motorcycle helmet which fits properly.
Always wear eye protection (goggles or face shield). You should also
wear gloves, boots, long sleeve shirt or jacket, and long pants.
You should wear eye protection when you ride. If a rock or a branch hits your
eyes, you could be severely injured. Wear goggles or a face shield.
Wear proper clothing when you ride. The proper clothes can protect you from
injury. Wear a good pair of gloves, strong boots that are over the ankle, long
pants, and a long sleeve shirt.
CAUTION
Never perform any unauthorized modifications to this vehicle. Only
use original replacement part which can be obtained through Baja
Motorsports 888-863-2252.
safety
LOCATION OF LABELS
1 2
3
4
WARNING
1
No one under the age of 16
should operate this vehicle
without adult supervision.
2
4
WARNING
Riding on slope
greater than 15 Degrees
15 Degrees
increases
the risk of an
accident.
DO NOT
-Return Mini Bike to store
-Attempt wheelies
-Ride on rough rocky terrain
-Attempt stunts
-Attempt steep hills
-Operate without first reading owners manual
DO
-Call Baja 1-888-863-2252
for Service Centers and parts
-Practice safe riding skills
-Always wear a helmet
-Ride on surfaces no greater
than 15 degrees
-Practice safety first
4
WARNING
WEIGHT LIMIT
5
DO NOT EXCEED 150 LBS.
!••
3
!
THIS VEHICLE IS AN OFF ROAD VEHICLE
AND IS NOT INTENDED FOR USE ON
PUBLIC ROADS OR HIGHWAYS
SAFETY
LOCATION OF LABELS
7
5
5
7
76
STOP!
! WARNING
-Moving parts
can crush and
cut.
-Keep hands
clear.
-Do not operate
with guard
removed.
DO NOT RETURN THIS ITEM TO THE
STORE. IN THE EVENT THIS UNIT IS
DEEMED “DEFECTIVE”, IT CANNOT
BE RETURNED TO THE STORE
CONTAINING ANY GAS OR OIL.
ATTENTION!
! WARNING
TIRE PRESSURES
• Improper tire pressure can cause loss of
control resulting in serious injury or death.
• Check pressures on all tires only when
tires are cold. 4 psi (27.6 kpa)
• Remove air from tires before demounting.
• Only use replacement tires specified by
manufacture.
6
CALL 888-863-2252
FOR YOUR LOCAL
SERVICE CENTER
AND PARTS
ASSISTANCE
www.bajamotorsports.net
SPECIFICATIONS
Description
Data
Overall length
1295mm (50.98 inches)
Overall width
640mm (25.20 inches)
Overall height
860mm (33.86 inches)
Wheelbase
935mm (36.81 inches)
Dead weight
36kg (80lbs.)
Payload
68.04kg (150 lbs.)
Front wheel
145x70-6
Rear wheel
145x70-6
Brake type
Disc
Capacity of gasoline tank
1.4L (0.36 gal)
Capacity of oil tank
0.45L (0.40 qt.)
Starting method
Recoil pull start
Bore a stroke
52mm x 46mm
PTO shaft rotation
Counter clockwise
Horsepower
2.5Hp
Displacement
97.7cc
Max power
1.84KW/3600rpm
Max torque
3.8Nm/2500rpm
Spark plug
Autolite-258, AC-CS49, Champion-CJ14,
NGK-BPMR6A, Denso-W14M-US
Spark plug gap
0.7mm-0.79mm
Ground clearance
102mm (4 inches)
Ignition system
Non contact transistor magneto
LOCATION OF PARTS
Hand brake
Seat Cushion
Spark plug
Front Wheel
Rear Wheel
Oil fill
plug
Clutch cover
Oil drain plug
Kick Stand
Drive Chain
ON/Off Button
Throttle
handle
Gas Tank
Air Filter
Foot pegs
Pull Start Cord
Brake Caliper
OPERATION
Left and right hand grip operation
Brake Lever
Throttle control grip
ON button
Right Hand Grip
Left Hand Grip
•
CCW
OFF button
Pulling in brake lever located on left hand grip will stop mini bike.
Applying the hand throttle (moving throttle CCW (Counter Clockwise) ) will
cause engine rpms to increase which will move the mini bike forward.
When the ON/OFF button switch is at “ ” (off) position, the engine will not
start. If the engine is running and the Off button is pushed the engine will
shut off.
When the ON/OFF button is turned to “
when the pull start cord is pulled.
” (on) position, the engine will start
Engine pull START CORD OPERATION
Pulling the pull start cord will start the
engine when the ON/OFF button is at “ON”
position.
10
Pull Start Cord
OPERATION
Fuel and fuel valve operation
Fuel filling
The capacity of the fuel tank is 1.4L (.40 qal.) 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 mini bike using a cloth.
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.
WARNING
Overfilling the fuel tank could be hazardous.
