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Baja Comet 90cc BC90 Owner's Manual

Manual is about: Mini Bike

Summary of Comet 90cc BC90

  • Page 1

    Always wear a helmet; it could save your life! Do not remove this operator’s manual from this vehicle. Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle. Owner’s manual model number: bc90 minimum age requir...

  • Page 2

    Ii congratulations on your purchase of the baja inc. Mini bike. Your mini bike is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days from the date of purchase. During the warranty period baja, inc. Will at its option, repair, provide replacement parts o...

  • Page 3: The Vehicle.

    Iii 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. Wa...

  • Page 4: Table of Contents

    1 notice to users .............................................................................................2 safe operation ..............................................................................................3 safety gear ...................................................................

  • Page 5

    2 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 attention to the messages. Note: indicating special information which is to make maintenance easier or instructions clear...

  • Page 6: Safe Operation

    3 safe operation rules for safe operation · a pre-operation check must be conducted before starting engine to 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. · f...

  • Page 7: Safety Gear

    4 safety gear 1. Never operate this mini bike without wearing a dot approved motorcycle helmet which fits properly. Operators should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. 2. Loose clothes are not suitable for motorcycle drivin...

  • Page 8: Pre-Ride Checklist

    5 pre-ride checklist before starting the engine 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. D) replace cap tightly. E) do not refuel...

  • Page 9: Main Data

    6 main data description data description data overall length 1539 mm (60.61 in.) brake type drum overall width 669.8 mm (26.37 in.) capacity of gasoline tank 3l (.79 gal.) 87 octane or higher unleaded gasoline overall height 959.6 mm (37.78 in.) capacity of oil tank .24l (.25 qt.) wheelbase 1070 mm ...

  • Page 10: Parts & Subassemblies

    7 parts & subassemblies brake lever throttle twist grip engine stop switch.

  • Page 11: Parts & Subassemblies

    8 front wheel front shock absorber side stand rear wheel seat cushion air filter headlight foot pegs drive chain vehicle identification number brake drum rear shock kick start lever oil fill plug/dipstick carburetor spark plug ignition key switch taillight parts & subassemblies fuel tank located und...

  • Page 12: Location of Warning Labels

    9 1 2 location of warning labels read and follow all of the warnings labels on your mini bike. Make sure you understand all the labels. Keep the labels on the mini bike. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting b...

  • Page 13: Operation

    10 operation fuel filling the capacity of the fuel tank is 3l (.79 gal) use only 87 octane or higher unleaded gasoline. 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 engi...

  • Page 14: Engine Starting

    11 engine starting 1. Set ignition key switch to “ ” (on) position. 2. Place mini bike in neutral gear. 3. Ensure there is fuel in fuel tank. To start a cold engine: 1. Place choke lever in “up” (on) position. 2. Start engine with kick lever 3. Once engine has started, allow engine to warm up approx...

  • Page 15: Left Handlebar Switch

    12 left handlebar switch engine stop switch the engine stop switch is provided on the left handlebar. When the switch is turned to “ ” (off) position, the engine will not start or will stop engine if running. When the switch is turned to “ ” (on) position, the engine can start and the vehicle can be...

  • Page 16: Gear Shifting

    13 gear shifting reduce throttle before shifting. Never increase the throttle while shifting gears. Depress shift lever to place gear in 1st, 2nd, 3rd or 4th. Lift up on shift lever to down shift or place gear in neutral. Do not rest foot on gear-shift lever while operating mini bike. Resting foot o...

  • Page 17

    14 check-ups, adjustment and maintenance checking the oil check engine oil each time prior to operating mini bike. The oil level should be between the upper and lower lines on oil dipstick. 1. Set mini bike on level ground, remove oil plug/dipstick, wipe dipstick clean, insert dipstick into crankcas...

  • Page 18: Changing The Oil

    15 changing the oil 1. Let engine warm up approximately 3 minutes to warm up oil. 2. Shut off engine, remove “screw plug” located at bottom of the engine and let oil drain into an approved collection container. Do not perform this procedure while the engine is hot. Serious burns could result from co...

