Baja motorsports WR65 Owner's manual

Brand: Baja motorsports

Model: WR65

Type: Owner's manual

This manual is also suitable for

MinimumAge Requirement:16

Rev.F (US)

012209

Alwaysweara helmet; It couldsaveyour Life!

Donot removethis operator's manualfromthis vehicle.

Pleaseobtain,review,and follow provincial/ municipal governmentacts and

regulations pertainingto owningand operatingan off-roadvehicle.

CongratulationsonyourpurchaseoftheBAJAINC.MiniBike.

YourMinibikeiswarrantedtobefreeof manufacturingdefectsin

materialandworkmanshipfor a periodof90daysfrom thedateof

purchase.DuringthewarrantyperiodBAJA,INC.willat itsoption,

repair,providereplacementpartsor replaceyourBAJAINC.MiniBike

atnocharge. Thiswarrantydoesnotcovernormalwearitemsor

damagecausedbyneglector misuseoftheproduct.

EngineWarranty- 90days

FrameWarranty- 90days

Warrantyisvoidif:

Frameisbentor brokenduetoabuse

Wheelsarebentor broken

Fenderbentor brokenduetoabuse

Anysignofimpact,accident,jumping,spin-outsor rollover.

BAJA,INC.is notliablefor anydamageclaimor liabilityclaimperson

orotherwiseresultingfrom theoperationofthisproductin anyway.

Shouldyouexperiencea problemwithyourvehicle,pleasecontactBajaInc.

customerservicelinetollfree at 1-888-863-2252betweenthehoursof7amand

5proMondaythroughFridayMST(MountainStandardTime).MDT(Mountain

DaylightTime)duringthedaylightsavingtime.Youwillbeinstructedhowto

proceed.

A COPYOFTHESALESRECEIPTISREQUIRED.

Thismanualshouldbeconsideredas a permanent

partof thevehicleand shouldremainwith the

vehiclewhen resoldor otherwisetransferredto

anew useror operator. The manualcontains

importantsafety informationand instructions

whichshouldbe readcarefullybeforeoperating

thevehicle.

The engineexhaustfrom this productcontains

chemicalsknownto theStateof Californiato cause

cancer,birthdefectsor otherreproductiveharm.

CALIFORNIAPROPOSITION65

iii

TableofContents

SAFEOPERATION..............................................................................................3

SAFETYGEAR....................................................................................................4

MODIFICATIONOFVEHICLE.............................................................................4

MAINDATA..........................................................................................................5

PARTS&SUBASSEMBLIES..............................................................................6

OPERATION........................................................................................................8

FUELVALVE................................................................................................8

ENGINESTARTINGANDSTOPPING.........................................................9

SWITCHESONTHERIGHTHANDLEBAR................................................10

CHECK-UPS,ADJUSTMENTANDMAINTENANCE..........................................11

CHANGINGTHEOIL...................................................................................12

CHECK-UPOFSPARKPLUG....................................................................12

CHECKING&CLEANINGTHEAIRFILTER...............................................13

ADJUSTINGTHETHROTTLECABLE.......................................................14

ADJUSTINGTHECARBURETOR..............................................................14

ADJUSTMENTOFREARBRAKE..............................................................15

ADJUSTMENTOFCHAIN...........................................................................16

GREASINGPROCEDURESTOTHEDRIVINGCHAIN..............................16

VEHICLEWASHING....................................................................................17

INSTRUCTIONSFORSTORAGE...............................................................18

RESUMPTIONOFSERVICEAFTERSTORAGE.......................................19

TABLEANDTORQUEOFFASTENERS....................................................19

MAINTENANCEROUTINEDIAGRAM........................................................20

TROUBLESHOOTING................................................................................21

EMISSIONCONTROLSYSTEMWARRANTY............................................22

Pleasereadthismanualandfollow all instructionscarefully.Toemphasizethe

specialinformation,thesymbol-&andthewordsWARNINGorCAUTIONhave

somespecialmeanings.Paygreatattentiontothemessages.

Indicatesa potentialhazardthatcouldresultindeathor injury.

