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TNG Baja 150cc Owner's Manual

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Owner's Manual
Baja 150cc (BJ150)
Revised 11/07

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Summary of Contents for TNG Baja 150cc

  • Page 1 Owner’s Manual Baja 150cc (BJ150) Revised 11/07...
  • Page 2 LOCATING YOUR VIN# The serial numbers of the frame and engine are used for vehicle registration. The VIN# and label are located in the glove box. Then engine # is located on the back of the engine. VIN # Engine #...

  • Page 3: A: Introduction

    Thank you for purchasing a CMSI Manufactured TNG motor scooter. CMSI has invested over 15 years in establishing the facilities, technical infrastructure and nationwide sales and service network that exists today as TNG, a trademark of CMSI. TNG Scooters is growing rapidly due to its reputation in quality research, styling & design, production and service.
  • Page 4 SPECIAL SYMBOLS Significant safety messages are provided both in this manual and on the scooter. For your safety and the safety of others please pay special attention to all warnings preceded by !. ! WARNING - Indicates risk of severe injury or DEATH may result to the scooter operator, a bystander or a person inspecting or repairing the scooter if failure to follow these instructions.

  • Page 5: Table Of Contents

    B: TABLE OF CONTENTS INTRODUCTION Page 3 TABLE OF CONTENTS Page 5 WARRANTY INFORMATION Page 6 SAFETY INSTRUCTIONS Page 7 SPECIFICATIONS Page 13 COMPONENT DESCRIPTIONS & FUNCTIONS Page 14 PRE-RIDE CHECKLIST Page 22 PROPER OPERATION Page 24 SERVICE MAINTENANCE SCHEDULE Page 30 WINTERIZING Page 40...

  • Page 6: C: Warranty Information

    WARRANTY: CMSI, Inc., warrants to the first retail purchaser of all TNG vehicles from an Authorized CMSI Dealer, and each subsequent owner, that the vehicle is free from defects in materials and workmanship for the period stated in this warranty section. For complete warranty information see the Warranty Appendix.

  • Page 7: D: Safety Instructions

    D: SAFETY INSTRUCTIONS RIDING SCOOTERS IS FUN ONLY IF YOU PUT SAFETY AS YOUR TOP PRIORITY. ! WARNING: Before you start operating your scooter: • Be sure you read this owner manual completely and understand all operating features. • Take sufficient time training with safe and proper riding technique. •...
  • Page 8 • Meet U.S. Department of Transportation (DOT) and state standards. In addition with labels from the Safety Helmet Council of America, the American National Standard Institute (ANSI), or the Snell Memorial Foundation to assure the integrity of the product. • Fits snugly on your head.
  • Page 9 SAFE RIDING • Keep enough distance from the other vehicles around you as this gives you time to react. • Ensure that you have a driver’s license with correct classification to ride this scooter in your state. • Always observe the rules of the road. Observe the posted speed limit, and signal your turns well in advance.
  • Page 10 • Always use turn signals when you are planning to turn or merge to main road and turn it off after you have made your turn. • Flash brake lights whenever you are going to slow down more quickly or where others may not expect you are going to slow down.
  • Page 11 • Hold firmly to your waist, hips, or belt or passenger handle. • Keep both feet on the pegs at all time, even when the scooter is stopped. • Keep legs away from the muffler. • Stay directly behind you, leaning as you lean. •...
  • Page 12 GASolINe & exHAuST FuMeS ! WARNING Gasoline is highly flammable and exhaust fumes are poisonous: • Turn off engine before refueling. • Do not to spill any gasoline on the engine, exhaust system or the plastic body. • Do not refuel while smoking or near any open flame. •...

