Baja DB30 Owner's manual

Type
Owner's manual

This manual is also suitable for

MinimumAge Requirement:16
Weightcapacity: 150 Ibs.
Rev.l(US)
020509
Alwaysweara helmet;It couldsaveyourLife!
Pleaseobtain,review,and followprovincial/ municipalgovernmentactsand
regulationspertainingto owningand operatingan off-roadvehicle.
0
CongratulationsonyourpurchaseoftheBAJAINC.DB30MiniBike.
YourMinibike iswarrantedtobefreeofmanufacturingdefectsinmaterial
andworkmanshipfor a periodof90daysfrom thedateofpurchase.
DuringthewarrantyperiodBAJA,INC.willat itsoption,repair,provide
replacementpartsorreplaceyourBAJAINC.DB30MiniBikeatno charge.
Thiswarrantydoesnotcovernormalwearitemsor damagecausedby
neglectormisuseoftheproduct.
EngineWarranty- 90days
FrameWarranty- 90days
Warrantyisvoidif:
Frameisbentor brokenduetoabuse
Wheelsarebentor broken
Fenderbentor brokenduetoabuse
Anysignofimpact,accident,jumping,spin-outsor rollover.
BAJA,INC.is notliablefor anydamageclaimor liabilityclaimpersonor
otherwiseresultingfrom theoperationofthisproductinanyway.
Shouldyouexperiencea problemwithyourvehicle,pleasecalltheBajaInc.
customerservicelinetollfreeat 1-888-863-2252betweenthehoursof7amand
5proMondaythroughFridayMST(MountainStandardTime).MDT(Mountain
DaylightTime)duringthedaylightsavingtime.Youwillbeinstructedhowto
proceed.
ACOPYOFTHESALES RECEIPTISREQUIRED.
Thismanualshouldbe consideredas a permanent
partof thevehicleandshouldremainwith the
vehiclewhen resoldor otherwisetransferredto
a newuser oroperator. The manualcontains
importantsafetyinformationand instructions
whichshouldbereadcarefullybeforeoperatingthe
vehicle.All operatorsshouldobtain,review,and
follow provincialand municipalgovernmentacts
and regulationspertainingto owningandoperating
an off-roadvehicle. Childrenunderthe age of 16
shouldneveroperatethisvehicle withoutadult
supervision.
The engineexhaustfrom this productcontains
chemicalsknownto the Stateof Californiato cause
cancer,birthdefectsorotherreproductiveharm.
CALIFORNIAPROPOSITION65
iii
SAFETY.......................................................
SafeOperation ....................................
Safety Gear .........................................
Location of Labels...............................
SPECIFICATIONS..........................................
LOCATIONOF PARTS...................................
OPERATION.................................................
Left and Right HandGrip .......................
Engine ON/OFF switchand Pull Cord......
Fuel Fill ..............................................
FuelValve ...........................................
INSPECTIONBEFORE RIDING.........................
ENGINESTARTINGAND STOPPING.................
INSPECTIONAND MAINTENANCE..................
Checking Oil ........................................
ChangingOil .......................................
Check-up of Spark Plug.........................
Checking and cleaningAir Filter ..............
AdjustingThrottleCable ........................
AdjustingCarburetor............................
Adjustment of Rear Brake......................
Adjustment of Chain .............................
Clutchcleaning and maintenance...........
VehicleWashing ...................................
Instructionfor Storage ..........................
Resumption of Serviceafter Storage........
MAINTENANCESCHEDULE ............................
TROUBLESHOOTING....................................
ELECTRICALSCHEMATIC...............................
EMISSIONSCONTROL SYSTEMWARRANTY-......
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Pleasereadthis manualandfollow all instructionscarefully.Toemphasizethe
specialinformation,thesymbolA andthewordsWARNINGorCAUTIONhave
somespecialmeanings.Paygreatattentiontothemessages.
Indicatesa potentialhazardthatcouldresultindeathor injury.
CAUTION I
ndcatesa potentialhazardthatcouldresultinvehicledamage.
NOTE:Indicatingspecialinformationwhichistomakemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONarearrangedlikethis:
Thefirst partwillidentify a POTENTIALHAZARD.
ThesecondpartwilldescribeWHATCOULDHAPPENifyou ignore
theWARNINGor CAUTION.
ThethirdpartwilldescribeHOWTOAVOIDTHEHAZARD.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.Read
itcarefullybeforeriding. Failingtofollow thewarningscontainedinthismanual
couldresultinINJURYor DEATH.
Itisimportantthatthis manualremainwiththevehiclewhenyoutransferitto
anotheruserorowner.
