Baja motorsports BV250 Owner's Manual
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Baja motorsports BV250 Owner's Manual

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BV250 Motorcycle
Owner's Manual
Minimum age requirement: 16
REVA
073107
Always wear a helmet; It could save your Life!
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.

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  • Page 1 BV250 Motorcycle Owner’s Manual Minimum age requirement: 16 REVA 073107 Always wear a helmet; It could save your Life! 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.
  • Page 2 Introduction Congratulations on your purchase of the Baja Motorsports BV250 Motorcycle. Take time to understand how your motorcycle works before riding. Scheduled service is a must and it is important to follow the break-in guidelines and pre-ride instructions. Make certain that you read the warranty coverage information provided and understand your responsibilities.
  • Page 3 Safety The most important thing to remember is your safety and the safety of others. We have included procedures and labels to help you make safe informed decisions. This information is provided to make you aware of potential hazards that could hurt you and/or others. It is impossible to warn you of ALL potential hazardous so you must use your own best judgement.

  • Page 4: Table Of Contents

    Contents Warranty............... Pg.6 Safety Information..........Pg.7 Safety Labels........... Pg.9 Component Locations........... Pg.10 Indicators..........Pg.12 Controls........... Pg.13 Before Riding............Pg.16 Pre-Ride Inspection......... Pg.17 Loading guidelines and Load Limits..Pg.18 Starting Procedures..........Pg.19 Starting and Stopping Engine....Pg.19 Shifting Gears.......... Pg.21 Braking............ Pg.23 Parking............
  • Page 5 Contents Brakes........... Pg.43 Tires............Pg.47 Drive Chain.......... Pg.51 Battery........... Pg.55 Appearance Care..........Pg.58 Vehicle Identification........Pg.59 Specifications........... Pg.60 Wire Diagram........... Pg.63 Emission Control System Warranty....Pg.64 ...

  • Page 6: Warranty

    Should you experience a problem or need to return your Baja Motorsports BV250 Motorcycle for repair, please call the BAJA MOTORSPORTS customer service department TOLL FREE at 1-888-863-BAJA (2252) between the hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm PST.

  • Page 7: Safety Information

    Safety Information 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. ALWAYS WEAR A HELMET The operator and passenger (if any) of this vehicle should always wear a helmet approved by agencies such as Department of Transportation (DOT), Safety Helmet Council of America (SHCA), or Snell Memorial Foundation (SNELL).
  • Page 8 However, NHTSA cannot become involved in any individual problems between you, your dealer or Baja Motorsports. To contact NHTSA you may call the Auto Safety Hot line toll-free within the United States on 1-800-424-9393 or write to: NHTSA, 400...

  • Page 9: Safety Labels

    Safety Labels The safety labels on your motorcycle provide you with important information do not remove them. If a label becomes too difficult to read or comes off contact Baja Motorsports for replacement. WARNING • Study the owners manual carefully •...

  • Page 10: Component Locations

    Component Locations Steering lock Fuel tank cap Cargo rack Battery Main fuse Taillight Exhaust Oil filler cap/ Rear brake dipstick pedal Mirrors Fuel valve Air cleaner Headlight Carburetor Driver Passenger footrest footrest Brake caliper Kickstand Shift Lever...
  • Page 11 Component Locations Fuel indicator Rearview mirror Speedometer Indicator lights Brake fluid reservoir Ignition switch Brake brake lever Clutch lever Throttle grip Engine stop switch Horn Headlight Start button Turn signal dimmer switch switch Fuel fill cap...

  • Page 12: Indicators

    Indicators The indicators on your motorcycle help make you aware of possible issues, refer to them often. Speedometer (1)-Shows the speed you are traveling in km. Odometer (2)-Tracks the total miles driven. Tripmeter (3)-Displays the number of miles you have traveled since last reset.

  • Page 13: Controls

    Controls Fuel Valve Fuel valve- Used to control the flow of gasoline from the fuel tank to the carburetor. RESERVE Choke Button Choke Button- May be used when starting engine. See starting procedures using choke lever on page 19.
  • Page 14 Controls Ignition Switch Ignition switch- Used for starting and stopping the engine. The key is used to lock the steering, preventing theft. ON- All electrical components are ON. OFF- All electrical components are OFF. Start button and Engine stop switch Engine stop switch Start button - Pushing the start...
  • Page 15 Controls Headlight dimmer switch, Turn signal switch and Horn Headlight dimmer switch Turn signal Horn switch Turn signal switch- Use this switch to signal a lane change or turn. -Left -Right Horn- The horn is used to warn other motorist. Tripmeter reset knob Tripmeter reset knob- By turning the knob counter clockwise you...

  • Page 16: Before Riding

    Before Riding Before your first ride on your new motorcycle we strongly recommended you: ● Read the owner’s manual. ● Understand all safety labels. ● Know how to operate all controls. Before you ride each time, make sure: ● You are in good physical and mental health. ●...

