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 manufacturingdefectsin material
andworkmanshipfor a periodof 90daysfrom the dateof purchase.
Duringthe warrantyperiodBAJA,INC.will at itsoption,repair,provide
replacementpartsor replaceyour BAJAINC.DB30MiniBike at no charge.
Thiswarrantydoesnot covernormalwear 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 thisproductin anyway.
Shouldyouexperiencea problemwith yourvehicle,pleasecallthe Baja Inc.
customerservicelinetoll free at 1-888-863-2252betweenthe hoursof 7amand
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
vehiclewhen resoldor otherwisetransferredto
a new user or operator. The manual contains
importantsafety informationand instructions
which should be read carefully beforeoperatingthe
vehicle.All operatorsshould obtain, review,and
follow provincialand municipalgovernmentacts
and regulationspertainingto owning and operating
an off-roadvehicle. Childrenunderthe age of 16
should never operatethis vehicle without adult
supervision.
The engineexhaustfrom this productcontains
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 ........
MAINTENANCESCHEDULE ............................
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 manualandfollow all instructionscarefully.To emphasizethe
specialinformation,the symbolA andthewordsWARNINGorCAUTIONhave
somespecialmeanings.Pay greatattentiontothe messages.
Indicatesa potentialhazardthatcouldresultin deathor injury.
CAUTION I
ndcates a potentialhazardthatcouldresultinvehicledamage.
NOTE:Indicatingspecialinformationwhichis to makemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONare arrangedlikethis:
Thefirst partwill identify a POTENTIALHAZARD.
Thesecondpartwill describeWHATCOULDHAPPENif you ignore
theWARNINGor CAUTION.
Thethirdpart will describeHOWTOAVOIDTHE HAZARD.
Thisuser'smanualcontainsimportantsafetyand maintenanceinformation.Read
it carefullybeforeriding. Failingtofollow thewarningscontainedinthismanual
couldresultin INJURYor DEATH.
It is importantthatthis manualremainwiththe vehiclewhenyou transferit to
anotheruseror owner.
All information,illustrations,photographsandspecificationscontainedin
thismanualare basedonthe latestproductinformationavailableatthe time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesinthis manual.We reservetherightto makeproductchangesat
anytime,withoutnoticeand withoutincurringany obligationto makethesameor
similarchangesto thevehiclepreviouslybuiltorsold.
SAFEOPERATION
Rulesfor SafeOperation
A pre-operationcheckmustbe conducted,beforestartingtheengine,insure
safety,preventmishaps,anddamageto components.
ITEMTOCHECK CONTENT
Steering Smoothness;No restrictionof 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;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 Bolts and nuts are tight;no rattlefrom any partsof the engine
whenrunning, no visibleevidenceof Damage
It is stronglysuggestedthatall operatorstakea certifiedmotorcyclerider's
coursepriorto operatingthevehicle.
Fullattentionis requiredduringdriving;payingcloseattentionto the
following pointsto avoidanyinjuryto you byothermotorizedvehicles:
Donot drivetoo closeto othervehicles.
Nevercarrya passenger.Thisminibikeisfor oneoperatoronly
Neveroperatethisminibikeat night. Nightis definedasthe periodof time30
minutesbeforesunsetto 30minutesaftersunrise.
Drivingat highspeedsis the causeof manyaccidents;donotdriveat aspeed
thatthe actualsituationdoesnot permit.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.
Readitcarefullybeforeriding.Failingtofollow thewarningscontainedinthis
manualcouldresultin INJURYor DEATH.
It is importantthatthis manualremainwiththe vehiclewhenyou transferit to
anotheruseror owner.
All information,illustrations,photographsandspecificationscontainedin
thismanualarebasedon thelatestproductinformationavailableat the time
of publication.Dueto improvementsor otherchanges,therewill besome
discrepanciesinthis manual. Wereservethe rightto makeproductchanges
atany time,withoutnoticeand withoutincurringany obligationto makethe
sameor similarchangesto thevehiclepreviouslybuiltor sold
Alwaysavoidoperating thisminibikeonpavedsurfaces,including;
sidewalks,paths,parkinglots,driveways,streets,roads,and highways.
