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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Page Count: 33
MinimumAge Requirement:16
Weight capacity: 150 Ibs.
Rev.l(US)
020509
Alwayswear a helmet;It couldsaveyour Life!
Pleaseobtain,review,and followprovincial/municipalgovernmentactsand
regulationspertainingto owningand operatingan off-roadvehicle.
0
Congratulationsonyourpurchaseof the BAJAINC.DB30MiniBike.
YourMinibike iswarrantedto be free of manufacturingdefectsinmaterial
andworkmanshipfor a periodof 90daysfrom the dateof purchase.
Duringthe warrantyperiodBAJA,INC.will at itsoption,repair,provide
replacementpartsorreplaceyour BAJAINC.DB30MiniBikeatno charge.
Thiswarrantydoesnotcovernormalwear itemsor damagecausedby
neglectormisuseof the product.
EngineWarranty-90days
FrameWarranty-90days
Warranty isvoid if:
Frameis bentor brokendueto abuse
Wheelsarebentor broken
Fenderbentor brokendueto abuse
Anysignof impact,accident,jumping,spin-outsor rollover.
BAJA,INC.is notliablefor anydamageclaimor liabilityclaimpersonor
otherwiseresultingfrom the operationof thisproductinanyway.
Shouldyouexperiencea problemwithyourvehicle,pleasecallthe BajaInc.
customerservicelinetoll free at 1-888-863-2252betweenthe hoursof 7amand
5proMondaythroughFridayMST(MountainStandardTime).MDT(Mountain
DaylightTime)duringthe daylightsavingtime.Youwill be instructedhowto
proceed.
ACOPYOFTHESALES RECEIPTIS REQUIRED.
This manualshouldbe consideredas a permanent
part of the vehicle andshould remainwith the
vehiclewhen resoldor otherwisetransferredto
a newuser or operator. The manual contains
importantsafety informationand instructions
which shouldbe read carefullybeforeoperatingthe
vehicle.All operatorsshouldobtain,review,and
follow provincialand municipalgovernmentacts
and regulationspertainingto owning andoperating
an off-roadvehicle. Childrenunderthe age of 16
shouldnever operatethisvehicle withoutadult
supervision.
The engineexhaustfrom this productcontains
chemicalsknownto the Stateof Californiato cause
cancer,birthdefects 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 ..............................................
FuelValve ...........................................
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 ...................................
Instructionfor Storage ..........................
Resumption of Service after Storage ........
MAINTENANCESCHEDULE ............................
TROUBLE SHOOTING ....................................
ELECTRICAL SCHEMATIC...............................
EMISSIONSCONTROL SYSTEMWARRANTY-......
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Pleasereadthis manualandfollow all instructionscarefully.Toemphasizethe
specialinformation,the symbolAandthewordsWARNINGorCAUTIONhave
somespecialmeanings.Paygreatattentiontothe messages.
Indicatesa potentialhazardthatcouldresultindeathor injury.
CAUTION I
ndcatesa potentialhazardthatcouldresultinvehicledamage.
NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONare arrangedlikethis:
Thefirst partwill identify a POTENTIALHAZARD.
Thesecondpartwill describeWHATCOULDHAPPENif you ignore
theWARNINGor CAUTION.
Thethirdpartwill describeHOWTOAVOIDTHEHAZARD.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.Read
it carefullybeforeriding. Failingtofollow thewarningscontainedinthismanual
couldresultinINJURYor DEATH.
It is importantthatthis manualremainwiththe vehiclewhenyoutransferit to
anotheruserorowner.
All information,illustrations,photographsandspecificationscontainedin
thismanualare basedonthe latestproductinformationavailableatthe time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesinthismanual.We reservetherightto makeproductchangesat
anytime,withoutnoticeandwithoutincurringany obligationto makethesameor
similarchangesto thevehiclepreviouslybuiltorsold.
SAFEOPERATION
Rulesfor SafeOperation
A pre-operationcheckmustbe conducted,beforestartingtheengine,insure
safety,preventmishaps,anddamageto components.
ITEMTOCHECK CONTENT
Steering Smoothness;No restrictionof movement;Noplayorlooseness
Brakes Properbrakeleverfree play;enoughbrakeforce
Tires Properair pressure;Enoughtreaddepth;No cracks,rips,or
otherdamages
Fuel Enoughfuel for theintendedtrip;Fuelhoseconnectedsecurely;
No damagetofuel tankorcap;Fueltankcapclosedsecurely
Enginestopswitch Proper operation
Engineoil Proper level- Checkoil byinspectingEngineOil Dip Stick.
