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Baja DR49 Owner's Manual

Summary of DR49

  • Page 1

    Dr49 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 provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle. No one under the age of...

  • Page 2

    Ii congratulations on your purchase of the baja inc. Dr49 dirt bike. Your 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: 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 table of contents safe operation ..............................................................................................3 safety gear ....................................................................................................4 location of warning labels................................

  • Page 5

    2 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 cle...

  • Page 6: Safe Operation

    3 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 th...

  • Page 7: Pre-Ride Checklist

    4 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 ...

  • Page 8: Safety Gear

    5 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...

  • Page 9: Location of Warning Labels

    6 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 in...

  • Page 10: Main Data

    7 description data description data overall length 1420mm (55.91 inches) max torque 3.2n.M/6500 r/min overall width 450mm (17.72 inches) idle speed 1500r/min±150r/min overall height 740mm (29.13 inches) displacement of cylinder 49ml wheelbase 1020mm (10.16 inches) spark plug a7rtc dry weight 60kg (1...

  • Page 11: Parts & Subassemblies

    8 parts & subassemblies throttle twist grip front brake lever fuel tank cover on/off switch.

  • Page 12: Left

    9 left right seat cushion exhaust silencer kick lever rear brake pedal front wheel fuel valve gear shifting pedal side stand rear wheel carburetor choke lever on carburetor front shocks gas cap oil cap drive chain front brake lever.

  • Page 13: Operation

    10 operation fuel valve fuel filling the capacity of the fuel tank is 3.3l . 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 aligni...

  • Page 14: Engine Starting

    11 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 cho...

  • Page 15: Breaking In The Engine

    12 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 mor...

  • Page 16: Ignition Switch

    13 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 “ ” (on) posi...

  • Page 17: Gear Shifting

    14 gear shifting reduce throttle before shifting. Never increase the throttle while shifting gears. Depress the gear shift pedal to place the gear in 1st, lift up the lever to shift to 2nd, 3rd, 4th. Do not place your foot on the gear-shifting pedal while operating the dirt bike to avoid damaging th...

  • Page 18: Checking The Oil

    15 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 fill cap/ dipstick. 1. Set the motorcycle on level ground. Remove the oil fill cap/dipstick, wipe it clean a...

  • Page 19: Changing The Oil

    16 changing the oil 1. 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. 2. Dispose of the used oil properly. For proper d...

  • Page 20: Valve Inspection

    17 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 (0.076 mm) the engine will make excess noise if the gap is too large in air valve. If gap is too small valve...

  • Page 21

    18 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. Tap the air filter clean. If necessary use compressed air to gently clean. Caution the air filter element mu...

  • Page 22: Adjusting The Carburetor

    19 adjusting the throttle cable make sure the throttle works properly. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078” - .24”) if the grip cannot be moved freely, turn the adjusting nut located on top of the throttle twist...

  • Page 23: Adjustment of Front Brake

    20 the front brake lever has a free operating movement of 10-20mm as shown. 1. Turn the adjusting nut beneath the front hub, clockwise to increase and counter clockwise to decrease the free operating movement. 2. You can also adjust the nut on the handlebar; clockwise to increase and counter clockwi...

  • Page 24: Adjustment Of Chain

    21 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 maximu...

  • Page 25: Exhaust

    22 exhaust warning the hot exhaust muffler could burn you. The muffler will be hot enough to burn you after stopping the engine. Wait until the exhaust muffler cools to remove it. Warning running the engine indoors or in a garage could be hazardous. Exhaust gas contains carbon monoxide that is color...

  • Page 26: Troubleshooting

    23 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 fue...

  • Page 27: Ignition System Check

    24 ignition system check 1. Remove the spark plug and reattach it to the spark plug lead. 2. Turn engine switch to “on”. Start the engine. If the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is no spark, take your machine to your service center....

  • Page 28: Vehicle Washing

    25 vehicle washing cleaning the vehicle regularly can slow down color fading. It will also make it easier to check to see if there is any damage and/or 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 sub...

  • Page 29: Instructions For Storage

    26 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 ma...

  • Page 30

    27 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 fr...

  • Page 31: Resumption Of Service

    28 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...

  • Page 32: Inspection And Maintenance

    29 item initial 1 months/ 20 hrs initial 3 months/ 50 hrs every 3 months/ 50 hrs every 6 months/ 100 hrs * valves i i spark plug c c r valve clearance-check- adjust i 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 engin...

  • Page 33: Serial Number Location

    30 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...

  • Page 34: Dr49 Electrical Diagram

    31 dr49 electrical diagram black/yellow black/red black/white green blue/white black/yellow green green black/ white blue/ white green black/red.

  • Page 35

    32 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 36

    33 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 original...

  • Page 37

    34 o 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. • failures not caused by a defect in material or ...

  • Page 38: Baja, Inc.

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