  • Page 13: E: Specifications

    E: SPECIFICATIONS Model Baja 150 Tire Size (rear) 130/60x13 Model Number BJ150 Tire pressure (Front) 29psi Length 75 inches Tire pressure (rear) 33psi Width 23 inches Idle rpM 1500 Height 48 inches exhaust Valve Gap (Cold) 0.15mm / 0.006 inch Dry Weight (no fuel) 249 lbs Intake Valve Gap (Cold)

  • Page 14: F: Component Descriptions & Functions

    F: COMPONENT DESCRIPTIONS & FUNCTIONS 1. Battery 5. Handle Bars 9. Air box & Filter 13. Instrument Panel 2. Center Stand 6. Turn Signals 10. Kick Starter 14. Ignition Switch 3. Muffler 7. Headlight 11. Side Stand 15. Fuel Cap 4.
  • Page 15 1. Horn Button 6. Front Brake Lever 2. Rear Brake 7. Throttle 3. Turn Signal Switch 8. Electric Starter Button 4. Hi / Lo Beam Switch 9. Engine Stop Switch 5. Speedometer 15 15...
  • Page 16 Ignition Switch / Steering & Seat lock TABLE 1.1 NOTE: Steering can only lock when the handle bar is turned left. CAUTION: Make sure key is in ‘OFF’ position after riding or opening seat. When key is left in ‘ON’ position and engine is off you will drain your battery.
  • Page 17 ! WArNING Do NoT CHANGe THe Key poSITIoN WHIle THe SCooTer IS IN MoTIoN. IT MAY RESULT IN LOSS OF CONTROL OR AN ACCIDENT. INSTRUMENT PANEL 1. Turn Signal Indicator 2. Speedometer 3. Odometer, Clock 4. Hi Beam Indicator 5. Gas Gauge 6.
  • Page 18 lo / HI beAM SWITCH AND HI beAM INDICATor • When illuminated high beam is selected. • See page 15 for Lo/Hi beam switch location. • See page 17 for indicator location. CAuTIoN: be sure to always use lo beAM light when facing oncoming traffic. SPEEDOMETER (See page 17) - Indicates the operating speed.
  • Page 19 ELECTRIC STARTER (see page 15) • Starts Engine using battery power. • NOTE: Never engage starter for more than 3-5 seconds at a time to avoid possible damage. HorN buTToN (see page 15) - To sound the horn, press this button. eNGINe STop SWITCH (see page 15) •...

  • Page 20: Luggage Rack

    ! WARNING: • The storage compartment can carry 6.5 lbs max. • Do not exceed maximum 17.5 lbs for cargo. • Ensure the storage compartment is locked before riding. CAUTION: • Do not store anything susceptible to heat inside storage compartments. •...
  • Page 21 Hinge Seat Forward to Access Gas Cap Seat Latch ! WARNING: • Always turn the engine off prior to refueling the scooter. • Ensure the fuel tank cap is properly installed before riding. • Do not overfill the tank as it may overflow when the fuel warms up and expands. •...

  • Page 22: G: Pre-Ride Checklist

    G: pre-rIDe CHeCKlIST 1. CHeCK THe Fuel leVel • Remove the gas cap by turning the cap counterclockwise. • Fill the tank up to the bottom of the filler tube. Do not fill past that point. • Replace the gas cap and turn it clockwise until it is secure. NOTE: Always turn the engine off prior to refueling the scooter.

  • Page 23: Check The Brakes

    Front 29 PSI Rear 33 PSI • Visually inspect the tires for damage and wear. Look for nails, glass or stones what are cutting into the tire casing. • Look for partial or abnormal tread wear. The middle of the tread should have: Front Tire 1.5 mm minimum tread depth Rear Tire...

  • Page 24: H: Proper Operation

    8. CHeCK THe SpArK pluG • The spark plug will need to be checked if you find the scooter hard to start. The gap should be between 0.023 & 0.032 inches. The electrode should be a light brown color. • Incorrect gap can cause many problems for the scooter engine.
  • Page 25 ENGINE STARTING PROCEDURE • Normal Start - Place scooter on the center stand • Turn the ignition key to the “ON” position. • While holding brake lever, firmly push the electric start. • Repeat 5 second intervals of starter motor activation and 5 second rest. Do NOT twist throttle open to start.
  • Page 26 of time. The battery may become depleted to the point that the vehicle cannot be started. • To preserve the scooter, each starting attempt should be less than 5 seconds. • To maximize the engine life, warm up the engine for 2 to 3 minutes prior to riding. No fast acceleration when the engine is still cold.