Neveroperatedthisor any Off-RoadVehicleon a publicstreet,roador
highwaywheremotorvehiclesare inoperation.
SAFETYGEAR
ADOTapprovedmotorcyclehelmetisthemostimportantpartofyousafety
gear.ADOTapprovedmotorcyclehelmetcanhelppreventaseriousheadinjury.
Chooseahelmetthatfits snugly.Motorcycledealerscanhelp in selectinga good
quality helmetwhichfits properly.
Operatingthis Mini Bikewithoutwearingan approvedDOT motorcycle
helmet,eyeprotection,and protectiveclothingcouldbe hazardous.
Operatingwithoutan approvedDOTmotorcyclehelmetor eyeprotection
increasesyourchancesof a severeheadinjuryor deathin an accident.
Operatingwithoutprotectiveclothingalsoincreasesyour chancesof
severeinjuryin an accident.
Alwayswearan approvedDOTmotorcyclehelmetwhichfits properly.
Alwaysweareye protection(gogglesor face shield). You shouldalso
weargloves,boots,longsleeveshirtor jacket,andlongpants.
Youshouldweareye protectionwhenyou ride. If a rockor a branchhitsyour
eyes,you couldbeseverelyinjured.Wear gogglesor a face shield.
Wearproperclothingwhenyou ride. The properclothescanprotectyoufrom
injury.Weara good pairof 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_ I F
_._ IF_ DO NOF _THP_[|bL%_ftJJ_=
2
TIRE P_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
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 HANDGRIP OPERATION
BrakeLever ON button Throttlecontrolgrip
LeftHandGrip Ric
OFF button
Pullinginbrake leverlocatedon 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 PULLCORD OPERATION
Pullingthe pullcordwillstartthe engine.
PullCord
10
FUELAND FUEL VALVEOPERATION
Fuel filling
The capacityof thefuel tankis 1.4L(.40 qt .) Unscrewthegas capby turningit
counterclockwiseand carefullyfill thetankwithunleadedgasolinethroughthe
opening. DONOTMIX GASAND OILTOGETHER,THISIS A 4-STROKEENGINE.
Replacethegas capby carefullyaligningthe threadsonthe capandthe tankand
turningthe cap clockwise. Wipeanyspilledfuel from thedirt bikeusinga cloth
anddisposeof the clothproperly.DONOTSMOKEOR REFUELTHE VEHICLE
NEAROPENFLAMESOR NEARHEATINGUNITS. ONLYREFUELTHEVEHICLE
INOPENAREASTO REDUCETHE LIKELIHOODOFTHE BUILDUPOFGASOLINE
FUMES. Fillerneck
Fuellevel
Overfillingthefuel tankcouldbehazardous.
If youoverfillthefuel tank,fuel mayoverflowwhen it expands. Expanding
is dueto heatfrom engineor sun. Overheatedfuel couldeasilycatchfire.
Stopaddingfuel whenthefuel levelreachesthe bottomof the filler neck.
FUEL VALVEOPERATION
ON: Withthe handleof thefuel valveto "ON" position,the fuel supplywill flow to
the carburetor.Inthis positionthe engineis ableto start andrun.
OFF: Withthe handleof thefuel valveto "OFF" position,the fuel supplyis cutoff
to the carburetor. In thispositionthemini bikewill not startandwill notrun.
FuelValveHandle
ON
OFF
11
ITEMTO CHECK CONTENT
Steering Smoothness;No restrictionof 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 shouldbebetweentheMinimumandMaximumlines.
Throttle Properfree playof throttlelever;smoothresponse;quickreturnto idle
position
Generalcondition Boltsandnuts are tight;no rattlefrom any partsof the enginewhen
running, no visibleevidenceof Damage
Failingto inspecttheMiniBikebeforeoperatingcouldbe hazardous.
