Baja DB30S User Manual DOODLE BUG MINI BIKE Manuals And Guides L0912189

BAJA Gokarts/Minibikes Manual L0912189 BAJA Gokarts/Minibikes Owner's Manual, BAJA Gokarts/Minibikes installation guides

User Manual: Baja DB30S DB30S BAJA DOODLE BUG MINI BIKE - Manuals and Guides View the owners manual for your BAJA DOODLE BUG MINI BIKE #DB30S. Home:Toys & Games Parts:Baja Parts:Baja DOODLE BUG MINI BIKE Manual

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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.

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.
EngineWarranty- 90 days
FrameWarranty- 90 days
Warranty isvoid if:
Frameis bentor brokendue to abuse
Wheels arebent or broken
Fenderbentor brokendue to abuse
Any signof impact,accident,jumping,spin-outsor roll over.
BAJA,INC.is not liablefor anydamageclaimor liabilityclaimpersonor
otherwiseresultingfrom the operationof this productin anyway.

Shouldyou experiencea problemwith yourvehicle,pleasecallthe Baja Inc.
customerservicelinetoll free at 1-888-863-2252betweenthe hoursof 7am and
5proMondaythroughFridayMST(MountainStandardTime).MDT(Mountain
DaylightTime)duringthe daylightsavingtime.Youwill be instructedhowto
proceed.
A COPYOFTHESALES RECEIPTIS REQUIRED.

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. Children underthe age of 16
should never operatethis vehicle without adult
supervision.

The engine exhaustfrom this product contains
chemicalsknownto the State of Californiato cause
cancer,birth defects or other reproductiveharm.
CALIFORNIAPROPOSITION65

iii

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 ..............................................
Fuel Valve ...........................................
INSPECTION BEFORE RIDING .........................
ENGINE STARTINGAND STOPPING .................
INSPECTIONAND MAINTENANCE ..................
Checking Oil ........................................
Changing Oil .......................................
Check-up of Spark Plug.........................
Checking and cleaning Air Filter ..............
Adjusting Throttle Cable ........................
Adjusting Carburetor ............................
Adjustment of Rear Brake ......................
Adjustment of Chain .............................
Clutch cleaning and maintenance ...........
VehicleWashing ...................................
Instruction for Storage ..........................
Resumption of Service after Storage ........
MAINTENANCE SCHEDULE ............................
TROUBLE SHOOTING ....................................
ELECTRICAL SCHEMATIC...............................
EMISSIONS CONTROL SYSTEMWARRANTY-......

2
3
5
6
8
9
10
10
10
11
11
12
13
14
14
15
15
16
17
17
18
19
20
21
22
23
24
25
26
27

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.

NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONare arrangedlike this:

The first partwill identify a POTENTIALHAZARD.
The secondpartwill describeWHATCOULDHAPPENif you ignore
theWARNINGor CAUTION.
The thirdpart will describeHOWTOAVOIDTHE HAZARD.

Thisuser'smanualcontainsimportantsafetyand maintenanceinformation.Read
it carefullybeforeriding. Failingtofollow thewarningscontainedin this manual
couldresultin INJURYor DEATH.
It is importantthatthis manualremainwith the vehiclewhenyou transferit to
anotheruser or owner.
All information,illustrations,photographsandspecificationscontainedin
this manualare basedon the latestproductinformationavailableat the time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesin this manual. We reservetherightto makeproductchangesat
anytime,withoutnoticeand withoutincurringany obligationto makethesame or
similarchangesto thevehiclepreviouslybuilt or sold.

SAFE
OPERATION
Rulesfor SafeOperation
A pre-operationcheckmustbe conducted,beforestartingtheengine,insure
safety,preventmishaps,and damageto components.
ITEMTO CHECK

CONTENT

Steering

Smoothness;No restriction
of movement;Noplayor looseness

Brakes

Properbrakeleverfree play;enoughbrakeforce

Tires

Properair pressure;Enoughtreaddepth;No cracks,rips,or
other damages

Fuel

Enoughfuel for the intendedtrip;Fuelhoseconnectedsecurely;
No damagetofuel tankor cap;Fueltank capclosedsecurely

Enginestopswitch

Proper operation

Engineoil

Proper level- Checkoil byinspectingEngineOil Dip Stick.
Theengineoil shouldbe betweenthe MinimumandMaximum
lines.

