Baja motorsports DR125 User manual

DR125 Dirt Bike
Read this manual carefully. It contains important safety information.
Always wear a helmet; It could save your Life!
Please obtain, review, and follow the municipal, provincial and government
acts and regulations pertaining to owning and operating an off-road vehicle.
No one under the age of 16 should operate this Dirtbike without adult
supervision. Parents should consider child’s age, size, maturity and ability
before allowing to ride.
Rev. C
052208
OWNER’S MANUAL
Max. Weight Limit: 250lbs. (113kg)

II
Congratulations on your purchase of the BAJA INC. DR125 Dirt
Bike.
Your bike is warranted to be free of manufacturing defects in the
material of workmanship for a period of 90 days from the date of
purchase. During the warranty period BAJA, INC. will at its option,
repair, provide replacement parts or replace your BAJA INC. DR125
Dirt bike at no charge. This warranty does not cover normal wear
items or damage caused by neglect or misuse of the product.
Engine Warranty – 90 days
Frame Warranty – 90 days
Warranty is void if:
Frame is bent or broken due to abuse
Wheels are bent or broken
Fender bent or broken due to abuse
Any sign of impact, accident, jumping, spin-outs or roll over.
BAJA, INC. is not liable for any damage claim or liability claim
person or otherwise resulting from the operation of this product in
any way.
Should you experience a problem or need to return your BAJA INC. DR125
Dirt Bike for repair, please call the BAJA INC. customer service department
TOLL FREE at 1-866-250-7155 between the hours of 7am and 5pm Monday
thru Friday PST. During DST hours change to MT. You will be instructed how
to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.

III
This manual should be considered as a
permanent part of the vehicle and should
remain with the vehicle when resold or
otherwise transferred to a new user or
operator. The manual contains important
safety information and instructions which
should be read carefully before operating the
vehicle.
WARNING
!
The engine exhaust from this product contains
chemicals known to the State of California
to cause cancer, birth defects or other
reproductive harm.
CALIFORNIA PROPOSITION 65
WARNING
!
Never drive vehicle at night. Night is dened
as 30 minutes before sunset to 30 minutes
after sunrise.
WARNING
!

1
NOTICE TO USER’S............................................................................................2
SAFE OPERATION..............................................................................................3
PRE-RIDE CHECKLIST.......................................................................................4
SAFETY GEAR....................................................................................................5
LOCATION OF WARNING LABELS................................................................... 6
MAIN DATA..........................................................................................................7
PARTS & SUBASSEMBLIES ..............................................................................8
OPERATION ........................................................................................................10
FUEL VALVE................................................................................................10
ENGINE STARTING.....................................................................................11
BREAKING IN THE ENGINE.......................................................................12
SWITCHES ON THE RIGHT HANDLEBAR ................................................13
GEAR SHIFTING .........................................................................................14
CHECK-UPS, ADJUSTMENT AND MAINTENANCE..........................................15
CHECKING THE OIL ...................................................................................15
CHANGING THE OIL, CLEANING OIL FILTER SCREEN..........................16
CHECK-UP OF SPARK PLUG ....................................................................16
CHECKING & CLEANING THE AIR FILTER...............................................17
ADJUSTING THE THROTTLE CABLE .......................................................18
ADJUSTING THE CARBURETOR ..............................................................18
INSPECTION OF FRONT HYDRAULIC BRAKE .......................................19
INSPECTION OF REAR HYDRAULIC BRAKE..........................................19
CLUTCH ADJUSTMENT .............................................................................20
ADJUSTMENT OF CHAIN...........................................................................21
GREASING PROCEDURES TO THE DRIVING CHAIN..............................21
TROUBLE SHOOTING ................................................................................22
VEHICLE WASHING....................................................................................24
INSTRUCTIONS FOR STORAGE ...............................................................25
RESUMPTION OF SERVICE AFTER STORAGE .......................................26
TABLE OF TORQUE OF FASTENERS.......................................................26
RESUMPTION OF SERVICE.......................................................................27
INSPECTION AND MAINTENANCE ...........................................................28
SERIAL NUMBER LOCATION ....................................................................29
ELECTRICAL DIAGRAM.............................................................................30
EMISSION CONTROL SYSTEM WARRANTY............................................31
TABLE OF CONTENTS

