Baja motorsports HT65 Owner's Manual

Mini bike

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Owner's manual (27 pages)

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Page 1 HT65/WR65/MB165/MB165-BC Mini Bike Read this manual carefully. It contains important safety information. No one under the age of 16 should operate this Mini Bike. OWNER’S MANUAL Minimum Age Requirement: 16 Rev. F (US) 012209 Always wear a helmet; It could save your Life! Do not remove this operator’s manual from this vehicle.
Page 2 Congratulations on your purchase of the BAJA INC. Mini Bike. Your Mini 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.
Page 3 WARNING 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.
Page 4: Table Of Contents
Table of Contents SAFE OPERATION ....................3 SAFETY GEAR ....................4 MODIFICATION OF vEHICLE ................4 MAIN DATA ......................5 PARTS & SUBASSEMBLIES ................6 OPERATION ......................8 FUEL vALvE ....................8 ENGINE STARTING AND STOPPING ............9 SWITCHES ON THE RIGHT HANDLEBAR ..........10 CHECk-UPS, ADJUSTMENT AND MAINTENANCE..........11 CHANGING THE OIL ...................12 CHECk-UP OF SPARk PLUG ..............12 CHECkING &...
Page 5 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. WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in vehicle damage.
Page 6: Safe Operation
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 certified motorcycle rider’s course prior to operating the vehicle. ·...
Page 7: Safety Gear
SAFETY GEAR Never operate this mini bike without wearing a DOT approved motorcycle helmet which fits properly. Operators should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Loose clothes are not suitable for motorcycle driving or riding as they may get caught on footrest or wheel, resulting in danger.
Page 8: Main Data
MAIN DATA Description Data Description Data Overall length 1680mm Cylinder bore x 6.8cm X 15.41cm (66.14 inches) stroke (2.68” X 2.13”) Overall width 800.1mm (31.5 PTO shaft rotation Counter clockwise inches) Overall height 979.9mm Output, max 6.5hp at 3600 rpm (38.58 inches) Wheelbase 1162mm (45.75...
Page 9: Parts & Subassemblies
PARTS & SUBASSEMBLIES Rear brake lever Throttle twist grip...
Page 10 Headlight Hand brake Front Shock Absorber Front Wheel Rear Wheel Clutch cover Drive Chain Side Stand Foot pegs Decorative tank Vehicle Identification Number Seat Cushion Air Filter Brake Drum Gas Tank Pull Start Cord EPA Sticker...
Page 11: Operation
OPERATION FUEL vALvE Fuel filling The capacity of the fuel tank is 4.2L (.95 gal) . Unscrew the gas cap by turning it counter clockwise and carefully fill 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.
Page 12: Engine Starting And Stopping
CAUTION verify oil level prior to starting (see page 11) Starting the engine with low or no oil will damage the engine. ENGINE STARTING AND STOPPING WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide. Starting Engine: Choke Lever 1.
Page 13: Switches On The Right Handlebar
SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is provided on the right handlebar. When the switch is turned to “ ” (off) position, the engine will not start or stops the engine. When the switch is turned to “ ”...
Page 14: Check-Ups, Adjustment And Maintenance
CHECk-UPS, ADJUSTMENT AND MAINTENANCE Checking the Oil Check the engine oil each time prior to operating the mini bike. The oil level should be between the upper and lower lines of the oil gauge. Set the Mini Bike on level ground, screw off 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.
Page 15: Changing The Oil
CHANGING THE OIL 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. Dispose of the used oil properly.
Page 16: Checking & Cleaning The Air Filter
CHECkING & CLEANING THE AIR FILTER 1. Remove seat to access air filter. Seat is removed by removing nut located under seat (see photo). Locate Air Filter Box under seat and remove cover. Seat nut 3. Remove air filter. 4. Remove foam cover from Air filter element. 5.
Page 17: Adjusting The Throttle Cable
ADJUSTING THE THROTTLE CABLE Make sure the throttle cable is adjusted properly. To adjust throttle cable, rotate adjustment nut located at the hand throttle. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078 -.24in) . If the grip cannot be moved freely, turn the adjusting nut to ensure proper operating movement.
Page 18: Adjustment Of Rear Brake
ADJUSTMENT OF REAR BRAkE The front brake hand grip should have free operating movement of 5-7mm (.2-.3in) . To make adjustment, turn rear adjusting nut clockwise to reduce and counterclockwise to increase the free operating movement of the hand brake. 3.
Page 19: Adjustment Of Chain
ADJUSTMENT OF CHAIN When chain adjustment is needed, loosen rear axle bolt . Turn the chain adjusting nuts on the left and right sides to adjust the tension of the chain and to align the marking of the chain adjuster with the engraved lines in the similar position on both sides.
Page 20: Vehicle Washing
vEHICLE WASHING Cleaning the vehicle regularly can slow down the color fading of its body and make it easier to check if there is any damage and any oil leakage. CAUTION Washing the Mini Bike with over-pressurized water may cause damage to some of its components.
Page 21: Instructions For Storage
INSTRUCTIONS FOR STORAGE If the vehicle is not going to be used for a long period of time, for example, in winter time, some steps should be taken to prevent malfunction of and damage to its components which might be caused by long storage. Before storing the vehicle for a long period , proper maintenance has to be carried in case maintenance is not completed when the vehicle is put back into use after storage.
Page 22: Resumption Of Service After Storage
RESUMPTION OF SERvICE AFTER STORAGE Remove the covering and remove the wooden blocks used in storing the vehicle. Change the engine oil if the vehicle has been out of service for over 4 months. Drain off the remaining atomized anti-rust oil from the fuel tank, followed by filling it with fresh gasoline therein.
Page 23: Maintenance Routine Diagram
MAINTENANCE SCHEDULE ITEM OF EA. USE 1ST MO./20 EvERY 3 MO./50 EvERY 6 MO./100 EvERY YR./300 MAINTENANCE HRS. HRS. HRS. HRS. Engine oil-Check *Engine oil-Change Air filter-Check *Air filter-Clean *Air filter-Change *Carburetor sediment cup-Clean Spark plug-Check-Adjust Spark plug-Replace Idle speed-Check-Adjust **valve clearance-Check- Adjust Fuel tank and...
Page 24: Troubleshooting
TROUBLESHOOTING Engine will not Start 1. Fuel valve OFF Move Fuel valve lever to ON. 2. Choke OPEN Move Chock Lever to CLOSED 3. Out of fuel Refuel 4. Bad fuel; engine stored without Drain fuel and carburetor. treating or draining gasoline, or Refuel with fresh gasoline refueled with bad gasoline 5.
Page 25: Emission Control System Warranty
BAJA INC. – EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is deliv- ered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstra- tor, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
Page 26 EXCLUSIONS AND LIMITATIONS This warranty does not cover the following: • Failures or malfunctions of the emission control systems caused by abuse, alteration, accident, misuse, the use of leaded gasoline. • Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use, and the first required replacement inter- val for the item has not been reached.
Page 27 Baja, INC. P.O. Box 61150 Phoenix, AZ 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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Wr65 Mb165 Mb165-bc

Baja motorsports HT65 Owner's Manual

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