Throttle

Properfree play ofthrottlelever;smoothresponse;quick
return to idle position

Generalcondition

Bolts andnuts are tight;no rattlefrom any partsof the engine
whenrunning, no visibleevidenceof Damage

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.Thisminibike isfor one operatoronly
Neveroperatethis minibikeat night. Nightis definedas the periodof time30
minutesbeforesunsetto 30 minutesaftersunrise.
Drivingat high speedsis the causeof manyaccidents;do not driveat a speed
thatthe actualsituationdoes not permit.

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. Wereservethe rightto makeproductchanges
at any time,withoutnoticeand withoutincurringany obligationto makethe
sameor similarchangesto thevehiclepreviouslybuiltor sold
Alwaysavoidoperating this minibike on pavedsurfaces,including;
sidewalks,paths,parkinglots,driveways,streets,roads,and highways.
Neveroperatedthisor any Off-RoadVehicleon a publicstreet,roador
highwaywheremotorvehiclesare in operation.

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.
Operatingwithoutan approvedDOTmotorcyclehelmetor eye protection
increasesyourchancesof a severehead injuryor deathin an accident.
Operatingwithoutprotectiveclothingalso increasesyour chancesof
severeinjuryin an accident.
Alwayswearan approvedDOT motorcyclehelmetwhichfits properly.
Alwaysweareye protection(gogglesor face shield). You shouldalso
weargloves,boots,longsleeveshirtor jacket, and longpants.

Youshouldweareye protectionwhenyou ride. If a rockor a branchhits your
eyes,you couldbeseverelyinjured.Wear gogglesor a face shield.
Wearproperclothingwhenyou ride. The properclothescanprotectyou from
injury. Weara good pairof gloves,strongbootsthatare overthe ankle,long
pants,and a long sleeveshirt.

_CAUTION

Neverperformany unauthorizedmodificationsto thisvehicle. Only use_
originalreplacementpartwhichcanbe obtainedthroughBAJAINC. |
888-863-2252.

LOCATIONOF LABELS

TI"I_ELE
_._

IF_

BIENATJ_DO

I,L_llD_OP I_F_

DO NOF _THP_[|bL%_ftJJ_=

2
TIRE P_SSUR_

• C_k

_:_ess_s

t_res am¢_,

o_ a_ t_s
4 p_ _7_

o_y _he_
_pa)

REGULA_SERWGEFROGEDU

LOCATIONOF LABELS

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

1.84KW/3600rpm

Maxtorque

3.8Nm/2500rpm

Sparkplug

Autolite-258,AC-CS49,Champion-C
J14,
NGK-BM4A,Denso-W14M-US

Sparkplug gap

0.7mm-0.79mm

Groundclearance

102mm(4 inches)

Ignitionsystem

Noncontacttransistormagneto

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.
Whenthe switchis turnedto "C_J' (on) position,the enginecanstartby using
the manualpullstart cord,

ENGINE PULLCORD OPERATION
Pullingthe pull cordwillstartthe engine.

PullCord

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. ONLYREFUELTHEVEHICLE
IN OPENAREASTO REDUCETHE LIKELIHOODOFTHE BUILDUPOFGASOLINE
FUMES.

Fillerneck
Fuellevel

Overfillingthefuel tankcould behazardous.
If you overfillthefuel tank, fuel may overflowwhen it expands. Expanding
is due to heatfrom engineor sun. Overheatedfuel couldeasily catchfire.
Stopaddingfuel when thefuel level reachesthe bottomof the filler neck.

FUEL VALVEOPERATION
ON: Withthe handleof thefuel valveto "ON" position,the fuel supplywill flow to
the carburetor.In this positionthe engineis ableto start and run.
OFF: Withthe handleof thefuel valveto "OFF" position,the fuel supplyis cutoff
to the carburetor. In this positionthemini bikewill not startandwill not run.
FuelValveHandle

OFF
11

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. Theengine
oil shouldbebetweenthe MinimumandMaximumlines.

