Baja motorsports MB165 Owner's Manual
Mini bike
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Also See for MB165:
- Owner's manual (27 pages) ,
- Owner's manual (53 pages) ,
- Repair operation manual (33 pages)
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Summary of Contents for Baja motorsports MB165
- Page 1 Minimum Age Requirement: 1 6 Rev.F (US) 012209 Always wear a helmet; It couldsaveyour Life! Do not remove this operator's manual from this vehicle. Pleaseobtain,review, and follow provincial/ municipal government acts and regulations pertaining to owningand operatingan off-roadvehicle.
- Page 2 Congratulations on your purchase of the BAJAINC. MiniBike. YourMini bike iswarrantedto be free of manufacturing defectsin materialand workmanship for a periodof 90 daysfrom the dateof purchase.Duringthe warrantyperiodBAJA,INC.will at itsoption, repair,providereplacement p artsor replaceyour BAJAINC.Mini Bike at no charge. Thiswarrantydoes not covernormalwear itemsor damagecausedby neglector misuseof the product.
- Page 3 This manualshould be consideredas a permanent part of the vehicle and should remainwith the vehicle when resoldor otherwisetransferredto a new user or operator. The manualcontains importantsafety informationand instructions which should be read carefully beforeoperating the vehicle. The engine exhaustfrom this product contains chemicalsknownto the State of Californiato cause cancer,birth defectsor other reproductiveharm.
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Page 4: Table Of Contents
Tableof Contents SAFEOPERATION ....................SAFETYGEAR....................MODIFICATION OFVEHICLE................MAINDATA......................PARTS& SUBASSEMBLIES ................OPERATION ......................FUELVALVE ....................ENGINESTARTING ANDSTOPPING ............SWITCHESONTHE RIGHTHANDLEBAR ..........CHECK-UPS, A DJUSTMENT AND MAINTENANCE .......... 11 CHANGING THE OIL................... CHECK-UP OF SPARKPLUG..............CHECKING & CLEANING THEAIR FILTER ..........ADJUSTING THE THROTTLE CABLE............ - Page 5 Please read thismanual and follow all instructions carefully.To emphasize the specialinformation, t he symbol-& and thewordsWARNING or CAUTIONhave somespecialmeanings.Paygreat attentionto themessages. Indicatesa potentialhazardthatcouldresultin deathor injury. CAUTION Indicatesa potentialhazardthatcouldresultin vehicledamage. NOTE:Indicatingspecialinformation whichis to makemaintenance easieror instructions clearer. WARNINGand CAUTION are arrangedlikethis: The first partwill identifya POTENTIAL HAZARD.
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Page 6: Safeoperation
SAFE OPERATION Rules for SafeOperation A pre-operation checkmustbe conducted, b eforestartingtheengine,insure safety,preventmishaps, a nd damageto components. It is stronglysuggested thatall operatorstake a certifiedmotorcycle rider's coursepriorto operatingthevehicle. Full attentionis requiredduringdriving;payingcloseattentionto the following pointsto avoidanyinjuryto you byothermotorized vehicles: Do not drivetoo closeto othervehicles. Nevercarrya passenger.Thisminibike isfor one operatoronly Neveroperatethis minibikeat night. -
Page 7: Safetygear
SAFETYGEAR Neveroperatethis minibikewithoutwearinga DOT approvedmotorcycle helmetwhichfits properly.Operators shouldalso weareye protection (gogglesor face shield),gloves,boots,long-sleeved shirtor jacket,and long pants. Looseclothesare not suitablefor motorcycle drivingor ridingas theymay get caughton footrest or wheel,resultingin danger. MODIFICATIONOF THE VEHICLE CAUTION Never perform any unauthorized modifications to this vehicle. Only use original replacement part which canbe obtained through BAJA INC.888- 863-2252. -
Page 8: Maindata
MAIN DATA 1680mm 6.8cmX 15.41cm Overall length Cylinderborex stroke (66.14inches) (2.68"X 2.13") Overall width PTOshaftrotation Counterclockwise 800.1ram(31.5 inches) 979.9mm Overall height Output,max 6.5hpat 3600 rpm (38.58inches) Wheelbase 1162mm (45.75 Torque,max 9.76ft-lbs, at 2500 rpm inches) 1400+200 Deadweight 64.46kg Idlingspeed -150 (142.11bs.) 197cc Payload... -
Page 9: Parts& Subassemblies
PARTS& SUBASSEMBLIES Rearbrake lever Throttletwist grip... - Page 10 Headlight Hand b rake Front Shock Absorber Front Wheel Clutch c overDrive C hain Side Stand Footpegs Decorative tank Vehicle Identification Seat Cushion AirFilter Brake D rum GasTank PullStartCord Sticker...