CAUTION

Indicatesa potentialhazardthatcouldresultinvehicledamage.

NOTE:Indicatingspecialinformationwhichistomakemaintenanceeasieror

instructionsclearer.

WARNINGandCAUTIONarearrangedlikethis:

Thefirst partwillidentifya POTENTIALHAZARD.

ThesecondpartwilldescribeWHATCOULDHAPPENifyou ignore

theWARNINGor CAUTION.

ThethirdpartwilldescribeHOWTOAVOIDTHEHAZARD.

Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.Read

itcarefullybeforeriding. Failingtofollow thewarningscontainedinthismanual

couldresultinINJURYor DEATH.

Itis importantthatthis manualremainwiththevehiclewhenyoutransferitto

anotheruserorowner.

All information,illustrations,photographsandspecificationscontainedin

thismanualarebasedon thelatestproductinformationavailableatthetime

ofpublication.Duetoimprovementsorotherchanges,therewillbesome

discrepanciesinthismanual. Wereservetherightto makeproductchangesat

anytime,withoutnoticeandwithoutincurringanyobligationto makethesameor

similarchangestothevehiclepreviouslybuiltorsold.

SAFE OPERATION

Rulesfor SafeOperation

Apre-operationcheckmustbeconducted,beforestartingtheengine,insure

safety,preventmishaps,anddamagetocomponents.

Itisstronglysuggestedthatall operatorstakea certifiedmotorcyclerider's

coursepriortooperatingthevehicle.

Fullattentionisrequiredduringdriving;payingcloseattentiontothe

following pointstoavoidanyinjurytoyoubyothermotorizedvehicles:

Donotdrivetooclosetoothervehicles.

Nevercarrya passenger.Thisminibikeisfor oneoperatoronly

Neveroperatethisminibikeat night. Nightisdefinedastheperiodoftime30

minutesbeforesunsetto30minutesaftersunrise.

Drivingat highspeedsisthecauseof manyaccidents;donotdriveat aspeed

thattheactualsituationdoesnotpermit.

Thisuser'smanualcontainsimportantsafetyand maintenanceinformation.

Readitcarefullybeforeriding. Failingtofollow thewarningscontainedinthis

manualcouldresultinINJURYor DEATH.

Itisimportantthatthis manualremainwiththevehiclewhenyoutransferitto

anotheruserorowner.

Allinformation,illustrations,photographsandspecificationscontainedin

thismanualarebasedon thelatestproductinformationavailableatthetime

ofpublication.Duetoimprovementsor otherchanges,therewillbesome

discrepanciesinthis manual.Wereservetherighttomakeproductchanges

atanytime,withoutnoticeandwithoutincurringanyobligationtomakethe

sameor similarchangestothevehiclepreviouslybuiltor sold

Alwaysavoidoperatingthisminibikeonpavedsurfaces,including;

sidewalks,paths,parkinglots,driveways,streets,roads,andhighways.

Neveroperatedthisor anyOff-RoadVehicleon a publicstreet,roador

highwaywheremotorvehiclesareinoperation.

SAFETYGEAR

Neveroperatethisminibikewithoutwearinga DOTapprovedmotorcycle

helmetwhichfits properly.Operatorsshouldalsoweareyeprotection

(gogglesor faceshield),gloves,boots,long-sleevedshirtorjacket,and long

pants.

2. Looseclothesarenotsuitablefor motorcycledrivingor ridingastheymay

getcaughton footrest orwheel,resultingindanger.

MODIFICATIONOFTHEVEHICLE

CAUTION

Neverperform any unauthorizedmodifications to this vehicle. Only use

original replacementpartwhich canbe obtainedthrough BAJAINC.888-

863-2252.

MAINDATA

Overalllength

Overallwidth

Overallheight

Wheelbase

Deadweight

Payload

Frontwheel

Rearwheel

BrakeType

Capacityof

gasolinetank

Capacityofoil

tank

Drive

1680mm

(66.14inches)

800.1ram(31.5

inches)

979.9mm

(38.58inches)

1162mm(45.75

inches)

64.46kg

(142.11bs.)