Throttle

Properfree play of throttlelever;smoothresponse;quickreturn to idle
position

Generalcondition

Boltsandnuts are tight;no rattlefrom any partsof the enginewhen
running, no visibleevidenceof Damage

Failingto inspecttheMini Bike beforeoperatingcouldbe hazardous.
Failingto performpropermaintenancecouldalso behazardous.
Failingto inspectand maintainyour MiniBike couldincreasesthe
chancesof an accidentor equipmentdamage
Alwaysinspect
yourMiniBike eachtimebeforeriding,andmakesureitisina
safeoperating
condition.
RefertotheINSPECTION
ANDMAINTENANCE
sectionin
thismanual.

Operating
thisMiniBikewithimproper
tires,or improper
tireairpressurecouldbe
hazardous.
If you use impropertires or improperair pressure,you may losecontrolof
the MiniBike. Thiswill causean accident.
Alwaysusethetires with sizeand typetires specifiedin this user's
manual. Alwaysmaintainpropertire air pressureas describedin the
INSPECTIONANDMAINTENANCEsection.

_, 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

Startenginewith pull startcord.

5. Allow engineto idleuntilengine iswarm
6.

Placecarburetorchokelevertowardthe "OFF" positionwhenenginehas
sufficientlywarmedup. Note: Engineusuallyrunsbestwith the chokelever
betweentheon andoff positions
OFF ,=
J, ON
Fuelvalvelever

OFF

ChokeLever
'=
= ON

Proceduresfor stoppinqenqine:
1. Release throttletwistgrip to slowdownengine.
2. Depressstop buttonlocatedon righthandgrip. Depressbuttonuntilengine
comesto a completestop
3. Set fuel valvelever (thefuel tankvalve)handleto "OFF" position.
_,CAUTION
UnnecessarilyincreasingRPM'sto a highlevelwhilethe Mini Bike is
warmingup is harmfulto the engine.

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.

Add lubricatingoil up to the edgeof thefuel plug.

Screwoil gageplug tightly.

,_ CAUTION

Oil dipstick

Neverstarttheenginewhen thereis insufficientlubricating
oil. Otherwise,itwill causeharmto the engine.
LubricatingOil Recommended
The lubricating oil is an important factor affectingthe performanceandservicelife
of theengine.Pleaserefer to the chartfor the correctgradeof engineoil basedon
the environmentalconditionsin your area. Do not useany othertypeof oil other
than whatis recommendedin the chart. DONOT MIX OILWITH THE GASOLINE.
.45L(.40qt.)Oil
i

Lubricatingoilsof different
viscosityshallbe employed
in differentregionsand at
differenttemperatures.

IP',[I_v_]li',[IW_ _l|
MACHINE
OIL

TEMP.

°C

-30

-20

-10

°F

-22

-4

104

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.

Cleanand replacethe "Screw Plug"tightly.

Refillthe enginewith the properamountof oil and rechecktheamountof oil
in the engineby usingtheoil gaugeplug.

Screwplugfor oil draining

CHECK-UPOF SPARKPLUG
1.
2.
3.
4.

Removethe capof sparkplug and screwoff the
sparkplug usingthe plugwrench.
Cleanthe sparkplug all aroundor replaceit if it is
corrodedor there istoo muchdepositon it.
Regulatethe gapof the sparkplug to
.7mm-.79mm (.028"-.031").
The sparkplugof the designatedtypeshouldbe
used. The applicabletypeof sparkplug:

IAutolite-258,AC-CS49,Champion-CJ14,
NGK-BM4A,Denso-W14M-US
I

.7ram- .79ram
(.028"- .031")

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.

_ CAUTION
The air filter elementmustbe intactor the enginewill suckin dust and
dirt, resultingin a shorterservicelifeof theengine.
Watershouldbe preventedfrom enteringintothefilter whenwashing
thevehicle.
The filter elementshall be cleanedgentlywithouttwistingto prevent
itfrom cracking. Neverwash itwith gasolineor any acid,alkalineor
organicvolatileoilto avoiditsaging,whichwill resultin reducingthe
effectof the air filter oil to catchparticlesbeforetheyenter theengine.
Replacethe filter elementwith a newone if it is brokenor cracked.