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Page 11: Operation
OPERATION FUELVALVE Fuelfilling The capacityof thefuel tank is 4.2L (.95 gal). Unscrew the gas capby turningit counterclockwiseand carefullyfill thetankwith unleadedgasolinethroughthe opening. DONOT MIX GASAND OILTOGETHER, T HISIS A 4-STROKEENGINE. Replacethegas capby carefullyaligningthe threadson the capand the tankand turningthe capclockwise. Wipeanyspilledfuel from the dirtbike usinga cloth and disposeof the clothproperly.DONOT SMOKEOR REFUELTHEVEHICLE NEAROPENFLAMESOR NEARHEATINGUNITS. -
Page 12: Enginestarting Andstopping
CAUTION Verify o illevel prior t ostarting ( see page 11) Starting theengine withlow ornooilwilldamage the engine. ENGINESTARTINGAND STOPPING Neverstartthe enginein a closedplaceas theexhaustedgas from the vehiclecontainstoxic carbonmonoxide. StartingEngine: Choke Lever 1. Placefuel valve leverto "ON" Position. = OFF 2. PlaceChokeleverto "ON" Position. 3. -
Page 13: Switchesonthe Righthandlebar
SWITCHESON RIGHT HANDLEBAR Ignitionswitch The ignitionswitch is provided on the righthandlebar. Whenthe switchis turnedto "(_" (off) position,theenginewill notstart or stops theengine. Whenthe switchis turnedto "_" (on) position,the enginecanstartand the vehiclecan bedriven. ON button OFF button... -
Page 14: Check-Ups,Adjustmentand Maintenance
CHECK-UPS,ADJUSTMENTAND MAINTENANCE Checkingthe Oil Checktheengineoil eachtimepriorto operating the mini bike. The oil levelshouldbe betweenthe upperand lowerlinesof the oil gauge. Set the MiniBike on level ground,screwoff theoil gage plug,wipe theoil gagerod cleanand then insertthe gageplug intothe crankcase againto checkthe oil level. Thereis no needto screwtheoil gage plug intoits holein the crankcase. -
Page 15: Changing The Oil
CHANGING THE OIL Removethe "Screw Plug" located at the bottomof the engineand let the oil drainintoan approvedcollectioncontainer. DONOT PERFORM THIS PROCEDURE WHILETHE ENGINEIS HOT. SERIOUSBURNSCOULDRESULT FROMCONTACT WITH HOTOIL. Disposeof the usedoil properly.For properdisposalprocedures,contact yourlocaloil recyclingcenter. Cleanand replacethe "Screw Plug"tightly. Torqueto 18 ft.lb. Refillthe enginewith 0.53qt. -
Page 16: Checking& Cleaning Theair Filter
CHECKING& CLEANING THEAIR FILTER 1. Removeseatto accessair filter. Seat is removedby removingnut locatedunderseat (see photo). LocateAir Filter Box underseat and removecover. Seat nut 3. Removeair filter. 4. Removefoam coverfrom Air filter element. 5. TaptheAir filter elementgentlyto removemostof thedust and dirt. Blowout remaining dustwith compressed air. -
Page 17: Adjustingthe Throttlecable
ADJUSTINGTHE THROTTLECABLE Makesure the throttlecableis adjustedproperly.To adjust throttlecable, rotate adjustment nut locatedat the handthrottle. Checkif thethrottletwistgrip hasthe requiredfreeoperatingmovement. The required free operatingmovement:2-6ram(.078-.24in). If the grip cannotbe movedfreely, turnthe adjustingnut to ensureproperoperatingmovement. Afteradjustment, s tart theengineand checkfor the operatingmovement again. Repeatthe adjustment if necessaryuntilthe desiredoperatingmovement is obtained. -
Page 18: Adjustment Of Rearbrake