2
Please read this manual and follow all instructions carefully. To emphasize
special information, the symbol and the words WARNING or CAUTION have
some special meanings. Pay great attention to the messages.
NOTE: Indicating special information which is to make maintenance easier or
instructions clearer.
WARNING and CAUTION are arranged like this:
This user’s manual contains important safety and maintenance information.
Read it carefully before riding. Failing to follow the warnings contained in this
manual could result in INJURY or DEATH.
It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
All information, illustrations, photographs and specications contained in
this manual are based on the latest product information available at the time
of publication. Due to improvements or other changes, there will be some
discrepancies in this manual. We reserve the right to make product changes
at any time, without notice and without incurring any obligation to make the
same or similar changes to the vehicle previously built or sold.
WARNING-or-CAUTION
The rst part will identify a POTENTIAL HAZARD.
The second part will describe WHAT COULD HAPPEN if you ignore
the WARNING or CAUTION.
The third part will describe HOW TO AVOID THE HAZARD.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
WARNING
Indicates a potential hazard that could result in death or injury.

3
SAFE OPERATION
Rules for Safe Operation
A pre-operation check must be conducted before starting the engine.
This check will insure safety, prevent mishaps, and prevent damage to
components.
It is strongly suggested that all operators take a certied motorcycle
rider’s course prior to operating the vehicle.
Full attention is required during driving; paying close attention to the
following points to avoid any injury to you by other motorized vehicles:
· Do not drive too close to other vehicles.
· Never carry a passenger. This dirt bike is for one operator only.
· Never operate this dirt bike at night. Night is dened as the period of
time 30 minutes before sunset to 30 minutes after sunrise.
· Driving at high speeds is the cause of many accidents; do not drive
at a speed that the actual situation does not permit.
· Always avoid operating this dirt bike on paved surfaces, including;
sidewalks, paths, parking lots, driveways, streets, roads, and highways.
Never operated this or any Off-Road Vehicle on a public street, road or
highway where motor vehicles are in operation.

4
Pre-Ride Checklist
Before Starting the Engine/Motor
1. Engine oil level
a) Check for leaks
b) Tighten filler cap securely.
c) Add oil if required.
2. Fuel level
a) Add fuel as necessary.
b) Do not overfill (no fuel in the filler neck).
c) Do not mix oil with gas.
d) Replace cap tightly.
e) Do not refuel a hot engine. Allow engine to cool before adding
fuel.
3. Warning decals
a) Make sure all warning decals are legible and securely attached.
b) Replace as necessary.
4. Tires
a) Ensure that both tires are in safe riding condition.
b) Both tires must be inflated to the pressure indicated on the tire
sidewalls.
5. Drive chain
a) Check condition and tension.
b) Lubricate and adjust tension as necessary.
6. Throttle
a) Check for smooth operation. Make sure the throttle “snaps” back
to idle.
b) Check for frayed cable or damaged cable housing. Replace
damaged cable.
c) Check for mud, debris and ice in the throttle cable/mechanism.
Clean out any contamination.