91kg(200Ibs)

19X7-8

10psi

19X7-8

10psi

Drum

4.2L(.95gal.)

.5L(.53qt.)

Centrifugal

clutch

Cylinderborex

stroke

PTOshaftrotation

Output,max

Torque,max

Idlingspeed

Displacementof

cylinder

Sparkplug

Sparkpluggap

Gapofair valveIN

Gapofair valveEX

Groundclearance

Ignitionmeans

6.8cmX 15.41cm

(2.68"X 2.13")

Counterclockwise

6.5hpat 3600rpm

9.76ft-lbs, at2500rpm

1400+200

-150

197cc

MEIYA-F7RTC,NGK-

BPR6ES,Champion

- RN9YC

0.7ram-0.79ram

(.028"-.031")

0.15+-.02ram(cold)

0.20+-.02ram(cold)

139mm (5.5")

Magneto

PARTS& SUBASSEMBLIES

Rearbrakelever

Throttletwist

grip

Headlight

FrontShock

Absorber

Handbrake

FrontWheel

Footpegs

ClutchcoverDriveChain

SideStand

AirFilter

BrakeDrum

Decorativetank

SeatCushion

VehicleIdentification

EPASticker

GasTank

PullStartCord

OPERATION

FUELVALVE

Fuelfilling

Thecapacityofthefuel tankis4.2L(.95gal). Unscrewthegascapby turningit

counterclockwiseandcarefullyfill thetankwith unleadedgasolinethroughthe

opening.DONOTMIXGASANDOILTOGETHER,THISISA4-STROKEENGINE.

Replacethegascapbycarefullyaligningthethreadsonthecapandthetankand

turningthecapclockwise. Wipeanyspilledfuel from thedirtbikeusinga cloth

anddisposeoftheclothproperly.DONOTSMOKEORREFUELTHEVEHICLE

NEAROPENFLAMESORNEARHEATINGUNITS.ONLYREFUELTHEVEHICLE

INOPENAREASTOREDUCETHELIKELIHOODOFTHEBUILDUPOFGASOLINE

FUMES.

Fillerneck

Fuellevel /

Operationofthefuel valve(thevalveunderthefueltank)

ON: Withthehandleofthefuel valveto"ON" position,thefuel supplywillflow to

thecarburetor.

OFF: Withthehandleofthefuel valveto"OFF" position,thefuel supplyiscutoff

tothecarburetor.

FuelValveHandle

CAUTION

Verifyoillevelpriortostarting(seepage11)

Startingtheenginewithlowornooilwilldamagetheengine.

ENGINESTARTINGAND STOPPING

Neverstarttheengineina closedplaceas theexhaustedgas

from thevehiclecontainstoxiccarbonmonoxide.

StartingEngine:

1.Placefuel valveleverto "ON" Position.

2.PlaceChokeleverto"ON" Position.

3. Settheignitionswitchto "__" Position.

4. PulltheStartRecoilcorduntilenginestarts.

5. Afterenginehassufficientlywarmedup,place

Chokeleverin "OFF" Position.

ChokeLever

ON '= = OFF

Proceduresfor stoppinqenqine:

OFF '= J' ON

Fuelvalvelever

1.Releasethrottletwistgriptoslowdownengine.

2. Settheignitionswitchto" _" position.

3. Setthefuel valvelever(thefuel tankvalve)handleto "OFF"position.

CAUTION

Unnecessarilyincreasing RPM'sto ahigh levelwhile

the MiniBike is warming up is harmful to theengine.

SWITCHESON RIGHTHANDLEBAR

Ignitionswitch

Theignitionswitchisprovidedon therighthandlebar.

Whentheswitchisturnedto"(_" (off)position,theenginewillnotstartorstops

theengine.

Whentheswitchisturnedto"_" (on)position,theenginecanstartandthe

vehiclecanbedriven.

ONbutton

OFF button

CHECK-UPS,ADJUSTMENTAND MAINTENANCE

CheckingtheOil

Checktheengineoileachtimepriortooperatingtheminibike.

