MinimumAge Requirement:16 Rev.F (US) 012209 Always wear a helmet; It couldsaveyour Life! Do not remove this operator's manual from this vehicle. Pleaseobtain,review, and follow provincial/ municipal government acts and regulations pertainingto owningand operatingan off-roadvehicle.
8 Congratulationson your purchaseof the BAJAINC. MiniBike. YourMini bike iswarrantedto be free of manufacturingdefectsin materialand workmanshipfor a periodof 90 daysfrom the dateof purchase.Duringthe warrantyperiodBAJA,INC.will at itsoption, repair,providereplacementpartsor replaceyour BAJAINC.Mini Bike 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 manualcontains importantsafety informationand instructions which should be read carefully beforeoperating the vehicle. The engine exhaustfrom this product contains chemicalsknownto the State of Californiato cause cancer,birth defectsor other reproductiveharm.
Tableof Contents SAFEOPERATION .............................................................................................. 3 SAFETYGEAR.................................................................................................... 4 MODIFICATIONOFVEHICLE............................................................................. 4 MAINDATA.......................................................................................................... 5 PARTS& SUBASSEMBLIES.................................
Please readthismanual andfollow all instructionscarefully.To emphasizethe specialinformation,the symbol-& and thewordsWARNINGor CAUTIONhave somespecialmeanings.Paygreat attentionto themessages. Indicatesa potentialhazardthatcouldresultin deathor injury. CAUTION Indicatesa potentialhazardthatcouldresultin vehicledamage. NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror instructionsclearer. WARNINGand CAUTIONare arrangedlikethis: The first partwill identifya POTENTIALHAZARD.
SAFE OPERATION Rules for SafeOperation A pre-operationcheckmustbe conducted,beforestartingtheengine,insure safety,preventmishaps,and damageto components. It is stronglysuggestedthatall operatorstake a certifiedmotorcyclerider's coursepriorto operatingthevehicle. Full attentionis requiredduringdriving;payingcloseattentionto the following pointsto avoidanyinjuryto you byothermotorizedvehicles: Do not drivetoo closeto othervehicles. Nevercarrya passenger.
SAFETYGEAR Neveroperatethis minibikewithoutwearinga DOT approvedmotorcycle helmetwhichfits properly.Operatorsshouldalso weareye protection (gogglesor face shield),gloves,boots,long-sleevedshirtor jacket,and long pants. 2. Looseclothesare not suitablefor motorcycledrivingor ridingas theymay get caughton footrest or wheel,resultingin danger. MODIFICATIONOF THE VEHICLE CAUTION Never perform any unauthorized modifications to this vehicle.
MAIN DATA Overall length 1680mm (66.14inches) Cylinderborex stroke 6.8cmX 15.41cm (2.68"X 2.13") Overall width 800.1ram(31.5 inches) PTOshaftrotation Counterclockwise Overall height 979.9mm (38.58inches) Output,max 6.5hpat 3600 rpm Wheelbase 1162mm(45.75 Torque,max inches) 9.76ft-lbs, at 2500 rpm Deadweight 64.46kg (142.11bs.
PARTS& SUBASSEMBLIES Rearbrake lever J Throttletwist grip
Headlight Hand brake FrontShock Absorber FrontWheel Clutch coverDriveChain Footpegs Decorative tank SeatCushion AirFilter Brake Drum GasTank PullStartCord EPA Sticker SideStand Vehicle Identification
OPERATION FUELVALVE Fuelfilling The capacityof thefuel tank is 4.2L (.95 gal). Unscrew the gas capby turningit counterclockwiseand carefullyfill thetankwith unleadedgasolinethroughthe opening. DONOT MIX GASAND OILTOGETHER,THISIS A 4-STROKEENGINE. Replacethegas capby carefullyaligningthe threadson the capand the tankand turningthe capclockwise. Wipeanyspilledfuel from the dirtbike usinga cloth and disposeof the clothproperly.DONOT SMOKEOR REFUELTHEVEHICLE NEAROPENFLAMESOR NEARHEATINGUNITS.
CAUTION Verify oillevelpriortostarting (seepage11) Starting theengine withlowornooilwilldamage theengine. ENGINESTARTINGAND STOPPING Neverstartthe enginein a closedplaceas theexhaustedgas from the vehiclecontainstoxic carbonmonoxide. StartingEngine: 1. Placefuel valve leverto "ON" Position. ON Choke Lever '= = OFF 2. PlaceChokeleverto "ON" Position. 3. Set the ignitionswitchto "__" Position. 4. Pullthe StartRecoilcorduntilenginestarts. 5.
