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Baja motorsports DR125 Owner's Manual - Adjustment Of Chain

Other manuals for DR125: Owner's Manual
Manual is about: Dirt Bike

Summary of DR125

  • Page 1

    Dr125/dr150 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 un...

  • Page 2

    Ii congratulations on your purchase of the baja inc. Dr125/dr150 dirt bike. Your bike is warranted to be free of manufacturing defects in the 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 replacem...

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

  • 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 Dr125

    7 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...

  • Page 11: Main Data Dr150

    8 description data description data overall length 1930mm (76 inches) cylinder bore x stroke 69mm x 53mm overall width 100mm (43.3 inches) compression ratio 9.0:1 overall height 1199mm (47.2 inches) max output 8.5kw/9500rpm (11.4hp) wheelbase 1320mm (51.97 inches) max torque 8.2n.M/7500r/min dead we...

  • Page 12: Parts & Subassemblies

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

  • Page 13: Dr125/dr150

    10 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 dr125/dr150

  • Page 14: Operation

    11 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 15: Engine Starting

    12 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 16: Breaking In The Engine

    13 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 17: On Button

    14 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 tu...

  • Page 18: Gear Shifting

    15 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-shift...

  • Page 19

    16 ! 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...

  • Page 20: Check-Up Of Spark Plug

    17 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 w...

  • Page 21: Valve Inspection

    18 valve inspection refer to maintenance schedule in this owner’s manual for valve adjustment inspection intervals. Valve clearance should be: intake: 0.002 inch (0.051 mm) exhaust: 0.002 inch (0.051 mm) the engine will make excess noise if the gap is too large in air valve. If gap is too small valv...

  • Page 22

    19 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 mac...

  • Page 23: Adjusting The Carburetor

    20 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 th...

  • Page 24

    21 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 pa...

  • Page 25: Clutch Adjustment

    22 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. Re...

  • Page 26: Adjustment Of Chain

    23 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 27: Troubleshooting

    24 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 28: Ignition System Check

    25 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 ...

  • Page 29: Vehicle Washing

    26 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 subasse...

  • Page 30

    27 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 mai...

  • Page 31

    28 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 32: Resumption Of Service

    29 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 33: Maintenance Schedule

    30 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 engine...

  • Page 34: Serial Number Location

    31 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 35: Dr125/dr150 Wire Diagram

    32 off run engine stop switch cdi ignition coil magneto b/w g g g bl/w b/w b/r b/y b-black w-white r-red g-green bl-blue y-yellow b/y dr125/dr150 wire diagram.

  • Page 36

    33 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 37

    34 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 38

    35 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 39: Baja Inc.

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