Theoillevelshouldbebetweentheupperandlowerlinesoftheoilgauge.

SettheMiniBikeonlevelground,screwofftheoilgageplug,wipetheoil

gagerodcleanandtheninsertthegageplugintothecrankcaseagainto

checktheoillevel. Thereisnoneedtoscrewtheoilgageplugintoitsholein

thecrankcase.

2. Addlubricatingoiluptotheedgeofthefill plug.

3. Finallyscrewintheoilgageplugtightly.

CAUTION

Neverstarttheenginewhenthere is insufficient lubricating

oil. Otherwise, itwill causeharmto theengine.

LubricatingOilRecommended

Oildipstick

Thelubricating oilis animportantfactor affectingthe performanceandservicelife

oftheengine.Pleaserefertothechartfor thecorrectgradeofengineoilbasedon

theenvironmentalconditionsinyourarea. Donotuseanyothertypeofoilother

thanwhatisrecommendedinthechart. DONOTMIXOILWITHTHEGASOLINE.

Lubricatingoilsofdifferent viscosity shallbeemployedindifferentregionsandat

differenttemperatures.

MACHINE I

EgiI

°C -30 -20 -10 0 10 20 30 40

TEMP. I

°F -22 -4 14 32 50 68 86 104

CHANGINGTHEOIL

Removethe"ScrewPlug"locatedat thebottomoftheengineandletthe

oildrainintoanapprovedcollectioncontainer.DONOTPERFORMTHIS

PROCEDUREWHILETHEENGINEISHOT.SERIOUSBURNSCOULDRESULT

FROMCONTACTWITHHOTOIL.

2. Disposeoftheusedoilproperly.Forproperdisposalprocedures,contact

yourlocaloilrecyclingcenter.

3. Cleanand replacethe "Screw Plug"tightly.Torqueto 18ft.lb.

4. Refilltheenginewith0.53qt. (0.5L) ofrecommendedoilandrecheckthe

amountofoilintheenginebyusingtheoilgaugeplug.

Screwplugfor oildraining

CHECK-UPOF SPARKPLUG

1. Removethe capofsparkplugandscrewoff

thesparkplugusingthe plugwrench.

2. Cleanthe sparkplugallaroundor replaceit

if it is corrodedor thereistoo muchdeposit

onit.

3. Regulatethe gapofthe sparkplugto

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

Thesparkplugofthe designated type

shouldbeused. Theapplicabletypeof

sparkplug: Meiya-F7RTC Champion-

RN9YC, NGK- BPR6ES

.79ram

(.028"- .031")

CHECKING& CLEANINGTHEAIR FILTER

1. Removeseatto accessairfilter. Seatis removedby

removingnutlocatedunderseat(seephoto).

2. LocateAirFilterBox underseatandremovecover.

3. Removeairfilter.

4. RemovefoamcoverfromAirfilter element.

5. TaptheAirfilter elementgentlytoremovemostof

thedustanddirt. Blowoutremainingdustwith

compressedair. Iftheelementisdamaged,replaceit.

6. Washthefoam elementcoverperinstructionsbelow

thenallowtodrythoroughly.

7. Reinstallfoamcovertotheairfilter element.

8. Reinstallair filterand closecover. Air Filter

AirFilterbox

Seatnut

Foa_

Removalofcover

Removaloffilter

Washwithmildsoap

andwater

Airfilter element

Rinsewithfresh waterthen

squeezeoutexcess.

CAUTION

Theair filter elementmust be intactor theenginewill suckin dust anddirt,

resulting in a shorterservicelifeof the engine.

Watershouldbe preventedfrom enteringintothefilter whenwashingthe

vehicle.

Thefilter elementshallbe cleanedgentlywithouttwistingtopreventit

from cracking.Neverwashitwithgasolineor anyacid,alkalineor organic

volatileoiltoavoiditsaging,whichwillresultin reducingtheeffectofthe

airfilter oiltocatchparticlesbeforetheyentertheengine. Replacethefilter

elementwitha newoneifit isbrokenor cracked.

