Baja motorsports SSR200 User manual

I
SSR200 Dirt Bike
Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this dirt bike.
Always wear a helmet; It could save your Life!
Do not remove this operator’s manual from this vehicle.
Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an o-road vehicle.
OWNER’S MANUAL
Minimum Recommended Age
Requirement: 16
200cc Model
Rev. A

II
Congratulations on your purchase of the Baja
Motorsports SSR200 Dirt Bike.
Your bike is warranted to be free of manufacturing defects in the material of workmanship for a
period of 90 days form the date of purchase. During the warranty period BAJA MOTORSPORTS,
LLC will at its option, repair, provide replacement parts or replace your Baja Motorsports SSR200
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
If wheels are bent or broken
Fender bent or broken due to abuse
Any sign of impact, accident, jumping, spin-outs or roll over.
BAJA MOTORSPORTS, LLC 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 Motorsports SSR200 for repair,
please call the BAJA MOTORSPORTS customer service department TOLL FREE at 1-888-863-
BAJA (2252) between the house of 7am and 5pm Monday thru Friday PST and Saturday 8am to
4pm 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. All operators should obtain, review,
and follow provincial and municipal government acts and
regulations pertaining to owning and operating an o-
road vehicle. Children under the age of 16 should never
operate this vehicle.
WARNING
!

1
SAFE OPERATION............................................................................... 3
SAFETY GEAR ...................................................................................... 4
MAIN DATA........................................................................................... 5
PARTS & SUBASSEMBLIES .............................................................. 6
OPERATION .......................................................................................... 8
FUEL VALVE................................................................................... 8
ENGINE STARTING...................................................................... 9
BREAKING IN THE ENGINE ...................................................... 10
SWITCHES ON THE RIGHT HANDLEBAR............................ 11
GEAR SHIFTING ........................................................................... 12
BATTERY INSTALLATION................................................................. 13
CHECKUPS, ADJUSTMENT AND MAINTENANCE................. 16
CHANGING THE OIL, CLEANING OIL FILTER SCREEN... 17
CHECKUP OF SPARK PLUG .................................................... 17
CHECKING & CLEANING THE AIR FILTER ........................... 18
ADJUSTING THE THROTTLE CABLE..................................... 19
ADJUSTING THE CARBURETOR............................................. 19
INSPECTION OF FRONT HYDRAULIC BRAKE .................. 20
INSPECTION OF REAR HYDRAULIC BRAKE ..................... 20
CLUTCH ADJUSTMENT............................................................. 21
ADJUSTMENT OF CHAIN......................................................... 22
GREASING PROCEDURES TO THE DRIVING CHAIN....... 22
TROUBLE SHOOTING ................................................................ 23
VEHICLE WASHING .................................................................... 25
INSTRUCTIONS FOR STORAGE.............................................. 26
RESUMPTION OF SERVICE AFTER STORAGE ................... 27
TABLE AND TORQUE OF FASTNERS .................................... 27
RESUMPTION OF SERVICE ...................................................... 28
INSPECTION AND MAINTENANCE....................................... 28
SERIAL NUMBER LOCATION................................................... 30
ELECTRICAL DIAGRAM............................................................. 31
Table of Contents

2
Please read this manual and follow all instructions carefully. To emphasize the 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
Indicates a potential hazard that could
result in death or injury.
CAUTION
Indicates a potential hazard that could
result in vehicle damage.
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.

3
SAFE OPERATION
Rules for Safe Operation
· A pre-operation check must be conducted, before starting the engine, insure safety,
prevent mishaps, and 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.
· 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
· Always avoid operating this dirt bike on paved surfaces, including; sidewalks, paths,
parking lots, driveways, streets, roads, and highways. Never operated this or any O-Road
Vehicle on a public street, road or highway where motor vehicles are in operation.

4
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.

