Baja motorsports DR125 Owner's Manual
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Baja motorsports DR125 Owner's Manual

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DR125 Dirt Bike
Read this manual carefully. It contains important safety information.
OWNER'S MANUAL
No one under the age of 16 should operate this Dirtbike without adult
supervision. Parents should consider child's age, size, maturity and ability
before allowing to ride.
Max. Weight Limit: 250lbs. (113kg)
Always wear a helmet; It could save your Life!
Please obtain, review, and follow the municipal, provincial and government
acts and regulations pertaining to owning and operating an off-road vehicle.
Rev. C
052208

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  • Page 1 DR125 Dirt Bike Read this manual carefully. It contains important safety information. OWNER’S MANUAL No one under the age of 16 should operate this Dirtbike without adult supervision. Parents should consider child’s age, size, maturity and ability before allowing to ride.
  • Page 2 Should you experience a problem or need to return your BAJA INC. DR125 Dirt Bike for repair, please call the BAJA INC. customer service department TOLL FREE at 1-866-250-7155 between the hours of 7am and 5pm Monday thru Friday 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS NOTICE TO USER’S ....................2 SAFE OPERATION ....................3 PRE-RIDE CHECkLIST ..................4 SAFETY GEAR ....................5 LOCATION OF WARNING LABELS..............6 MAIN DATA ......................7 PARTS & SUBASSEMBLIES ................8 OPERATION ......................10 FUEL VALVE ....................10 ENGINE STARTING ..................11 BREAkING IN THE ENGINE ...............12 SWITCHES ON THE RIGHT HANDLEBAR ..........13 GEAR SHIFTING ..................14 CHECk-UPS, ADJUSTMENT AND MAINTENANCE..........15...

  • Page 5: Notice To User's

    Please read this manual and follow all instructions carefully. To emphasize 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

    SAFE OPERATION Rules for Safe Operation A pre-operation check must be conducted before starting the engine. This check will 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. Full attention is required during driving;...

  • Page 7: Pre-Ride Checklist

    Pre-Ride Checklist Before Starting the Engine/Motor 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 8: Safety Gear

    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. WARNING Operating this Dirt bike without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be...

  • Page 9: Location Of Warning Labels

    Dirtbike. 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. WARNING/AVERTISSMENT No one under the age of 16 should operate this vehicle without adult supervision.

  • Page 10: Main Data

    MAIN DATA DESCRIPTION DATA DESCRIPTION DATA Overall length 1930mm (76 inches) Cylinder bore X 56.5mm X 49.5mm stroke Overall width 100mm (43.3 inches) Compression 8.9:1 ratio Overall height 1199mm (47.2 inches) Max output 7.5kW/8500rpm (11.4hp) Wheelbase 1320mm (51.97 inches) Max torque 8.0kW/6500r/min Dead weight 100kg (220.5 lbs.)

  • Page 11: Parts & Subassemblies

    PARTS & SUBASSEMBLIES Brake fluid reservoir Clutch Lever Front brake lever On/Off switch Throttle twist grip Fuel tank cover...
  • Page 12 DR125 Gas Cap Reflectors Exhaust Silencer Seat Cushion Front Shocks Reflectors Rear Fork Rear Wheel Carburetor Oil Cap Front brake caliper Rear brake kick start lever Side Stand caliper Front Wheel...

  • Page 13: Operation

    OPERATION FUEL VALVE Fuel filling The capacity of the fuel tank is 5.7L (1.5gal) . 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

    ENGINE STARTING CAUTION Verify oil level prior to starting (see page 15) 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. Set the key of the ignition switch to “...

  • Page 15: Breaking In The Engine

    BREAkING IN THE ENGINE The first 600 Miles of operation should be considered the “Break-in” period and special attention shall be paid to the following points: 1. Take special care not to increase the RPM’s of the engine while climbing steep slopes.

  • Page 16: Switches On The Right Handlebar

    SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is Located on the right handlebar. When the switch is turned to “ ” (off) position, the engine will not start. If the engine is running and the Off button is pushed the engine will turn off. When the switch is turned to “...

