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DB30 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
Weight capacity: 150 lbs.
Always wear a helmet; It could save your Life!
Please obtain, review, and follow provincial / municipal government acts and
regulations pertaining to owning and operating an off-road vehicle.
Rev. G
052108
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Table of Contents
Summary of Contents for Bajaj Motorsport DB30 Mini Bike
- Page 1 DB30 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 Weight capacity: 150 lbs. Rev. G 052108 Always wear a helmet; It could save your Life! Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle.
- Page 2 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. Should you experience a problem or need to return your BAJA INC. DB30 Mini Bike for repair, please call the BAJA INC. 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 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY ------------------------------------------------------- Safe Operation ------------------------------------ Safety Gear ----------------------------------------- Location of Labels ------------------------------- SPECIFICATIONS ------------------------------------------ LOCATION OF PARTS ----------------------------------- OPERATION ------------------------------------------------- Left and Right Hand Grip ----------------------- Engine ON/ OFF switch and Pull Cord ------ Fuel Fill ---------------------------------------------- Fuel Valve ------------------------------------------- INSPECTION BEFORE RIDING ------------------------- ENGINE STARTING AND STOPPING -----------------... -
Page 5: Safety
SAFETY 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
SAFETY 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. ITEM TO CHECK CONTENT Steering Smoothness; No restriction of movement; No play or looseness Brakes Proper brake lever free play;... - Page 7 SAFETY · 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. · It is important that this manual remain with the vehicle when you transfer it to another user or owner.
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Page 8: Safety Gear
SAFETY SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear. A DOT approved motorcycle helmet can help prevent a serious head injury. Choose a helmet that fits snugly. Motorcycle dealers can help in selecting a good quality helmet which fits properly. -
Page 9: Location Of Labels
SAFETY LOCATION OF LABELS... - Page 10 SAFETY LOCATION OF LABELS...
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Page 11: Specifications
SPECIFICATIONS Description Data Overall length 1295mm (50.98 inches) Overall width 640mm (25.20 inches) Overall height 860mm (33.86 inches) Wheelbase 935mm (36.81 inches) Dead weight 36kg (80lbs.) Payload 68.04kg (150 lbs.) Front wheel 145x70-6 Rear wheel 145x70-6 Brake type Disc Capacity of gasoline tank 1.4L (0.36 gal) Capacity of oil tank 0.45L (0.40 qt.) -
Page 12: Location Of Parts
LOCATION OF PARTS Hand brake Seat Cushion Spark plug Front Wheel Rear Wheel Oil fill Clutch cover plug Drive Chain Oil drain plug Kick Stand On/Off Button Throttle handle Gas Tank Air Filter Foot pegs Pull Start Cord Brake Caliper... -
Page 13: Operation
OPERATION LEFT AND RIGHT HAND GRIP OPERATION Brake Lever Throttle control grip ON button Right Hand Grip Left Hand Grip OFF button Pulling in brake lever located on left hand grip will stop mini bike. Applying the hand throttle (moving throttle counter clockwise ) will cause engine rpms to increase, causing mini bike to move forward. -
Page 14: Fuel Fill
OPERATION FUEL AND FUEL VALVE OPERATION Fuel filling The capacity of the fuel tank is 1.4L (.40 qt .) 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 15: Inspection Before Riding
INSPECTION BEFORE RIDING ITEM TO CHECK CONTENT Steering Smoothness; No restriction of movement; No play or looseness Brakes Proper brake lever free play; enough brake force. Tires Proper air pressure; Enough tread depth; No cracks, rips, or other damages Note: Check tire pressure, spec is located on side of tire. Fuel Enough fuel for the intended trip;... -
Page 16: Engine Starting And Stopping
ENGINE STARTING AND STOPPING CAUTION Verify fuel and oil level prior to starting (see pages 11 and 14) Starting the engine with low or no oil will damage the engine. WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide. -
Page 17: Inspection And Maintenance
INSPECTION AND MAINTENANCE CHECKING THE OIL Check engine oil each time prior to operating mini bike. The oil level should be between upper and lower lines of 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 18: Changing Oil
INSPECTION AND MAINTENANCE 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. -
Page 19: Checking And Cleaning Air Filter
INSPECTION AND MAINTENANCE CHECKING & CLEANING THE AIR FILTER Locate Air Filter Box at rear of engine 2. Remove air filter cover by unscrewing phillips head screw 3. Remove foam Air filter element. 4. Tap Air filter element gently to remove most of the dust and dirt. 5. -
Page 20: Adjusting The Throttle Cable
INSPECTION AND MAINTENANCE 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 21: Adjustment Of Rear Brake
INSPECTION AND MAINTENANCE ADJUSTMENT OF REAR BRAKE The front brake hand grip should have free operating movement of 5-7mm (.2-3in.) . Adjust with free play adjustment bolt. To make rear brake pad adjustment, turn rear adjusting bolt clockwise to loosen and counter clockwise to tighten brake tension. 3. -
Page 22: Adjustment Of Chain
INSPECTION AND MAINTENANCE ADJUSTMENT OF CHAIN When chain adjustment is needed, loosen 4 bolts under engine. Move engine forward to tighten chain or backward to loosen chain. Tighten bolts under engine Torque bolts to 25 ft./lbs. Repetitively check tension of chain. Nut 2 Nut 1 Tighten... -
Page 23: Clutch Cleaning And Maintenance
INSPECTION AND MAINTENANCE CLUTCH CLEANING AND MAINTENANCE After every 5 hour of use, your clutch will need cleaning and lubrication. If clutch becomes too dirty or has lack of lubrication, the clutch will have a tendency to stick. This will cause the Mini-Bike to want to take off before throttle is applied. -
Page 24: Vehicle Washing
INSPECTION AND MAINTENANCE 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 25: Instruction For Storage
INSPECTION AND MAINTENANCE 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 26: Resumption Of Service After Storage
INSPECTION AND MAINTENANCE 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 27: Maintenance Schedule
INSPECTION AND MAINTENANCE Every Every Each Use 1st MO/ Every Items of Maintenance Year/ 6 MO/ 3 MO/ 20 HR 300 HR 100 HR 50 HR 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,... -
Page 28: Troubleshooting
TROUBLESHOOTING Notes: Maintenance should be conducted more frequently when Mini Bike is driven in dusty areas. When Mini bike has exceeded the maximum figures specified in the table, maintenance should be still cycled according to the intervals of time or hours stated herein. -
Page 29: Electrical Schematic
ELECTRICAL SCHEMATIC Engine Switch Transistor Magneto Spark Plug Ignition Coil... -
Page 30: Emissions Control System Warranty
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 demonstrator, lease, or company vehicle, whichever comes first and continues for 30 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance... - Page 31 EMISSION CONTROL SYSTEM WARRANTY Your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injection system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assemblies.
- Page 32 EMISSION CONTROL SYSTEM WARRANTY • Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance • • Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. •...
- Page 33 Baja, INC. P.O. Box 61150 Phoenix, AZ 85082 Tel: 602-443-9180 Toll Free: 888-863-BAJA (2252)
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