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Baja Comet 90cc BC90 Owner's Manual

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Baja Comet 90cc 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
Model Number: BC90
Minimum Age Requirement: 16
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 off-road vehicle.
Rev. A (US)
012709

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Summary of Contents for Baja Comet 90cc BC90

  • Page 1 Baja Comet 90cc 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 Model Number: BC90 Minimum Age Requirement: 16 Rev. A (US) 012709 Always wear a helmet;...
  • Page 2 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.
  • 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 NOTICE TO USERS .....................2 SAFE OPERATION ....................3 SAFETY GEAR ....................4 MODIFICATION OF vEHICLE ................4 PRE-RIDE CHECKLIST ..................5 MAIN DATA ......................6 PARTS & SUBASSEMBLIES ................7 LOCATION OF WARNING LABELS ..............9 OPERATION ......................10 FUEL FILLING .....................10 ENGINE STARTING AND STOPPING ............11 LEFT HANDLEBAR SWITCH ..............12 GEAR SHIFTING ..................13 CHECK-UPS, ADJUSTMENT AND MAINTENANCE..........14...

  • Page 5: Notice To Users

    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 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 engine to insure safety, prevent mishaps, and prevent 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

    Loose clothes are not suitable for motorcycle driving or riding as they may get caught on footrest or in moving parts. MODIFICATION OF THE vEHICLE CAUTION Never perform any unauthorized modifications to this vehicle. Only use original replacement part which can be obtained through BAJA INC. 888-863-2252...

  • Page 8: Pre-Ride Checklist

    Pre-Ride Checklist Before Starting the Engine 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.

  • Page 9: Main Data

    MAIN DATA Description Data Description Data Overall length Brake Type 1539 mm Drum (60.61 in.) Overall width Capacity of 669.8 mm 3L (.79 gal.) 87 octane or higher gasoline tank (26.37 in.) unleaded gasoline Overall height Capacity of oil tank .24L (.25 qt.) 959.6 mm (37.78 in.) Wheelbase...

  • Page 10: Parts & Subassemblies

    PARTS & SUBASSEMBLIES Brake lever Engine stop switch Throttle twist grip...
  • Page 11 PARTS & SUBASSEMBLIES Fuel tank located Headlight under seat Front Shock Ignition key switch Absorber Taillight Front Wheel Rear Wheel Air Filter Foot pegs Shift lever Side Stand Brake Drum Drive Chain Oil drain bolt Vehicle Identification Number Seat Cushion Carburetor Muffler Rear...

  • Page 12: Location Of Warning Labels

    Keep the labels on the Mini bike. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting Baja Inc. THIS VEHICLE IS AN OFF ROAD VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS OR HIGHWAYS.

  • Page 13: Operation

    OPERATION Fuel filling The capacity of the fuel tank is 3L (.79 gal) Use only 87 octane or higher unleaded gasoline. 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.

  • Page 14: Engine Starting And Stopping

    ENGINE STARTING CAUTION verify oil level prior to starting Starting the engine with low or no oil will damage engine. WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide. Set ignition key switch to “...

  • Page 15: Left Handlebar Switch

    LEFT HANDLEBAR SWITCH Engine stop switch The engine stop switch is provided on the left handlebar. When the switch is turned to “ ” (off) position, the engine will not start or will stop engine if running. When the switch is turned to “ ”...

  • Page 16: Gear Shifting

    GEAR SHIFTING Reduce throttle before shifting. Never increase the throttle while shifting gears. Depress Shift lever to place gear in 1st, 2nd, 3rd or 4th. Lift up on shift lever to down shift or place gear in neutral. Do not rest foot on gear-shift lever while operating mini bike. Resting foot on shift lever could damage the transmission, or cause transmission to shift unexpectedly.

  • Page 17: Check-Ups, Adjustment And Maintenance

    CHECK-UPS, ADJUSTMENT AND MAINTENANCE Checking the Oil Check engine oil each time prior to operating mini bike. The oil level should be between the upper and lower lines on oil dipstick. Set Mini Bike on level ground, remove oil plug/dipstick, wipe dipstick clean, insert dipstick into crankcase to check oil level.