Theengineoil shouldbe betweenthe MinimumandMaximum
lines.
Throttle Properfree play ofthrottlelever;smoothresponse;quick
returnto idle position
Generalcondition Boltsandnutsaretight;norattlefrom any partsof theengine
whenrunning, no visibleevidenceof Damage
It is stronglysuggestedthatall operatorstakea certifiedmotorcyclerider's
coursepriorto operatingthevehicle.
Fullattentionis requiredduringdriving;payingcloseattentionto the
following pointsto avoidanyinjuryto youbyothermotorizedvehicles:
Donotdrivetoocloseto othervehicles.
Nevercarrya passenger.Thisminibikeisfor oneoperatoronly
Neveroperatethisminibikeat night. Nightis definedasthe periodof time30
minutesbeforesunsetto 30minutesaftersunrise.
Drivingat highspeedsis the causeof manyaccidents;donotdriveat aspeed
thatthe actualsituationdoesnotpermit.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.
Readitcarefullybeforeriding.Failingtofollow thewarningscontainedinthis
manualcouldresultinINJURYor DEATH.
It is importantthatthis manualremainwiththe vehiclewhenyoutransferit to
anotheruserorowner.
All information,illustrations,photographsandspecificationscontainedin
thismanualarebasedon thelatestproductinformationavailableatthe time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesinthis manual.Wereservethe rightto makeproductchanges
atany time,withoutnoticeandwithoutincurringany obligationto makethe
sameor similarchangesto thevehiclepreviouslybuiltor sold
Alwaysavoidoperatingthisminibikeonpavedsurfaces,including;
sidewalks,paths,parkinglots,driveways,streets,roads,andhighways.
Neveroperatedthisor any Off-RoadVehicleon a publicstreet,roador
highwaywheremotorvehiclesare inoperation.
SAFETYGEAR
ADOTapprovedmotorcyclehelmetisthemostimportantpartofyousafety
gear.ADOTapprovedmotorcyclehelmetcanhelppreventaseriousheadinjury.
Chooseahelmetthatfits snugly.Motorcycledealerscanhelp inselectinga good
quality helmetwhichfits properly.
OperatingthisMiniBikewithoutwearingan approvedDOTmotorcycle
helmet,eyeprotection,andprotectiveclothingcouldbe hazardous.
Operatingwithoutan approvedDOTmotorcyclehelmetoreyeprotection
increasesyourchancesof a severeheadinjuryor deathinan accident.
Operatingwithoutprotectiveclothingalsoincreasesyour chancesof
severeinjuryinan accident.
Alwayswearan approvedDOTmotorcyclehelmetwhichfits properly.
Alwaysweareyeprotection(gogglesorface shield). Youshouldalso
weargloves,boots,longsleeveshirtorjacket,andlongpants.
Youshouldweareyeprotectionwhenyou ride. Ifa rockor a branchhitsyour
eyes,you couldbeseverelyinjured.Weargogglesora face shield.
Wearproperclothingwhenyou ride. Theproperclothescanprotectyoufrom
injury.Weara goodpairof gloves,strongbootsthatare overthe ankle,long
pants,anda longsleeveshirt.
_CAUTION /
Neverperformany unauthorizedmodificationsto thisvehicle. Onlyuse_
originalreplacementpartwhichcanbe obtainedthroughBAJAINC. |
888-863-2252. /
LOCATIONOF LABELS
TI"I_ELE _BIENATJ_DO I,L_llD_OP I_F_ IF
_._ IF_ DO NOF _THP_[|bL%_ftJJ_=
2
TIREP_SSUR_
•C_k _:_ess_s o_ a_ t_s o_y _he_
t_res am¢_, 4 p_ _7_ _pa)
4
5
REGULA_SERWGEFROGEDU
LOCATIONOF LABELS
1
1
DO
1
Description Data
Overalllength 1295mm(51inches)
Overallwidth 622mm(24.5 inches)
Overallheight 863mm(34 inches)
Wheelbase 927mm(36.5 inches)
Deadweight 35.38kg (78Ibs.)
Payload 68.04kg(150Ibs.)
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-CJ14,
NGK-BM4A,Denso-W14M-US
Sparkpluggap 0.7mm-0.79mm
Groundclearance 102mm(4 inches)
Ignitionsystem Noncontacttransistormagneto
Hand brake
Seat Cushion
FrontWheel 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
LEFTAND RIGHTHANDGRIPOPERATION
BrakeLever ON button Throttlecontrolgrip
LeftHandGrip Ric
OFF button
Pullinginbrakeleverlocatedon left handgripwill stopminibike.
