Minimum Age Requirement: 16 Weight capacity: 150 Ibs. Rev.l(US) 020509 Alwayswear a helmet;It couldsaveyour Life! Pleaseobtain,review,and followprovincial/ municipalgovernmentacts and regulationspertainingto owningand operatingan off-roadvehicle.
0 Congratulationson yourpurchaseof the BAJAINC. DB30Mini Bike. YourMini bike iswarrantedto be free of manufacturingdefectsin material andworkmanshipfor a periodof 90 daysfrom the dateof purchase. Duringthe warrantyperiodBAJA,INC.will at itsoption,repair,provide replacementparts or replaceyour BAJAINC.DB30 MiniBike at no charge. Thiswarrantydoes not covernormalwear itemsor damagecausedby neglector misuseof the product.
This manualshould be consideredas a permanent part of the vehicle and should remainwith the vehicle when resoldor otherwisetransferredto a new user or operator. The manual contains importantsafety informationand instructions which should be read carefully before operatingthe vehicle.All operatorsshould obtain, review,and follow provincial and municipalgovernmentacts and regulationspertainingto owning and operating an off-roadvehicle.
SAFETY ....................................................... Safe Operation .................................... Safety Gear ......................................... Location of Labels ............................... SPECIFICATIONS.......................................... LOCATIONOF PARTS ................................... OPERATION................................................. Left and Right Hand Grip ....................... Engine ON/OFF switch and Pull Cord ...... Fuel Fill ......................
Pleasereadthis manualand follow all instructionscarefully.To emphasizethe specialinformation,the symbolA and thewordsWARNINGor CAUTIONhave somespecialmeanings.Pay great attentiontothe messages. Indicatesa potentialhazardthatcouldresultin deathor injury. CAUTION nd cates a potentialhazardthatcouldresultin vehicledamage. I NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror instructionsclearer. WARNINGand CAUTIONare arrangedlike this: The first partwill identify a POTENTIALHAZARD.
SAFE OPERATION Rulesfor SafeOperation A pre-operationcheckmustbe conducted,beforestartingtheengine,insure safety,preventmishaps,and damageto components.
Thisuser'smanual contains important safety andmaintenance information. Readitcarefully before riding.Failing tofollow thewarningscontainedin this manualcouldresultin INJURYor DEATH. It is importantthatthis manualremainwith the vehiclewhenyou transferit to anotheruser or owner. All information,illustrations,photographsandspecificationscontainedin this manualarebasedon thelatestproductinformationavailableat the time of publication.Dueto improvementsor otherchanges,therewill besome discrepanciesin this manual.
SAFETY GEAR ADOT approved motorcycle helmet isthemostimportant partofyousafety gear.ADOTapproved motorcycle helmet canhelpprevent aserious headinjury. Choose ahelmet thatfits snugly.Motorcycledealerscanhelp in selectinga good quality helmetwhichfits properly. Operatingthis Mini Bikewithoutwearingan approvedDOT motorcycle helmet,eye protection,and protectiveclothingcouldbe hazardous.
LOCATIONOF LABELS TI"I_ELE _.
LOCATIONOF LABELS 1 1 DO 1
Description Data Overalllength 1295mm(51 inches) Overallwidth 622mm(24.5 inches) Overallheight 863mm(34 inches) Wheelbase 927mm(36.5 inches) Deadweight 35.38kg (78 Ibs.) Payload 68.04kg(150 Ibs.) Frontwheel 145x70-6 Rearwheel 145x70-6 Braketype Disc Capacityof gasolinetank 1.4L(0.36 gal) Capacityofoil tank 0.45L(0.40qt.) Startingmethod Recoilpullstart Borea stroke 52ramx 46ram PTOshaftrotation Counterclockwise Horsepower 2.5Hp Displacement 97.7cc Max power 1.
Hand brake Seat Cushion Front Wheel Rear Wheel Oil fill plug Oil drain plug Kick Stand Drive Chain On/Off Button Throttle handle Tank Air Filter Footpegs Pull Start Cord Brake Caliper
LEFT AND RIGHT HAND GRIP OPERATION BrakeLever ON button Throttlecontrolgrip LeftHandGrip Ric Grip OFF button Pullingin brake leverlocatedon left handgrip will stopminibike. Applyingthe handthrottle(movingthrottlecounterclockwise) will cause enginerpmsto increase, causingmini biketo moveforward. Whenthe switchis turnedto '_(_" (off) position,theenginewill notstart. If theengineis runningand the Off buttonis pushedtheenginewill turnoff.