All information,illustrations,photographsandspecificationscontainedin
thismanualarebasedonthelatestproductinformationavailableatthetime
ofpublication.Duetoimprovementsor otherchanges,therewill besome
discrepanciesinthismanual.Wereservetherightto makeproductchangesat
anytime,withoutnoticeandwithoutincurringanyobligationto makethesameor
similarchangestothevehiclepreviouslybuiltorsold.
SAFEOPERATION
Rulesfor SafeOperation
Apre-operationcheckmustbeconducted,beforestartingtheengine,insure
safety,preventmishaps,anddamagetocomponents.
ITEMTOCHECK CONTENT
Steering Smoothness;Norestrictionofmovement;Noplayorlooseness
Brakes Properbrakeleverfree play;enoughbrakeforce
Tires Properairpressure;Enoughtreaddepth;Nocracks,rips,or
otherdamages
Fuel Enoughfuelfor theintendedtrip;Fuelhoseconnectedsecurely;
Nodamagetofuel tankorcap;Fueltankcapclosedsecurely
Enginestopswitch Proper operation
Engineoil Proper level- Checkoil byinspectingEngineOilDipStick.
Theengineoil shouldbe betweenthe MinimumandMaximum
lines.
Throttle Properfreeplayofthrottlelever;smoothresponse;quick
returntoidleposition
Generalcondition Boltsandnutsaretight;norattlefrom anypartsoftheengine
whenrunning, novisibleevidenceofDamage
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'smanualcontainsimportantsafetyandmaintenanceinformation.
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
ADOTapprovedmotorcyclehelmetisthemostimportantpartofyousafety
gear.ADOTapprovedmotorcyclehelmetcanhelppreventaseriousheadinjury.
Chooseahelmetthatfits snugly.Motorcycledealerscanhelpinselectinga good
quality helmetwhichfits properly.
OperatingthisMiniBikewithoutwearinganapprovedDOTmotorcycle
helmet,eyeprotection,andprotectiveclothingcouldbehazardous.
OperatingwithoutanapprovedDOTmotorcyclehelmetoreyeprotection
increasesyourchancesofa severeheadinjuryor deathinanaccident.
Operatingwithoutprotectiveclothingalsoincreasesyourchancesof
severeinjuryinanaccident.
AlwayswearanapprovedDOTmotorcyclehelmetwhichfits 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 goodpairofgloves,strongbootsthatareovertheankle,long
pants,anda longsleeveshirt.
_CAUTION /
Neverperformanyunauthorizedmodificationstothisvehicle. Onlyuse_
originalreplacementpartwhichcanbeobtainedthroughBAJAINC. |
888-863-2252. /
LOCATIONOF LABELS
TI"I_ELE _ BIENATJ_DO I,L_llD_OPI_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(24.5inches)
Overallheight 863mm(34 inches)
Wheelbase 927mm(36.5inches)
Deadweight 35.38kg(78Ibs.)
Payload 68.04kg(150Ibs.)
Frontwheel 145x70-6
Rearwheel 145x70-6
Braketype Disc
Capacityofgasolinetank 1.4L(0.36gal)
Capacityofoiltank 0.45L(0.40qt.)
Startingmethod Recoilpullstart
Borea stroke 52ramx 46ram
PTOshaftrotation Counterclockwise
Horsepower 2.5Hp
Displacement 97.7cc
Maxpower 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
SeatCushion
FrontWheel
RearWheel
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 lefthandgripwillstopminibike.
Applyingthehandthrottle(movingthrottlecounterclockwise) willcause
enginerpmstoincrease,causingminibiketomoveforward.
Whentheswitchisturnedto'_(_" (off)position,theenginewillnotstart. If
theengineisrunningandtheOffbuttonispushedtheenginewillturnoff.
Whentheswitchisturnedto"C_J' (on)position,theenginecanstartbyusing
themanualpullstartcord,
Grip
ENGINEPULLCORDOPERATION
Pullingthepullcordwillstarttheengine.
PullCord
10
FUELAND FUELVALVEOPERATION
Fuelfilling
Thecapacityofthefuel tankis 1.4L(.40qt .) Unscrewthegascapby turningit
counterclockwiseandcarefullyfill thetankwithunleadedgasolinethroughthe
opening.DONOTMIXGASANDOILTOGETHER,THISISA4-STROKEENGINE.
