Baja motorsports MB165 User manual

MinimumAge Requirement:16
Rev.F (US)
012209
Alwayswearahelmet; It couldsaveyour Life!
Donot removethis operator's manualfrom this vehicle.
Pleaseobtain,review,and follow provincial/municipal governmentacts and
regulations pertainingto owningand operatingan off-roadvehicle.

8
CongratulationsonyourpurchaseoftheBAJAINC.MiniBike.
YourMinibikeiswarrantedtobefreeof manufacturingdefectsin
materialandworkmanshipfor a periodof90daysfrom thedateof
purchase.DuringthewarrantyperiodBAJA,INC.willat itsoption,
repair,providereplacementpartsor replaceyourBAJAINC.MiniBike
atnocharge. Thiswarrantydoesnotcovernormalwearitemsor
damagecausedbyneglector misuseoftheproduct.
EngineWarranty-90days
FrameWarranty-90days
Warrantyisvoidif:
Frameisbentor brokenduetoabuse
Wheelsarebentor broken
Fenderbentor brokenduetoabuse
Anysignofimpact,accident,jumping,spin-outsor rollover.
BAJA,INC.is notliablefor anydamageclaimor liabilityclaimperson
orotherwiseresultingfrom theoperationofthisproductin anyway.
Shouldyouexperiencea problemwithyourvehicle,pleasecontactBajaInc.
customerservicelinetollfree at 1-888-863-2252betweenthehoursof7amand
5proMondaythroughFridayMST(MountainStandardTime).MDT(Mountain
DaylightTime)duringthedaylightsavingtime.Youwillbeinstructedhowto
proceed.
ACOPYOFTHESALESRECEIPTISREQUIRED.

Thismanualshouldbeconsideredas a permanent
partof thevehicleand shouldremainwith the
vehiclewhen resoldor otherwisetransferredto
anew useror operator. The manualcontains
importantsafety informationand instructions
whichshouldbe readcarefullybeforeoperating
thevehicle.
The engineexhaustfrom this productcontains
chemicalsknownto theStateof Californiato cause
cancer,birthdefectsor otherreproductiveharm.
CALIFORNIAPROPOSITION65
iii

TableofContents
SAFEOPERATION..............................................................................................3
SAFETYGEAR....................................................................................................4
MODIFICATIONOFVEHICLE.............................................................................4
MAINDATA..........................................................................................................5
PARTS&SUBASSEMBLIES..............................................................................6
OPERATION........................................................................................................8
FUELVALVE................................................................................................8
ENGINESTARTINGANDSTOPPING.........................................................9
SWITCHESONTHERIGHTHANDLEBAR................................................10
CHECK-UPS,ADJUSTMENTANDMAINTENANCE..........................................11
CHANGINGTHEOIL...................................................................................12
CHECK-UPOFSPARKPLUG....................................................................12
CHECKING&CLEANINGTHEAIRFILTER...............................................13
ADJUSTINGTHETHROTTLECABLE.......................................................14
ADJUSTINGTHECARBURETOR..............................................................14
ADJUSTMENTOFREARBRAKE..............................................................15
ADJUSTMENTOFCHAIN...........................................................................16
GREASINGPROCEDURESTOTHEDRIVINGCHAIN..............................16
VEHICLEWASHING....................................................................................17
INSTRUCTIONSFORSTORAGE...............................................................18
RESUMPTIONOFSERVICEAFTERSTORAGE.......................................19
TABLEANDTORQUEOFFASTENERS....................................................19
MAINTENANCEROUTINEDIAGRAM........................................................20
TROUBLESHOOTING................................................................................21
EMISSIONCONTROLSYSTEMWARRANTY............................................22