5
SAFETY GEAR
A DOT approved motorcycle helmet is the most important part of you safety
gear. A DOT approved motorcycle helmet can help prevent a serious head
injury. Choose a helmet that ts snugly. Motorcycle dealers can help in
selecting a good quality helmet which ts properly.
You should wear eye protection when you ride. If a rock or a branch hits your
eyes, you could be severely injured. Wear goggles or a face shield.
Wear proper clothing when you ride. The proper clothes can protect you from
injury. Wear a good pair of gloves, strong boots that are over the ankle, long
pants, and a long sleeve shirt.
WARNING
Operating this Dirt bike without wearing an approved DOT
motorcycle helmet, eye protection, and protective clothing could be
hazardous.
Operating without an approved DOT motorcycle helmet or eye
protection increases your chances of a severe head injury or death
in an accident. Operating without protective clothing also increases
your chances of severe injury in an accident.
Always wear an approved DOT motorcycle helmet which ts
properly. Always wear eye protection (goggles or face shield). You
should also wear gloves, boots, long sleeve shirt or jacket, and long
pants.

6
LOCATION OF WARNING LABELS
Read and follow all of the warnings labels on your Dirtbike. Make sure you
understand all the labels. Keep the labels on the Dirtbike. Do not remove
them for any reason. If a label comes off or becomes difcult to read, you
should get a replacement by contacting BAJA INC.
1
2
!
!
WARNING/AVERTISSMENT
WARNING/AVERTISSMENT
No one under the age of 16 should operate
this vehicle without adult supervision.
Les personnes de moine de 16 ans ne
doivent pas utiliser ce RUM sans être
supervisées par un adulte.
• Study the owner’s manual carefully.
• Always wear a helmet, eye protection and protective gear.
• Never operate this vehicle while under the influence of
alcohol, drugs or medication of any kind.
• Etudiez soigneusement le manuel de l’utilisateur.
• Portez toujours un casque, une protection pour les
yeux et des vêtements de protection.
• Ne conduisez jamais sous l’influence de l’alcool, de
la drogue ou après avoir consommé des médicaments.
12

7
DESCRIPTION DATA DESCRIPTION DATA
Overall length 1930mm (76 inches) Cylinder bore X
stroke
56.5mm X 49.5mm
Overall width 100mm (43.3 inches) Compression
ratio
8.9:1
Overall height 1199mm (47.2 inches) Max output 7.5KW/8500rpm
(11.4hp)
Wheelbase 1320mm (51.97 inches) Max torque 8.0KW/6500r/min
Dead weight 100kg (220.5 lbs.) Idle speed 1500 r/min
Payload 113kg (250 lbs.) Displacement of
cylinder
125cc
Ground
clearance
197.8mm (7.08 inches) Spark plug DR8EA (NGK)
Gap .6mm - .8mm
(.024” - .032” )
Max speed ≥72.42km/h (45 mph) Front wheel 70/100-19
Transmission 5 gear mesh Rear wheel 19/100-16
Capacity of fuel
tank
5.7L (1.5 gal.) Ignition means CDI
Oil capacity 1L (1 qt.)
Lubrication
method
Pressure, splash Fuse 15A
Clutch Manual/wet Brake Front-Disc
Rear- Disc
MAIN DATA

8
PARTS & SUBASSEMBLIES
Throttle twist
grip
Front brake lever
Fuel tank
cover
Brake uid reservoir
Clutch Lever
On/Off switch

9
Seat Cushion
Exhaust Silencer
Kick start lever Side Stand
Rear Fork
Rear Wheel
Carburetor
Rear brake
caliper
Front Shocks
Front brake
caliper
Gas Cap
Oil Cap
Front Wheel
Reectors
Reectors
DR125

