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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 and 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
! WARNING
instructions are not followed.
! DANGER
Death or serious injury WILL occur if proper
instructions are not followed.
! CAUTION
You CAN be hurt if proper instructions are not
followed.
! WARNING
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
Warranty........................................................................ Pg. 6
Safety Information..................................................... Pg. 7
Safety Labels................................................... Pg. 9
Component Locations................................................ Pg. 10
Indicators......................................................... Pg. 12
Controls............................................................ Pg. 13
Before Riding.................................................................. Pg. 16
Pre-ride Inspection......................................... Pg. 17
Loading guidelines and Load limits..........
Pg. 18
Starting Procedures.....................................................
Starting and Stopping Engine...................
Shifting gears.................................................
Braking..............................................................
Parking..............................................................
Pg. 19
Pg. 19
Pg. 21
Pg. 23
Pg. 24
Maintenance Safety....................................................
Pg. 26
Servicing.........................................................................
Side cover removal.......................................
Fuel.....................................................................
Fuel and Engine oil.......................................
Air cleaner........................................................
Crankcase breather and throttle..............
Clutch................................................................
Engine idle speed..........................................
Spark plug........................................................
Pg. 32
Pg. 33
Pg. 34
Pg. 35
Pg. 39
Pg. 40
Pg. 41
Pg. 43
Pg. 44
Contents
Suspension..................................................
Brakes............................................................
Tires................................................................
Drive chain....................................................
Battery............................................................
Pg. 45
Pg. 47
Pg. 51
Pg. 54
Pg. 58
Appearance care.......................................................... Pg. 61
Vehicle Identification................................................... Pg. 62
Specifications............................................................... Pg. 63
Wire Diagram................................................................ Pg. 66
Emission Control System Warranty........................... Pg. 67
Warranty
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. 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
7am and 5pm Monday through Friday MST (Mountain Standard Time). MDT
(Mountain Daylight Time) during daylight saving time. You will be instructed
how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.
6
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 operator’s ability to exercise proper judgement. The operator must be of
sufficient age, understanding, mental capacity, and physical
capability to safely 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
A 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 replacements.
!
WARNING
Failure to follow these safety precautions may
increase your risk of injury!
• Wear a helmet, eye protection and bright protective clothing.
• Do not ride after consuming alcohol or otherdrugs.
• Slow down when road is slippery or visibility is
reduced.
• Read owner’s manual carefully.
DRIVE CHAIN
IMPORTANT DESCRIPTION
ADJUST DRIVE CHAIN AND APPLY CHAIN OIL
CHAIN FREE PLAY SHOULD BE .375 inches (10mm) .750 inches (20mm)
COLD TIRE PRESSURES:
DRIVER AND PASSENGER:
FRONT 200kpa (2.00kgf/cm²) REAR 250kpa (2.50kgf/cm²)
DRIVER ONLY:
FRONT 200kpa (2.00kgf/cm²) REAR 225kpa (2.25kgf/cm²)
TIRE SIZE:
FRONT 110/90-16
REAR 130/90-15
.375 inches - .750 inches
Components Locations
Tail light
Battery
Steering lock
Indicators
Main fuse
Oil cap/dipstick
Tool kit compartment
Fuel valve
Headlight
Shift lever
Rear brake pedal
Air cleaner
Kick stand
footrest
10
Rear shock
preload adjuster
Passenger
footrest
Safety Labels
Rear view mirror
Brake fluid reservoir
Speedometer
Ignition
switch
Indicator lights
Brake lever
Clutch lever
Headlight dimmer
switch
Throttle grip
Engine stop switch
Turn signal switch
Fuel fill cap
11
Indicators
The indicators on your motorcycle help make you aware of possible
issues, refer to them often.
Speedometer
Odometer
Trip meter
reset knob
Trip meter
Hi beam
indicator
Neutral
indicator
Lamp check
The high beam and neutral
indicators illuminate when
you turn the ignition switch
on and will remain on until
you select low beam or
shift out of neutral.
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 - Illuminates when hi beam lights are on.
Turn signal indicator - Flashes when left/right turn signal is on.
Neutral indicator - Illuminates when transmission is in neutral.
Trip meter reset know - Turn this knob to reset the trip meter.
12
Controls
FUEL VALVE
Fuel valve - Used to control the flow of gasoline from the fuel tank to
the carburetor.
ON
OFF
RES
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.
Choke lever
ON
13
OFF
Controls
IGNITION SWITCH
OFF
ON
Ignition switch- Used for
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
- Pushing the
start button will start the engine.