ADJUSTINGTHE THROTTLECABLE

Makesure thethrottlecableisadjustedproperly.Toadjustthrottlecable, rotate

adjustmentnutlocatedatthehandthrottle.

Checkifthethrottletwistgriphastherequiredfreeoperatingmovement.

Therequiredfreeoperatingmovement:2-6ram(.078-.24in). Ifthegripcannotbe

movedfreely,turntheadjustingnuttoensureproperoperatingmovement.

Afteradjustment,starttheengineandcheckfor theoperatingmovementagain.

Repeattheadjustmentifnecessaryuntilthedesiredoperatingmovementis

obtained.

Throttlecableadjustnt_

ADJUSTINGTHE CARBURETOR

Adjustinqproceduresofidlinqspeed:

1. Supportthevehiclebya stand.

2. Adjusttheidlespeedbythethrottlestopscrewto 1400+200RPM

-150.

CAUTION

Donottrytocorrecta malfunctioningcarburetorbyadjustingtheidling

speed. Ifthecarburetorisnotfunctioning properly,itshouldberepaired

byaservicecenter.

Adjustidling speedonlywhentheengineiswarmedupor 10minutesafter

operation.

ADJUSTMENTOFREARBRAKE

Thefront brakehandgripshouldhavefree operatingmovementof

5-7mm(.2-.3in).

Tomakeadjustment,turnrearadjustingnutclockwisetoreduceand

counterclockwisetoincreasethefreeoperatingmovement

ofthehandbrake.

Brakeshoesshouldbereplacedbya qualified servicetechnicianoncebrake

shoesareworn. 5-7ramfree play

(.2-.3in)

Rearbrakeadjustingnut

Rearbrakearm

Brakecable

ADJUSTMENTOF CHAIN

1. Whenchainadjustmentisneeded,loosenrear axlebolt.

2. Turnthechainadjustingnutsontheleftand right sidestoadjustthetension

of thechainandtoalignthemarkingofthechainadjusterwiththeengraved

linesinthesimilarpositionon bothsides.

3. Tightenrearaxlebolt bya torqueof 50-60Nm(37-44ft.lb.).

4. Repetitivelycheckthetensionofthechain.

Rearaxlebolt

15-20mm

1/2"- 3/4" Chainadjustingnut

BothSides

GREASINGPROCEDURESTOTHE DRIVINGCHAIN

1. Shutofftheengine

2. Addlightamountsofmachineoilorchaingreasetothedrivingchain.(Too

muchmachineoilor chaingreasemaycausesplatteringtooccur.)

Attention:

Thechainshouldbereplacedwhentheadjustinglimithasreachedit'smaximum.

VEHICLEWASHING

Cleaningthevehicleregularlycanslowdownthecolorfading ofitsbodyand

makeiteasiertocheckifthereisanydamageandanyoilleakage.

CAUTION

Washing theMiniBikewithover-pressurizedwatermaycausedamageto

someofitscomponents.Therefore,dousea pressurewashertocleanthe

vehicle. Thefollowing partsshouldbecleanedusinglowpressurewater:

-- Wheelhub

-- Exhaustpipe

-- Fueltankandlowerportionofcushion

-- Carburetor

-- Headlockandignitionswitch

-- Meters

Afterpre-wiping,thevehicleshouldbe washedwithcleanwatertoremove

dirtyresiduessoastopreventcorrosion.Plasticsubassembliesshouldbe

cleanedbywipingwitha clothorfoam soakedin neutraldetergentsolution,

followed bywashingwithcleanwater.

Afterthecleanedvehicleisairdried,greasethechainandruntheengineat

idlingspeedfor a few minutes.

Priorto driving, carefullycheckthebraking systemrepeatedlyandrepairor

adjustit ifnecessary.

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Baja motorsports WR65 Owner's manual

Brand: Baja motorsports

Model: WR65

Type: Owner's manual

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Baja motorsports WR65 Owner's manual

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Baja motorsports WR65 Owner's manual

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