Applyingthe handthrottle(movingthrottlecounterclockwise) will cause
enginerpmsto increase,causingmini biketo moveforward.
Whenthe switchis turnedto '_(_" (off) position,theenginewill notstart. If
theengineis runningandthe Offbuttonis pushedtheenginewill turnoff.
Whenthe switchis turnedto "C_J' (on)position,the enginecanstartby using
the manualpullstart cord,
Grip
ENGINE PULLCORDOPERATION
Pullingthe pullcordwillstartthe engine. PullCord
10
FUELAND FUELVALVEOPERATION
Fuel filling
The capacityof thefuel tankis 1.4L(.40 qt .) Unscrewthegas capby turningit
counterclockwiseandcarefullyfill thetankwithunleadedgasolinethroughthe
opening. DONOTMIXGASAND OILTOGETHER,THISIS A 4-STROKEENGINE.
Replacethegas capby carefullyaligningthe threadsonthe capandthe tankand
turningthe cap clockwise. Wipeanyspilledfuel from thedirt bikeusinga cloth
anddisposeof the clothproperly.DONOTSMOKEOR REFUELTHEVEHICLE
NEAROPENFLAMESOR NEARHEATINGUNITS. ONLYREFUELTHEVEHICLE
INOPENAREASTO REDUCETHELIKELIHOODOFTHEBUILDUPOFGASOLINE
FUMES. Fillerneck
Fuellevel
Overfillingthefuel tankcouldbehazardous.
If youoverfillthefuel tank,fuel mayoverflowwhenit expands. Expanding
is dueto heatfrom engineor sun. Overheatedfuel couldeasilycatchfire.
Stopaddingfuel whenthefuel levelreachesthe bottomof the filler neck.
FUELVALVEOPERATION
ON: Withthe handleof thefuel valveto "ON" position,the fuel supplywill flow to
the carburetor.Inthispositionthe engineis ableto start andrun.
OFF: Withthe handleof thefuel valveto "OFF" position,the fuel supplyis cutoff
to the carburetor. In thispositionthemini bikewill notstartandwill not run.
FuelValveHandle
ON
OFF
11
ITEMTOCHECK CONTENT
Steering Smoothness;No restrictionof movement;Noplayorlooseness
Brakes Properbrakeleverfree play;enoughbrakeforce.
Tires Properair pressure;Enoughtreaddepth;No cracks,rips,or other
damages Note: Checktire pressure,specis locatedonsideof tire.
Fuel Enoughfuel for theintendedtrip;Fuelhoseconnectedsecurely;Nodamage
tofuel tankorcap;Fueltankcapclosedsecurely
Enginestopswitch Properoperation
Engineoil Properlevel- Checkoil by inspectingEngineOil Dip Stick. Theengine
oil shouldbebetweentheMinimumandMaximumlines.
Throttle Properfree play of throttlelever;smoothresponse;quickreturnto idle
position
Generalcondition Boltsandnuts aretight;no rattlefrom any partsof theenginewhen
running,no visibleevidenceof Damage
Failingto inspecttheMiniBikebeforeoperatingcouldbe hazardous.
Failingto performpropermaintenancecouldalsobehazardous.
Failingto inspectandmaintainyour MiniBikecouldincreasesthe
chancesof an accidentor equipmentdamage
AlwaysinspectyourMiniBikeeachtimebeforeriding,andmakesureitisina
safeoperatingcondition.RefertotheINSPECTIONANDMAINTENANCEsectionin
thismanual.
OperatingthisMiniBikewithimpropertires,orimpropertireairpressurecouldbe
hazardous.
If youuse impropertiresor improperair pressure,you maylosecontrolof
the MiniBike. Thiswill causean accident.
Alwaysusethetireswithsizeandtypetiresspecifiedinthisuser's
manual.Alwaysmaintainpropertireairpressureas describedinthe
INSPECTIONANDMAINTENANCEsection.
12
_, CAUTION
Verifyfuel andoil levelpriortostarting(seepages11and 14)
Startingthe enginewithlowor nooilwill damagethe engine.
Neverstarttheengineina closedplaceasthe exhaustedgas
from the vehiclecontainstoxiccarbonmonoxide.