Failingto performpropermaintenancecouldalsobehazardous.
Failingto inspectandmaintainyour MiniBike couldincreasesthe
chancesof an accidentor equipmentdamage
AlwaysinspectyourMiniBikeeachtimebeforeriding,andmakesureitisina
safeoperatingcondition.RefertotheINSPECTIONANDMAINTENANCEsectionin
thismanual.
OperatingthisMiniBikewithimpropertires,orimpropertireairpressurecouldbe
hazardous.
If youuse impropertires or improperair pressure,you may losecontrolof
the MiniBike. Thiswill causean accident.
Alwaysusethetires with sizeandtypetiresspecifiedinthis user's
manual.Alwaysmaintainpropertire airpressureas describedin the
INSPECTIONANDMAINTENANCEsection.
12
_, CAUTION
Verifyfuel andoil level priortostarting(see pages11and 14)
Startingthe enginewithlow or no oilwill damagethe engine.
Neverstarttheengine in a closedplaceasthe exhaustedgas
from the vehiclecontainstoxiccarbonmonoxide.
1. Ensurethereisfuel infuel tank andoil in crankcase.
2. Setfuel valve leverto "ON" position
3. Placechokeleverto "ON" position
4. Startenginewith pullstartcord.
5. Allow engineto idleuntilengine iswarm
6. Placecarburetorchokelevertowardthe "OFF" positionwhenenginehas
sufficientlywarmedup. Note: Engineusuallyrunsbestwiththe chokelever
betweentheon andoff positions
OFF ,= J, ON
Fuelvalvelever
ChokeLever
OFF '= = ON
ON
OFF
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 MiniBike is
warmingupis harmfulto the engine.
13
CHECKINGTHE OIL
Checkengineoil eachtimepriorto operatingminibike.
Theoil level shouldbe between upperandlower lines of oil gauge.
.
Set theMini Bikeon levelground,screwoffthe oil gageplug,wipetheoil
gagerod cleanandthen insertthe gageplugintothecrankcaseagainto
checkthe oil level. Thereis noneedto screwthe oil gageplugcompletelyin
the holeto checktheoil.
2. Add lubricatingoil upto the edgeof thefuel plug.
3. Screwoil gageplugtightly.
,_ CAUTION
Neverstarttheenginewhen thereis insufficientlubricating
oil. Otherwise,itwill causeharmto the engine.
LubricatingOilRecommended
Oildipstick
The lubricating oil is an important factor affectingthe performanceandservicelife
of theengine.Pleaserefer to the chartfor the correctgradeof engineoil basedon
the environmentalconditionsinyour area. Donot useany othertypeof oil other
thanwhatis recommendedinthe chart. DONOTMIX OILWITH THEGASOLINE.
.45L(.40qt.)Oil
Lubricatingoilsof different
viscosityshallbe employed
indifferentregionsand at
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. DONOT PERFORMTHIS
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 sparkplugand screwoff the
sparkplugusingthe plugwrench.
2. Cleanthe sparkplugall aroundor replaceit if it is
corrodedorthere istoo 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& CLEANING THEAIR FILTER
1. LocateAir FilterBox at rear of engine
2. Removeairfilter coverby unscrewingphillipsheadscrew
3. RemovefoamAir filter element.
4. TapAir filter elementgentlyto removemostof the dustand dirt.
5. Washfoam elementper instructionsbelowthenallowto drythoroughly.
6. Reinstallfoam airfilter element.
7. Reinstallair filter cover
Air Filterbox
Phillipshead
screw
Washwithmildsoap
andwater
FoamAir filter
element
Rinsewithfresh waterthen
squeezeoutexcess.
_ CAUTION
Theair filter elementmustbe intactor the enginewill suckin dustand
dirt,resultingin a 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 elementwith a newoneif it is brokenorcracked.
16
ADJUSTINGTHE THROTTLECABLE
Makesure the throttlecableis adjustedproperly.To adjust throttlecable, rotate
adjustmentnutlocatedat the handthrottle.