10
Fuel Valve ON Fuel Valve OFF
Fuel Valve RESERVE
OPERATION
FUEL VALVE
Fuel lling
The capacity of the fuel tank is 5.7L (1.5gal) . Unscrew the gas cap by turning
it counter clockwise and carefully ll the tank with unleaded gasoline through
the opening. DO NOT MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE
ENGINE. Replace the gas cap by carefully aligning the threads on the cap
and the tank and turning the cap clock wise. Wipe any spilled fuel from the
dirt bike using a cloth and dispose of the cloth properly. DO NOT SMOKE
OR REFUEL THE VEHICLE NEAR OPEN FLAMES OR NEAR HEATING UNITS.
ONLY REFUEL THE VEHICLE IN OPEN AREAS TO REDUCE THE LIKELIHOOD
OF THE BUILD UP OF GASOLINE FUMES.
Operation of the fuel valve (the valve under the fuel tank)
ON: With the handle of the fuel valve at “ON” position, the fuel supply will
ow to the carburetor.
OFF: With the handle of the fuel valve at “OFF” position, the fuel supply will
not ow to the carburetor.
RES: If fuel level in the fuel tank becomes too low for engine to stay running
while fuel valve is at “ON” position, turn fuel valve to “RESERVE”. Turning
fuel valve to “RESERVE” will allow engine to begin using reserve fuel supply.
You will need to re-fuel as soon as possible. There is approximately 1L of fuel
left in tank when fuel valve is placed at “RESERVE”. Once re-fueled, turn fuel
valve back to the “ON “ Position

11
ENGINE STARTING
1. Set the key of the ignition switch to “ ” position.
2. Put the dirt bike in the neutral gear.
3. Ensure that there is fuel in the tank.
4. Set the fuel valve handle to “ON” or “RES” position.
To start a cold engine:
1. Pull up the choke lever of the carburetor
(to close the choke).
2. Start the engine with electric start or kick lever
3. Slightly turn the throttle twist grip to increase the speed of the engine so
as to warm up the engine.
4. Turn the carburetor choke bar downward to fully open the choke when
the engine is sufciently warmed up.
Procedures for stopping the engine:
1. Release the throttle twist grip to slow down the engine.
2. Shift to the neutral position.
3. Set the ignition switch key to “ ” position.
4. Set the fuel valve handle to “OFF” position.
CAUTION
Unnecessarily increasing RPM’s to a high level while the dirt
bike is in neutral is harmful to the engine.
CAUTION
Verify oil level prior to starting (see page 15)
Starting the engine with low or no oil will damage the engine.
WARNING
Never start the engine in a closed place as the exhausted
gas from the vehicle contains toxic carbon monoxide.
Closed
Open choke lever

12
BREAKING IN THE ENGINE
The rst 600 Miles of operation should be considered the “Break-in” period
and special attention shall be paid to the following points:
1. Take special care not to increase the RPM’s of the engine while climbing
steep slopes. Never drive your dirt bike continuously for more than 50km (30
miles) without increasing and decreasing the throttle.
2. The engine shall be warmed up for 3-5 minutes prior to operation so all
components are lubricated sufciently.
3. The driving speed shall not be over 40 kmph (25 MPH) maximum during the
rst 500 km (300 miles) of operation and not over 65 kmph (40 MPH) maximum
during the remaining 500 km (300 miles) of the “Break-In” period.

13
ON button
OFF button
SWITCHES ON RIGHT HANDLEBAR
Ignition switch
The ignition switch is Located on the right handlebar.
When the switch is turned to “ ” (off) position, the engine will not start. If
the engine is running and the Off button is pushed the engine will turn off.
When the switch is turned to “ ” (on) position, the engine can start by using
the kick start lever.

14
GEAR SHIFTING
Reduce throttle before shifting. Never increase the throttle while shifting
gears.
Pull in the clutch lever, located on the
left hand grip.
Depress the Shift lever to place the gear in 1st, lift up the lever to shift to 2nd,
3rd, 4th and 5th.
Do not place your foot on the gear-shifting pedal while operating the dirt bike
to avoid clutch damage caused by accidental gear shifting.
Shifting sequence
(1) 1st gear
(N) Neutral
(2) 2nd gear
(3) 3rd gear
(4) 4th gear
(5) 5th gear
Points for Attention during Drive
1. 1. To warm the engine let engine idle. Do not rev the engine to prevent
damage to the engine components.
2. The clutch will wear out quickly if the dirt bike is operated with the clutch in
a semi-engaged position.
3. Shift to the low speed gears when you feel that there is insufcient power
to climb hills or continue forward.
4. Do not use the front brake only or coast using the neutral gear especially
when descending or driving at a high speed.
5. Decrease the throttle when braking.
Shifting forward
Shifting backward
1 N 2 3 4 5
Clutch lever