FUEL AND FUEL VALVE OPERATION Fuel filling The capacityof thefuel tankis 1.4L(.40 qt .) Unscrewthegas capby turningit counterclockwiseand carefullyfill thetankwith unleadedgasolinethroughthe opening. DONOT MIX GASAND OILTOGETHER,THISIS A 4-STROKEENGINE. Replacethegas capby carefullyaligningthe threadson the capand the tankand turningthe cap clockwise. Wipeanyspilledfuel from thedirt bike usinga cloth and disposeof the clothproperly.DONOT SMOKEOR REFUELTHE VEHICLE NEAROPENFLAMESOR NEARHEATINGUNITS.
ITEM TO CHECK CONTENT Steering Smoothness;No restriction of movement;Noplayor looseness Brakes Properbrakeleverfree play;enoughbrakeforce. Tires Properair pressure;Enoughtreaddepth;No cracks,rips,or other damages Note: Checktire pressure,specis locatedon sideof tire. Fuel Enoughfuel for the intendedtrip;Fuelhoseconnectedsecurely;Nodamage tofuel tankor cap;Fueltankcapclosedsecurely Enginestop switch Proper operation Engineoil Proper level- Checkoil by inspectingEngineOil Dip Stick.
_, CAUTION Verifyfuel and oil level priortostarting(see pages11and 14) Startingthe enginewith low or no oilwill damagethe engine. Neverstarttheengine in a closedplaceas the exhaustedgas from the vehiclecontainstoxic carbonmonoxide. 1. Ensurethere isfuel in fuel tank and oil in crankcase. 2. 3. Set fuel valve leverto "ON" position Placechokeleverto "ON" position 4. Startenginewith pull startcord. 5. Allow engineto idleuntilengine iswarm 6.
CHECKINGTHE OIL Checkengineoil eachtimepriorto operatingminibike. The oil level shouldbe between upperand lower lines of oil gauge. . Set theMini Bikeon levelground,screwoffthe oil gageplug,wipe theoil gagerod cleanand then insertthe gageplug intothecrankcaseagainto checkthe oil level. Thereis no needto screwthe oil gage plugcompletelyin the holeto checktheoil. 2. Add lubricatingoil up to the edgeof thefuel plug. 3. Screwoil gageplug tightly.
CHANGING THE OIL Removethe "Screw Plug" located at the bottomof the engineand let the oil drainintoan approvedcollectioncontainer. DONOT PERFORMTHIS PROCEDUREWHILETHE ENGINEIS HOT. SERIOUSBURNSCOULDRESULT FROMCONTACTWITH HOTOIL. 2. Disposeof the usedoil properly.For properdisposalprocedures,contact yourlocaloil recyclingcenter. 3. Cleanand replacethe "Screw Plug"tightly. 4. Refillthe enginewith the properamountof oil and rechecktheamountof oil in the engineby usingtheoil gaugeplug.
CHECKING& CLEANING THEAIR FILTER 1. LocateAir Filter Box at rear of engine 2. Removeair filter coverby unscrewingphillipsheadscrew 3. Removefoam Air filter element. 4. 5. 6. 7. TapAir filter elementgentlyto removemostof the dust and dirt. Washfoam elementper instructionsbelowthenallowto dry thoroughly. Reinstallfoam air filter element. Reinstallair filter cover Air Filterbox Phillipshead screw FoamAir filter element Washwith mildsoap and water Rinsewith fresh waterthen squeezeout excess.
ADJUSTINGTHE THROTTLECABLE Makesure the throttlecableis adjustedproperly.To adjust throttlecable, rotate adjustmentnut locatedat the handthrottle. Checkif thethrottletwistgrip hasthe requiredfreeoperatingmovement. The requiredfree operatingmovement:2-6ram(.078-.24in.). If thegrip cannotbe movedfreely, turnthe adjustingnut to ensureproperoperatingmovement. Afteradjustment,start theengineand checkfor the operatingmovementagain. Repeatthe adjustmentif necessaryuntilthe desiredoperatingmovementis obtained.
ADJUSTMENTOF REAR BRAKE Thefront brakehandgripshouldhavefree operatingmovementof 5-7ram (.2-3in.). Adjustwith free playadjustmentbolt. , To make rear brakepad adjustment,turnrear adjustingboltclockwiseto loosenand counterclockwiseto tightenbraketension. . Brakepads shouldbe replacedbya qualified servicetechnicianoncebrake shoesareworn. . Brakesareadjustedbyturningin or outthe rearbrakeadjustingbolt 5-7ramfree play (.2-3in.
ADJUSTMENTOF CHAIN 1. Whenchainadjustment is needed,loosen4 boltsunderengine. 2. Moveengineforward to tightenchainor backwardto loosenchain. 3. Tightenboltsunderengine Torqueboltsto 25 ft./Ibs. 4. Repetitivelychecktensionof chain. Nut2 Nut1 Loosen_ Chain _ Tighten ,'_ Chain Engineadjustingbolts Tighten Chain _ y Loosen Chain MINORCHAIN ADJUSTMENT Whenminorchainadjustment is needed,loosen"Nut 2". Turn "Nut 1" clockwiseto tighten chainor counterclockwise to loosenchain. 19-25mm 3/4 in.- 1 in.