When button is 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.
-OFF
-RUN
14
Controls
HEADLIGHT DIMMER SWITCH, TURN SIGNAL SWITCH AND HORN
Headlight dimmer switch
Headlight dimmer switch- This
switch is used to change from
“HI” to “LO” beam.
-HI
Turn signal
switch
-LO
Horn
Turn signal switch- Use this switch to signal a lane change or
turn.
-Left
-Right
Horn- The horn is used to warn other motorist.
TRIP METER RESET
Trip meter reset knob- By turning
the knob counter clockwise you
can reset the trip meter to zero (0).
Tripmeter reset knob
15
Before Riding
Before your first ride on your new motorcycle we strongly
recommend you:
● Read the owner’s manual.
● Understand all safety labels.
● Know how to operate all controls.
Before you ride each time, make sure:
● You are in good physical and mental health.
● You are wearing protective gear (helmet, clothing, eye protection
etc.) If you have a passenger be sure they also have protective gear
on.
● You do not have ANY alcohol or drugs in your system.
Protective Clothing
For your protection we urge you to ALWAYS wear protective clothing. The proper clothes can protect you from injury. Wear an approved 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. Motorcycle dealers can help in selecting a good quality helmet which fits
properly.
! WARNING
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
wearing a helmet and eye protection.
16
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.
! WARNING
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 brake 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 periodic maintenance section).
17
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 lbs (150kg)
Maximum cargo weight: 25lbs (10kg)
Loading guidelines
! WARNING
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 always 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:
● Both tires are properly inflated.
● Rear suspension may need adjusting.
● Secure all cargo.
● Balance cargo weight
● Do not attach large or heavy items to the front of your motorcycle.
18
Starting and Stopping the Engine
Always follow proper starting procedures.
! WARNING
Never start the engine in a closed place as the exhausted
gas from the vehicle contains toxic carbon monoxide.
Starting procedure
● Insert key into ignition, turn to “ON” position.
● Make sure the transmission is in the “NEUTRAL” position.
● Turn the engine stop switch to “RUN”.
● Turn fuel valve to “ON”.
If you are restarting a warm engine, follow procedure for High Air
Temperature.
Normal Air Temperature : 10º -35ºC (50º -95ºF)
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.
Open
Closed
Choke lever
ON
19
OFF
Starting and Stopping the Engine
High Air Temperature : 35ºC (95ºF) or above
DO NOT OPEN CHOKE
1) Slightly open throttle
2) Start engine.
Low Air Temperature : 10ºC (50ºF) or below
1) Follow Normal Air Temperature procedures 1-2.
2) After RPM’s pick up, open the choke to keep fast 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
● Shift into neutral and turn the ignition switch “OFF”.
● 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. Simply move the emergency stop switch to “OFF”.
23
Shifting Gears
You motorcycle is equipped
with a cable-operated clutch.
It has five forward gears, one
down and four up.
45
N
1
Tips for learning how to shift for the inexperienced rider :
● Shift while moving a straight line.
● Let loose on the throttle and pull in clutch lever completely before
shifting (improper shifting may cause damage to the engine).
● Recognize the engaging point when you release the clutch lever.
21
Shifting Gears
Tips for learning how to shift for the inexperienced rider (continued):
● Reduce the throttle or shift to a higher gear before engine RPM’s
get too high.
● Shift to a lower gear before the engine RPM’s get too low.
● When the engine RPM’s are too high do not downshift to slow your
motorcycle, this could cause damage.
● Do not coast or tow your motorcycle for a long period of time while
the engine is off.
● 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 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 stopping 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 place.
- Turn the handlebars left.
- Insert ignition key into lock and turn clockwise 90º, remove key.
- Turn fuel valve “OFF”.
Steering lock
Theft-Prevention tips
● You should park your motorcycle in a garage if possible, otherwise
make certain to park in a well lit area.
● Never leave the ignition key with the motorcycle.
● Always use the steering lock, even for a short period of time,
● You should invest in a good quality anti-theft device that will
secure your motorcycle to a stationary object.
● 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
service
page
When to perform?
Who performs?
Pre-ride inspection 17
before every ride
You
Maintenance
schedule
Interval on schedule Service Center
29
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.
! WARNING
Follow all maintenance and inspection recommendations.
Improper maintenance can cause an accident resulting in
injury or death.
In 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
● Always turn the engine off before performing any maintenance or
repairs.
● Let the engine cool before touching any related parts.
