Baja DB30 Owner's manual

Brand: Baja

Model: DB30

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.

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-......

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_=

TIREP_SSUR_

• C_k _:_ess_s o_ a_ t_s o_y _he_

t_res am¢_, 4 p_ _7_ _pa)

REGULA_SERWGEFROGEDU

LOCATIONOF LABELS

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

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

OFF

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.

_, 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

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.

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

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

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

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.

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

Brand: Baja

Model: DB30

Type: Owner's manual

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Baja DB30 Owner's manual

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