Baja motorsports DR49 User manual

DR49 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 provincial / municipal 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
030909
OWNER’S MANUAL

II
Congratulations on your purchase of the BAJA INC. DR49 Dirt Bike.
Your bike is warranted to be free of manufacturing defects in 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. DR49 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 the 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
!

1
Table of Contents
SAFE OPERATION..............................................................................................3
SAFETY GEAR....................................................................................................4
LOCATION OF WARNING LABELS................................................................... 5
MAIN DATA..........................................................................................................6
PARTS & SUBASSEMBLIES ..............................................................................7
OPERATION ........................................................................................................9
FUEL VALVE................................................................................................9
ENGINE STARTING.....................................................................................10
BREAKING IN THE ENGINE.......................................................................11
SWITCHES ON THE RIGHT HANDLEBAR ................................................12
GEAR SHIFTING .........................................................................................13
CHECK-UPS, ADJUSTMENT AND MAINTENANCE..........................................14
CHANGING THE OIL...................................................................................15
CHECK-UP OF SPARK PLUG ....................................................................16
VALVE INSPECTION....................................................................................17
CHECKING & CLEANING THE AIR FILTER...............................................18
ADJUSTING THE THROTTLE CABLE .......................................................19
ADJUSTING THE CARBURETOR ..............................................................19
ADJUSTMENT OF FRONT BRAKE............................................................20
ADJUSTMENT OF REAR BRAKE .............................................................20
ADJUSTMENT OF CHAIN...........................................................................21
GREASING PROCEDURES TO THE DRIVING CHAIN..............................21
EXHAUST ....................................................................................................22
TROUBLE SHOOTING ................................................................................23
VEHICLE WASHING....................................................................................25
INSTRUCTIONS FOR STORAGE ...............................................................26
RESUMPTION OF SERVICE AFTER STORAGE .......................................27
TABLE AND TORQUE OF FASTENERS ....................................................27
RESUMPTION OF SERVICE.......................................................................28
INSPECTION AND MAINTENANCE ...........................................................29
SERIAL NUMBER LOCATION ....................................................................30
ELECTRICAL DIAGRAM.............................................................................31
EMISSION CONTROL SYSTEM WARRANTY............................................32

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
1
2
!
WARNING
No one under the age of 16 should operate
this vehicle without adult supervision.
!
WARNING
• Study the owner’s manual carefully.
• Always wear a helemt, eye protection and protective gear.
• Never operate this vehicle while under the inuence of
alcohol, drugs or medication of any kind.

7
DESCRIPTION DATA DESCRIPTION DATA
Overall length 1420mm
(55.91 inches)
Max torque 3.2N.m/6500 r/min
Overall width 450mm
(17.72 inches)
Idle speed 1500r/min±150r/min
Overall height 740mm
(29.13 inches)
Displacement of
cylinder
49mL
Wheelbase 1020mm
(10.16 inches)
Spark plug A7RTC
Dry weight 60kg (132 lbs.) Front wheel 2.50-10
Payload 75kg (165 lbs.) Rear wheel 2.50-10
Ground clearance 250mm
(9.84 inches)
Ignition means CDI
Max speed  1st gear 3.273
Transmission 4 gear mesh 2nd gear 1.938
Capacity of fuel
tank
3.3L 3rd gear 1.350
Cylinder
bore x stroke
39mm X 41.4mm 4th gear 1.043
Compression ratio 8.8:1 Transmission ratio
of sprocket
2.929
Max output 2.5KW/8500rpm
(3.3hp)
Primary
transmission ratio
3.722
MAIN DATA

8
PARTS & SUBASSEMBLIES
Throttle twist grip
Front brake lever
Fuel tank cover
On/Off switch

9
LEFT
RIGHT
Seat Cushion
Exhaust Silencer
Kick Lever Rear Brake pedal
Front Wheel
Fuel Valve
Gear Shifting
Pedal Side Stand
Rear Wheel
Carburetor
Choke lever
on Carburetor
Front Shocks
Gas Cap
Oil Cap
Drive Chain
Front Brake Lever

10
OPERATION
FUEL VALVE

The capacity of the fuel tank is 3.3L . Unscrew the gas cap by turning it

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
Fuel Valve ON Fuel Valve OFF
Fuel Valve RESERVE

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

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.
choke lever
CLOSED
OPEN
!
!

12
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 30
miles without increasing and decreasing the throttle.
2. The engine shall be warmed up for 3-5 minutes prior to operation so all

 
miles of operation and not over 40 MPH maximum during the remaining
300 miles of the “Break-In” period.

13
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.
ON button
OFF button

14
GEAR SHIFTING
Reduce throttle before shifting. Never increase the throttle while shifting
gears.
Depress the gear shift pedal to place the gear in 1st, lift up the lever to shift to
2nd, 3rd, 4th.
Do not place your foot on the gear-shifting pedal while operating the dirt bike
to avoid damaging the clutch caused by sudden gear shifting accidentally.
Shifting sequence
(N) Neutral
(1) 1st gear
(2) 2nd gear
(3) 3rd gear
(4) 4th gear
Points for Attention during Drive
1. Avoid unnecessary idling of the engine at a high speeds. Doing so will
damage the engine components seriously.
 
power to climb hills or continue forward.
3. Do not use the front brake only or coast using the neutral gear especially
when descending or driving at a high speed.
4. Decrease the throttle when braking.
Shifting forward
Shifting backward
N 1 2 3 4

15
CHECK-UPS, ADJUSTMENT AND MAINTENANCE
Checking the Oil
Check the engine oil each time prior to operating the dirt bike.

dipstick.
 
it clean and then insert the dipstick into the crankcase again to check the

the crankcase.
 

 
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

will cause harm to the engine.
MACHINE
OIL
TEMP.
°C
°F
20W-50
5W-40 15W-50
10W-40 10W-50
10W-30

and dip stick
-30 -20 -10 0 10 20 30 40
-22 -4 -14 32 50 68 86 104
!

16
CHANGING THE OIL
1. Remove the screw plug 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 and replace the screw plug tightly.
4. 

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.
The spark plug of the designated type
should be used. The applicable type of
spark plug: A7RTC
0.6~0.8mm
Screw plug

17
VALVE INSPECTION
REFER TO MAINTENANCE SCHEDULE IN THIS OWNER’S MANUAL FOR
VALVE ADJUSTMENT INSPECTION INTERVALS.
Valve clearance should be:
Intake: 0.002 inch (0.05 mm)
Exhaust: 0.003 inch (0.076 mm)
The engine will make excess noise if the gap is too large in air valve. If
gap is too small valve operation will be hindered which could result in
valve malfunction and failure. Therefore, air valve gap must be checked
periodically.

adjusting the valve clearance are given in the service manual. If assistance is