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.
Throttlecableadjustnut

ADJUSTINGTHE CARBURETOR
Adjustinqproceduresof idlinqspeed:
1.

Supportthe vehicleby a stand.

Adjustthe idlespeedbythe throttlestop screwto 1400+200RPM
-150.
_CAUTION
Do not try to correcta malfunctioningcarburetorby adjustingthe idling
speed. If thecarburetoris notfunctioning properly,it shouldbe repaired
by a servicecenter.
Adjustidlingspeedonlywhentheengineiswarmedupor 10minutesafter
operation.

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.)

Free playadjustmentbolt

Rearbrakeadjustingbolt

ADJUSTMENTOF CHAIN
1.

Whenchainadjustment is needed,loosen4 boltsunderengine.

Moveengineforward to tightenchainor backwardto loosenchain.

Tightenboltsunderengine Torqueboltsto 25 ft./Ibs.

Repetitivelychecktensionof chain.

Nut2

Nut1

Loosen_
Chain

_ Tighten
,'_ Chain

Engineadjustingbolts
Tighten
Chain _

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.

GREASINGPROCEDURES
TO THE DRIVINGCHAIN
1.

Whenadjustmentis
accomplished,tightenNut2.

Shutoff the engine

Addlight amountsof machineoil or chaingreaseto the drivingchain.(Too
muchmachineoilor chaingreasemay causesplatteringto occur.)
Attention:
The chainshouldbe replacedwhen theadjustinglimithas reachedit'smaximum.

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.

RemoveClutchCover

Withcompressedair, blowthroughholesto removeany dustand/orparticles.

Oil Clutch bearingwith a few dropsof 30Wmotoroil.
NOTE:Makesure oildoes not get insideclutchitself.

Pushminibikeforward withoutstartingallowingoilto flow throughbearing
surface.

6. Re-installclutchcover.

Startingenginewith clutchcover removedcouldbe hazardous
Startingenginewith clutchcover removed,increasesthe chanceof
gettingyour personcaughtin movingcomponentswhichcouldresultin
severeinjury.
NeverstartMini Bikewith clutchcoverremoved.
Blowout clutchwith
compressedair through
largeholes

Oil Clutchhere
ONLY

Clutch

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. Thefollowing partsshouldbe cleanedusing lowpressurewater:
-- Wheelhub
-- Exhaustpipe
-- Fueltankand lowerportionof cushion
-- Carburetor
-- Headlock and ignitionswitch
-- Meters

Afterpre-wiping,the vehicleshouldbe washedwith cleanwaterto remove
dirtyresiduesso as to preventcorrosion. Plasticsubassembliesshouldbe
cleanedbywipingwith a clothor foam soakedin neutraldetergentsolution,
followed bywashingwith cleanwater.
,

Afterthe cleanedvehicleis air dried,greasethechainand runthe engineat
idlingspeedfor a few minutes.

Priorto driving,carefullycheckthebrakingsystemrepeatedlyand repairor
adjustit if necessary.

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.

Drainoff fuelfrom thefuel tank and carburetor,sprayatomizedanti-rust
oil ontothe insidewall of thetank andthen closethe tank. Disposeof any
drainedfuel properlyso as not to adverselyaffectthe environment.

Attention:

CarburetorDrainscrew

If the storagewill lastfor morethan one month,fuel in the carburetormustbe
fully drained.Thiswill helpensurethatthe carburetormaintainsits normal
performanceafterthestorage.

Gasolineis flammable and maycausefire and evenanexplosionunder
certainconditions.Therefore,do not smoke,makea fire or haveany fire
aroundwhiledrainingoff fuel.
.

Takeout the sparkplug,pourabout15-20ml(.5- .68oz.) of cleanengineoil
intothe cylinder,stepdownon the kicklever repetitivelyseveraltimesso as
to havemachineoil distributedall over theengineand finally fit thespark
plug backon.
Washthevehicleclean,wipe it dry and applyan evencoatof wax to the
paintedsurfaceanda coatofanti-rustoil on the chrome-platedsurfaces.
Inflatethe tiresas requiredand putthe vehicleup on woodenblockswith the
twowheelsclearingthe ground.
Putthe vehiclein a shadyand coolplacefree from humidityand direct
sunlightand coverit properly(notwith plasticor other paintedmaterials). If
there isa garage,storeit within.