Pleasereadthismanualandfollow all instructionscarefully.Toemphasizethe
specialinformation,thesymbol-&andthewordsWARNINGorCAUTIONhave
somespecialmeanings.Paygreatattentiontothemessages.
Indicatesa potentialhazardthatcouldresultindeathor injury.
CAUTION
Indicatesa potentialhazardthatcouldresultinvehicledamage.
NOTE:Indicatingspecialinformationwhichistomakemaintenanceeasieror
instructionsclearer.
WARNINGandCAUTIONarearrangedlikethis:
Thefirst partwillidentifya POTENTIALHAZARD.
ThesecondpartwilldescribeWHATCOULDHAPPENifyou ignore
theWARNINGor CAUTION.
ThethirdpartwilldescribeHOWTOAVOIDTHEHAZARD.
Thisuser'smanualcontainsimportantsafetyandmaintenanceinformation.Read
itcarefullybeforeriding. Failingtofollow thewarningscontainedinthismanual
couldresultinINJURYor DEATH.
Itis importantthatthis manualremainwiththevehiclewhenyoutransferitto
anotheruserorowner.
All information,illustrations,photographsandspecificationscontainedin
thismanualarebasedon thelatestproductinformationavailableatthetime
ofpublication.Duetoimprovementsorotherchanges,therewillbesome
discrepanciesinthismanual. Wereservetherightto makeproductchangesat
anytime,withoutnoticeandwithoutincurringanyobligationto makethesameor
similarchangestothevehiclepreviouslybuiltorsold.

SAFE OPERATION
Rulesfor SafeOperation
Apre-operationcheckmustbeconducted,beforestartingtheengine,insure
safety,preventmishaps,anddamagetocomponents.
Itisstronglysuggestedthatall operatorstakea certifiedmotorcyclerider's
coursepriortooperatingthevehicle.
Fullattentionisrequiredduringdriving;payingcloseattentiontothe
following pointstoavoidanyinjurytoyoubyothermotorizedvehicles:
Donotdrivetooclosetoothervehicles.
Nevercarrya passenger.Thisminibikeisfor oneoperatoronly
Neveroperatethisminibikeat night. Nightisdefinedastheperiodoftime30
minutesbeforesunsetto30minutesaftersunrise.
Drivingat highspeedsisthecauseof manyaccidents;donotdriveat aspeed
thattheactualsituationdoesnotpermit.
Thisuser'smanualcontainsimportantsafetyand maintenanceinformation.
Readitcarefullybeforeriding. Failingtofollow thewarningscontainedinthis
manualcouldresultinINJURYor DEATH.
Itisimportantthatthis manualremainwiththevehiclewhenyoutransferitto
anotheruserorowner.
Allinformation,illustrations,photographsandspecificationscontainedin
thismanualarebasedon thelatestproductinformationavailableatthetime
ofpublication.Duetoimprovementsor otherchanges,therewillbesome
discrepanciesinthis manual.Wereservetherighttomakeproductchanges
atanytime,withoutnoticeandwithoutincurringanyobligationtomakethe
sameor similarchangestothevehiclepreviouslybuiltor sold
Alwaysavoidoperatingthisminibikeonpavedsurfaces,including;
sidewalks,paths,parkinglots,driveways,streets,roads,andhighways.
Neveroperatedthisor anyOff-RoadVehicleon a publicstreet,roador
highwaywheremotorvehiclesareinoperation.

SAFETYGEAR
Neveroperatethisminibikewithoutwearinga DOTapprovedmotorcycle
helmetwhichfits properly.Operatorsshouldalsoweareyeprotection
(gogglesor faceshield),gloves,boots,long-sleevedshirtorjacket,and long
pants.
2. Looseclothesarenotsuitablefor motorcycledrivingor ridingastheymay
getcaughton footrest orwheel,resultingindanger.
MODIFICATIONOFTHEVEHICLE
CAUTION
Neverperform any unauthorizedmodifications to this vehicle. Only use
original replacementpartwhich canbe obtainedthrough BAJAINC.888-
863-2252.