  • Page 17: Pre-Ride Inspection

    Pre-ride Inspection Before each ride check the condition of your motorcycle to make sure that it does not have mechanical problems. Your motorcycle should always be in good riding condition to ensure the safety of you, your passenger (if any) and others around you. WARNING Improper maintenance of this motorcycle or failure to correct any problems can result in serious injury or death.

  • Page 18: Loading Guidelines And Load Limits

    Loading guidelines and load limits Your motorcycle has been designed to carry you and one passenger. When a passenger is riding with you there will be a difference in the acceleration and braking. Load Limits Maximum weight capacity (including rider, passenger, accessories and cargo): 330 lbs(150kg) Maximum cargo weight: 11 lbs(5kg) Loading guidelines...

  • Page 19: Starting Procedures

    Starting and Stopping the Engine Always follow proper starting procedures. WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide. Starting Procedure ● Insert key into ignition, turn to “ON” position. ●...
  • Page 20 Starting and Stopping the Engine High Air Temperature: 35˚C (95˚F) or above DO NOT TURN CHOKE ON 1) Slightly open throttle. 2) Start engine. Low Air Temperature: 10˚C (50˚F) or below 1) Follow Normal Air Temperature procedures 1-2. 2) After RPM’s pick up, turn choke ON to keep fast idle. 3) Keep warming the engine until it responds to the throttle when choke is OFF.

  • Page 21: Shifting Gears

    Starting and Stopping the Engine, Shifting Gears How to Stop the Engine Normal Engine Stop ● Shift into neutral and turn the ignition switch “OFF”. ● Leave engine stop switch in the “RUN” position even when engine is “OFF”. DO NOT leave the ignition switch “ON” while the engine stop switch if “OFF”, this will allow the lights to stay “ON”...
  • Page 22 Shifting Gears ● Reduce the throttle or shift to a higher gear before engine RPM’s get too high. ● Shift to a lower gear before the engine RPM’s get too low. ● When the engine RPM’s are too high do not downshift to slow your motorcycle, this could cause damage.

  • Page 23: Braking

    Braking Your motorcycle is equipped with a hand operated front hydraulic disc brake and a foot operated rear drum brake. Your front brake provides 70% of your braking power. By using both front and rear brakes you will achieve faster, more stable and effective braking. To slow down or stop your motorcycle apply front and rear brakes while downshifting.

  • Page 24: Parking

    Parking Try, when possible, to park on level ground. If you have no paved surface to park on, make sure the ground is firm. If it is necessary for you to park on a hill, position your rear wheel against the curb at an angle and leave the transmission in gear.

  • Page 25: Servicing Your Motorcycle

    Servicing your Motorcycle This section is provided to help you keep your motorcycle in good running condition. The following table provides you with the three types of inspections recommended for you motorcycle. Type of Inspection/ Refer to When to perform Who performs? Service page...

  • Page 26: Maintenance Safety

    Maintenance Safety This section will instruct you on how to perform some important routine maintenance. You can perform many of these tasks with the tools provided with the motorcycle. The more difficult tasks, such as wheel removal, should be performed by a professional technician. If you do not feel capable of performing any one task do not hesitate to contact your local Service Center for help.
  • Page 27 Maintenance Safety Including the regular maintenance and pre-ride inspection, perform the periodic checks once a month and once a week if you ride frequently. Check the odometer and perform any scheduled maintenance necessary. Tires- ● Check the air pressure and add air if needed. ●...

  • Page 28: Maintenance Schedule

    Service Center perform extensive maintenance and repairs unless you have advanced mechanical skills. If needed you can purchase a Service Manual from Baja Motorsports. Every maintenance item requires some mechanical knowledge, some parts require more technical information and tools than others.
  • Page 29 Maintenance Schedule items related Emission ...
  • Page 30 Maintenance Schedule items related Non-Emission ...
  • Page 31 Maintenance Records To ensure proper maintenance keep record. If the motorcycle is sold be sure to include the maintenance records. All scheduled maintenance is considered normal operator cost, if a Service Center performs these tasks you will be charged. Please use the tables below to keep track of all maintenance performed.

  • Page 32: Fuel

    Fuel Fuel Recommendation Type- Unleaded Octane number- 86 (or higher) Unleaded fuel produces fewer engine deposits and will extend the life of the exhaust system components. We suggest you use regular unleaded fuel. Be sure to only use an octane number of 86 or higher. Using a lower octane gasoline can cause severe damage to the engine.