  • Page 27: Using The Brakes

    4. ACCelerATIoN & DeCelerATIoN • Speed can be adjusted by twisting the throttle control. Twist the throttle slowly towards you to increase speed and twist the throttle away from you quickly to decrease speed. CAUTION: Fast acceleration when the engine is cold can damage transmission.
  • Page 28 Take extra care while riding in these conditions. CAUTION: Test your brakes after washing your scooter or riding through a large pool of water. When this happens, apply the brakes gently until they dry themselves and work effectively again. SToppING & pArKING •...
  • Page 29 breAK IN proCeDureS • It is very important to follow this procedures during the first 300km to achieve the best performance from the scooter. • Limit full throttle operation and avoid any condition that may result in engine overheating. • Always keep the speed below 40 mph.

  • Page 30: I: Service Maintenance Schedule

    I: SerVICe MAINTeNANCe SCHeDule Item Initial 300 km 1000 km 4000 km or every 6 Months Fuel Line Fuel Filter Air Filter Spark Plug Valves Engine Oil Oil Filter Carburetor Drive Belt REPLACE EVERY TWELVE MONTHS Transmission Oil Braking System Wheels Wheel Bearings Steering Bearings...
  • Page 31 Item Initial 300 km 1000 km 4000 km or every 6 Months Chassis Fasteners Control Meter Cables Throttle Grip Housing/Cable Centerstand/Sidestand Headlight and Other Lights Additional Fasteners R: Replace or Service/Adjustment Due I: Inspect and Replace as Necessary NoTe: For the best performance from your TNG scooter have a TNG dealer perform all service maintenance.

  • Page 32: Rear Brake Adjustment

    CAUTION: This scooter uses tubeless tires on the front and rear wheels, always replaced with tires of the same type. Fig. 4 Fig. 5, Brake Adjustment Nut reAr brAKe ADjuSTMeNT Total free play for brake lever should not exceed 30 mm. See Fig. 4. To firm up brake, turn nut clockwise until you reach the acceptable level.
  • Page 33 Fig. 6, Reservoir Level Fig. 7, Opening the Reservoir CAUTION: • Be sure not to introduce any water or air into the brake system when changing the fluid. • Do not spill any brake fluid on any other scooter parts as the fluid can damage metal and paint. •...
  • Page 34 SpArK pluG replACeMeNT Check spark plug if scooter is hard to start. The gap should be between 0.023 & 0.032 inches. The electrode should be a light brown color. Replacing the spark plug, • Remove the plug cover and remove the spark plug using the spark plug wrench in the tool kit. •...
  • Page 35 Stop the scooter on a level surface and turn the engine off. Put the scooter on its center stand and let the engine sit for a few minutes. Remove the oil dipstick, wipe it with a clean towel and replace it. Just rest the dipstick on the threads, do not screw it down into place when measuring the oil level.
  • Page 36 Refill the gearbox until full. Reinstall the oil fill plug. Transmission Oil Drain Plug Transmission Oil Fill Plug ! WARNING: Use caution when changing oil to avoid burns! CAUTION: • If the scooter is used in excessively wet areas, or used in severe conditions replace the transmission oil more often than recommended.
  • Page 37 AIR FILTER MAINTENANCE • The air filter should be inspected and cleaned every 1000 km interval. • Remove left body cover. • Remove the screws that hold the cover of the air cleaner in place and lift off the air cleaner cover. (See page 13 for air box location) •...

  • Page 38: Battery Maintenance

    BATTERY MAINTENANCE Your Scooter uses a calcium sealed, maintenance free, VRLA battery and you should not remove the sealing strip once the battery has been installed and prepped by a TNG dealer. NOTE: To protect your battery against failure it is important to keep your battery fully charged. This applies primarily if you are not riding your scooter on a regular basis or are traveling only short distances while you ride.
  • Page 39 FUSE REPLACEMENT Main Fuse The main fuse is located next to the battery in the floorboard; it is rated at 15 Amps. A visual inspection of the fuse will tell if the fuse is “open” (burned out). If the fuse is open, then it needs replacement. NOTE: Check fuse for good tight contact within fuse housing.