Checkif thethrottletwistgrip hasthe requiredfreeoperatingmovement.
Therequiredfree operatingmovement:2-6ram(.078-.24in.). If thegrip cannotbe
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 throttlestop screwto 1400+200RPM
-150.
_CAUTION
Donot try 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 rear brakepad adjustment,turnrear adjustingboltclockwiseto
loosenandcounterclockwiseto tightenbraketension.
Brakepadsshouldbe replacedbya qualified servicetechnicianoncebrake
shoesareworn.
Brakesareadjustedbyturningin or outthe rearbrakeadjustingbolt
5-7ramfree play
(.2-3in.)
Freeplayadjustmentbolt
Rearbrakeadjustingbolt
18
ADJUSTMENTOF CHAIN
1. Whenchainadjustment is 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. Addlight amountsof machineoil or chaingreaseto the drivingchain.(Too
muchmachineoilor chaingreasemaycausesplatteringto occur.)
Attention:
Thechainshouldbe replacedwhentheadjustinglimithas reachedit'smaximum.
19
CLUTCH CLEANINGAND MAINTENANCE
Afterevery5 hourof use, yourclutchwill needcleaningandlubrication.If
clutchbecomestoo dirtyor has lackof lubrication,theclutchwill havea
tendencytostick. Thiswill causethe Mini-Biketowantto takeoff before
throttleis applied.
Tocleanand lubricateclutch, followthe instructionsbelow:
1. Makesureengineisturnedoff and engineis coolbeforeremovingclutch
cover.
2. RemoveClutchCover
3. Withcompressedair, blowthroughholesto removeany dustand/orparticles.
4. Oil Clutchbearingwith afew dropsof 30Wmotoroil.
NOTE:Makesure oildoes notget insideclutchitself.
5. Pushminibikeforward withoutstartingallowingoilto flow throughbearing
surface.
6. Re-installclutchcover.
Startingenginewithclutchcover removedcouldbe hazardous
Startingenginewithclutchcover removed,increasesthe chanceof
gettingyour personcaughtinmovingcomponentswhichcouldresultin
severeinjury.
NeverstartMini Bikewithclutchcoverremoved.
Blowout clutchwith
compressedair through
largeholes
Clutch
OilClutchhere
ONLY
20
VEHICLEWASHING
Cleaningthevehicleregularlycanslowdownthe colorfading of its bodyand
makeiteasierto checkif thereis anydamageand any oil leakage.
CAUTION
Washingthe Mini Bikewithover-pressurizedwatermay causedamageto
someof its components.Therefore,dousea pressurewasherto cleanthe
vehicle. Thefollowing partsshouldbe cleanedusinglowpressurewater:
-- Wheelhub
-- Exhaustpipe
-- Fueltankand lowerportionof cushion
-- Carburetor
-- Headlockand ignitionswitch
-- Meters
,
.
Afterpre-wiping,the vehicleshouldbe washedwithcleanwaterto remove
dirtyresiduesso asto preventcorrosion. Plasticsubassembliesshouldbe
cleanedbywipingwith a clothor foam soakedin neutraldetergentsolution,
followed bywashingwithcleanwater.
Afterthe cleanedvehicleis air dried,greasethechainandrunthe engineat
idlingspeedfor a few minutes.
Priorto driving,carefullycheckthebrakingsystemrepeatedlyand repairor
adjustit if necessary.
21
INSTRUCTIONSFOR STORAGE
If thevehicleis not goingto 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 put backinto useafterstorage.
1. Changeengineoil.
2. Drainoff fuelfromthefueltank andcarburetor,sprayatomizedanti-rust
oil ontothe insidewallof thetank andthen closethe tank. Disposeof any
drainedfuel properlyso asnot to adverselyaffectthe environment.
Attention: CarburetorDrainscrew
If the storagewill lastfor morethanone month,fuel inthe carburetormustbe
fully drained.Thiswill helpensurethatthe carburetormaintainsits normal
performanceafterthestorage.
.