SWITCHESON RIGHT HANDLEBAR Ignitionswitch The ignitionswitch is providedon the righthandlebar. Whenthe switchis turnedto "(_" (off) position,theenginewill notstart or stops theengine. Whenthe switchis turnedto "_" vehiclecan bedriven.
CHECK-UPS,ADJUSTMENTAND MAINTENANCE Checkingthe Oil Checktheengineoil eachtimepriorto operatingthe mini bike. The oil levelshouldbe betweenthe upperand lowerlinesof the oil gauge. Set the MiniBike on level ground,screwoff theoil gage plug,wipe theoil gagerod cleanand then insertthe gageplug intothe crankcaseagainto checkthe oil level. Thereis no needto screwtheoil gage plug intoits holein the crankcase. 2. Addlubricatingoil up to the edgeof the fill plug. 3. Finallyscrewin the oil 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. Torqueto 18 ft.lb. 4. Refillthe enginewith 0.53qt. (0.
CHECKING& CLEANING THEAIR FILTER 1. Removeseatto accessair filter. Seat is removedby removingnut locatedunderseat (see photo). 2. LocateAir Filter Box underseat and removecover. 3. Removeair filter. 4. Removefoam coverfrom Air filter element. 5. TaptheAir filter elementgentlyto removemostof thedust and dirt. Blowout remainingdustwith compressedair. If the elementis damaged,replaceit. 6. Washthe foam elementcover per instructionsbelow thenallowto dry thoroughly. 7.
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 the grip cannotbe movedfreely, turnthe adjustingnut to ensureproperoperatingmovement. Afteradjustment,start theengineand checkfor the operatingmovementagain. Repeatthe adjustmentif necessaryuntilthe desiredoperatingmovementis obtained.
ADJUSTMENTOF REAR BRAKE Thefront brakehandgripshouldhavefree operatingmovementof 5-7mm(.2-.3in). , . To makeadjustment,turn rearadjustingnut clockwiseto reduceand counterclockwise to increasethe free operatingmovement of the handbrake. Brakeshoesshouldbereplacedby a qualified servicetechnicianonce brake shoesareworn. 5-7ramfree play (.2-.
ADJUSTMENTOF CHAIN 1. Whenchainadjustment is needed,loosenrear axlebolt. 2. Turnthe chainadjustingnutson the leftand right sidesto adjustthe tension of thechainand to alignthe markingof the chainadjusterwith the engraved linesin the similarpositionon bothsides. 3. Tightenrear axlebolt by a torqueof 50-60Nm(37-44ft.lb.). 4. Repetitivelycheckthe tensionof the chain. Rearaxlebolt 15-20mm 1/2"- 3/4" Chainadjustingnut BothSides GREASINGPROCEDURESTO THE DRIVINGCHAIN 1. Shutoff the engine 2.
VEHICLEWASHING Cleaningthevehicleregularlycanslowdownthe colorfading of its bodyand make iteasierto checkif there is anydamageand any oil leakage. CAUTION Washing the Mini Bikewith over-pressurized watermay causedamageto someof its components.Therefore,do use a 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.
MAINTENANCESCHEDULE iTEMOF MAINTENANCE Engine oil-Cheek EA. USE EVERY3 MO./50 HRS. EVERY6 MO./100 HRS. EVERYYR./300 HRS. X *Engine oil-Change Air filter-Cheek 1ST MOJ20 HRS. X X *Air filter-Clean *Air filter-Change X *Carburetor sediment cup-Clean X Spark plug-Cheek-Adjust X Spark plug-Replace idle speed-Cheek-Adjust X **Valveclearance-Check- X Adjust Fueltank and filter-Clean Fueltube-Check Front shock X bolts-Tightento spec.
TROUBLESHOOTING Enginewill not Start 1. FuelValveOFF MoveFuelvalveleverto ON. 2. ChokeOPEN MoveChockLeverto CLOSED 3. Outof fuel Refuel 4. Badfuel; enginestoredwithout treatingor draininggasoline,or refueledwith bad gasoline Drainfuel and carburetor. Refuelwith fresh gasoline 5. Spark plugfaulty, fouled, or improperlygapped Removeand inspectspark plug. Clean,gap,or replace 6. Spark plugwet withfuel (flooded engine) Removeand inspectspark plug. Dryand reinstallspark plug. 7.
BAJA INC. - 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 5,000kin, whichever comes first, providedthere has been no abuse, neglect or improper maintenance of your vehicle.
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.
8 Baja, INC. P.O.