  • Page 33: Fuel And Engine Oil

    Fuel and Engine Oil Refueling 1) Pull tab up revealing key hole. 2) Insert ignition key in the fuel fill cap and turn clockwise. 3) Open cap 4) Add fuel to the bottom of the filler neck. Do not overfill. Key hole Filler neck Fuel fill cap...
  • Page 34 Engine Oil Recommended Oil API classification SE or SG Viscosity (weight) SAE 15W-40 SAE 20W-0 SAE 20W-0 SAE 10W-0 SAE 10W-30 100˚F 40˚C ● Use the recommended oil, the oil does not need additives. ● Do not use graphite oil or oil with molybdenum additives. ●...
  • Page 35 Engine Oil Checking and Adding Oil 1) Park your motorcycle on level ground and use the side stand for support. 2) Start the engine and let it run for 3-5 minutes. 3) Turn the engine off and wait for at least 3 minutes. 4) Remove the oil fill plug/dipstick and wipe clean.
  • Page 36 Engine Oil Draining Engine Oil cont.: 4) Remove the oil fill plug/dipstick, engine oil drain bolt and washer, to drain the oil into an oil pan. NOTICE: Improper disposal of oil can be hazardous to the environment. 5) Dispose oil in an appropriate manner. 6) Make sure the sealing washer is in good condition, if not replace.

  • Page 37: Air Cleaner

    Air Cleaner Be sure to clean the air cleaner more frequently if you are riding in dusty or wet areas. Your local service center can help you determine the correct service interval for your riding conditions. Use only the air cleaner specified for your motorcycle or one of equivalent quality.

  • Page 38: Crankcase Breather And Throttle

    Crankcase Breather and Throttle Crankcase Breather You should service the crankcase breather more often if you are ridding at full throttle or in rain. Be sure to service, if there are deposits in the transparent section of the drain tube. Draining 1) Place a drain/oil pan under the crankcase breather tube plug.

  • Page 39: Clutch

    Clutch System The proper free play adjustment of the clutch allows for a gradual, smooth engagement when shifting gears. Early wear can occur if you do not properly adjust the free play. Clutch Free play Left handlebar inspection 1) Check free play, if needed adjust to specified adjustment Free play: 3/8-13/16in.
  • Page 40 Clutch System Lower Adjustment If the upper clutch cable adjuster has reached it’s limit or you cannot obtain the correct free play, you may also use the lower clutch cable adjuster. 1) Loosen the upper lock nut and rotate the upper clutch cable ad- juster in to maximum free play.

  • Page 41: Engine Idle Speed

    Engine Idle Speed For the best servicing you should visit your local Service Center. Adjusting the Idle Speed will not cure all problems in the engine fuel delivery system. Idle Speed Adjustment 1) If the engine is cold, start it and run for ten minutes of Stop and Go riding.

  • Page 42: Spark Plug

    Spark Plug Spark Plug recommendation Do not use any spark plug other than the one recommended in the heat recommended. Standard spark plug MEIYA-D8RTC/NGK-DR8EA/CHAMPION-RA8YC NOTICE: If you use a spark plug in the improper heat range you can cause engine damage. Spark Plug Replacement: 1) Clean any/all dirt around the spark plug base.

  • Page 43: Brakes

    Brakes Your motorcycle uses a front hydraulic disk brake and a rear drum brake. Hydraulic Liquid Front Brake The brake fluid will drop as the brake pads wear or if there is a leak. To ensure there are no leaks, often check the brake system. You should also check the brake pads for wear and the brake fluid level.
  • Page 44 Brakes Other Inspections ● Make sure there no leaks in the fluid lines ● Check for loose fittings or damage to the fluid lines. NOTICE: Brake fluid can damage painted surfaces and plastic, handle with care. Clean any spills immediately. In case of contact with skin, wash thoroughly.
  • Page 45 Brakes Rear Brake Pedal Free play Inspection 1) Park your motorcycle on the side stand for support. 2) Depress the brake pedal until it starts to engage to check the free play: 13/16-13/16in(20-30mm). If needed, adjust to specified range. Adjustment 1) Turn the rear brake adjusting nut clockwise to increase free play and counter-clockwise to decrease, the cut-out should be seated on the brake arm pin.
  • Page 46 Brakes Other Inspections ● Make sure the brake pedal is positioned properly and the securing bolts are tight. ● Inspect the Brake rod, arm, spring and fasteners, make sure the are in good condition. Brake Shoe Wear You are able to check brake shoe wear without having to disassemble the rear end.

  • Page 47: Tires

    Tires The tires on your motorcycle should be the proper type and size. They should be in good condition and properly inflated for the load that you are carrying. WARNING Operating this motorcycle with improper tires, or even improper tire air pressure could be hazardous.
  • Page 48 Tires Inspection Always look for the following when checking tire pressure: ● Bumps or bulges on the tire, if there are any replace the tire. ● Cuts or cracks, replace tire if any fabric is visible. ● Any foreign objects such as nails embedded in the tire. ●...
  • Page 49 Tires Tire and Tube Repair If your tire is punctured or damaged replace the tire, do not repair. A repaired tube may fail while riding, and is not as reliable as a new one. A temporary repair can be made in an emergency situation, but will not perform at it’s best.
  • Page 50 Tires When replacing a tire: ● Have the wheel balanced after installation. ● If possible, have tire replaced by your local Service Center. ● Replace the tube. Safety Reminders ● Do not replace tire with a Radial tire. Using a different type of tire may affect stability and handling.