If you overfill the fuel tank, fuel may overflow when it expands. Expanding
is due to heat from engine or sun. Overheated fuel could easily catch fire.
Stop adding fuel when the fuel level reaches the bottom of the filler neck.
Filler neck
Fuel level
FUEL VALVE OPERATION
ON: With the handle of the fuel valve at “ON” position, the fuel supply will flow to
the carburetor. In this position the engine is able to start and run.
OFF: With the handle of the fuel valve at “OFF” position, the fuel supply is cut off
to the carburetor. In this position the mini bike will not start and will not run.
Fuel Valve Handle
ON
OFF
11
INSPECTION BEFORE RIDING
ITEM TO CHECK
CONTENT
Steering
Smoothness; No restriction of movement; No play or looseness
Brakes
Proper brake lever free play; Proper braking
Tires
Proper air pressure; enough tread depth; no cracks, rips, or other
damages Note: Check tire pressure.
Fuel
Enough fuel for the intended trip; Fuel hose connected securely; No damage
to fuel tank or cap; Fuel tank cap closed securely
Engine stop switch Proper operation
Engine oil
Proper level – Check oil by inspecting Engine Oil Dip Stick. The engine
oil should be between the Minimum and Maximum lines.
Throttle
Proper free play of throttle lever; smooth response; quick return to idle
position
General condition
Bolts and nuts are tight; no rattle from any parts of the engine when
running, no visible evidence of Damage
WARNING
Failing to inspect the Mini Bike before operating could be hazardous.
Failing to perform proper maintenance could also be hazardous.
Failing to inspect and maintain your Mini Bike could increases the
chances of an accident or equipment damage
Always inspect your Mini Bike each time before riding, and make sure it is in a
safe operating condition. Refer to the INSPECTION AND MAINTENANCE section in
this manual.
WARNING
Operating this Mini Bike with improper tires, or improper tire air pressure could be
hazardous.
If you use improper tires or improper air pressure, you may lose control of
the Mini Bike. This will cause an accident.
Always use the tires with size and type specified in this user’s manual.
Always maintain proper tire air pressure as described in the INSPECTION
AND MAINTENANCE section.
12
ENGINE STARTING AND
STOPPING
CAUTION
Verify fuel and oil level prior to starting (see pages 11 and 14)
Starting the engine with low or no oil will damage the engine.
WARNING
Never start the engine in a closed place as the exhausted gas
from the vehicle contains toxic carbon monoxide.
1. Ensure there is fuel in fuel tank and oil in crank case.
2. Set fuel valve lever at “ON” position.
3. Place choke lever at “ON” position.
4.
Depress
“ON” button located on right hand grip
5. Start engine with pull start cord.
6. Allow engine to idle until engine is warm
7. Place carburetor choke lever at “Off” position when engine has sufficiently
warmed up.
Fuel Valve Handle
OFF
Choke Lever
ON
OFF
Procedures for stopping engine:
Fuel valve lever
ON
1. Release throttle twist grip to slow down engine.
2. Depress
“OFF” button located on right hand grip to shut off engine.
3. Set fuel valve lever (the fuel tank valve) handle to “OFF” position.
CAUTION
Unnecessarily increasing RPM’s to a high level while the Mini Bike is
warming up is harmful to the engine.
13
INSPECTION AND MAINTENANCE
CHECKING THE OIL
Check engine oil each time prior to operating mini bike.
The oil level should be between upper and lower lines of 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 completely in
the hole to check the oil.
2. Add lubricating oil up to the edge of the fuel plug.
3. Screw oil gage plug tightly.
CAUTION
Oil dip stick
Never start the engine when there is insufficient lubricating
oil. Otherwise, it will cause harm to the engine.
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.
.45L (.40qt.) Oil
Lubricating oils of different
viscosity shall be employed
in different regions and at
different temperatures.
20W-40 20W-50
15W-40 15W-50
MACHINE
OIL
10W-40
10W-30
TEMP.
°C
-30
-20
-10
0
10
20
30
40
°F
-22
-4
14
32
50
68
86
104
14
INSPECTION AND MAINTENANCE
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.
4. 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
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”).
4. The spark plug of the designated type should be
used.
Autolite-258, AC-CS49, Champion-CJ14,
NGK-BPMR6A, Denso-W14M-US
15
.7mm - .79mm
(.028” - .031”)
INSPECTION AND MAINTENANCE
Checking & Cleaning the Air Filter
1.
2.
3.
4.
5.
6.
7.
Locate Air Filter Box at rear of engine
Remove air filter cover by unscrewing phillips head screw
Remove foam Air filter element.
Tap Air filter element gently to remove most of the dust and dirt.
Wash foam element per instructions below then allow to dry thoroughly.
Reinstall foam air filter element.