  • Page 17: Gear Shifting

    GEAR SHIFTING Reduce throttle before shifting. Never increase the throttle while shifting gears. Clutch lever Pull in the clutch lever, located on the left hand grip. Depress the Shift lever to place the gear in 1st, lift up the lever to shift to 2nd, 3rd, 4th and 5th.

  • Page 18: Check-Ups, Adjustment And Maintenance

    CHECk-UPS, ADJUSTMENT AND MAINTENANCE Checking the Oil Check the engine oil each time prior to operating the dirt bike. The oil level should be between the upper and lower lines of the oil sight gauge located on the right cover of the crankcase. The level can also be checked on the dip stick.

  • Page 19: Changing The Oil, Cleaning Oil Filter Screen

    CHANGING THE OIL, CLEANING OIL FILTER SCREEN 1. Remove the oil drain plug, spring and oil filter screen 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 20: Checking & Cleaning The Air Filter

    CHECkING & CLEANING THE AIR FILTER Air filter is located under left side plastic cowling. Cowling will need to be removed. Take the air filter out and check to see if it is dirty or torn. Remove foam element and wash with water and allow it to dry per instructions below.

  • Page 21: Adjusting The Throttle Cable

    ADJUSTING THE THROTTLE CABLE Make sure the throttle works normally. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078 inches - .24 inches) If the grip cannot be moved freely, turn the adjusting nut located on top of the throttle twist grip to ensure proper operating movement.

  • Page 22: Inspection Of Front Hydraulic Brake

    FRONT HYDRAULIC DISk BRAkE INSPECTION Brake fluid reservoir Brake fluid cap Brake hose Lower mark Brake fluid level Front disk brake caliper 1. Inspect the front disk brake caliper for leakage. If brake fluid leaks, the safety of riding could be affected. 2.

  • Page 23: Clutch Adjustment

    CLUTCH ADJUSTMENT Clutch lever adjustment nut 3.0 - 5.0mm play (0.12 inches-0.20 inches) To adjust the clutch lever play: Remove the adjuster cover (slide back on cable). Loosen adjuster nut and move adjuster in or out to obtain the correct play.

  • Page 24: Adjustment Of Chain

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

  • Page 25: Troubleshooting

    Failing to troubleshoot a problem correctly would damage your Dirt Bike. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty. If you are not sure about the proper action, consult your authorized service center or BAJA INC. about the problem. Fuel Supplying Check Make sure there is adequate fuel in the fuel tank.
  • Page 26 Ignition System Check Remove the spark plug and reattach it to the spark plug lead. Turn ignition key to the “RUN” position. Slide the engine stop switch to the “Run” position. Push the electric button “START “(grey button). If the ignition system is operating properly, a blue spark should jump across the spark plug gap.

  • Page 27: Vehicle Washing

    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 motorcycle with over-pressurized water may cause damage to some of its components. Therefore, do not use a pressure washer to clean the vehicle.

  • Page 28: 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 its components which might be caused by long storage. Before storing the vehicle for a long period, proper maintenance has to be done.

  • Page 29: Resumption Of Service After Storage

    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 30: Resumption Of Service

    RESUMPTION OF SERVICE Remove the covering and clean the vehicle. Change the lubricating oil if the vehicle has been off service for more than 4 months. Charge the battery, if applicable, and remount it. Drain off the anti-rust solution from the fuel tank, followed by filling fuel therein to the required level.

  • Page 31: Inspection And Maintenance

    INSPECTION AND MAINTENANCE It is very important to inspect and maintain your DR125 regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed.

  • Page 32: Serial Number Location

    You need to know the frame and engine serial numbers to get title documents for your Dirt Bike. You also need these numbers to help your authorized service center or BAJA INC. order parts. The Frame number is stamped on front of Dirt bike frame. The engine number is located on the left side of the engine housing.

  • Page 33: Electrical Diagram

    DR125 wire diagram...

  • Page 34: 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...
  • Page 35 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 36 No dealer is authorized to modify this Emission Control System Warranty. If you have any questions regarding your warranty rights and responsibilities, you should contact BAJA INC. (888) 863-2252.
  • Page 37 Baja INC. P.O. Box 61150 Phoenix, AZ. 85082 Toll Free: 866-250-7155 Service Center Line: 866-401-2252...

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