● Do not touch any moving parts while engine is running.
● Make sure you have the tools and skills required before performing any maintenance repairs.
● Use the side stand or maintenance stand to prevent the motorcycle from falling over.
● 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 necessary please contact them to ensure greater quality and reliability.
26
Maintenance Safety
Including the regular maintenance and pre-ride inspection, perform
the periodic checks once a month and once a week if you ride
frequently.
Check the odometer and perform any scheduled maintenance
necessary.
Tires -
● Check the air pressure and add air if needed.
● Check for any excessive wear on the tread.
● Check for any damage that may have occurred.
● Check the rims and spokes for any possible
damage.
Fluids - ● Check the level of engine oil.
● Check the level of the brake fluid.
● Add the correct fluids if necessary.
Lights - ● Check the headlight, brake light, tail light and turn signals. Make certain they all work properly.
Free play -
● Check the clutch lever. rear brake pedal and
throttle grip.
Drive Chain - ● Check the condition, adjust the slack and lubricate if necessary.
Fuses -
● Always have spare fuses.
Nut and bolts -● Check all nuts and bolts, tighten if needed.
27
Maintenance Schedule
This portion of the manual will tell you how often to perform maintenance. 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 extensive 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.
* Unless 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
29
Evaporative emission 5
control system
*
I
I
I
R
Engine idle speed
R
I
R
C
I
I
I
*
R
Engine oil
I
I
12
16
20
24
I
I
R
I
I
C
R
I
C
R
I
R
C
I
I
I
I
R
I
I
C
I
I
C
R
I
R
C
R
I
I
I
12.8 19.2 25.6 32 38.4
8
C
I
Valve clearance
6.4
1.0
C
4
0.6
** Engine oil strainer
screen
*
Spark plug
3
Crankcase breather
Carburetor choke
*
2
Throttle operation
*
X 1,000mi
Note X 1,000km
Air cleaner
Fuel line
Frequency
*
Item
Emission Related Items
Maintenance Safety
I - Inspect, clean, adjust, lubricate or replace if necessary
C - Clean
A - Adjust
L - Lubricate R - Replace
6.4
1.0
30
I
** Steering head bearings
I
I
Nuts, bolts, fasteners
*
** Wheels/tires
Suspension
*
I
I
I
I
I
I
Clutch system
Side stand
I
Headlight aim
*
I
I
Brake light switch
I
I
I
I
*
I
I
I
Brake shoe/pad wear
Brake system
12
16
20
24
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
12.8 19.2 25.6 32 38.4
8
1, L Every 500 miles (800km)
4
0.6
I
4
Note X 1,000km
X 1,000mi
Brake fluid
Drive chain
Item
Frequency
Non - Emission Related Items
Maintenance Schedule
I - Inspect, clean, adjust, lubricate or replace if necessary
C - Clean
A - Adjust
L - Lubricate R - Replace
Maintenance Records
To ensure proper maintenance keep record. If the motorcycle is sold
be sure to include the maintenance records. All scheduled maintenance is considered normal operator cost, if a service center performs these tasks you will be charged. Please use the tables below
to keep track of all maintenance performed.
Miles (km)
Odometer
Date
Performed
by:
Notes
Odometer
Date
Performed
by:
Notes
600 (1,000)
4,000 (6,400)
8,000 (12,000)
12,000 (19,200)
16,000 (25,600)
20,000 (32,000)
Miles (km)
24,000(38,400)
28,000(44,800)
32,000(51,200)
36,000(57,600)
40,000(64,000)
44,000(70,400)
48,000(76,800)
52,000(83,200)
56,000(89,600)
60,000(96,000)
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 :
● 10mmx12mm open end wrench
● Standard phillips screw driver
● Screw driver handle
● Spark plug wrench
● Tool bag
The tool kit compartment can be found under the seat assembly. You
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.
Bolt
2. Remove bolt.
3. Remove cover.
Left side
cover
Key slot
Installation
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.
Bolt
3. Remove cover.
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 components. 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 immediately. 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
Ignition key
Fuel fill cap
! WARNING
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
SE or SG
Viscosity (weight)
SAE 15W-40
SAE 20W-50
SAE 20W-40
SAE 10W-40
SAE 10W-30
0
20
-20
-10
40
0
60
10
80
20
100ºF
30
40ºC
● Use the recommended oil, the oil does not need additives.
● Do not use graphite oil or oil with molybdenum additives.
● Do not use castor based racing oil, vegetable oil, or non-detergent
oil.
