Baja motorsports DR125 User manual

DR125/DR150 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. D (US)
031109
OWNER’S MANUAL
Max. Weight Limit: 250lbs. (113kg)

II
Congratulations on your purchase of the BAJA INC. DR125/DR150
Dirt Bike.
Your bike is warranted to be free of manufacturing defects in the
material and 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/
DR150 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 with your vehicle, please call Baja Inc.
customer service line toll free at 1-888-863-2252 between the hours of
7am and 5pm Monday through Friday MST (Mountain Standard Time).
MDT (Mountain Daylight Time) during the daylight saving time. 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
!

as 30 minutes before sunset to 30 minutes
after sunrise.
WARNING
!

1
TABLE OF CONTENTS
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 ..............................................................................9
OPERATION ........................................................................................................11
FUEL VALVE................................................................................................11
ENGINE STARTING.....................................................................................12
BREAKING IN THE ENGINE.......................................................................13
SWITCHES ON THE RIGHT HANDLEBAR ................................................14
GEAR SHIFTING .........................................................................................15
CHECK-UPS, ADJUSTMENT AND MAINTENANCE..........................................16
CHECKING THE OIL ...................................................................................16
CHANGING THE OIL, CLEANING OIL FILTER SCREEN..........................17
CHECK-UP OF SPARK PLUG ....................................................................17
VALVE INSPECTION....................................................................................18
CHECKING & CLEANING THE AIR FILTER...............................................19
ADJUSTING THE THROTTLE CABLE .......................................................20
ADJUSTING THE CARBURETOR ..............................................................20
INSPECTION OF FRONT HYDRAULIC BRAKE .......................................21
INSPECTION OF REAR HYDRAULIC BRAKE..........................................21
CLUTCH ADJUSTMENT .............................................................................22
ADJUSTMENT OF CHAIN...........................................................................23
GREASING PROCEDURES TO THE DRIVING CHAIN..............................23
TROUBLE SHOOTING ................................................................................24
VEHICLE WASHING....................................................................................26
INSTRUCTIONS FOR STORAGE ...............................................................27
RESUMPTION OF SERVICE AFTER STORAGE .......................................28
TABLE OF TORQUE OF FASTENERS.......................................................28
RESUMPTION OF SERVICE.......................................................................29
INSPECTION AND MAINTENANCE ...........................................................30
SERIAL NUMBER LOCATION ....................................................................31
ELECTRICAL DIAGRAM.............................................................................32
EMISSION CONTROL SYSTEM WARRANTY............................................33

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.

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 second part will describe WHAT COULD HAPPEN if you ignore
the WARNING or CAUTION.

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.
 
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.
  
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


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.

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

should get a replacement by contacting BAJA INC.
1
2
!
!
WARNING
WARNING
No one under the age of 16 should operate
this vehicle without adult supervision.



alcohol, drugs or medication of any kind.
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  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.) Battery 12V7AH
Lubrication
method
Pressure, splash Fuse 15A
Clutch Manual/wet Brake Front-Disc
Rear- Disc
MAIN DATA DR125

8
DESCRIPTION DATA DESCRIPTION DATA
Overall length 1930mm (76 inches) Cylinder bore X
stroke
69mm X 53mm
Overall width 100mm (43.3 inches) Compression
ratio
9.0:1
Overall height 1199mm (47.2 inches) Max output 8.5KW/9500rpm
(11.4hp)
Wheelbase 1320mm (51.97 inches) Max torque 8.2N.m/7500r/min
Dead weight 100kg (220.5 lbs.) Idle speed 1500 r/min
Payload 113kg (250 lbs.) Displacement of
cylinder
149cc
Ground
clearance
197.8mm (7.08 inches) Spark plug DR8EA (NGK)
Gap .6mm - .8mm
(.024” - .032” )
Max speed  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.) Battery 12V7AH
Lubrication
method
Pressure, splash Fuse 15A
Clutch Manual/wet Brake Front-Disc
Rear- Disc
MAIN DATA DR150

9
PARTS & SUBASSEMBLIES
Throttle twist
grip
Front brake lever
Fuel tank
cover

Clutch Lever
On/Off switch

10
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
DR125/DR150

11
Fuel Valve ON Fuel Valve OFF
Fuel Valve RESERVE
OPERATION
FUEL VALVE

The capacity of the fuel tank is 5.7L (1.5gal) . Unscrew the gas cap by turning

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

OFF: With the handle of the fuel valve at “OFF” position, the fuel supply will

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

12
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

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

13
BREAKING IN THE ENGINE

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

3. The driving speed shall not be over 40 kmph (25 MPH) maximum during the

during the remaining 500 km (300 miles) of the “Break-In” period.

14
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.

15
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.

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

16
!
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

hole.

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

it will cause harm to the engine.
Oil sight gauge

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

17
CHANGING THE OIL, CLEANING OIL FILTER SCREEN

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.

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

Spring