1. Ensurethereisfuel infuel tank andoil incrankcase.
2. Setfuel valve leverto "ON" position
3. Placechokeleverto "ON" position
4. Startenginewithpullstartcord.
5. Allowengineto idleuntilengineiswarm
6. Placecarburetorchokelevertowardthe "OFF" positionwhenenginehas
sufficientlywarmedup. Note: Engineusuallyrunsbestwiththe chokelever
betweentheon andoff positions
OFF ,= J, ON
Fuelvalvelever
ChokeLever
OFF '= =ON
ON
OFF
Proceduresfor stoppinqenqine:
1. Releasethrottletwistgripto slowdownengine.
2. Depressstopbuttonlocatedon righthandgrip. Depressbuttonuntilengine
comesto a completestop
3. Setfuel valvelever(thefuel tankvalve)handleto "OFF" position.
_,CAUTION
UnnecessarilyincreasingRPM'sto a highlevelwhilethe MiniBikeis
warmingupis harmfulto the engine.
13
CHECKINGTHE OIL
Checkengineoil eachtimepriorto operatingminibike.
Theoil level shouldbe betweenupperandlower lines of oil gauge.
.Set theMiniBikeon levelground,screwoffthe oil gageplug,wipetheoil
gagerod cleanandtheninsertthe gageplugintothecrankcaseagainto
checkthe oil level. Thereis noneedto screwthe oil gageplugcompletelyin
the holeto checktheoil.
2. Add lubricatingoil upto the edgeof thefuel plug.
3. Screwoil gageplugtightly.
,_ CAUTION
Neverstarttheenginewhenthereis insufficientlubricating
oil. Otherwise,itwill causeharmto the engine.
LubricatingOilRecommended
Oildipstick
The lubricating oil is an important factor affectingthe performanceandservicelife
of theengine.Pleasereferto the chartfor the correctgradeof engineoil basedon
the environmentalconditionsinyour area. Donotuseany othertypeof oil other
thanwhatis recommendedinthe chart. DONOTMIXOILWITHTHEGASOLINE.
.45L(.40qt.)Oil
Lubricatingoilsof different
viscosityshallbe employed
indifferentregionsandat
differenttemperatures.
MACHINE
OIL
i
IP',[I_v_]li',[IW__l|
°C -30 -20 -10 0 10 20 30 40
TEMP. |
°F -22 -4 14 32 50 68 86 104
14
CHANGINGTHE OIL
Removethe "Screw Plug"locatedat the bottomof the engineandlet the
oil drainintoan approvedcollectioncontainer.DONOTPERFORMTHIS
PROCEDUREWHILETHEENGINEIS HOT. SERIOUSBURNSCOULDRESULT
FROMCONTACTWITHHOTOIL.
2. Disposeof the usedoil properly.For properdisposalprocedures,contact
yourlocaloil recyclingcenter.
3. Cleanand replacethe "Screw Plug"tightly.
4. Refillthe enginewiththe properamountof oil andrechecktheamountof oil
inthe engineby usingtheoil gaugeplug.
Screwplugfor oil draining
CHECK-UPOF SPARKPLUG
1. Removethe capof sparkplugandscrewoff the
sparkplugusingthe plugwrench.
2. Cleanthe sparkplugallaroundor replaceit if it is
corrodedorthereistoo muchdepositon it.
3. Regulatethe gapof the sparkplugto
.7mm-.79mm (.028"-.031").
4. Thesparkplugof the designatedtypeshouldbe
used. Theapplicabletypeof sparkplug:
.7ram-.79ram
(.028"- .031")
IAutolite-258,AC-CS49,Champion-CJ14,
NGK-BM4A,Denso-W14M-US I
15
CHECKING& CLEANINGTHEAIR FILTER
1. LocateAir FilterBox at rearof engine
2. Removeairfilter coverby unscrewingphillipsheadscrew
3. RemovefoamAir filter element.
4. TapAir filter elementgentlyto removemostof the dustanddirt.
5. Washfoam elementperinstructionsbelowthenallowto drythoroughly.
6. Reinstallfoam airfilter element.
7. Reinstallair filter cover
Air Filterbox
Phillipshead
screw
Washwithmildsoap
andwater
FoamAir filter
element
Rinsewithfresh waterthen
squeezeoutexcess.
_CAUTION
Theairfilter elementmustbe intactor the enginewill suckindustand
dirt,resultingina shorterservicelifeof theengine.
Watershouldbe preventedfrom enteringintothefilter whenwashing
thevehicle.