Oil fill plug/ dipstick
Checking and Adding Oil
Upper level mark
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.
7. Remove the dipstick and check the oil level.
● If the oil is at or near the upper level mark there is no need to add oil.
● 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 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 environment.
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
7. 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, damage, 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 cause 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.
Key slot
Bolt
Left side cover
39
Screws
Crankcase Breather and Throttle
Crankcase Breather
You should service the crankcase breather more often if you are ridding 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
1. Make sure that all nuts and bolts are securely fastened and the
throttle 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.
Decrease
Clutch cable adjuster
Upper lock nut
Increase
41
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.
Decrease
Clutch cable adjuster
Upper lock nut
Increase
3. Loosen lower lock nut.
4. Rotate lower adjusting nut until the proper free play has been accomplished.
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 release the clutch lever and open the throttle, your motorcycle should
accelerate gradually and move smoothly.
Lower lock nut
Lower adjusting nut
Decrease
Increase
If you cannot accomplish the correct free play using both adjustments, 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
Increase
Decrease
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 deposits, if it has great corrosion replace the plug.
5. Using a wire-type feeler, check 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.
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 hydraulic 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 suspension.
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 setting, 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 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.
Shock absorber
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
1-5
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 DOT3 brake fluid or any brake fluid of
the same quality. Always use a fresh, new container of brake fluid,
never use an opened container that may be contaminated.
Brake fluid
DOT3
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 immediately. Have your local service center do this.
47
Brakes
Other Inspections
● Make sure there are no leaks in the fluid lines.
● 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
Lock nut
Inspection
1. Park your motorcycle on the side stand for support.
2. Depress the brake 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
free play correctly see your local service center.
Brake arm pin
Adjusting nut
49
Brakes
Other Inspections
● Make sure the brake pedal is positioned properly and the securing
bolts are tight.
● 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 disassemble 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 load
that you are carrying.
! WARNING
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,
you 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)
Rear Tire Pressure
33 psi (227kpa)
51
Tires
Inspection
Always look for the following when checking tire pressure :
● Bumps or bulges on the tire, if there are any replace the tire.
● Cuts or cracks, replace tire if any fabric is visible.
● Any foreign objects such as nails embedded in the tire.
● 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
locaiton mark
Wear indicator
Replace tire immediately if the wear indicators are visible.
52
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. A 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.
! WARNING
Only use the tire size and type recommended.
Using improper tires can affect stability and handling
which may cause an accident resulting in injury or death.
Recommended Tire Size :
Front - 110/90-16
Rear - 130/90-15
When replacing a tire :
● Have the wheel balanced after installation.
● If possible, have tire replaced by your local service center.
● Replace the tube.
Safety Reminders
● Do not replace tire with a Radial tire. Using a different type of tire
may affect stability and handling.
● 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 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 maintenance 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
Chain
- 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 sprocket will cause
quick wear to the chain.
Replace
Replace
Good
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
55
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.lbs (88Nm). If you do not have a
torque wrench available make sure to have your local service center
perform 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 removed or replace by your local service center.
Do not use a steam cleaner, high pressure washer or certain solvents. 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.
! WARNING
Immediately wash hands after handling 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
! WARNING
● To avoid possibility of explosion, always connect battery cable in order specified: Negative first, Positive last.
An exploding battery can cause serious injury or death.
● Batteries contain sulfuric acid.
● Always shield eyes with protective eye wear when
working around battery acid.
● Battery acid is poisonous and can cause severe burns.
● 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).
7. Clean battery box before storing.
8. Use a slow trickle charger every 30 days to maintain life of the
battery.
Negative terminal
lead
Positive terminal
lead
Rubber strap
Battery
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
● You may use the following to clean your motorcycle:
- a mild, neutral detergent and water
- a mild spray and cleaner/polisher
- a mild cleaner/de greaser
● Do not use products that contain chemical solvents or harsh detergents.
● Before cleaning, make sure the engine is cool.
● Wash your motorcycle in a shady area. Direct sunlight can cause
water spots and fading.
● 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.
● When you are finished cleaning your motorcycle, always check for
wear or leaks.