  • Page 51: Drive Chain

    Drive Chain There is a riveted master link on the chain which connects the countershaft to the rear wheel sprockets. To keep out moisture and dirt the O-ring chain uses rubber rings between the side plates of the pin and roller links to seal in the lubricating grease. Proper lubrication and adjustment will help extend the life of the chain.
  • Page 52 Drive Chain The chain should be replaced if there is damage to the rollers, or if there are loose pins. Lubricate any kinks or binds to work them out. If the chain appears too dry or rusty, lubricate. 4) Check both the front and rear sprocket teeth for excessive wear or damage.
  • Page 53 Drive Chain 1) Place the motorcycle on level ground using the side stand. Make sure the transmission is in neutral and the ignition switch if in the “OFF” position. 2) Loosen the axle nut. 3) Turn both adjusting nuts the same amount of turns until you have reached the correct slack.
  • Page 54 Drive Chain Removal, Cleaning and Replacement Your motorcycle has a riveted master link and should only be removed or replaced by your local Service Center. Do not use a Steam cleaner, high pressure washer or certain solvents. These products can damaged the o-rings. 1) Use a dry cloth to clean the side surface of the chain.

  • Page 55: Battery

    Battery Your motorcycle is equipped with a maintenance free battery. You do not have to check the electrolyte level or add distilled water. NOTICE: If you remove the cap strip you can permanently damage the battery. Any electrical accessory will use currents from the battery. If you have electrical accessories on your motorcycle and you do ride often, be sure to charge the battery frequently.
  • Page 56 Battery WARNING ● To avoid possibility of explosion, always connect battery cable in the order specified: Negative first; Positive last. An exploding battery can cause serious injury or death. ● Batteries contain sulfuric acid. ● Always shield eyes with protective eyewear when working around battery acid.
  • Page 57 Battery Charging the Battery Charging the battery incorrectly may cause damage. Always read the instructions that came with the battery charger and follow all directions on the battery. For home charging we suggest you use a trickle charger. A trickle charger can be left connected for a long period of time without causing damage to the battery.

  • Page 58: Appearance Care

    Appearance Care You should always clean and polish your motorcycle on a regular basis to keep it looking newer longer. General Recommendations • You may use the following to clean your motorcycle: - a mild, neutral detergent and water - a mild spray and cleaner/polisher - a mild cleaner/degreaser •...

  • Page 59: Vehicle Identification

    Vehicle Identification Serial Numbers The frame (VIN) and engine serial numbers will be required when you register your motorcycle. You may also need this informa- tion when ordering parts, make sure to keep these numbers in a safe spot. Frame number (VIN- Vehicle Identification Number) can be found on the left side of the front forks stamped into a metal plate.

  • Page 60: Specifications

    Specifications Dimensions Overall length 88.9 inches (2258mm) Overall width 29.7 inches (754.4mm) Overall height 45.67 inches (1160mm) Wheelbase 54 inches (1372mm) Dry Weight 331lbs(150kg) Fuel and Lubrication Fuel recommendation Unleaded, Octane 86 or higher Fuel tank capacity 3.12US gal Fuel tank reserve capacity 0.47US gal Engine oil recommendation API service classification SF...
  • Page 61 Specifications Engine Specification Displacement 14.2cu-in(233cm³) Bore and Stroke 2.09x2.09in(53.0x53.0mm) Compression ratio 9.4:1 Spark plug (standard) MEIYA-D8RTC/NGK-DR8EA/ CHAMPION-RA8YC Spark plug gap 0.024-0.028in(0.60-0.70mm) Valve clearance 0.03x0.05mm Idle speed 1500±50 Transmission Power Primary transmission ratio 3.631 1st gear ratio 2.84 2nd gear ratio 1.777 3rd gear ratio 1.333...
  • Page 62 Specifications Battery 12V-9AH Lights Headlight 12V35W/35 Brake/Taillight 12V20W/8 Turn signal light 12V2W Neutral indicator 12V2W Fuses Main...

  • Page 64: Emission Control System Warranty

    Emission Control System Warranty BAJA MOTORSPORTS – 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 65 Emission Control System Warranty Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility. The Distributor will not cover repairs performed outside of an authorized dealer or repair facility, except in an emergency situation. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle’s emission control system.
  • Page 66 Emission Control System Warranty LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to/from the authorized dealer.
  • Page 67 Baja, INC. P.O. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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