Thefilter elementshall be cleanedgentlywithouttwistingto prevent
itfrom cracking. Neverwash itwith gasolineorany acid,alkalineor
organicvolatileoilto avoiditsaging,whichwill resultin reducingthe
effectof the airfilter oil to catchparticlesbeforetheyentertheengine.
Replacethe filter elementwitha newoneif it is brokenorcracked.
16
ADJUSTINGTHE THROTTLECABLE
Makesure the throttlecableis adjustedproperly.Toadjust throttlecable, rotate
adjustmentnutlocatedatthe handthrottle.
Checkif thethrottletwistgriphasthe requiredfreeoperatingmovement.
Therequiredfree operatingmovement:2-6ram(.078-.24in.). If thegripcannotbe
movedfreely, turnthe adjustingnutto ensureproperoperatingmovement.
Afteradjustment,start theengineandcheckfor the operatingmovementagain.
Repeatthe adjustmentif necessaryuntilthe desiredoperatingmovementis
obtained.
Throttlecableadjustnut
ADJUSTINGTHE CARBURETOR
Adjustinqproceduresof idlinqspeed:
1. Supportthe vehicleby a stand.
2. Adjustthe idlespeedbythe throttlestopscrewto 1400+200RPM
-150.
_CAUTION
Donottry to correcta malfunctioningcarburetorby adjustingthe idling
speed. If thecarburetoris notfunctioning properly,it shouldbe repaired
by aservicecenter.
Adjustidlingspeedonlywhentheengineiswarmedupor 10minutesafter
operation.
17
ADJUSTMENTOF REAR BRAKE
,
.
.
Thefront brakehandgripshouldhavefree operatingmovementof 5-7ram
(.2-3in.). Adjustwithfree playadjustmentbolt.
Tomake rearbrakepadadjustment,turnrearadjustingboltclockwiseto
loosenandcounterclockwiseto tightenbraketension.
Brakepadsshouldbe replacedbya qualified servicetechnicianoncebrake
shoesareworn.
Brakesareadjustedbyturninginor outthe rearbrakeadjustingbolt
5-7ramfree play
(.2-3in.)
Freeplayadjustmentbolt
Rearbrakeadjustingbolt
18
ADJUSTMENTOF CHAIN
1. Whenchainadjustmentis needed,loosen4boltsunderengine.
2. Moveengineforward to tightenchainor backwardto loosenchain.
3. Tightenboltsunderengine Torqueboltsto 25ft./Ibs.
4. Repetitivelychecktensionof chain.
Engineadjustingbolts
Tighten Loosen
Chain _ y Chain
Nut2 Nut1
Loosen_ _ Tighten
Chain ,'_ Chain
MINORCHAIN
ADJUSTMENT
19-25mm
3/4 in.- 1 in.
Whenminorchainadjustment
is needed,loosen"Nut 2". Turn
"Nut 1" clockwiseto tighten
chainor counterclockwiseto
loosenchain.
GREASINGPROCEDURES
TO THE DRIVINGCHAIN
2. Whenadjustmentis
accomplished,tightenNut2.
1. Shutoff the engine
2. Addlightamountsof machineoil orchaingreaseto the drivingchain.(Too
muchmachineoilor chaingreasemaycausesplatteringto occur.)
Attention:
Thechainshouldbe replacedwhentheadjustinglimithas reachedit'smaximum.
19
CLUTCHCLEANINGAND MAINTENANCE
Afterevery5 hourof use, yourclutchwill needcleaningandlubrication.If
clutchbecomestoodirtyorhas lackof lubrication,theclutchwill havea
tendencytostick. Thiswill causethe Mini-Biketowantto takeoff before
throttleis applied.
Tocleanand lubricateclutch,followthe instructionsbelow:
1. Makesureengineisturnedoff andengineis coolbeforeremovingclutch
cover.
2. RemoveClutchCover
3. Withcompressedair, blowthroughholesto removeany dustand/orparticles.
4. Oil Clutchbearingwithafew dropsof 30Wmotoroil.
NOTE:Makesureoildoesnotget insideclutchitself.
5. Pushminibikeforward withoutstartingallowingoilto flow throughbearing
surface.
6. Re-installclutchcover.
Startingenginewithclutchcoverremovedcouldbe hazardous
Startingenginewithclutchcoverremoved,increasesthe chanceof
gettingyour personcaughtinmovingcomponentswhichcouldresultin
severeinjury.
NeverstartMiniBikewithclutchcoverremoved.