Reinstall air filter cover
Air Filter box
Phillips head
screw
Wash with mild soap
and water
Foam Air filter
element
Rinse with fresh water then
squeeze 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.
16
INSPECTION AND MAINTENANCE
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.
17
INSPECTION AND MAINTENANCE
Adjustment of Rear Brake
1. The front brake hand grip should have free operating movement of 5-7mm
(.2-3in.) . Adjust with free play adjustment bolt.
2. To make rear brake pad adjustment, turn rear adjusting bolt clockwise to
loosen and counter clockwise to tighten brake tension.
3. Brake pads should be replaced by a qualified service technician once brake
shoes are worn .
4. Brakes are adjusted by turning in or out the rear brake adjusting bolt
5-7mm free play
(.2-3in.)
Free play adjustment bolt
Rear brake adjusting bolt
18
INSPECTION AND MAINTENANCE
Adjustment of Chain
1. When chain adjustment is needed, loosen 4 bolts under engine.
2. Move engine forward to tighten chain or backward to loosen chain.
3. Tighten bolts under engine Torque bolts to 25 ft./lbs.
4. Repetitively check tension of chain.
Nut 2
Loosen
Chain
Engine adjusting bolts
Tighten
Chain
Nut 1
Loosen
Chain
Tighten
Chain
Minor chain
adjustment
1. When minor chain adjustment
is needed, loosen “Nut 2”. Turn
19-25mm
“Nut 1” clockwise to tighten
3/4 in. - 1 in.
chain or counterclockwise to
loosen chain.
2. When adjustment is
accomplished, tighten Nut 2.
Greasing procedures
to the driv chain
1. Shut off the engine
2. Add light amounts of chain oil to the driving chain. (Too much chain oil may
cause splattering to occur.)
Attention:
The chain should be replaced when the adjusting limit has reached it’s maximum.
19
INSPECTION AND MAINTENANCE
Clutch cleaning and maintenance
After every 5 hour of use, your clutch will need cleaning and lubrication. If
clutch becomes too dirty or has lack of lubrication, the clutch will have a
tendency to stick. This will cause the Mini-Bike to want to take off before
throttle is applied.
To clean and lubricate clutch, follow the instructions below:
1. Make sure engine is turned off and engine is cool before removing clutch
cover.
2. Remove Clutch Cover
3. With compressed air, blow through holes to remove any dust and/or particles.
4. Oil Clutch bearing with a few drops of 30W motor oil.
NOTE: Make sure oil does not get inside clutch itself.
5. Push mini bike forward without starting allowing oil to flow through bearing
surface.
6. Re-install clutch cover.
WARNING
Starting engine with clutch cover removed could be hazardous
Starting engine with clutch cover removed, increases the chance of
getting your person caught in moving components which could result in
severe injury.
Never start Mini Bike with clutch cover removed.
Blow out clutch with
compressed air through
large holes
Oil Clutch here
ONLY
Clutch
Cover
20
INSPECTION AND MAINTENANCE
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
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.
21
INSPECTION AND MAINTENANCE
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.
Carburetor Drain screw
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.
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.
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-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.
22
INSPECTION AND MAINTENANCE
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
35-45Nm (26-33 ft.lb.)
23
INSPECTION AND MAINTENANCE
Items of Maintenance
Engine Oil-Check
Each Use
1st MO/
20 HR
Every
6 MO/
100 HR
Every
Year/
300 HR
X
*Engine Oil-Change
Air Filter-Check
Every
3 MO/
50 HR
X
X
X
*Air Filter-Clean
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 FilterClean
X
Fuel Tube-Check
X
Centrifugal Clutch-Clean
and Lube
X Every 5
hours
All nuts and bolts-check
for tightness
X
Chain tension-Check
X
*Brakes-Check
X
*Throttle-Check
X
*Throttle cable-Check
X
“*” 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 tools
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.
24
TROUBLESHOOTING
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.
Engine will not Start
1. Fuel Valve OFF
Move Fuel valve lever to ON.
2. Choke OPEN
Move Choke 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,
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
Engine Lacks Power
1. Filter element(s) clogged
Check air filter
clean or replace.
2. Choke lever may be not
fully open
Check choke lever
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.
25
ELECTRICAL SCHEMATIC
Engine Switch
B1
B1
Transistor Magneto
Spark Plug Ignition Coil
26
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, or 10,000km, 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
emission-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
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 2007 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 confirm with applicable regulations of the United States
Environmental Protection Agency or the California Air Resources Board for the
periods specified above.
27
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 repairing
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.
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,
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
28
EMISSION CONTROL SYSTEM
WARRANTY
•
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 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 control 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
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 questions regarding your warranty rights and responsibilities, you
should contact BAJA MOTORSPORTS.
29
Baja Motorsports, LLC
P.O. Box 61150
Phoenix, AZ 85082
Tel: 602-443-9180
Toll Free: 888-863-BAJA (2252)