  • Page 19: Valve Inspection

    16 valve inspection refer to maintenance schedule in this owner’s manual for valve adjustment inspection intervals. Valve clearance should be: intake: 0.002 inch (0.05 mm) exhaust: 0.003 inch (0.0762 mm) excessive clearance will cause noise. Insufficient clearance will cause loss of power and possib...

  • Page 20

    17 checking & cleaning the air filter tap air filter on a firm surface to dislodge as much dirt and debris as possible. Note: if tapping air filter does not remove the dirt and debris, replace air filter. Caution the air filter element must be intact or the engine will suck in dust and dirt, resulti...

  • Page 21: Adjusting Throttle Cable

    18 adjusting throttle cable make sure throttle cable is adjusted properly. To adjust throttle cable, rotate adjustment nut located at the hand throttle. Check if throttle twist grip has the required free operating movement. The required free operating movement: 2 - 6 mm (0.078 -0.24in) . If the grip...

  • Page 22: Adjustment Of Rear Brake

    19 adjustment of rear brake 1. To make adjustment, turn rear adjusting nut clockwise to increase braking or counterclockwise to decrease braking. 2. Brake shoes should be replaced by a qualified service technician once brake shoes are worn. Brake cable rear brake arm rear brake adjusting nut adjustm...

  • Page 23: Adjustment Of Chain

    20 greasing procedures to drive chain 1. Shut off engine 2. Add a light amount of chain lube to drive chain. (too much oil or chain grease may cause splattering to occur.) attention: the chain should be replaced when the adjusting limit has reached it’s maximum. Adjustment of chain 1. When chain adj...

  • Page 24: Vehicle Washing

    21 vehicle washing cleaning the vehicle regularly can slow down color fading and make it easier to check for damage and/or oil leakage. 1. After pre-wiping, the vehicle should be washed with clean water to remove dirty residues so as to prevent corrosion. Plastic subassemblies should be cleaned by w...

  • Page 25: Instructions For Storage

    22 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 components. 1. Change engine oil. 2. Drain fuel from the fuel tank and carburetor. Spray atomized anti-rust oi...

  • Page 26

    23 resumption of service after storage 1. Remove covering and remove wooden blocks used in storing the vehicle. Change engine oil if the vehicle has been out of service for over 4 months. 2. Drain off any remaining atomized anti-rust oil from the fuel tank. Fill tank with fresh gasoline. 3. Prior to...

  • Page 27: Maintenance Schedule

    24 “*” means: this item of maintenance should be carried out at a service center. It may be also done by the user with reference to this manual provided special tools and authorized spare parts are used. The user must also be capable of completing the procedure. “**” means: this item can only be car...

  • Page 28: Troubleshooting

    25 troubleshooting symptom possible fix 1. Choke open move choke lever to closed 2. Out of fuel refuel 3. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline drain fuel from fuel tank and carburetor. Refuel with fresh gasoline 4. Spark plug faulty, fouled, or...

  • Page 29: Wire Diagram

    26 wire diagram ig nition swit ch fron t brake s witch rear br ake swit ch tail/br ake ligh t 12vdc 5/21w fuse 10a batt ery head ligh t 12v ac 18w regula tor m ag net o ig nition c oil spark plug cdi b/y w/b b/w b/r b/w w y r g y g g g g g b b g/y g g b b/w r w w hit e r r ed y yello w g gr een b/w ...

  • Page 30

    27 vin. And serial number location you need to know the frame vin# and engine serial numbers. You need these numbers to help your authorized service center or baja inc. Order parts. The frame number is stamped on front of mini bike frame. The engine number is located on the left side of the engine h...

  • Page 31

    28 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,...

  • Page 32

    29 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 i...

  • Page 33: Baja, Inc.

    Baja, inc. P.O. Box 61150 phoenix, az 85082 tel: 602-443-9180 toll free: 1-888-863-2252.