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Baja motorsports DR90 Owner's Manual - Front Wheel

Manual is about: Dirt Bike

Summary of DR90

  • Page 1

    Dr90/wr90 dirt bike read this manual carefully. It contains important safety information. No one under the age of 16 should operate this dirt bike. 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 / mu...

  • Page 2

    Congratulations on your purchase of the baja inc. Dr90/wr90 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 replacement p...

  • 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. All op...

  • Page 4: Table of Contents

    Safe operation ..............................................................................................3 safety gear ....................................................................................................3 modification of vehicle ......................................................

  • Page 5

    Please read this manual and follow all instructions carefully. To emphasize special information, the symbol and the words warning or caution have special meaning. Pay attention to warnings and cautions. Note: indicating special information which makes maintenance easier and/or instructions clearer. ...

  • 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: 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 8: Parts & Subassemblies

    Parts & subassemblies front brake lever throttle twist grip fuel tank cover.

  • Page 9: Front Wheel

    Front wheel front shock absorber fuel valve gear shifting pedal engine number side stand rear fork rear wheel seat cushion exhaust silencer kick lever rear braking pedal.

  • Page 10: Operation

    Operation fuel valve fuel filling the capacity of the fuel tank is 5.2l in total including 1.0l of reserve. 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 ...

  • Page 11: Engine Starting

    Engine starting 1. Set the ignition key to “ ” (on) position. 2. Place transmission in neutral. 3. Ensure that there is fuel in tank. 4. Set fuel valve handle to “on” or “res” position. To start a cold engine: 1. Place choke lever on carburetor up (to close the choke). 2. Rotate throttle twist grip ...

  • Page 12: Breaking In The Engine

    Breaking in the engine the first 600 miles of operation should be considered the “break-in” period and special attention should be paid to the following points: 1. Take special care not to increase the rpm’s of engine while climbing steep slopes. Never drive your dirt bike continuously for more than...

  • Page 13

    Switches on right handlebar ignition switch the ignition switch is provided on the right handlebar. When ignition switch is turned to “ ” (off) position, engine will not start. If engine is running this will stop engine. When ignition switch is turned to “ ” (on) position, engine can start and the v...

  • Page 14: Gear Shifting

    Gear shifting a non-cycling mode of gear shifting is employed for this motorcycle. Reduce throttle before shifting. Never increase throttle while shifting gears. Do not place your foot on gear-shifting pedal while operating dirt bike to avoid damaging the clutch caused by sudden accidental gear shif...

  • Page 15: Lubricating Oil Recommended

    Check-ups, adjustment and maintenance checking the oil check engine oil each time prior to operating dirt bike. The oil level should be between the upper and lower lines of oil gauge fitted in a screw plug, which is on right cover of crankcase. 1. Set dirt bike on level ground, screw off oil gage pl...

  • Page 16: Changing The Oil*

    Changing the oil* 1. Remove “screw plug” located at bottom of engine and let oil drain into an approved collection container. Do not perform this procedure while engine is hot. Serious burns could result from contact with hot oil. 2. Dispose of used oil properly. For proper disposal procedures, cont...

  • Page 17

    Checking & cleaning the air filter take air filter out and check if it is dirty or torn. Dismounting: wash filter in clean water and wipe dry with a clean cloth. Soak filter element in clean machine oil. Squeeze it with a dry cloth to remove excess oil. Recommended oil: 15w/40qe caution the air filt...

  • Page 18: Adjusting The Carburetor

    Adjusting the throttle cable make sure that the adjusting and lock nuts of throttle cable work normally. Check if throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm. If grip cannot be moved freely, turn adjusting nut to ensure proper operating m...

  • Page 19: Valve Inspection

    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: 0.003 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 o...

  • Page 20

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

  • Page 21: Adjustment Of Rear Brake

    Adjustment of rear brake the vehicle should be supported for check by the side stand. 1. The rear brake pedal has a free operating movement of 20-30mm (9/16 inch - 1 1/8 inches). 2. To make adjustment, turn rear adjusting nut clockwise to reduce and counterclockwise to increase free operating moveme...

  • Page 22: Drive Chain Lubrication

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

  • Page 23: Vehicle Washing

    Vehicle washing cleaning the vehicle regularly can slow down 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 subassemblies ...

  • Page 24: 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 maint...

  • Page 25

    Resumption of service after storage 1. Remove covering and wooden blocks used in storing vehicle. Change engine oil if 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 gasoline therein. 3. Prior...

  • Page 26: Resumption Of Service

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

  • Page 27: Maintenance Schedule

    Items of maintenance frequency odometer km/hours 1000km 4000km 8000km 12000km * circuit of fuel system i i i * fuel filter c c c c * throttle operating system i i i i * choke of carburetor i i i air filter element i c c valve clearance - adjust i spark plug i i i i *air valve gap i i i i engine lubr...

  • Page 28: Electrical Diagram

    Electrical diagram gr b/w gr b/y b/y bl/w b/r gr b/w bl/w gr b/r b: black w: white r: red gr: green bl: blue.

  • Page 29

    Baja motorsports – 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, le...

  • Page 30

    Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility. The distributor will not cover repairs performed outside of an authorized dealer or repair facility. The use of replacement parts not equivalent to the original parts may impai...

  • Page 31

    No express emission control system warranty is given by the distributor except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warran...

  • Page 32: Baja, Inc.

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