.
Gasolineis flammable andmaycausefire and evenanexplosionunder
certainconditions.Therefore,donot smoke,makea fire or haveany fire
aroundwhiledrainingoff fuel.
Takeoutthe sparkplug,pourabout15-20ml(.5- .68oz.) of cleanengineoil
intothe cylinder,stepdownonthe kickleverrepetitivelyseveraltimesso as
to havemachineoil distributedall overtheengineandfinally fit thespark
plugbackon.
Washthevehicleclean,wipe it dryand applyan evencoatof wax to the
paintedsurfaceanda coatofanti-rustoil on the chrome-platedsurfaces.
Inflatethe tiresas requiredandputthe vehicleup on woodenblockswiththe
twowheelsclearingthe ground.
Putthe vehiclein a shadyand coolplacefree from humidityand direct
sunlightandcoverit properly(notwith plasticor other paintedmaterials).If
thereisa garage,storeit within.
22
RESUMPTIONOF SERVICEAFTER STORAGE
1. Removethe coveringand removethe woodenblocksusedin storingthe
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 lowspeed inan 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 theuser with referenceto this manualprovidedspecialtools
andauthorizedspare partsare used.Theuser mustalsobe capableof completing
the procedure.
"**" means: This itemcan onlybe carriedout by an authorizedservicecenter in
orderto ensuresafety.
24
Notes:
1. Maintenanceshouldbe conductedmorefrequently when MiniBike isdriven in
dustyareas.
2. WhenMinibike hasexceededthe maximumfigures specifiedinthetable,
maintenanceshouldbestill cycledaccordingto the intervalsof timeor hours
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. Sparkplugwetwith fuel Removeandinspectsparkplug. Dry
(floodedengine) andreinstallspark 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 Checkairfilter
cleanorreplace.
2. Chokelever maybe not Checkchokelever
fully open
2. Badfuel; enginestored
withouttreatingor draining
gasoline,or refueledwith
badgasoline.
3. Fuelfilter clogged,
carburetormalfunction,
ignitionmalfunction,valves
stuck,etc.
Drainfuel tankand carburetor.Refuel
withfresh gasoline.
Takeengineto a qualified mechanic.
Replaceor repairfaulty components
asnecessary.
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EngineSwitch
B1 B1
TransistorMagneto
Spark Plug Ignition Coil
26
BAJAINC.- EMISSIONCONTROLSYSTEMWARRANTY
YOURWARRANTYRIGHTSANDOBLIGATIONS
Theemissioncontrolsystemwarrantyperiodfor this vehiclebeginsonthe date
thevehicleis deliveredto thefirst purchaserotherthanan authorizeddealer,or
thedate it is first usedas a demonstrator,lease,or companyvehicle,whichever
comesfirst and continuesfor 60monthsafterthat date,or 5,000kin,whichever
comesfirst, providedtherehasbeenno abuse,neglector impropermaintenance
of yourvehicle.Whereawarrantableconditionexists,the Distributorwill
repairyour vehicleat nocostto you,includingdiagnosis,partsand labor. If an
emission-relatedpartonyourvehicleisdefective,thepart will be repairedor
replacedby the Distributor.This isyour emissioncontroldefectswarranty.
OWNER'SWARRANTYRESPONSIBILITIES
Asthe vehicleowner,youare responsiblefor the performanceof the required
maintenance.Youshouldmaintaina recordof all maintenanceperformedon
yourvehicleand retainall receiptscoveringmaintenanceonyour vehicle. You
maynot bedenieda warrantyclaimsolelybecauseof yourfailure to ensurethe
performanceof allscheduledmaintenanceor lackof maintenancerecordsor
receipts.Youare responsiblefor presentingyourvehicletoan authorizeddealer
assoonasa problemexists.Thewarrantyrepairsshouldbe completedin a
reasonableamountof time,notto exceed30 days.
Asthe vehicleowner,youshouldbeawarethatyoumay be deniedyourwarranty
coverageifyourvehicleora part hasfailed dueto abuse,neglect,improper
maintenance,or unapprovedmodifications.