RESUMPTIONOF SERVICEAFTER STORAGE
1.

Removethe coveringand removethe woodenblocksusedin storingthe
vehicle. Changetheengineoil if the vehiclehas beenout of servicefor over4
months.

Drainoff the remainingatomizedanti-rustoilfrom thefuel tank, followed by
filling it with fresh gasolinetherein.

Priorto driving,all the requiredcheck-upsmustbe made. It is betterto
driveit at a lowspeed in an openareato test its performancebeforenormal
operation.

TABLEAND TORQUEOF FASTENERS

Frontwheel axlenut

35-45Nm (26-33ft.lb.)

Rearwheelaxlenut

35-45Nm (26-33ft.lb.)

Items of Maintenance

EngineOil-Check

Each Use

1st MO/
20 HR

Every
6 MO/
100HR

Every
Year/
300HR

*EngineOil-Change
Air Filter-Check

Every
3 MO/
50HR

*Air Filter-Clean

*Air Filter-Change

*CarburetorSediment
cup-Clean

SparkPlug-Check,Adjust

SparkPlug-Replace

IdleSpeed-Check,Adjust

**Valveclearance-Check,
Adjust

FuelTankand FilterClean

FuelTube-Check

CentrifugalClutch-Clean
and Lube

X Every5
hours

All nutsand bolts-check
for tightness

Chaintension-Check

*Brakes-Check

*Throttle-Check

*Throttlecable-Check

"*" means: Thisitemof maintenanceshouldbe carriedout at a servicecenter. It
may bealso doneby theuser with referenceto this manualprovidedspecialtools
and authorizedspare partsare used.The user mustalsobe capableof completing
the procedure.
"**" means: This itemcan onlybe carriedout by an authorizedservicecenter in
orderto ensuresafety.

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.Refuelwith
fresh gasoline

5. Sparkplugfaulty, fouled,
or improperlygapped

Removeand inspectsparkplug.
Clean,gap,or replace

6. Spark plugwet with fuel
(floodedengine)

Removeand inspectsparkplug. Dry
and reinstallspark plug.

7. Fuelfilter clogged,
carburetormalfunction,
ignitionmalfunction,valves
stuck,etc.

Takethe engineto a qualified
mechanic. Replaceor repairfaulty
componentsas necessary

Engine Lacks Power
1. Filterelement(s)clogged

Checkair filter
cleanor replace.

2. Chokelever maybe not
fully open

Checkchoke lever

2. Badfuel; enginestored
withouttreatingor draining
gasoline,or refueledwith
bad gasoline.

Drainfuel tankand carburetor.Refuel

3. Fuelfilter clogged,
carburetormalfunction,
ignitionmalfunction,valves
stuck,etc.

Takeengineto a qualified mechanic.
Replaceor repairfaulty components
as necessary.

withfresh gasoline.

EngineSwitch
B1

TransistorMagneto

Spark Plug Ignition Coil

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. Wherea warrantableconditionexists,the Distributorwill
repairyour vehicleat no costto you,includingdiagnosis,partsand labor. If an
emission-related
part on yourvehicleisdefective,thepart will be repairedor
replacedby the Distributor.This isyour emissioncontroldefectswarranty.
OWNER'SWARRANTYRESPONSIBILITIES
Asthe vehicleowner,you are responsiblefor the performanceof the required
maintenance.You shouldmaintaina recordof all maintenanceperformedon
yourvehicleand retainall receiptscoveringmaintenanceon your vehicle. You
may not bedenieda warrantyclaimsolelybecauseof yourfailure to ensurethe
performanceof all scheduledmaintenanceor lackof maintenancerecordsor
receipts. Youare responsiblefor presentingyourvehicletoan authorizeddealer
as soonas a problemexists.Thewarrantyrepairsshouldbe completedin a
reasonableamountof time, notto exceed30 days.
Asthe vehicleowner,you shouldbeawarethatyou may be deniedyourwarranty
coverageifyourvehicleor a part hasfailed dueto abuse,neglect,improper
maintenance,or unapprovedmodifications.
WARRANTYCOVERAGE
The Distributorwarrantsthateach new2009and latervehicle:
•
is designed,built,and equippedso as to conformat the time of initial
retailpurchasewith all applicableregulationsof the UnitedStatesEnvironmental
ProtectionAgency,and the CaliforniaAir ResourcesBoard;and
•
is free from defectsin materialand workmanshipwhichcausesuch
vehicleto fail to confirmwith applicableregulationsof the UnitedStates
EnvironmentalProtectionAgencyor the CaliforniaAir ResourcesBoardfor the
periodsspecifiedabove.