15
CHECK-UPS, ADJUSTMENT AND MAINTENANCE
Checking the Oil
Check the engine oil each time prior to operating the dirt bike.
The oil level should be between the upper and lower lines of the oil sight
gauge located on the right cover of the crankcase. The level can also be
checked on the dip stick.
1. Set the motorcycle on level ground, look at the sight gauge for current oil
level. Remove the oil gage plug, wipe the oil gage rod clean and then
insert the gage plug into the crankcase again to check the oil level. There
is no need to completely install the oil gage plug in the crankcase ll
hole.
2. Add lubricating oil up to the upper line when needed, but do not overll.
3. Finally screw on the oil gage plug tightly.
Lubricating Oil Recommended
The lubricating oil is an important factor affecting the performance and
service life of the engine. Please refer to the chart for the correct grade of
engine oil based on the environmental conditions in your area. Do not use
any other type of oil other than what is recommended in the chart. DO NOT
MIX OIL WITH THE GASOLINE.
Lubricating oils of different
viscosity shall be employed
in different regions and at
different temperatures.
CAUTION
Never start the engine when there is
insufcient lubricating oil. Otherwise,
it will cause harm to the engine.
Oil sight gauge
Oil ll cap
and dip stick
MACHINE
OIL
TEMP.
°C
°F
20W-50
5W-40 15W-50
10W-40 10W-50
10W-30
-30 -20 -10 0 10 20 30 40
-22 -4 -14 32 50 68 86 104

16
CHANGING THE OIL, CLEANING OIL FILTER SCREEN
1. Remove the oil drain plug, spring and oil lter screen located at the bottom
of the engine and let the oil drain into an approved collection container.
DO NOT PERFORM THIS PROCEDURE WHILE THE ENGINE IS HOT.
SERIOUS BURNS COULD RESULT FROM CONTACT WITH HOT OIL.
2. Dispose of the used oil properly. For proper disposal procedures, contact
your local oil recycling center
3. Clean oil screen and spring with solvent
4. Clean and replace the oil drain plug making sure it is secure.
5. Rell the engine with the proper amount of oil and recheck the amount of
oil in the engine by using the oil gauge plug and/or sight gauge.
CHECK-UP OF SPARK PLUG
1. Remove the cap of spark plug and screw off
the spark plug using the plug wrench.
2. Clean the spark plug all around or replace it
if it is corroded or there is too much deposit
on it.
3. Regulate the gap of the spark plug to 0.6-
0.8mm. (.024 inches - .032 inches)
The spark plug of the designated type
should be used. The applicable type of
spark plug: D8EA (NGK)
0.6~0.8mm
(.024 inches -
.032 inches)
Oil drain plug
Oil lter screen
Spring

17
CHECKING & CLEANING THE AIR FILTER
Air lter is located under left side plastic cowling. Cowling will need to be
removed.
Take the air lter out and check to see if it is dirty or torn.
Remove foam element and wash with water and allow it to dry per instructions
below.
Apply a few drops of machine oil. Squeeze it with a dry cloth to remove
excess oil.
Recommended oil:
SAE 15W-40
CAUTION
The air lter element must be intact or the engine will suck in dust and
dirt, resulting in a shorter service life of the engine.
Water should be prevented from entering into the lter when washing
the vehicle.
The lter element shall be cleaned gently without twisting to prevent
it from cracking. Never wash it with gasoline or any acid, alkaline or
organic volatile oil to avoid its aging, which will result in reducing the
effect of the air lter oil to catch particles before they enter the engine.
Replace the lter element with a new one if it is broken or cracked.
Removal of foam
lter element
Removal of cover
Squeeze out
excess water
Wash foam
element with
water
Air Filter cover
Air lter
Plastic
Cowling