  • Page 40: Winterizing

    intermittent electrical problems and possible overheating of the fuse contacts. • Always replace the open fuse with another of the same type! • When washing your scooter, be sure not to get water into the fuse box as this could cause electrical problem.
  • Page 41 BATTERY Maintaining the state of charge of your scooter battery during an extended period of storage is essential to insure the maximum service life of the battery. If at all possible, remove the battery from the vehicle. Clean the battery and terminals using a solution of baking soda and water, making sure that none of the solution enters the battery during cleaning.
  • Page 42 charging again until power to the charger has been disconnected and reconnected. If your charger is one that will continue to charge even after the battery reaches 100%, you must manually disconnect power to the charger when charging is complete or the battery may be damaged from overcharging. These chargers should normally be connected for only a few hours at a time.
  • Page 43 B. WET FUEL SYSTEM This technique is suitable if you are going to store your bike in a heated location where condensation due to temperature fluctuations is not a problem. purchase fuel stabilizer and add it to a nearly full tank of gasoline in the concentration indicated on the label for long-term storage.
  • Page 44 In most cases it will require a little more work to get both wheels off the ground. Place a thick wooden plank or other object on the floor, making sure that the plank is long enough to easily accommodate the width of your center stand.

  • Page 45: Troubleshooting

    K. TroubleSHooTING ENGINE WON’T START Check For Fuel Ignition Key Must be to the Right Check Kill Switch is in the Run Position Depress Either Brake Lever Push Start Button on the Right Handle Bar If the Engine Doesn’t Turn Over Charge or Replace the Battery ENGINE IS DIFFICULT TO START 1.
  • Page 46 2. Check Compression Have TNG dealer inspect the No Compression scooter With Compression Check Spark Plug 3. Spark plug No Spark Remove Plug & Prime Kick Spark Plug Wet or Fouled the Start Pedal without Fuel & Ignition. Re-install Spark Plug Intermittent Spark Plug Lead Replace Lead Spark Plug Dirty or Wrong...
  • Page 47 4. Carburetor Carburetor Defective Blocked Idle Jet Clean Jet Dirty Float Bowl Clean Bowl Low Fuel in Bowl Adjust Bowl Carburetor OK Engine Overheated Check & Replace Lubricating Oil Air Inlet System Blocked or Remove Blockage or Leak Leaky KNoCKING SouND IN CylINDer Causes Solutions 1.
  • Page 48 LOW POWER OUTPUT FROM ENGINE Causes Solutions Clean Air Filter 1. Air Cleaner Blocked 2. Fuel Line in Carburetor Blocked Remove Residue 3. Excessive Carbon Deposit on Piston in Cylinder & Remove Carbon Build-up Exhaust System 4. Piston & Cylinder Excessively Warn Replace Piston &...
  • Page 49 POOR FUEL ECONOMY Causes Solutions 1. Fuel System Leaks Repair Leak 2. Spark Plug Worn Replace Spark Plug 3. Air Cleaner Blocked Clean Air Filter 4. Idle Speed Too High Adjust Idle Speed 5. Riding at Excessive Speeds Ride at More Economical Speeds FUEL DRAINING FROM CARBURETOR OVERFLOW TUBE Causes Solutions...
  • Page 50 Owner and dealer sign Owner Registration Card at time of purchase. This information is kept in CMSI’s warranty system and can be requested thru an authorized dealer. In the case of a transfer of ownership during the warranty period, the new owner must submit a written request to update the owner registration data on file for that particular vehicle.
  • Page 51 • The repair or replacement of defective parts under this limited warranty must be made by an Authorized CMSI Dealer or service center. Warranty repairs will be made at no charge to you for parts or labor. •...
  • Page 52 An authorized CMSI dealer is your best source for scheduled maintenance on your vehicle. If warranty repairs are needed, your dealer may ask you for documentation which may consist of one or more of the following: •...
