Bajaj Motorsport DB30 Owner's Manual

Manual is about: Mini Bike

Summary of DB30

  • Page 1

    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. Minimum age requirement: 16 weight capacity: 150 lbs. Rev. G 052108 db30 mini bike read this manual carefull...

  • Page 2

    Ii congratulations on your purchase of the baja inc. Db30 mini bike. Your mini bike is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days form the date of purchase. During the warranty period baja, inc. Will at its option, repair, provide replacement...

  • Page 3: Warning

    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. Al...

  • Page 4: Table Of Contents

    1 table of contents safety ------------------------------------------------------- 2 safe operation ------------------------------------ 3 safety gear ----------------------------------------- 5 location of labels ------------------------------- 6 specifications -------------------------------------...

  • Page 5: Safety

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

  • Page 6: Safety

    3 safe operation rules for safe operation · a pre-operation check must be conducted, before starting the engine, insure safety, prevent mishaps, and damage to components. · it is strongly suggested that all operators take a certified motorcycle rider’s course prior to operating the vehicle. · full a...

  • Page 7: Safety

    4 · this user’s manual contains important safety and maintenance information. Read it carefully before riding. Failing to follow the warnings contained in this manual could result in injury or death. · it is important that this manual remain with the vehicle when you transfer it to another user or o...

  • Page 8: Safety

    5 caution never perform any unauthorized modifications to this vehicle. Only use original replacement part which can be obtained through baja inc. 888-863-2252. Safety gear a dot approved motorcycle helmet is the most important part of you safety gear. A dot approved motorcycle helmet can help preve...

  • Page 9: Location of Labels

    6 3 1 4 2 5 1 2 3 4 5 location of labels safety.

  • Page 10: Safety

    7 safety location of labels 6- 7- 7 6 9- 9 8 8-.

  • Page 11: Specifications

    8 specifications description data overall length 1295mm (50.98 inches) overall width 640mm (25.20 inches) overall height 860mm (33.86 inches) wheelbase 935mm (36.81 inches) dead weight 36kg (80lbs.) payload 68.04kg (150 lbs.) front wheel 145x70-6 rear wheel 145x70-6 brake type disc capacity of gasol...

  • Page 12: Pull Start Cord

    9 pull start cord air filter gas tank foot pegs throttle handle on/off button brake caliper front wheel kick stand rear wheel seat cushion hand brake clutch cover drive chain spark plug oil drain plug oil fill plug location of parts.

  • Page 13: Operation

    10 left and right hand grip operation engine pull cord operation pulling in brake lever located on left hand grip will stop mini bike. Applying the hand throttle (moving throttle counter clockwise ) will cause engine rpms to increase, causing mini bike to move forward. When the switch is turned to “...

  • Page 14: Fuel Valve Operation

    11 fuel and fuel valve operation fuel filling the capacity of the fuel tank is 1.4l (.40 qt .) 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 b...

  • Page 15: Inspection Before Riding

    12 warning failing to inspect the mini bike before operating could be hazardous. Failing to perform proper maintenance could also be hazardous. Failing to inspect and maintain your mini bike could increases the chances of an accident or equipment damage always inspect your mini bike each time before...

  • Page 16: Engine Starting And

    13 1. Ensure there is fuel in fuel tank and oil in crank case. 2. Set fuel valve lever to “on” position 3. Place choke lever to “on” position 4. Start engine with pull start cord. 5. Allow engine to idle until engine is warm 6. Place carburetor choke lever to “off” position when engine has sufficien...

  • Page 17: Checking The Oil

    14 checking the oil check engine oil each time prior to operating mini bike. The oil level should be between upper and lower lines of oil gauge. 1. Set the mini bike on level ground, screw off the oil gage plug, wipe the oil gage rod clean and then insert the gage plug into the crankcase again to ch...

  • Page 18: Changing The Oil

    15 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...

  • Page 19: Inspection And Maintenance

    16 checking & cleaning the air filter 1. Locate air filter box at rear of engine 2. Remove air filter cover by unscrewing phillips head screw 3. Remove foam air filter element. 4. Tap air filter element gently to remove most of the dust and dirt. 5. Wash foam element per instructions below then allo...

  • Page 20: Adjusting The Carburetor

    17 adjusting the throttle cable make sure the throttle cable is adjusted properly. To adjust throttle cable, rotate adjustment nut located at the hand throttle. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078 -.24in.) . If ...

  • Page 21: Adjustment Of Rear Brake

    18 adjustment of rear brake 1. The front brake hand grip should have free operating movement of 5-7mm (.2-3in.) . Adjust with free play adjustment bolt. 2. To make rear brake pad adjustment, turn rear adjusting bolt clockwise to loosen and counter clockwise to tighten brake tension. 3. Brake pads sh...

  • Page 22: Greasing Procedures

    19 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 23: Inspection And Maintenance

    20 clutch cleaning and maintenance after every 5 hour of use, your clutch will need cleaning and lubrication. If clutch becomes too dirty or has lack of lubrication, the clutch will have a tendency to stick. This will cause the mini-bike to want to take off before throttle is applied. To clean and l...

  • Page 24: Vehicle Washing

    21 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 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 its components which might be caused by long storage. Before storing the vehicle for a long period , proper ma...

  • Page 26: Inspection And Maintenance

    23 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 27: Inspection And Maintenance

    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: Engine Lacks Power

    25 1. Fuel valve off move fuel valve lever to on. 2. Choke open move choke lever to closed 3. Out of fuel refuel 4. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline drain fuel and carburetor. Refuel with fresh gasoline 5. Spark plug faulty, fouled, or impr...

  • Page 29: Engine Switch

    26 engine switch transistor magneto ignition coil spark plug b1 b1 electrical schematic.

  • Page 30: Emission Control System

    27 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 31: Emission Control System

    28 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 32: Emission Control System

    29 emission control system warranty 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 c...

  • Page 33: Baja, Inc.

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