Blowoutclutchwith
compressedair through
largeholes
Clutch
OilClutchhere
ONLY
20
VEHICLEWASHING
Cleaningthevehicleregularlycanslowdownthe colorfading of its bodyand
makeiteasierto checkif thereis anydamageandany oil leakage.
CAUTION
Washingthe MiniBikewithover-pressurizedwatermaycausedamageto
someof its components.Therefore,dousea pressurewasherto cleanthe
vehicle. Thefollowing partsshouldbe cleanedusinglowpressurewater:
-- Wheelhub
-- Exhaustpipe
-- Fueltankandlowerportionof cushion
-- Carburetor
-- Headlockandignitionswitch
-- Meters
,
.
Afterpre-wiping,the vehicleshouldbe washedwithcleanwaterto remove
dirtyresiduesso asto preventcorrosion.Plasticsubassembliesshouldbe
cleanedbywipingwitha clothorfoam soakedin neutraldetergentsolution,
followed bywashingwithcleanwater.
Afterthe cleanedvehicleis airdried,greasethechainandrunthe engineat
idlingspeedfor afew minutes.
Priorto driving,carefullycheckthebrakingsystemrepeatedlyandrepairor
adjustit if necessary.
21
INSTRUCTIONSFOR STORAGE
If thevehicleis notgoingto be usedfor a longperiodof time,for example,in
wintertime,somestepsshouldbe takento preventmalfunctionof anddamageto
its componentswhichmightbe causedby longstorage. Beforestoringthe vehicle
for a longperiod, propermaintenancehasto be carriedin casemaintenanceis
notcompletedwhenthe vehicleis putbackinto useafterstorage.
1. Changeengineoil.
2. Drainoff fuelfromthefueltank andcarburetor,sprayatomizedanti-rust
oil ontothe insidewallof thetank andthenclosethe tank. Disposeof any
drainedfuel properlyso asnotto adverselyaffectthe environment.
Attention: CarburetorDrainscrew
If the storagewill lastfor morethanonemonth,fuel inthe carburetormustbe
fully drained.Thiswill helpensurethatthe carburetormaintainsits normal
performanceafterthestorage.
.
.
Gasolineis flammable andmaycausefire andevenanexplosionunder
certainconditions.Therefore,donotsmoke,makea fire orhaveany fire
aroundwhiledrainingoff fuel.
Takeoutthe sparkplug,pourabout15-20ml(.5- .68oz.) of cleanengineoil
intothe cylinder,stepdownonthe kickleverrepetitivelyseveraltimesso as
to havemachineoil distributedallovertheengineandfinally fit thespark
plugbackon.
Washthevehicleclean,wipeit dryandapplyan evencoatof waxto the
paintedsurfaceanda coatofanti-rustoil on the chrome-platedsurfaces.
Inflatethe tiresas requiredandputthe vehicleuponwoodenblockswiththe
twowheelsclearingthe ground.
Putthe vehiclein ashadyand coolplacefree from humidityanddirect
sunlightandcoverit properly(notwithplasticorother paintedmaterials).If
thereisa garage,storeit within.
22
RESUMPTIONOF SERVICEAFTER STORAGE
1. Removethe coveringandremovethe woodenblocksusedinstoringthe
vehicle. Changetheengineoil if the vehiclehas beenoutof servicefor over4
months.
2. Drainoff the remainingatomizedanti-rustoilfrom thefuel tank,followed by
filling it withfresh gasolinetherein.
3. Priorto driving,allthe requiredcheck-upsmustbe made. It is betterto
driveit ata lowspeedinan openareato testits performancebeforenormal
operation.
TABLEAND TORQUEOF FASTENERS
1 Frontwheelaxlenut 35-45Nm (26-33ft.lb.)
2 Rearwheelaxlenut 35-45Nm (26-33ft.lb.)
23
Items of Maintenance Each Use 1st MO/ Every Every Every
20 HR 3 MO/ 6 MO/ Year/
50HR 100HR 300HR
EngineOil-Check X
*EngineOil-Change X X
Air Filter-Check X
*Air Filter-Clean X X
*Air Filter-Change X
*CarburetorSediment X
cup-Clean
SparkPlug-Check,Adjust X
SparkPlug-Replace X
IdleSpeed-Check,Adjust X
**Valveclearance-Check, X
Adjust
FuelTankand Filter- X
Clean
FuelTube-Check X
CentrifugalClutch-Clean X Every5
and Lube hours
All nutsand bolts-check X
for tightness
Chaintension-Check X
*Brakes-Check X
*Throttle-Check X
*Throttlecable-Check X
"*" means: Thisitemof maintenanceshouldbe carriedoutat a servicecenter. It
maybealsodoneby theuserwithreferenceto thismanualprovidedspecialtools
andauthorizedsparepartsare used.Theusermustalsobe capableof completing
the procedure.