ADJUSTMENTOF REAR BRAKE Thefront brakehandgripshouldhavefree operatingmovement of 5-7mm(.2-.3in). To makeadjustment, t urn rearadjustingnut clockwiseto reduceand counterclockwise t o increasethe free operatingmovement of the handbrake. Brakeshoesshouldbereplacedby a qualified servicetechnicianonce brake shoesareworn. 5-7ramfree play (.2-.3in) Rearbrakearm Brakecable Rearbrakeadjustingnut... -
Page 19: Adjustmentof Chain
ADJUSTMENTOF CHAIN Whenchainadjustment is needed,loosenrear axlebolt. Turnthe chainadjustingnutson the leftand right sidesto adjustthe tension of thechainand to alignthe markingof the chainadjusterwith the engraved linesin the similarposition on bothsides. Tightenrear axlebolt by a torqueof 50-60Nm(37-44ft.lb.). Repetitively checkthe tensionof the chain. Rearaxlebolt 15-20mm 1/2"- 3/4"... -
Page 20: Vehiclewashing
VEHICLEWASHING Cleaningthevehicleregularlycanslowdownthe colorfading of its bodyand make iteasierto checkif there is anydamageand any oil leakage. CAUTION Washing the Mini Bikewith over-pressurized watermay causedamageto someof its components.Therefore,do use a pressure washerto cleanthe vehicle. The following partsshouldbe cleanedusinglow pressure water: -- Wheelhub -- Exhaustpipe -- Fueltankand lowerportionof cushion -- Carburetor... -
Page 21: Instructions Forstorage
INSTRUCTIONSFOR STORAGE If thevehicleis not goingto be usedfor a long periodof time,for example,in wintertime, somestepsshouldbe takento preventmalfunction of and damageto its components whichmightbe causedby longstorage. Beforestoringthe vehicle for a long period, propermaintenance hasto be carriedin casemaintenance is not completed whenthe vehicleis put backinto useafterstorage. Changeengineoil. -
Page 22: Resumption Ofserviceafterstorage
RESUMPTIONOF SERVICEAFTER STORAGE Removethe coveringand removethe woodenblocksusedin storingthe vehicle. Changetheengineoil if the vehiclehas beenout of servicefor over4 months. Drainoff the remaining atomizedanti-rustoilfrom thefuel tank, followed by filling it with fresh gasolinetherein. Priorto driving,all the requiredcheck-upsmustbe made. It is betterto driveit at a lowspeed in an openareato test its performance beforenormal operation. -
Page 23: Maintenance Routinediagram
MAINTENANCESCHEDULE iTEMOF EA. USE 1ST MOJ20 EVERY3 MO./50 EVERY6 MO./100 EVERYYR./300 MAINTENANCE HRS. HRS. HRS. HRS. Engine oil-Cheek *Engine oil-Change Air filter-Cheek *Air filter-Clean *Air filter-Change *Carburetor sediment cup-Clean Spark plug-Cheek-Adjust Spark plug-Replace idle speed-Cheek-Adjust **Valveclearance-Check- Adjust Fueltank and filter-Clean Fueltube-Check Front shock bolts-Tightento spec. -
Page 24: Troubleshooting
TROUBLESHOOTING Enginewill not Start 1. FuelValveOFF MoveFuelvalveleverto ON. 2. ChokeOPEN MoveChockLeverto CLOSED 3. Outof fuel Refuel 4. Badfuel; enginestoredwithout Drainfuel and carburetor. treatingor draininggasoline, o r Refuelwith fresh gasoline refueled with bad gasoline 5. Spark plugfaulty, fouled, or Remove and inspectspark improperlygapped plug. -
Page 25: Emission Controlsystem 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 5,000kin, whichever comes first, providedthere 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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