MAINDATA
Overalllength
Overallwidth
Overallheight
Wheelbase
Deadweight
Payload
Frontwheel
Rearwheel
BrakeType
Capacityof
gasolinetank
Capacityofoil
tank
Drive
1680mm
(66.14inches)
800.1ram(31.5
inches)
979.9mm
(38.58inches)
1162mm(45.75
inches)
64.46kg
(142.11bs.)
91kg(200Ibs)
19X7-8
10psi
19X7-8
10psi
Drum
4.2L(.95gal.)
.5L(.53qt.)
Centrifugal
clutch
Cylinderborex
stroke
PTOshaftrotation
Output,max
Torque,max
Idlingspeed
Displacementof
cylinder
Sparkplug
Sparkpluggap
Gapofair valveIN
Gapofair valveEX
Groundclearance
Ignitionmeans
6.8cmX 15.41cm
(2.68"X 2.13")
Counterclockwise
6.5hpat 3600rpm
9.76ft-lbs, at2500rpm
1400+200
-150
197cc
MEIYA-F7RTC,NGK-
BPR6ES,Champion
- RN9YC
0.7ram-0.79ram
(.028"-.031")
0.15+-.02ram(cold)
0.20+-.02ram(cold)
139mm (5.5")
Magneto

PARTS& SUBASSEMBLIES
Rearbrakelever
J
Throttletwist
grip

Headlight
FrontShock
Absorber
Handbrake
FrontWheel
Footpegs ClutchcoverDriveChain SideStand
AirFilter
BrakeDrum
Decorativetank
SeatCushion
VehicleIdentification
EPASticker
GasTank
PullStartCord

OPERATION
FUELVALVE
Fuelfilling
Thecapacityofthefuel tankis4.2L(.95gal). Unscrewthegascapby turningit
counterclockwiseandcarefullyfill thetankwith unleadedgasolinethroughthe
opening.DONOTMIXGASANDOILTOGETHER,THISISA4-STROKEENGINE.
Replacethegascapbycarefullyaligningthethreadsonthecapandthetankand
turningthecapclockwise. Wipeanyspilledfuel from thedirtbikeusinga cloth
anddisposeoftheclothproperly.DONOTSMOKEORREFUELTHEVEHICLE
NEAROPENFLAMESORNEARHEATINGUNITS.ONLYREFUELTHEVEHICLE
INOPENAREASTOREDUCETHELIKELIHOODOFTHEBUILDUPOFGASOLINE
FUMES. Fillerneck
Fuellevel /
Operationofthefuel valve(thevalveunderthefueltank)
ON: Withthehandleofthefuel valveto"ON" position,thefuel supplywillflow to
thecarburetor.
OFF: Withthehandleofthefuel valveto"OFF" position,thefuel supplyiscutoff
tothecarburetor.
FuelValveHandle

CAUTION
Verifyoillevelpriortostarting(seepage11)
Startingtheenginewithlowornooilwilldamagetheengine.
ENGINESTARTINGAND STOPPING
Neverstarttheengineina closedplaceas theexhaustedgas
from thevehiclecontainstoxiccarbonmonoxide.
StartingEngine:
1.Placefuel valveleverto "ON" Position.
2.PlaceChokeleverto"ON" Position.
3. Settheignitionswitchto "__" Position.
4. PulltheStartRecoilcorduntilenginestarts.
5. Afterenginehassufficientlywarmedup,place
Chokeleverin "OFF" Position.
ChokeLever
ON '= = OFF
Proceduresfor stoppinqenqine: OFF '= J' ON
Fuelvalvelever
1.Releasethrottletwistgriptoslowdownengine.
2. Settheignitionswitchto" _" position.
3. Setthefuel valvelever(thefuel tankvalve)handleto "OFF"position.
CAUTION
Unnecessarilyincreasing RPM'sto ahigh levelwhile
the MiniBike is warming up is harmful to theengine.