Replacethegascapbycarefullyaligningthethreadsonthecapandthetankand
turningthecapclockwise. Wipeanyspilledfuel from thedirtbikeusinga cloth
anddisposeoftheclothproperly.DONOTSMOKEORREFUELTHEVEHICLE
NEAROPENFLAMESORNEARHEATINGUNITS.ONLYREFUELTHEVEHICLE
INOPENAREASTOREDUCETHELIKELIHOODOFTHEBUILDUPOFGASOLINE
FUMES. Fillerneck
Fuellevel
Overfillingthefuel tankcouldbehazardous.
Ifyouoverfillthefuel tank,fuel mayoverflowwhenitexpands. Expanding
isduetoheatfrom engineor sun. Overheatedfuel couldeasilycatchfire.
Stopaddingfuel whenthefuel levelreachesthebottomofthefiller neck.
FUELVALVEOPERATION
ON: Withthehandleofthefuel valveto"ON" position,thefuel supplywillflow to
thecarburetor.Inthispositiontheengineisabletostartandrun.
OFF: Withthehandleofthefuel valveto"OFF" position,thefuel supplyiscutoff
tothecarburetor.In thispositiontheminibikewillnotstartandwillnotrun.
FuelValveHandle
ON
OFF
11
ITEMTOCHECK CONTENT
Steering Smoothness;Norestrictionofmovement;Noplayorlooseness
Brakes Properbrakeleverfree play;enoughbrakeforce.
Tires Properair pressure;Enoughtreaddepth;Nocracks,rips,or other
damages Note: Checktirepressure,specis locatedonsideof tire.
Fuel Enoughfuel for theintendedtrip;Fuelhoseconnectedsecurely;Nodamage
tofuel tankorcap;Fueltankcapclosedsecurely
Enginestopswitch Properoperation
Engineoil Properlevel- Checkoil by inspectingEngineOilDipStick. Theengine
oil shouldbebetweentheMinimumandMaximumlines.
Throttle Properfree playofthrottlelever;smoothresponse;quickreturntoidle
position
Generalcondition Boltsandnutsaretight;norattlefrom anypartsof theenginewhen
running,novisibleevidenceof Damage
FailingtoinspecttheMiniBikebeforeoperatingcouldbehazardous.
Failingtoperformpropermaintenancecouldalsobehazardous.
FailingtoinspectandmaintainyourMiniBikecouldincreasesthe
chancesofanaccidentor equipmentdamage
AlwaysinspectyourMiniBikeeachtimebeforeriding,andmakesureitisina
safeoperatingcondition.RefertotheINSPECTIONANDMAINTENANCEsectionin
thismanual.
OperatingthisMiniBikewithimpropertires,orimpropertireairpressurecouldbe
hazardous.
Ifyouuseimpropertiresor improperair pressure,you maylosecontrolof
theMiniBike. Thiswillcauseanaccident.
Alwaysusethetireswithsizeandtypetiresspecifiedinthisuser's
manual.Alwaysmaintainpropertireairpressureas describedinthe
INSPECTIONANDMAINTENANCEsection.
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_, CAUTION
Verifyfuel andoillevelpriortostarting(seepages11and 14)
Startingtheenginewithlowor nooilwilldamagetheengine.
Neverstarttheengineina closedplaceastheexhaustedgas
from thevehiclecontainstoxiccarbonmonoxide.
1. Ensurethereisfuel infuel tankandoilincrankcase.
2. Setfuelvalveleverto"ON" position
3. Placechokeleverto"ON" position
4. Startenginewithpullstartcord.
5. Allowengineto idleuntilengineiswarm
6. Placecarburetorchokelevertowardthe"OFF" positionwhenenginehas
sufficientlywarmedup. Note: Engineusuallyrunsbestwiththechokelever
betweentheon andoff positions
OFF ,= J, ON
Fuelvalvelever
ChokeLever
OFF '= = ON
ON
OFF
Proceduresfor stoppinqenqine:
1. Releasethrottletwistgriptoslowdownengine.
2. Depressstopbuttonlocatedon righthandgrip. Depressbuttonuntilengine
comestoa completestop
3. Setfuel valvelever(thefuel tankvalve)handleto"OFF" position.
_,CAUTION
UnnecessarilyincreasingRPM'sto a highlevelwhiletheMiniBikeis
warmingupisharmfultotheengine.
13
CHECKINGTHEOIL
Checkengineoileachtimepriortooperatingminibike.
Theoil levelshouldbe betweenupperandlower linesofoilgauge.
.
Set theMiniBikeon levelground,screwofftheoilgageplug,wipetheoil
gagerodcleanandtheninsertthegageplugintothecrankcaseagainto
checktheoillevel. Thereis noneedtoscrewtheoilgageplugcompletelyin
theholetochecktheoil.