"**" means: This itemcan onlybe carriedoutby an authorizedservicecenterin
orderto ensuresafety.
24
Notes:
1. Maintenanceshouldbe conductedmorefrequently whenMiniBikeisdrivenin
dustyareas.
2. WhenMinibikehasexceededthe maximumfigures specifiedinthetable,
maintenanceshouldbestill cycledaccordingto the intervalsof timeorhours
statedherein. Engine will not Start
1. FuelValveOFF
2. ChokeOPEN
3. Outof fuel
4. Badfuel; enginestored
withouttreatingor draining
gasoline,or refueledwith
badgasoline
MoveFuelvalve leverto ON.
MoveChokeLeverto CLOSED
Refuel
Drainfuel andcarburetor.Refuelwith
fresh gasoline
5. Sparkplugfaulty, fouled, Removeandinspectsparkplug.
or improperlygapped Clean,gap,or replace
6. Sparkplugwetwithfuel Removeandinspectsparkplug. Dry
(floodedengine) andreinstallsparkplug.
7. Fuelfilter clogged,
carburetormalfunction,
ignitionmalfunction,valves
stuck,etc.
Takethe engineto a qualified
mechanic.Replaceor repairfaulty
componentsas necessary
Engine Lacks Power
1. Filterelement(s)clogged Checkairfilter
cleanorreplace.
2. Chokelevermaybe not Checkchokelever
fully open
2. Badfuel; enginestored
withouttreatingor draining
gasoline,or refueledwith
badgasoline.
3. Fuelfilter clogged,
carburetormalfunction,
ignitionmalfunction,valves
stuck,etc.
Drainfuel tankandcarburetor.Refuel
withfresh gasoline.
Takeengineto a qualified mechanic.
Replaceor repairfaulty components
asnecessary.
25
EngineSwitch
B1 B1
TransistorMagneto
SparkPlug IgnitionCoil
26
BAJAINC.- EMISSIONCONTROLSYSTEMWARRANTY
YOURWARRANTYRIGHTSANDOBLIGATIONS
Theemissioncontrolsystemwarrantyperiodfor thisvehiclebeginsonthe date
thevehicleis deliveredto thefirst purchaserotherthanan authorizeddealer,or
thedate it is first usedas ademonstrator,lease,or companyvehicle,whichever
comesfirst andcontinuesfor 60monthsafterthat date,or 5,000kin,whichever
comesfirst, providedtherehasbeennoabuse,neglector impropermaintenance
of yourvehicle.Whereawarrantableconditionexists,the Distributorwill
repairyour vehicleat nocostto you,includingdiagnosis,partsandlabor. If an
emission-relatedpartonyourvehicleisdefective,thepartwill be repairedor
replacedby the Distributor.This isyour emissioncontroldefectswarranty.
OWNER'SWARRANTYRESPONSIBILITIES
Asthe vehicleowner,youare responsiblefor the performanceof the required
maintenance.Youshouldmaintaina recordof all maintenanceperformedon
yourvehicleandretainall receiptscoveringmaintenanceonyour vehicle.You
maynotbedenieda warrantyclaimsolelybecauseof yourfailure to ensurethe
performanceof allscheduledmaintenanceor lackof maintenancerecordsor
receipts.Youare responsiblefor presentingyourvehicletoan authorizeddealer
assoonasa problemexists.Thewarrantyrepairsshouldbe completedina
reasonableamountof time,notto exceed30days.
Asthe vehicleowner,youshouldbeawarethatyoumaybe deniedyourwarranty
coverageifyourvehicleora parthasfailed dueto abuse,neglect,improper
maintenance,or unapprovedmodifications.
WARRANTYCOVERAGE
TheDistributorwarrantsthateach new2009and latervehicle:
• is designed,built,andequippedso asto conformatthe time of initial
retailpurchasewithallapplicableregulationsof the UnitedStatesEnvironmental
ProtectionAgency,andthe CaliforniaAir ResourcesBoard;and
•is free from defectsin materialandworkmanshipwhichcausesuch
vehicleto fail to confirmwithapplicableregulationsof the UnitedStates
EnvironmentalProtectionAgencyor the CaliforniaAir ResourcesBoardfor the
periodsspecifiedabove.