CLUTCH CLEANINGAND MAINTENANCE After every5 hourof use, yourclutchwill need cleaningand lubrication.If clutchbecomestoo dirtyor has lackof lubrication,theclutchwill havea tendencytostick. Thiswill causethe Mini-Biketowantto takeoff before throttleis applied. To cleanand lubricateclutch, followthe instructionsbelow: 1. Makesure engineisturnedoff and engineis coolbeforeremovingclutch cover. 2. RemoveClutchCover 3. Withcompressedair, blowthroughholesto removeany dustand/orparticles. 4.
VEHICLEWASHING Cleaningthevehicleregularlycanslowdownthe colorfading of its bodyand make iteasierto checkif there is anydamageand any oil leakage. CAUTION Washingthe Mini Bikewith over-pressurized watermay causedamageto someof its components.Therefore,do usea pressurewasherto cleanthe vehicle.
INSTRUCTIONSFOR STORAGE If thevehicleis not goingto be usedfor a long periodof time,for example,in wintertime, somestepsshouldbe takento preventmalfunctionof and damageto its componentswhichmightbe causedby longstorage. Beforestoringthe vehicle for a long period, propermaintenancehasto be carriedin casemaintenanceis not completedwhenthe vehicleis put backinto useafterstorage. 1. Changeengineoil. 2.
RESUMPTIONOF SERVICEAFTER STORAGE 1. Removethe coveringand removethe woodenblocksusedin storingthe vehicle. Changetheengineoil if the vehiclehas beenout of servicefor over4 months. 2. Drainoff the remainingatomizedanti-rustoilfrom thefuel tank, followed by filling it with fresh gasolinetherein. 3. Priorto driving,all the requiredcheck-upsmustbe made. It is betterto driveit at a lowspeed in an openareato test its performancebeforenormal operation.
Items of Maintenance EngineOil-Check Each Use 1st MO/ 20 HR Every 6 MO/ 100HR Every Year/ 300HR X *EngineOil-Change Air Filter-Check Every 3 MO/ 50HR X X X *Air Filter-Clean X X *Air Filter-Change X *CarburetorSediment cup-Clean X SparkPlug-Check,Adjust X SparkPlug-Replace X IdleSpeed-Check,Adjust X **Valveclearance-Check, Adjust X FuelTankand FilterClean X FuelTube-Check X CentrifugalClutch-Clean and Lube X Every5 hours All nutsand bolts-check for tightness X Chaintension
Notes: 1. 2. Maintenanceshouldbe conductedmorefrequently when Mini Bike isdriven in dustyareas. WhenMinibike hasexceededthe maximumfigures specifiedin thetable, maintenanceshouldbestill cycledaccordingto the intervalsof timeor hours statedherein. Engine will not Start 1. FuelValveOFF Move Fuelvalve leverto ON. 2. ChokeOPEN MoveChokeLeverto CLOSED 3. Outof fuel Refuel 4. Badfuel; enginestored withouttreatingor draining gasoline,or refueledwith bad gasoline Drainfuel and carburetor.
EngineSwitch B1 B1 TransistorMagneto Spark Plug Ignition Coil 26
BAJA INC.- EMISSIONCONTROLSYSTEMWARRANTY YOURWARRANTYRIGHTSANDOBLIGATIONS The emissioncontrolsystemwarrantyperiodfor this vehiclebeginson the date thevehicleis deliveredto thefirst purchaserotherthanan authorizeddealer,or thedate it is first usedas a demonstrator,lease,or companyvehicle,whichever comesfirst and continuesfor 60 monthsafterthat date,or 5,000kin,whichever comesfirst, providedthere hasbeenno abuse,neglector impropermaintenance of yourvehicle.
Youremission control system warranty covers components whose failure would increasean engine'semission,includingelectroniccontrols,fuel injectionsystem, carburetor,the ignitionsystem,catalyticconverter,or any othersystemutilizedin thisvehicleto controlemissionif it is originallyequipped.Alsoincludedmay be hoses,connectorsand otheremission-relatedassemblies.
o Useofreplacement partsoraccessories notconforming totheoriginal specifications whichadversely affectperformance • Physical damage, corrosion, ordefects caused byfire, explosionsor similarcausesbeyondthe controlof the Distributor. • Failuresnot causedby a defectin materialor workmanship. Useof the vehiclein any typeof competitiveracingor relatedeventsimmediatelyand completelyvoidsthis and all otherwarranties.
Baja, INC. P.O.