2. Addlubricatingoiluptotheedgeofthefuel plug.
3. Screwoilgageplugtightly.
,_ CAUTION
Neverstarttheenginewhenthereisinsufficientlubricating
oil. Otherwise,itwillcauseharmtotheengine.
LubricatingOilRecommended
Oildipstick
The lubricating oil is animportantfactor affectingthe performanceandservicelife
of theengine.Pleaserefertothechartfor thecorrectgradeofengineoilbasedon
theenvironmentalconditionsinyourarea. Donotuseanyothertypeofoilother
thanwhatisrecommendedinthechart. DONOTMIXOILWITHTHEGASOLINE.
.45L(.40qt.)Oil
Lubricatingoilsofdifferent
viscosityshallbeemployed
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
CHANGINGTHEOIL
Removethe"ScrewPlug"locatedat thebottomoftheengineandletthe
oildrainintoanapprovedcollectioncontainer.DONOTPERFORMTHIS
PROCEDUREWHILETHEENGINEISHOT.SERIOUSBURNSCOULDRESULT
FROMCONTACTWITHHOTOIL.
2. Disposeoftheusedoilproperly.Forproperdisposalprocedures,contact
yourlocaloilrecyclingcenter.
3. Cleanand replacethe "Screw Plug"tightly.
4. Refilltheenginewiththeproperamountofoilandrechecktheamountofoil
intheenginebyusingtheoilgaugeplug.
Screwplugfor oildraining
CHECK-UPOFSPARKPLUG
1. Removethe capofsparkplugandscrewoffthe
sparkplugusingthe plugwrench.
2. Cleanthesparkplugallaroundor replaceitif itis
corrodedorthereistoo muchdepositonit.
3. Regulatethegapofthesparkplugto
.7mm-.79mm (.028"-.031").
4. Thesparkplugofthedesignatedtypeshouldbe
used. Theapplicabletypeofsparkplug:
.7ram-.79ram
(.028"- .031")
IAutolite-258,AC-CS49,Champion-CJ14,
NGK-BM4A,Denso-W14M-US I
15
CHECKING& CLEANINGTHEAIR FILTER
1. LocateAirFilterBox at rearofengine
2. Removeairfilter coverby unscrewingphillipsheadscrew
3. RemovefoamAirfilter element.
4. TapAirfilter elementgentlytoremovemostofthedustanddirt.
5. Washfoam elementperinstructionsbelowthenallowtodrythoroughly.
6. Reinstallfoam airfilter element.
7. Reinstallair filter cover
AirFilterbox
Phillipshead
screw
Washwithmildsoap
andwater
FoamAirfilter
element
Rinsewithfresh waterthen
squeezeoutexcess.
_ CAUTION
Theairfilter elementmustbeintactor theenginewillsuckindustand
dirt,resultingina shorterservicelifeof theengine.
Watershouldbepreventedfrom enteringintothefilter whenwashing
thevehicle.
Thefilter elementshallbecleanedgentlywithouttwistingtoprevent
itfrom cracking.Neverwashitwith gasolineoranyacid,alkalineor
organicvolatileoilto avoiditsaging,whichwillresultin reducingthe
effectoftheairfilter oilto catchparticlesbeforetheyentertheengine.
Replacethefilter elementwitha newoneifitisbrokenorcracked.
16
ADJUSTINGTHE THROTTLECABLE
Makesure thethrottlecableisadjustedproperly.Toadjustthrottlecable, rotate
adjustmentnutlocatedatthehandthrottle.
Checkifthethrottletwistgriphastherequiredfreeoperatingmovement.
Therequiredfreeoperatingmovement:2-6ram(.078-.24in.). If thegripcannotbe
movedfreely,turntheadjustingnuttoensureproperoperatingmovement.
Afteradjustment,starttheengineandcheckfor theoperatingmovementagain.
Repeattheadjustmentifnecessaryuntilthedesiredoperatingmovementis
obtained.
Throttlecableadjustnut
ADJUSTINGTHE CARBURETOR
Adjustinqproceduresofidlinqspeed:
1. Supportthevehiclebya stand.
2. Adjusttheidlespeedbythethrottlestopscrewto 1400+200RPM
-150.
_CAUTION
Donottrytocorrecta malfunctioningcarburetorbyadjustingtheidling
speed. Ifthecarburetorisnotfunctioning properly,itshouldberepaired
byaservicecenter.
Adjustidlingspeedonlywhentheengineiswarmedupor 10minutesafter
operation.
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Baja DB30 Owner's manual

Type
Owner's manual
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