SWITCHESON RIGHTHANDLEBAR
Ignitionswitch
Theignitionswitchisprovidedon therighthandlebar.
Whentheswitchisturnedto"(_" (off)position,theenginewillnotstartorstops
theengine.
Whentheswitchisturnedto"_" (on)position,theenginecanstartandthe
vehiclecanbedriven.
ONbutton
OFF button
10

CHECK-UPS,ADJUSTMENTAND MAINTENANCE
CheckingtheOil
Checktheengineoileachtimepriortooperatingtheminibike.
Theoillevelshouldbebetweentheupperandlowerlinesoftheoilgauge.
SettheMiniBikeonlevelground,screwofftheoilgageplug,wipetheoil
gagerodcleanandtheninsertthegageplugintothecrankcaseagainto
checktheoillevel. Thereisnoneedtoscrewtheoilgageplugintoitsholein
thecrankcase.
2. Addlubricatingoiluptotheedgeofthefill plug.
3. Finallyscrewintheoilgageplugtightly.
CAUTION
Neverstarttheenginewhenthere is insufficient lubricating
oil. Otherwise, itwill causeharmto theengine.
LubricatingOilRecommended
Oildipstick
Thelubricating oilis animportantfactor affectingthe performanceandservicelife
oftheengine.Pleaserefertothechartfor thecorrectgradeofengineoilbasedon
theenvironmentalconditionsinyourarea. Donotuseanyothertypeofoilother
thanwhatisrecommendedinthechart. DONOTMIXOILWITHTHEGASOLINE.
Lubricatingoilsofdifferent viscosity shallbeemployedindifferentregionsandat
differenttemperatures.
MACHINE I
EgiI
°C -30 -20 -10 0 10 20 30 40
TEMP. I
°F -22 -4 14 32 50 68 86 104
11

CHANGINGTHEOIL
Removethe"Screw Plug"locatedat thebottomoftheengineandletthe
oildrainintoanapprovedcollectioncontainer.DONOTPERFORMTHIS
PROCEDUREWHILETHEENGINEISHOT.SERIOUSBURNSCOULDRESULT
FROMCONTACTWITHHOTOIL.
2. Disposeoftheusedoilproperly.Forproperdisposalprocedures,contact
yourlocaloilrecyclingcenter.
3. Cleanand replacethe "Screw Plug"tightly. Torqueto 18ft.lb.
4. Refilltheenginewith0.53qt. (0.5L) ofrecommendedoilandrecheckthe
amountofoilintheenginebyusingtheoilgaugeplug.
Screwplugfor oildraining
CHECK-UPOF SPARKPLUG
1. Removethe capofsparkplugandscrewoff
thesparkplugusingthe plugwrench.
2. Cleanthe sparkplugallaroundor replaceit
if it is corrodedor thereistoo muchdeposit
onit.
3. Regulatethe gapofthe sparkplugto
.7ram-.79ram (.028"-.031").
.Thesparkplugofthe designated type
shouldbeused. Theapplicabletypeof
sparkplug: Meiya-F7RTC Champion-
RN9YC, NGK- BPR6ES 12
.79ram
(.028"- .031")

CHECKING& CLEANINGTHEAIR FILTER
1. Removeseatto accessairfilter. Seatis removedby
removingnutlocatedunderseat(seephoto).
2. LocateAirFilterBox underseatandremovecover.
3. Removeairfilter.
4. Removefoam coverfrom Airfilter element.
5. TaptheAirfilter elementgentlytoremovemostof
thedustanddirt. Blowoutremainingdustwith
compressedair. Iftheelementisdamaged,replaceit.
6. Washthefoam elementcoverperinstructionsbelow
thenallowtodrythoroughly.
7. Reinstallfoam covertotheairfilter element.
8. Reinstallair filter and closecover. Air Filter
AirFilterbox
Seatnut
Foa_
Removalofcover Removaloffilter
Washwithmildsoap
andwater
Airfilter element
Rinsewithfresh waterthen
squeezeoutexcess.
CAUTION
Theair filter elementmust be intactor theenginewill suckin dust anddirt,
resulting in ashorterservicelifeof the engine.
Watershouldbe preventedfrom enteringintothefilter whenwashingthe
vehicle.
Thefilter elementshallbe cleanedgentlywithouttwistingtopreventit
from cracking.Neverwashitwithgasolineor anyacid,alkalineor organic
volatileoiltoavoiditsaging,whichwillresultin reducingtheeffectofthe
airfilter oiltocatchparticlesbeforetheyentertheengine. Replacethefilter
elementwitha newoneifit isbrokenor cracked.
13