  • Page 53 *NOTICE: Basic engine warranty covers 12 months. Use of Opti-2 oil for all 2 stroke vehicles, and Opti-4 oil for all 4 stroke vehicles, purchased, registered with CMSI, and used throughout the entire warranty period, will double the engine warranty period to 24 months.
  • Page 54 WARRANTY DISCLAIMERS, LIMITATIONS & EXCLUSIONS Disclaimer of Consequential Damage & Limitation of Implied Warranties CMSI INC. DISCLAIMS ANY RESPONSIBILITY FOR: • Loss of time • Loss of use of vehicle • Transportation expenses (rental and /or towing) • Any other incidental or consequential damage •...
  • Page 55 YOUR LEGAL RIGHTS These warranties give you specific legal rights. You may also have other rights which vary from state to state. It is the responsibility of the owner to be aware of state laws which pertain to this issue in your particular state. THESE WARRANTIES DO NOT COVER Failures which are not due to a defect in material or factory workmanship.
  • Page 56 Replacement of expendable maintenance item including, but not limited to:  Spark Plug  Gaskets  Coolant  Belts  Filters  Hoses  Lubricants  Fuses  Tires  Light Bulbs (See Owner’s Manual)  Battery  Hand Grips ...
  • Page 57 Replacement parts refer to Distributors Limited Warranties – Replacement Parts DISTRIBUTORS LIMITED WARRANTY – NEW MOTORCYCLE CMSI warrants to the first retail purchaser and subsequent purchasers of this vehicle that the motorcycle is free from defects in materials and workmanship for the period stated in “Warranty Time Table.”...
  • Page 58 Tires distributed and sold by CMSI which are either • Original equipment on CMSI vehicles, or • Specified by CMSI for the model the tire is installed on and purchased from an Authorized Dealer for replacement use. • To qualify for this warranty •...
  • Page 59 The replacement of a defective tire under this warranty must be made by an Authorized CMSI Inc Dealer. REPLACEMENT CHARGES – UP TO 50% TREAD WEAR Tire: No charge for a new direct replacement tire.
  • Page 60 DISTRIBUTOR’S LIMITED WARRANTY – REPLACEMENT PARTS WARRANTY TIME PERIOD: See “Warranty Coverage Table” on page 4 of Warranty Section. Coverage begins: The date of purchase from an Authorized CMSI Dealer. To qualify for this warranty, the genuine CMSI part •...
  • Page 61 WARRANTY COVERAGE • CMSI Inc will repair or replace, at its option, any genuine CMSI part that is defective in material or workmanship under normal use. • Proof of date of purchase is required. Parts installed by an Authorized CMSI Dealer: Parts &...
  • Page 62 For this reason it is very important for you to notify CMSI of any change of address or ownership. NHTSA cannot become involved in individual problems between you, your dealer or CMSI.
  • Page 63 Also included may be hoses, belts, connector and other emission-related assemblies. Where a warrantable condition exists, CMSI will repair your vehicle at no cost to you, including diagnosis, parts and labor.
  • Page 64 As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. CMSI recommends that you retain all receipts covering maintenance on your vehicle, but CMSI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 65 Coverage. Warranty defects shall be remedied during customary business hours at any authorized CMSI dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board.
  • Page 66 Any vehicle equipped with an odometer on which the odometer mileage reading has been changed so that actual mileage cannot be readily determined. III. Limited Liability. The liability of CMSI under this Emission Control System Warranty is limited solely to Appendix...
  • Page 67 This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the CMSI dealer. CMSI SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE VEHICLE FOR ANY PURPOSE.
  • Page 68 ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, CMSI is not liable for these parts. The owner is responsible for the performance of all required maintenance.
  • Page 69 Inc. Motorsports CMSI Inc., Motorsports 8146 304th Ave. SE, P .O. B ox 969 Preston, WA 98050, USA Phone: 425-222-7738 Fax: 425-222-7739...

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