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Baja DR125 Owner's Manual

Summary of DR125

  • Page 1

    Dr125 dirt bike read this manual carefully. It contains important safety information. 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. No one under th...

  • Page 2

    Ii congratulations on your purchase of the baja inc. Dr125 dirt bike. Your bike is warranted to be free of manufacturing defects in the material of 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 par...

  • Page 3: 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

    Notice to user’s ............................................................................................2 safe operation ..............................................................................................3 pre-ride checklist ..............................................................

  • Page 5

    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. Note: indicating special information which is to make maintenance easier or instructions clear...

  • 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 ...

  • 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. D) replace cap tightly. E) do not re...

  • 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. You should wear e...

  • Page 9: Location of Warning Labels

    Location of warning labels read and follow all of the warnings labels on your dirtbike. Make sure you understand all the labels. Keep the labels on the 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....

  • Page 10: Main Data

    Description data description data overall length 1930mm (76 inches) cylinder bore x stroke 56.5mm x 49.5mm overall width 100mm (43.3 inches) compression ratio 8.9:1 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 w...

  • Page 11: Parts & Subassemblies

    Parts & subassemblies throttle twist grip front brake lever fuel tank cover brake fluid reservoir clutch lever on/off switch.

  • Page 12: Dr125

    Seat cushion exhaust silencer kick start lever side stand rear fork rear wheel carburetor rear brake caliper front shocks front brake caliper gas cap oil cap front wheel reflectors reflectors dr125.

  • Page 13: Operation

    0 fuel valve on fuel valve off fuel valve reserve 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 ...

  • Page 14: Engine Starting

    Engine starting 1. Set the key of the ignition switch to “ ” position. 2. Put the dirt bike in the neutral gear. 3. Ensure that there is fuel in the tank. 4. Set the fuel valve handle to “on” or “res” position. To start a cold engine: 1. Pull up the choke lever of the carburetor (to close the choke)...

  • 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. Never drive your dirt bike continuously for more t...

  • Page 16: On Button

    On button off button 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 turne...

  • Page 17: Gear Shifting

    Gear shifting reduce throttle before shifting. Never increase the throttle while shifting gears. 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. Do not place your foot on the gear-shifting...

  • Page 18

    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. 1. Set...

  • Page 19: Check-Up Of Spark Plug

    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...

  • Page 20

    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. Apply a few drops of machine...

  • Page 21: Adjusting The Carburetor

    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 throt...

  • Page 22

    1. Inspect the front disk brake caliper for leakage. If brake fluid leaks, the safety of riding could be affected. 2. Inspect the brake hose for cracks, and the joint for leakage. 3. Check the brake fluid level in the brake fluid reservoir, if level is at or below the lower mark, inspect brake pads ...

  • Page 23: Clutch Adjustment

    0 to adjust the clutch: 1. Loosen adjuster nut and move adjuster in or out to obtain the correct tension. 3. Tighten adjuster nut 4. Recheck the clutch lever free distance. Readjust it if it is not within the correct limits. Clutch adjustment clutch adjustment to adjust the clutch lever play: 1. Rem...

  • Page 24: Adjustment Of Chain

    Greasing procedures to the driving chain 1. Shut off the engine 2. Add light amounts of machine oil or chain grease to the driving chain. (too much machine oil or chain grease may cause splattering to occur.) attention: the chain should be replaced when the adjusting limit has reached it’s maximum. ...

  • Page 25: Troubleshooting

    Troubleshooting this troubleshooting guide is provided to help you to find the cause of some common complaints. Complaint: engine is hard to start or does not start at all. Something is probably wrong with the fuel system or ignition system. Fuel supplying check 1. Make sure there is adequate fuel i...

  • Page 26: Ignition System Check

    Ignition system check 1. Remove the spark plug and reattach it to the spark plug lead. 2. 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 jum...

  • 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. 1. After pre-wiping, the vehicle should be washed with clean water to remove dirty residues so as to prevent corrosion. Plastic subassembl...

  • Page 28

    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 mainte...

  • Page 29

    Resumption of service after storage 1. 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. 2. Drain off the remaining atomized anti-rust oil from the fuel tank, followed by filling it with fresh...

  • Page 30: Resumption Of Service

    Resumption of service 1. Remove the covering and clean the vehicle. Change the lubricating oil if the vehicle has been off service for more than 4 months. 2. Charge the battery, if applicable, and remount it. 3. Drain off the anti-rust solution from the fuel tank, followed by filling fuel therein to...

  • Page 31: Inspection And Maintenance

    Item initial 1 months initial 3 months every 3 months every 6 months * valves i i spark plug c c r air filter i every 20 - 40 hours (more often in dusty areas) * carburetor i i * exhaust system i spark arrester i fuel hose i i engine oil r r engine oil filter c c engine oil strainer c c brake fluid ...

  • Page 32: Serial Number Location

    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...

  • Page 33: Dr125 Wire Diagram

    0 dr125 wire diagram.

  • Page 34

    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...

  • 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 ...

  • Page 36

    6. Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the distributor. 7. Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immediately and completely voids this an...

  • Page 37: Baja Inc.

    Baja inc. P.O. Box 61150 phoenix, az. 85082 toll free: 866-250-7155 service center line: 866-401-2252.