ADJUSTINGTHE THROTTLECABLE
Makesure thethrottlecableisadjustedproperly.Toadjustthrottlecable, rotate
adjustmentnutlocatedatthehandthrottle.
Checkifthethrottletwistgriphastherequiredfreeoperatingmovement.
Therequiredfreeoperatingmovement:2-6ram(.078-.24in). Ifthegripcannotbe
movedfreely,turntheadjustingnuttoensureproperoperatingmovement.
Afteradjustment,starttheengineandcheckfor theoperatingmovementagain.
Repeattheadjustmentifnecessaryuntilthedesiredoperatingmovementis
obtained.
Throttlecableadjustnt_
ADJUSTINGTHE CARBURETOR
Adjustinqproceduresofidlinqspeed:
1. Supportthevehiclebya stand.
2. Adjusttheidlespeedbythethrottlestopscrewto 1400+200RPM
-150.
CAUTION
Donottrytocorrecta malfunctioningcarburetorbyadjustingtheidling
speed. Ifthecarburetorisnotfunctioning properly,itshouldberepaired
byaservicecenter.
Adjustidling speedonlywhentheengineiswarmedupor 10minutesafter
operation.
14

ADJUSTMENTOFREARBRAKE
,
.
Thefront brakehandgripshouldhavefree operatingmovementof
5-7mm(.2-.3in).
Tomakeadjustment,turnrearadjustingnutclockwisetoreduceand
counterclockwisetoincreasethefreeoperatingmovement
ofthehandbrake.
Brakeshoesshouldbereplacedbya qualified servicetechnicianoncebrake
shoesareworn. 5-7ramfree play
(.2-.3in)
Rearbrakeadjustingnut
Rearbrakearm
Brakecable
15

ADJUSTMENTOF CHAIN
1. Whenchainadjustmentisneeded,loosenrear axlebolt.
2. Turnthechainadjustingnutsontheleftand right sidestoadjustthetension
of thechainandtoalignthemarkingofthechainadjusterwiththeengraved
linesinthesimilarpositionon bothsides.
3. Tightenrearaxlebolt bya torqueof 50-60Nm(37-44ft.lb.).
4. Repetitivelycheckthetensionofthechain.
Rearaxlebolt
15-20mm
1/2"- 3/4" Chainadjustingnut
BothSides
GREASINGPROCEDURESTO THE DRIVINGCHAIN
1. Shutofftheengine
2. Addlightamountsofmachineoilorchaingreasetothedrivingchain.(Too
muchmachineoilor chaingreasemaycausesplatteringtooccur.)
Attention:
Thechainshouldbereplacedwhentheadjustinglimithasreachedit'smaximum.
16

VEHICLEWASHING
Cleaningthevehicleregularlycanslowdownthecolorfading ofitsbodyand
makeiteasiertocheckifthereisanydamageandanyoilleakage.
CAUTION
Washing theMiniBikewithover-pressurizedwatermaycausedamageto
someofitscomponents.Therefore,dousea pressurewashertocleanthe
vehicle. Thefollowing partsshouldbecleanedusinglowpressurewater:
-- Wheelhub
-- Exhaustpipe
-- Fueltankandlowerportionofcushion
-- Carburetor
-- Headlockandignitionswitch
-- Meters
,
.
Afterpre-wiping,thevehicleshouldbe washedwithcleanwatertoremove
dirtyresiduessoastopreventcorrosion.Plasticsubassembliesshouldbe
cleanedbywipingwitha clothorfoam soakedin neutraldetergentsolution,
followed bywashingwithcleanwater.
Afterthecleanedvehicleisairdried,greasethechainandruntheengineat
idlingspeedfor afew minutes.
Priorto driving, carefullycheckthebraking systemrepeatedlyandrepairor
adjustit ifnecessary.
17