5
MAIN DATA
Description Data Description Data
Overall length 2180mm
(85.83”)
Cylinder bore x
stroke
69mm X 53mm
Overall width 810mm
31.89”
Compression ratio 9.2:1
Overall height 1180mm
(46.46”)
Output, max 10.8KW/8000rpm
(14.4 hp/8000rpm)
Wheelbase 1360 mm
(53.54”)
Torque, max 13.0N.m/7200 r/min
Dead weight 130kg
(286.6 lbs)
Idling speed 1500r/min ± 150r/min
Payload 150kg
(331 lbs.)
Displacement of
cylinder
200cc
Ground clearance 250mm
(9.84”)
Spark plug D8EA (NGK)
Gap .6mm - .8mm (.024”
- .032” )
Speed, max ≥ 90km/h
(56 mph)
Front wheel 2.75 - 21
32 Psi
Transmission 5 gear mesh Rear wheel 4.10 - 18
36 Psi
Capacity of gasoline
tank
6.5L
(1.71 gal)
Ignition means CDI
Oil Capacity 1L (1Qt) Battery 12V7AH
Lubrication method Pressure, splash Fuse 10A
Clutch Manual/Wet Brake front: Disc; Rear: Disc

6
PARTS & SUBASSEMBLIES
Throttle twist grip
Front brake lever
Fuel tank cover
Brake uid reservoir
Clutch Lever
Ignition key switch
On/O switch
Electric start
button

7
Drive Chain
Seat Cushion
Exhaust Silencer
Kick Lever Rear Brake pedal
Front Wheel
Front Shock Absorber
Fuel Valve
Gear Shifting
Pedal
Side Stand Rear Fork
Rear Wheel
Battery
compartment
Carburetor
Choke lever
on Carburetor
Rear brake
caliper
Front Shocks
Front brake
caliper
Gas Cap
Oil Cap
Drive Chain

8
OPERATION
FUEL VALVE
Fuel lling
The capacity of the fuel tank is 6.5L (1.71 gal) . 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 to “ON” position, the fuel supply will ow to the
carburetor.
OFF: With the handle of the fuel valve to“OFF”position, the fuel supply is cut o to the
caburetor.
Fuel Valve ON Fuel Valve OFF

9
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 cock 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
su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 16)
Starting the engine with low or no oil will damage the engine.
Closed
Open
WARNING
Never start the engine in a closed place as the exhausted gas from the vehicle contains
toxic carbon monoxide.
choke lever

10
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 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 suciently.
3. The driving speed shall not be over 40 MPH maximum during the rst 300 miles of
operation and not over 50 MPH maximum during the remaining 300 miles of the “Break-
In” period.

11
SWITCHES ON RIGHT HANDLEBAR
Ignition switch
The ignition switch is Located on the right handlebar.
When the switch is turned to“ ” (o) position, the engine will not start. If the engine is
running and the O button is pushed the engine will turn o.
When the switch is turned to“ ” (on) position, the engine can start when the electric start
button is depressed, or when starting by the kick lever.
ON button
OFF button
Electric Start button

12
GEAR SHIFTING
Reduce throttle before shifting. Never increase the throttle while shifting gears.
Pull in the clutch lever, located on the right 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
damaging the clutch caused by sudden gear shifting accidentally.
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. Avoid unnecessary idling of the engine at a high speeds. Doing so will damage the engine
components seriously.
2. The clutch will wear out quickly if the dirt bike is operated with the clutch in a semi-
engaged position.
3. Only shift to the low speed gears when you feel that there is insu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

13
BATTERY INSTALLATION
INITIAL SERVICE AND INSTALLATION OF BATTERY:
WARNING
The following procedure is very dangerous and should be performed with utmost
care and attention. Wear protective eye wear, rubber gloves, and have water available
should electrolyte come in contact with skin or eyes. KEEP ALL CHILDREN AWAY FROM
THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
POISON  CAUSES SEVERE BURNS
Contains sulfuric acid.
Avoid contact with skin, eyes, or clothing
To prevent accidents, rinse empty container with water.
ANTIDOTE:
External – ush with water
Internal – Call physician immediately. Drink large quantities of water or milk.
Follow with milk of magnesia, beaten eggs or vegetable.
Eyes – Flush with water for 15 minutes and get prompt medical attention.
KEEP OUT OF REACH OF CHILDREN.

