Bajaj Electricals HT65/MB165 User's Manual

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.
OWNER’S 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.
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 1-888-863BAJA (2252) between the house 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 offroad vehicle. Children under the age of 16 should never
operate this vehicle.
iii
Table of Contents
safe operation................................................................................ 3
safety gear....................................................................................... 4
modification of vehicle........................................................... 4
main data............................................................................................ 5
parts & subassemblies............................................................... 6
OPERAtion........................................................................................... 8
fuel cock..................................................................................... 8
engine starting....................................................................... 9
switches on the right handlebar............................. 10
check-ups, adjustment and maintenance................. 11
changing the oil.................................................................... 12
check-up of spark plug..................................................... 12
checking & cleaning the air filter............................ 13
Adjusting the throttle cable...................................... 14
adjusting the carburetor.............................................. 14
adjustment of rear brake.............................................. 15
adjustment of chain.......................................................... 16
greasing procedures to the driving chain........ 16
vehicle washing..................................................................... 17
instructions for storage............................................... 18
resumption of service after storage.................... 19
table and torque of fastners..................................... 19
maintenance reoutine diagram................................. 20
Trouble shooting................................................................. 21
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.
SAFE OPERATION
Rules for Safe Operation
·
A pre-operation check must be conducted, before starting the engine, insure safety,
prevent mishaps, and damage to components.
·
It is strongly suggested that all operators take a certified motorcycle rider’s course prior to
operating the vehicle.
·
Full attention is required during driving; paying close attention to the following points to
avoid any injury to you by other motorized vehicles:
·
Do not drive too close to other vehicles.
·
Never carry a passenger. This mini bike is for one operator only
·
Never operate this mini bike at night. Night is defined as the period of time 30 minutes
before sunset to 30 minutes after sunrise.
·
Driving at high speeds is the cause of many accidents; do not drive at a speed that the
actual situation does not permit.
·
This user’s manual contains important safety and maintenance information. Read it
carefully before riding. Failing to follow the warnings contained in this manual could
result in INJURY or DEATH.
·
It is important that this manual remain with the vehicle when you transfer it to another
user or owner.
·
All information, illustrations, photographs and specifications contained in this manual
are based on the latest product 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
CAUTION
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
Data
Description
Data
Overall length
1624mm (64”)
Cylinder bore x
stroke
6.8cm X 15.41cm
(2.68” X 2.13”)
Overall width
737mm (29”)
PTO shaft rotation
Counter clockwise
Overall height
914mm (36”)
Output, max
6.5hp at 3600 rpm
Wheelbase
1162mm
(45.75”)
Torque, max
9.76 ft-lbs. at 2500 rpm
Dead weight
75kg (165 lbs.)
Idling speed
1400 +200
-150
Payload
91kg (200 lbs)
Displacement of
cylinder
197cc
Front wheel
19 X 7 - 8
10psi
Spark plug
MEIYA -F7RTC, NGKBPR6ES, Champion
- RN9YC
Rear wheel
19 X 7 - 8
10psi
Spark plug gap
0.7mm -0.79mm
(.028”-.031”)
Brake Type
Drum
Gap of air valve IN
0.15 +- .02mm (cold)
Capacity of gasoline
tank
4.2L (.95 gal.)
Gap of air valve EX
0.20+- .02mm (cold)
Capacity of oil tank
.5L (.53 qt.)
Ground clearance
139 mm (5.5”)
Drive
Cintrifugal
cutch
Ignition means
Magnito
PARTS & SUBASSEMBLIES
Rear brake lever
Throttle twist grip
Headlight
Hand brake
Front Shock Absorber
Front Wheel
Rear Wheel
Clutch cover
Drive Chain
Foot pegs
Decorative tank
Seat Cushion
Air Filter
Brake Drum
Gas Tank
Pull Start Cord
EPA Sticker
Side Stand
Vehicle Identifictaion Number
OPERATION
Fuel Valve
Fuel filling
The capacity of the fuel tank is 4.2L (.95 gal) . Unscrew the gas cap by turning it counter
clockwise and carefully fill the tank with unleaded gasoline through the opening. DO NOT
MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE ENGINE. Replace the gas cap by carefully
aligning the threads on the cap and the tank and turning the cap clock wise. Wipe any spilled
fuel from the dirt bike using a cloth and dispose 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.
OFF
ON
Fuel Valve Handle
Engine Starting
CAUTION
Verify oil level prior to starting (see page 11)
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. Set the ignition switch to “ ” position.
2. Ensure that there is fuel in the tank.
3. Set the fuel valve lever to “ON” position.
Choke Lever
Closed
ON
To start a cold engine:
1. Place the choke lever in the closed position
2. Start the engine with the pull start cord.
OFF
Fuel valve lever
ON
3. Allow the engine to idle until the engine is warm
4. Turn the carburetor choke lever to the ON position when the engine has sufficiently
warmed up.
CAUTION
Unnecessarily 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 “
” (off ) position, the engine will not start or stops the engine.