27
Youremissioncontrolsystemwarrantycoverscomponentswhosefailure would
increasean engine'semission,includingelectroniccontrols,fuel injectionsystem,
carburetor,the ignitionsystem,catalyticconverter,orany othersystemutilizedin
thisvehicleto controlemissionif it is originallyequipped.Alsoincludedmaybe
hoses,connectorsandotheremission-relatedassemblies.Replacingor repairing
othercomponents(includingparts,labor,andothercosts)notcoveredbythis
emissioncontrolsystemwarrantyorthe standardwarrantyisthe responsibilityof
theowner.
Coverageof repairsunderthiswarrantyappliesonlywhenrepairsare completed
atan authorizeddealeror repairfacility. TheDistributorwill notcoverrepairs
performedoutsideof an authorizeddealeror repairfacility. Theuseof
replacementpartsnotequivalentto theoriginalpartsmayimpairthe effectiveness
of yourvehicle'semissioncontrolsystem. If sucha replacementpartis usedand
an authorizeddealerdeterminesit is defectiveor causesafailure of a warranted
part,yourclaimfor repairto bringyourvehicleintocompliancewithapplicable
standardsmaybe denied.
ThisEmissionControlSystemWarrantyis in additionto thestandardLimited
Warranty.
EXCLUSIONSAND LIMITATIONS
Thiswarrantydoesnotcoverthefollowing:
• Failuresormalfunctionsof the emissioncontrolsystemscausedby
abuse,alteration,accident,misuse,the useof leadedgasoline.
•Replacementof expendablemaintenanceitemsunlesstheyare original
equipmentdefectiveinmaterialorworkmanshipundernormaluse,andthefirst
requiredreplacementintervalfor the itemhasnot beenreached.Expendable
maintenanceitemsincludebutnotlimitedto sparkplugs,filters, coolant,
lubricants,gaskets,hoses,andbelts.
•Replacementsof partsandotherservicesandadjustmentsfor required
maintenance.
•Anyvehicleequippedwithan odometeror hourmeterwherethe reading
is alteredso thatactualmileagecannotbereadilydetermined.
•Repairsor replacementsasa resultof:
o Accident
o Misuse
28
o Useofreplacementpartsoraccessoriesnotconformingtotheoriginal
specificationswhichadverselyaffectperformance
• Physicaldamage,corrosion,ordefectscausedbyfire, explosionsor
similarcausesbeyondthe controlof the Distributor.
•Failuresnotcausedby a defectin materialorworkmanship.
Useof the vehicleinany typeof competitiveracingorrelatedeventsimmedi-
atelyandcompletelyvoidsthisandallotherwarranties.
LIMITEDLIABILITY
Theliabilityof the DistributorunderthisEmissionControlSystemWarranty
is limitedsolelyto the remedyingof defectsinmaterialworkmanshipby an
authorizeddealerat its placeof businessduringcustomarybusinesshours.
Thiswarrantydoesnotcoverinconvenienceor lossof useof thevehicleor
transportationof thevehicleto/fromtheauthorizeddealer.TheDistributoris
notliableto any personfor incidental,consequentialorspecialdamagesof
anydescription,whetherarisingoutof expressor impliedwarrantyor any
othercontract,negligenceorothertortorotherwise.
Noexpressemissioncontrolsystemwarrantyis givenby the Distributor
exceptasspecificallysetforth herein. Anyemissioncontrolsystemwar-
rantyimpliedby law,includinganywarrantyof merchantabilityor fitness for a
particularpurposeislimitedto the expressemissioncontrolsystemwar-
rantytermsstatedin thiswarranty.Theforegoing statementsof warrantyare
exclusiveandin lieuof allotherremedies.All expresswarrantiesnotstated
inthiswarrantyaredisclaimed.Somestatesdo notallowlimitationson how
longan impliedwarrantylasts,so theabovelimitationsmaynotapply if it is
inconsistentwiththe controllingstatelaw.
Nodealerisauthorizedto modifythisEmissionControlSystemWarranty.If
youhaveanyquestions regardingyourwarrantyrightsandresponsibilities,
youshouldcontactBAJAINC.(888)863-2252.
29
Baja, INC.
P.O.Box 61150
Phoenix,AZ 85082
Tel: 602-443-9180
Toll Free: 888-863-BAJA(2252)