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.Replacingor repairing
othercomponents(includingparts,labor,and othercosts)not coveredbythis
emissioncontrolsystemwarrantyor the standardwarrantyisthe responsibilityof
theowner.
Coverageof repairsunderthis warrantyappliesonlywhen repairsare completed
at an authorizeddealeror repairfacility. The Distributorwill not coverrepairs
performedoutsideof an authorizeddealeror repairfacility. The useof
replacementpartsnot equivalentto theoriginalparts mayimpairthe effectiveness
of yourvehicle'semissioncontrolsystem. If sucha replacementpart is usedand
an authorizeddealerdeterminesit is defectiveor causesa failure of a warranted
part,yourclaimfor repairto bringyourvehicleintocompliancewith applicable
standardsmaybe denied.
ThisEmissionControlSystemWarrantyis in additionto thestandardLimited
Warranty.
EXCLUSIONSAND LIMITATIONS
Thiswarrantydoes not coverthefollowing:
•
Failuresor malfunctionsof the emissioncontrolsystemscausedby
abuse,alteration,accident,misuse,the useof leadedgasoline.
•
Replacementof expendablemaintenanceitemsunlesstheyare original
equipmentdefectivein materialor workmanshipundernormaluse, and thefirst
requiredreplacementintervalfor the itemhasnot beenreached. Expendable
maintenanceitemsincludebut not limitedto sparkplugs,filters, coolant,
lubricants,gaskets,hoses,and belts.
•
Replacementsof partsand otherservicesand adjustmentsfor required
maintenance.
•
Anyvehicleequippedwith an odometeror hour meterwherethe reading
is alteredso thatactualmileagecannotbereadilydetermined.
•
Repairsor replacementsas a resultof:
o
Accident
o
Misuse

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.
LIMITEDLIABILITY
The liabilityof the Distributorunderthis EmissionControlSystemWarranty
is limitedsolelyto the remedyingof defectsin materialworkmanshipby an
authorizeddealerat its placeof businessduring customarybusinesshours.
Thiswarrantydoes not coverinconvenienceor lossof useof thevehicleor
transportationof thevehicleto/fromtheauthorizeddealer.The Distributoris
not liableto any personfor incidental,consequentialor specialdamagesof
anydescription,whetherarisingout of expressor impliedwarrantyor any
othercontract,negligenceor othertort or otherwise.
No expressemissioncontrolsystemwarrantyis givenby the Distributor
exceptas specificallyset forth herein. Any emissioncontrolsystemwarrantyimpliedby law,includinganywarrantyof merchantabilityor fitness for a
particularpurposeislimitedto the expressemissioncontrolsystemwarrantytermsstatedin thiswarranty. Theforegoing statementsof warrantyare
exclusiveand in lieuof all otherremedies.All expresswarrantiesnot stated
in this warrantyaredisclaimed.Somestatesdo notallow limitationson how
longan impliedwarrantylasts,so theabove limitationsmay notapply if it is
inconsistentwith the controllingstate law.
No dealerisauthorizedto modifythis EmissionControlSystemWarranty.If
you haveanyquestions regardingyourwarrantyrightsand responsibilities,
you shouldcontactBAJAINC.(888) 863-2252.

Baja, INC.
P.O.Box 61150
Phoenix, AZ 85082
Tel: 602-443-9180
Toll Free: 888-863-BAJA(2252)

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Baja DB30S User Manual DOODLE BUG MINI BIKE Manuals And Guides L0912189

BAJA Gokarts/Minibikes Manual L0912189 BAJA Gokarts/Minibikes Owner's Manual, BAJA Gokarts/Minibikes installation guides

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