When the switch is turned to “
driven.
” (on) position, the engine can start and the vehicle can be
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 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.
20W-50
MACHINE
OIL
15W - 40
10W-30
TEMP.
°C
-30
-20
-10
0
10
20
30
40
°F
-22
-4
14
32
50
68
86
104
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.
2. Dispose of the used oil properly. For proper disposal procedures, contact your local oil
recycling center.
3. Clean and replace the “Screw Plug” tighly.
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”).
3. The spark plug of the designated type should be used.
The applicable type of spark plug: Meiya - F7RTC
Champion- RN9YC, NGK - BPR6ES
12
.7mm - .79mm
(.028” - .031”)
Checking & Cleaning the Air Filter
1. Remove seat to access air filter. Seat is removed by
removing nut located under seat (see photo).
2. Locate Air Filter Box under seat and remove cover.
3. Remove air filter.
4. Remove foam cover from Air filter element.
5. Tap the Air filter element gently to remove most of the dust
and dirt. Blow out remaining dust with compressed air. If
the element is damaged, replace it.
6. Wash the foam element cover per instructions below then
allow to dry thouroghly.
7. Reinstall foam cover to the air filter element.
8. Reinstall air filter and close cover.
Seat nut
Air Filter
Air Filter box
Removal of cover
Foam cover
Removal of filter
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
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
1. The front brake hand grip should have free operating
movement of 5-7mm (.2-.3in) .
5-7mm free play
(.2-.3in)
2. To make adjustment, turn rear adjusting
nut clockwise to reduce and counterclockwise
to increase the free operating movement
of the hand brake.
3. Brake shoes should be replaced by a qualified service
technition once brake shoes are worn .
Rear brake arm
Brake cable
Rear brake adjusting nut
15
Adjustment of Chain
1. When chain adjustment is needed, loosen rear axle bolt .
2. Turn the chain adjusting nuts on the left and right sides to adjust the tension of the chain
and to align the marking of the chain adjuster with the engraved lines in the similar
position on both sides.
3. Tighten rear axle bolt by a torque of 50-60Nm (37-44 ft.lb.).
4. Repetitively check the tension of the chain.
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 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.
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.
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.
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)
1
Front wheel axle nut
35-45Nm (26-33 ft.lb.)
2
Rear wheel axle nut
50-60Nm (37-44 ft.lb.)
3
Front Fork Bolts
45-47.5Nm (33-35
ft.lb)
19
20
X
X
Every 6
Months or
100 hours
X
X
X
X
X
All nuts and bolts - Check for
tightness
Chain tension - Check
*Brakes - Check
* Throttle - check
* Throttle cable - Check
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.
Notes:
1. Maintenance should be conducted more frequently when Mini Bike is driven in dusty areas.
“**” means: This item can only be carried out by an authorized service center in order to ensure safety.
“*” 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.
X
Front Shock bolts - Tighten to spec
Fuel Tube - Chcek
X
X
** Valve Clearance - Check, Adjust
X
X
Idle Speed - Check, Adjust
Fuel Tank and Filter- Clean
X
X
Every Year or
300 hours
Spark plug - Replace
X
X
Every 3
Months or
50 hours
Spark Plug- Check - Adjust
X
1st Month or
20 hours
X
X
X
Each Use
* Carburetor Sediment cup - Clean
* Air Filter- Change
* Air Filter-Clean
Air Filter-Check
* Engine Oil - Change
Engine Oil- Check
Items of Maintenance
MAINTENANCE SCHEDULE
troubleshooting
Engine will not Start
1. Fuel Valve OFF
2. Choke OPEN
3. Out of fuel
4. Bad fuel; engine stored
without treating or draining
gasoline, or refuled with bad
gasoline
5. Spark plug faulty, fouled,
or improperly gapped
6. Spark plug wet with fuel
(flooded engine)
7. Fuel filter clogged,
carburetor malfunction,
ignition malfunction, valves
stuck, etc.
Move Fuel valve lever to ON.
Move Chock Lever to CLOSED
Refuel
Drain fuel and carburetor. Refuel with
fresh gasoline
Remove and inspect spark plug. Clean,
gap, or replace
Remove and inspect spark plug. Dry and
reinstall spark plug.
Take the engine to a qualified mechanic.
Replace or repair faulty components as
necessary
Engine Lacks Power
1. Filter element(s) clogged
2. Bad fuel; engine stored
without treating or draining
gasoline, or refueled with
bad gasoline.
3. Fuel filter clogged,
carburetor malfunction,
ignition malfunction , valves
stuck, etc.
Check air filter
Cean or replace.
Drain fuel tank and carburetor. Refuel with
fresh gasoline.
Take engine to a qualified mechanic.
Replace or repair faulty components as
necessary.
21
Baja Motorsports, LLC
2910 South Hardy Drive, Suite 103
Tempe, AZ 85282
Tel: 480-222-8280
Toll Free: 888-863-2252