14
Note: The following page is for vehicles with battery’s containing separate electrolyte pack.
Most battery’s will come with the electrolyte already sealed into the battery.
Preparing the battery:
· Place battery on level surface. Remove sealing tape from
top. (see gure 20)
· Take the electrolyte container out of the plastic bag.
· Place electrolyte container upside down with the sealed
silver mouths of the electrolyte bottles in line with the
six ller holes of the battery. (see gure 21)
· Push the container down strongly enough to break the
silver seals. (see gure 22)
· As electrolyte starts owing into battery, air bubbles
will come up from the mouths of the plastic electrolyte
bottles.
· Leave bottles upside down in battery holes until
electrolyte is completely drained.
· Never leave children unattended around battery.
· If air bubbles cease to oat to the top of the electrolyte
bottles, tap lightly on top.
· DO NOT remove container from battery while it is
draining.
· Never cut or pierce electrolyte container.
· After all the electrolyte has drained from the bottles into
the battery, pull plastic electrolyte bottles gently out of
the battery.
· Discard empty electrolyte bottles in a waste area that is
inaccessible to children and animals.
· After lling let battery stand for at least 30 minutes
before charging. This allows the electrolyte to penetrate
plates for optimum performance and ensures longer
battery life.
· After 30 minutes the battery is ready for its initial charge.
Place cap strip loosely over the lling holes as shown in
the picture. (see gure 23)
Figure 20
Figure 21
Figure 22
Figure 23

15
How to Initially Charge the battery:
1. Connect the red positive (+) cable to the red positive (+)
pole of the battery.
(see gure 24)
2. Connect the black negative (-) cable to the black negative
(-) pole of the battery. (see gure 25)
Note: The red positive (+) cable has a larger diameter than
the black negative y cable.
3. Charging rate: Charge battery @ 0.7 Amps for
5 ~ 10 hours.
• After charging is complete, press down rmly with
both hands to seat the caps. (Do not pound or
hammer.) The battery is now sealed. (see gure 26 )
• Remove side cowling and battery compartment cover
from dirt bike (See gure 27)
• Install battery into battery compartment. The battery
terminals should be facing the front (see gure 28)
• Once battery is rmly seated in battery compartment
attach the red positive wire to the red positive terminal
on the battery. (see gure 28)
• Then attach the black negative wire to the black
negative terminal on the battery.
(see gure 28)
WARNING
NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY
WATER OR ELECTROLYTE.
Figure 24
Figure 25
Figure 26
Figure 27
Red +
Black -
Battery bracket
Battery
Compartment
Side Cowling
Figure 28

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. Screw
o 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 screw the oil gage plug into its
hole in the crankcase.
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 aecting 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 dierent
viscosity shall be employed
in dierent regions and at
dierent temperatures.
MACHINE
OIL
TEMP.
°C
°F
-30
-22
40
104
-20
-4
-10
14
0
32
10
50
20
68
30
86
20W-50
5W-40 15W-50
10W-40 10W-50
10W-30
CAUTION
Never start the engine when there is
insucient lubricating oil. Otherwise, it
will cause harm to the engine. Oil sight gauge
Oil ll cap
and dip stick

17
CHANGING THE OIL, CLEANING OIL FILTER SCREEN
1. Remove the“Screw 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
3. Clean and replace the Screw Plug” tighly.
4. 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.
Screw plug for oil draining
CHECKUP OF SPARK PLUG
1. Remove the cap of spark plug and screw o 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” - .032”
3. The spark plug of the designated type should be used.
The applicable type of spark plug: D8EA (NGK) 0.6~0.8mm
(.024” - .032”)
Oil lter screen
Spring