WARRANTYCOVERAGE
TheDistributorwarrantsthateach new2009and latervehicle:
• is designed,built,andequippedso as to conformatthe time of initial
retailpurchasewith allapplicableregulationsof the UnitedStatesEnvironmental
ProtectionAgency,andthe CaliforniaAir ResourcesBoard;and
• is free from defectsin materialand workmanshipwhichcausesuch
vehicleto fail to confirmwithapplicableregulationsof the UnitedStates
EnvironmentalProtectionAgencyor the CaliforniaAir ResourcesBoardfor the
periodsspecifiedabove.
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Youremissioncontrolsystemwarrantycoverscomponentswhosefailure would
increasean engine'semission,includingelectroniccontrols,fuel injectionsystem,
carburetor,the ignitionsystem,catalyticconverter,or any othersystemutilizedin
thisvehicleto controlemissionif it is originallyequipped.Alsoincludedmay be
hoses,connectorsandotheremission-relatedassemblies.Replacingor repairing
othercomponents(includingparts,labor,and othercosts)notcoveredbythis
emissioncontrolsystemwarrantyorthe standardwarrantyisthe responsibilityof
theowner.
Coverageof repairsunderthiswarrantyappliesonlywhen repairsare completed
atan authorizeddealeror repairfacility. TheDistributorwill not coverrepairs
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
Thiswarrantydoesnot coverthefollowing:
• Failuresormalfunctionsof the emissioncontrolsystemscausedby
abuse,alteration,accident,misuse,the useof leadedgasoline.
• Replacementof expendablemaintenanceitemsunlesstheyare original
equipmentdefectiveinmaterialor workmanshipundernormaluse,andthefirst
requiredreplacementintervalfor the itemhasnot beenreached. Expendable
maintenanceitemsincludebutnot limitedto sparkplugs,filters, coolant,
lubricants,gaskets,hoses,and belts.
• Replacementsof partsandotherservicesand adjustmentsfor required
maintenance.
• Anyvehicleequippedwith an odometeror hourmeterwherethe reading
is alteredso thatactualmileagecannotbereadilydetermined.
• Repairsor replacementsasa resultof:
o Accident
o Misuse
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o Useofreplacementpartsoraccessoriesnotconformingtotheoriginal
specificationswhichadverselyaffectperformance
• Physicaldamage,corrosion,ordefectscausedbyfire, explosionsor
similarcausesbeyondthe controlof the Distributor.
• Failuresnotcausedby a defectin materialor workmanship.
Useof the vehicleinany typeof competitiveracingor relatedeventsimmedi-
atelyand completelyvoidsthisand allotherwarranties.
LIMITEDLIABILITY
Theliabilityof the Distributorunderthis EmissionControlSystemWarranty
is limitedsolelyto the remedyingof defectsinmaterialworkmanshipby an
authorizeddealerat its placeof businessduringcustomarybusinesshours.
Thiswarrantydoesnot coverinconvenienceor lossof useof thevehicleor
transportationof thevehicleto/fromtheauthorizeddealer.The Distributoris
notliableto any personfor incidental,consequentialor specialdamagesof
anydescription,whetherarisingout of expressor impliedwarrantyor any
othercontract,negligenceor othertort orotherwise.
Noexpressemissioncontrolsystemwarrantyis givenby the Distributor
exceptasspecificallyset forth herein. Anyemissioncontrolsystemwar-
rantyimpliedby law,includinganywarrantyof merchantabilityor fitness for a
particularpurposeislimitedto the expressemissioncontrolsystemwar-
rantytermsstatedin thiswarranty. Theforegoing statementsof warrantyare
exclusiveand in lieuof all otherremedies.All expresswarrantiesnot stated
inthis warrantyaredisclaimed.Somestatesdo notallow limitationson how
longan impliedwarrantylasts,so theabovelimitationsmay notapply if it is
inconsistentwiththe controllingstate law.
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)