61
Vehicle Identification
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)
Wheelbase
57.5 inch (1,460mm)
Dry weight
331 lbs (150kg)
Fuel recommendation
Unleaded, Octane 86 or higher
Fuel tank capacity
3.12 US gal
Fuel tank reserve capacity
0.47 US gal
Engine oil recommendation
API service classification SF
or SG. SAE 15W-40
Engine oil capacity
1.6 US qt
Drive chain lubricant
SAE 80 or 90 gear oil
Passenger
Operator and one passenger
Maximum weight
331lbs (150kg)
Includes rider, passenger,
cargo and accessories
63
Specifications
Displacement
14.2 cu-in (233cm³)
Bore and Stroke
2.09 x 2.09 in (53 x 53 mm)
Compression ratio
9.2:1
Spark plug (standard)
A7TC
Valve clearance
intake : 0.002in (0.05mm)
exhaust : 0.002in (0.05mm)
Spark plug gap
0.024-0.028 (0.60-0.70mm)
Idle speed
1,400 ± 100rpm
Primary reduction
3.631
Gear ratio 1st
2.846
Gear ratio 2nd
1.777
Gear ratio 3rd
1.333
Gear ratio 4th
1.083
Gear ratio 5th
0.913
Final drive chain
520
Front tire size
110/90-16
Front tire pressure COLD
44psi (303kpa)
Rear tire size
130/90-15
Rear tire pressure COLD
33psi (227kpa)
Battery
12V-9Ah
64
Specifications
Headlight
12V35W/5W
Brake/Tail light
12V5W/21W
Turn signal light
12V10W
Neutral indicator
12V3W
Turn signal indicator
12V3W
High beam indicator
12V3W
Main fuse
10A
Oil drain bolt torque
18ft.lbs (25Nm)
Front wheel axle torque
45ft.lbs (61Nm)
Front wheel pinch bolts torque 16ft.lbs (22Nm)
Rear wheel axle nut torque
65ft.lbs. (88Nm)
65
66
Relay assy.
turn light
Front position light LH (12V, 5W)
Front indicator LH (12V, 21W)
Position light (12V, 4W)
Headlight (12V, 35W, 35W)
Indicator assy.
Front indicator RH (12V, 21W)
Front position light RH (12V, 5W)
Speedometer
High beam
Turn light
Meter
Illumination
Neutral
Fuel
indicator
Gear
indicator
Brake light switch rear
Clutch switch
Horn
Ignition lock
switch
Clutch switch
on/off
Switch Assy. RH
Brake light
switch front
Switch assy. LH
G L W W/L Cr O B
Lg
Lb
G/R
Rectifier/Regulator
Start relay
Switch Assy. LH
Diode
Battery
Gear
Fuse
15A
R
B G B/W Br/W
Br
Alternator
Fuel sensor
Starter motor
Ignition lock switch
12V, 9Ah
Brake
Spark plug
Switch assy. RH
G B B/W Y/R G/Y
C.D.I
Spark plug
Ignition coil
Rear indicator LH (21V, 21W)
Tail light (12V, 21/5W)
Rear indicator RH (12V, 21W)
Lg - Light green
G/R - Green/Red
Lb - Light blue
Y/R - Yellow/Red
G/Y - Green/yellow Lg/R - Light green/Red
Y/W - Yellow/White
B/W - Black/White
R/W - Red/White
Bl/W - Blue/White
Ignition coil
B - Black
R - Red
G - Green
Bl - Blue
Gr - Grey
Y - Yellow
O - Orange
Wire Diagram
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 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 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 2009 and later vehicle:
•
is designed, built, and equipped so as to conform at the time of initial
retail purchase with all applicable regulations of the United States Environmental
Protection Agency, and the California Air Resources Board; and
•
is free from defects in material and workmanship which cause such
vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods
specified above.
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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, except in an emergency 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 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 reasonably 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 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.
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Emission Control System Warranty
•
Replacements of parts and other services and adjustments for required
maintenance.
•
Any vehicle equipped with an odometer or hour meter where the reading
is altered so that actual mileage cannot be readily determined.
•
Repairs or replacements as a result of:
o
Accident
o
Misuse
o
Use of replacement parts or accessories not conforming to the original
specifications which adversely affect performance
•
Physical damage, corrosion, or defects caused by fire, explosions or
similar causes beyond the control of the Distributor.
•
Failures not caused by a defect in material or workmanship.
Use of the vehicle in any type of competitive racing or related events immediately
and completely voids this and all other warranties.
LIMITED LIABILITY
The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized
dealer at its place of 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 INC. (866) 401-2252 or the California Air Resources Board,
9528 Telstar Avenue, El Monte, CA 91731 (for California registered vehicles only).
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Baja INC.
P.O. Box 61150
Phoenix, AZ. 85082
Tel:602-443-9180
Toll Free:888-863-2252
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