Baja motorsports DR50 User manual

Follow all instructions when assembling this dirt bike. If any parts are damaged or missing, those parts must be replaced
before proceeding.
WARNING: To reduce the risk of injury, you must read and understand this assembly guide before attempting to
assemble this product.
ASSEMBLY GUIDE
GUÍA DE ARMADO
DIRT BIKE
MOTOCROSS
DR50
SAVE THIS GUIDE FOR FUTURE REFERENCE
Siga todas las instrucciones al armar este motocross. Si falta alguna pieza o hay piezas dañadas, dichas piezas deben
reemplazarse antes de proceder a utilizar el producto.
ADVERTENCIA: Para reducir el riesgo de lesiones, debe leer y comprender esta guía de armado antes de
intentar armar este producto.
GUARDE ESTE MANUAL PARA FUTURAS CONSULTAS

2 — English
©2010 Baja, Inc. All Rights Reserved.
Rules for Safe Assembly .................................................................................................................................................. 2
Symbols............................................................................................................................................................................ 3
Tools Needed.................................................................................................................................................................... 3
Unpacking......................................................................................................................................................................... 4
Loose Parts List................................................................................................................................................................ 5
Assembly .......................................................................................................................................................................6-9
Final Preparation ............................................................................................................................................................ 10
TABLE OF CONTENTS
WARNING:
Strictly adhere to all torque wrench tightening specica-
tions. Failure to do so could cause serious personal injury.
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 im-
provements or other changes, there may be some discrep-
ancies 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.
Any person attempting to assemble this product must
have proper training and experience. Read this manual
carefully and follow all assembly procedures as described.
In addition to completing all the items in this manual,
mechanic must read and complete the Dealer portion of
the Pre-Delivery Inspection Checklist.
All assembly must be completed with the unit on a level
surface.
RULES FOR SAFE ASSEMBLY

3 — English ©2010 Baja, Inc. All Rights Reserved.
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER: Indicates an imminently hazardous situation, which, if not avoided, will result in
death or serious injury.
WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in
minor or moderate injury.
CAUTION: (Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SYMBOLS
TOOLS NEEDED
The following tools (not included or drawn to scale) are needed for assembly:
TORQUE WRENCH
20
30
40
0
50
Some of the following symbols may be used on this product. Please study them and learn their meaning for safe opera-
tion of this product.
SYMBOL NAME EXPLANATION
Safety Alert Indicates a potential personal injury hazard.
METRIC HAND TOOLS

4 — English
©2010 Baja, Inc. All Rights Reserved.
NOTE: Having two people available will make the assembly
process easier, even if using an overhead hoist.
Cut packing straps and remove cardboard carton from
metal frame.
WARNING:
Do not stand at the front or the rear of the dirt bike while
the straps are being cut. Keep the carton level while lifting
and do not allow it to tip forward or backward. Failure to
follow these instructions could result in serious personal
injury.
Remove manufacturer’s statement of origin, assembly
guide, operator’s manual, and assembly hardware.
Remove all bolts, brackets, and ties that attach the metal
shipping crate to the dirt bike. See gure below.
With a person on each side, carefully lift shipping crate
off the dirt bike and set aside.
NOTE: If a second person is unavailable, use an overhead
hoist to lift and remove the metal frame.
WARNING:
Carefully support the crate at all times during the removal
process. Allowing the crate to drop could cause serious
injury and/or damage the dirt bike.
Remove and set aside all packaging and wrap from unit
and parts. Do not discard the packing material until you
have carefully inspected and satisfactorily operated the
product.
WARNING:
If any parts on the Loose Parts List are already assembled
to your product when you unpack it, verify the part is as-
sembled correctly, is properly tightened, and is torqued
correctly (where applicable) before proceeding to the next
assembly step. Use of a product that may have been im-
properly assembled could result in serious personal injury.
Inspect the product carefully to make sure no breakage
or damage occurred during shipping.
If any parts are damaged or missing, please call
1-888-863-2252 for assistance.
UNPACKING

5 — English ©2010 Baja, Inc. All Rights Reserved.
LOOSE PARTS LIST
Key
No. Description Qty.
1 Front Fender Hardware
Front Fender.................................................... 1
Washer ............................................................ 3
Bolt (M6 x 15 mm) ........................................... 3
Number Plate................................................... 1
2 Handlebar Hardware
Lock Washer.................................................... 2
Flat Washer ..................................................... 2
Nylon Nut (12 mm x 1.5).................................. 2
3 Wheel Hardware
Axle Bolt (M10 x 210 mm) ............................... 1
Spacer ............................................................. 1
Nut (M10 x 1.5)................................................ 1
Key
No. Description Qty.
4 Side Panel Hardware
Side Panel ....................................................... 2
Screw (M5 x 15 mm) ....................................... 6
5 Tool Kit ................................................................. 1
Assembly Guide (Not Shown) .............................. 1
Operator’s Manual (Not Shown)........................... 1
WARNING:
If any parts are damaged or missing do not assemble
this product until the parts are replaced with new original
manufacturer’s parts or their equivalent. Assembly of this
product with damaged, missing, or incorrect parts could
result in serious personal injury.
1. 2. 3.
4. 5.