  • Page 18: Changing The Oil

    CHANGING THE OIL Let engine warm up approximately 3 minutes to warm up oil. Shut off engine, remove “Screw Plug” located at bottom of the engine and let 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.

  • Page 19: Valve Clearance

    For those who are mechanically proficient and have the proper tools, instructions on adjusting the valve clearance are given in the service manual. If assistance is needed please contact Baja Inc. to find your local service center.

  • Page 20: Checking & Cleaning The Air Filter

    CHECKING & CLEANING THE AIR FILTER TAP AIR FILTER ON A FIRM SURFACE TO DISLODGE AS MUCH DIRT AND debris as possible. NOTE: If tapping air filter does not remove the dirt and debris, replace air filter. Clamp Air filter CAUTION The air filter element must be intact or the engine will suck in dust and dirt, resulting in a shorter service life of the engine.

  • Page 21: Adjusting The Throttle Cable

    ADJUSTING THROTTLE CABLE Make sure throttle cable is adjusted properly. To adjust throttle cable, rotate adjustment nut located at the hand throttle. Check if throttle twist grip has the required free operating movement. The required free operating movement: 2 - 6 mm (0.078 -0.24in) . If the grip cannot be moved freely, turn the adjusting nut to ensure proper operating movement.

  • Page 22: Adjustment Of Rear And Front Brake

    ADJUSTMENT OF REAR BRAKE To make adjustment, turn rear adjusting nut clockwise to increase braking or counterclockwise to decrease braking. Brake shoes should be replaced by a qualified service technician once brake shoes are worn. Brake cable Rear brake adjusting nut Rear brake arm ADJUSTMENT OF FRONT BRAKE The front hand brake lever should have free operating movement of...

  • Page 23: Adjustment Of Chain

    ADJUSTMENT OF CHAIN When chain adjustment is needed, loosen rear axle nut. Turn chain adjusting nuts on the left and right sides to adjust the tension of the chain. Align the marking of the chain adjuster with the engraved lines in the frame on both sides.

  • Page 24: Vehicle Washing

    vEHICLE WASHING Cleaning the vehicle regularly can slow down color fading and make it easier to check for damage and/or oil leakage. CAUTION Washing the Mini Bike with over-pressurized water may cause damage to some of its components. Therefore, do not use a pressure washer to clean the vehicle.

  • Page 25: 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 components. Change engine oil. Drain fuel from the fuel tank and carburetor. Spray atomized anti-rust oil to the inside walls of the tank.

  • Page 26: Resumption Of Service After Storage

    RESUMPTION OF SERvICE AFTER STORAGE Remove covering and remove wooden blocks used in storing the vehicle. Change engine oil if the vehicle has been out of service for over 4 months. Drain off any remaining atomized anti-rust oil from the fuel tank. Fill tank with fresh gasoline.

  • Page 27: 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 28: Troubleshooting

    TROUBLESHOOTING Engine will not Start SYMPTOM POSSIBLE FIX 1. Choke OPEN Move Choke Lever to CLOSED 2. Out of fuel Refuel 3. Bad fuel; engine stored without Drain fuel from fuel tank and treating or draining gasoline, or carburetor. Refuel with fresh refueled with bad gasoline gasoline 4.

  • Page 29: Wire Diagram

    WIRE DIAGRAM...

  • Page 30: Vin And Serial Number Location

    AND SERIAL NUMBER LOCATION You need to know the frame vIN# and engine serial numbers. You need these numbers to help your authorized service center or BAJA INC. order parts. The Frame number is stamped on front of Mini bike frame. The engine number is located on the left side of the engine housing.

  • Page 31: 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 delivered to the first purchaser other than an authorized dealer, or the date it is first used as a...
  • Page 32 No dealer is authorized to modify this Emission Control System Warranty. If you have any ques- tions regarding your warranty rights and responsibilities, you should contact BAJA INC. (888) 863-2252.
  • Page 33 Baja, INC. P.O. Box 61150 Phoenix, AZ 85082 Tel: 602-443-9180 Toll Free: 1-888-863-2252...

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