Bajaj Electricals DB30 manual

DB30 Doodle Bug M ini Bike Read this manual carefully . It contains impor tant saf ety information. No one under the age of 16 should operate this Mini Bike without adult super vision. Alway s wear a helmet; It could sav e your Lif e! Please obtain, review , and follow provincial / municipal government acts and regulations pertaining to owning and [...]

Cong ratulations on y our purchase of the Baja Motorspor ts DB30 Doodle Bug Mini Bike. Y our Mini bike is warranted to be fr ee of manufactur ing def ec ts in the material of workmanship for a period of 90 day s from the date of purchase . During the warranty period BA JA MO TORSPORTS, LL C will at its option, repair , provide r eplacement parts or[...]

This manual should be consider ed as a permanent par t of the vehicle and should r emain with the vehicle when resold or otherwise transferred to a new user or oper ator . The manual con tains impor tant saf ety information and instructions which should be read carefully bef ore operating the v ehicle. All oper ators should obtain, r eview , and fo[...]

1 T ABLE OF C ONTENT S SAFE T Y ----------------------------------------------------- 2 Safe Oper ation ------------------------------------ 3 Safety Gear ----------------------------------------- 4 L ocation of Labels -------------------------------- 5 SPECIFICA TIONS ----------------------------------------- 6 L OCA TION OF P AR TS --------------[...]

Please read this manual and f ollow all instructions carefully . T o emphasize the special information, the symbol and the words W ARNING or CA UTION hav e some special meanings. P ay gr eat attention t o the messages. NO TE: Indicating special information which is to make maint enance easier or instructions clearer . W ARNING and CA UTION are arra[...]

3 SAFE OPERA TION Rules for Saf e Operation · A pre- operation check must be conducted , before starting the engine, insur e safety , preven t mishaps, and damage to c omponents. · It is strongly suggested that all operators take a c er tied mot orcycle rider ’ s course prior to operating the vehicle . · F ull attention is required during d[...]

CA UTION Never perform any unauthorized modications to this v ehicle. Only use original replacement part which can be obtained through Baja Motorsports 888-863-2252. 4 SAFE T Y GEAR A DO T approv ed motorcycle helmet is the most important par t of you saf ety gear . A DOT approv ed motorcycle helmet can help prev ent a serious head injury. Choos[...]

!•• W ARNING -Moving parts can crush and cut. -Keep hands clear . -Do not operate with guard removed . ! W ARNING ! THIS VEHICLE CAN BE HAZARDOUS TO OPERA TER IF DRIVEN CARELESSL Y . SERIOUS INJURIES OR DEA TH CAN RESUL T IF Y OU DO NOT FOLL OW THESE INSTRUCTIONS: • Read and familiarize yourself with owners manual and all labels before operat[...]

MA I N DA T A Description Data Description Data Overall length 1295mm (51 inches) Bore x stroke 52x45 Overall width 476.2mm (18.75 inches) PT O shaft rotation Count er clockwise Overall height 863.6mm (34 inches) Displacement of cylinder 97cc Wheelbase 927.1mm (36.5 inches) Spark plug NGK- 6RTF , BM4A, BMR4A Dead weight 33.57kg (74 lbs.) Spark plug[...]

7 F ront Wheel Kick Stand Rear Wheel Seat Cushion Pull Start Cord Hand brake Air F ilter Clutch cov er Gas T ank F oot pegs Drive Chain Spark plug Throttle handle Off Button Brake Caliber L O C A T I O N O F P A R T S Oil drain plug Oil ll plug[...]

L E F T A N D RI G H T H A N D G R I P O P E R A T I ON E N G IN E P UL L CO RD O P ER A T I O N 8 OFF button Throttle contr ol grip Pulling in brake lev er located on left hand grip will stop mini bike. Applying the hand throttle (moving thr ottle count er clockwise ) will cause engine rpms to increase, causing mini bike to mov e for eward. Depres[...]

FUEL AND FUEL V AL VE OPERA TION F uel lling The capacity of the fuel tank is 4.2L (.95 gal) . Unscrew the gas cap by turning it coun ter clockwise and carefully ll the tank with unleaded gasoline through the opening . DO NO T MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE ENGINE. Replace the gas cap by carefully aligning the threads on the cap[...]

W ARNING F ailing to inspect the M ini Bike bef ore operating c ould be hazardous . F ailing to per form proper maintenanc e could also be hazardous . F ailing to inspect and maintain your Mini Bike could increases the chances of an accident or equipment damage A l w a y s i n s p e ct y ou r Mi n i B i k e e a c h t i m e b e f o r e r id i n g , [...]

1. Ensure there is fuel in fuel tank and oil in crank case. 2. Set fuel valve lever t o “ON” position 3. Place choke lev er in “ON” position 4. Star t eng ine with pull star t c ord. 5. Allow engine t o idle until engine is warm 6. Move carburetor choke lev er tow ard “OFF” position when engine has suciently warmed up . Note: Engine [...]

CHECKING THE OIL Check engine oil each time prior to operating mini bike . The oil level should be between upper and lo wer lines of oil gauge . 1. Set the Mini Bike on level ground, scr ew o the oil gage plug, wipe the oil gage r od clean and then inser t the gage plug int o the crankcase again to check the oil lev el. There is no need to screw[...]

CHANGING THE OIL 1. Remove the “Screw Plug” located at the bottom of the engine and let the oil dr ain into an approv ed collection container . DO NO T PERFORM THIS PROCEDURE WHILE THE ENGINE IS HO T . SERIOUS BURNS C OULD RESUL T FR OM C ONT A C T WITH HOT OIL. 2. Dispose of the used oil properly . F or proper disposal proc edures, c ontact yo[...]

CHECKING & CLEANING THE AIR FIL TER CA UTION The air lter element must be in tact or the engine will suck in dust and dir t, resulting in a shor t er ser vice lif e of the engine . W ater should be prevented fr om entering int o the lter when washing the vehicle . The lter element shall be cleaned gen tly without twisting to prevent it[...]

ADJUSTING THE THROT TLE CABLE Make sure the throttle cable is adjusted pr operly . T o adjust throttle cable, rota te adjustment nut located at the hand thr ottle. Check if the throttle twist grip has the requir ed free operating mo vement. The requir ed free opera ting movement: 2-6mm (.078 -.24in) . If the grip cannot be mov ed freely , turn the [...]

ADJUSTMENT OF REAR BRAKE 1. The fron t brake hand grip should hav e free operating movemen t of 5-7mm (.2-.3in) . Adjust with free pla y adjustment bolt. 2. T o make rear brake pad adjustment, turn rear adjusting bolt clockwise to loosen and counter clockwise to tighten brake tension. 3. Brake pads should be replac ed by a qualied ser vic e tech[...]

INSPEC TION AND M AINTENANCE GREASING PROCEDURES T O THE DRIVING CHAIN 1. Shut o the engine 2. Add light amounts of machine oil or chain g rease to the driving chain. ( T oo much machine oil or chain grease ma y cause splattering to occur .) Attention: The chain should be replac ed when the adjusting limit has reached it’ s maximum. 17 ADJUSTM[...]

INSPEC TION AND M AINTENANCE CL UT CH CLEANING AND MAINTENANCE After every 5 hour of use, your clutch will need cleaning and lubrication. If clutch becomes too dirt y or has lack of lubrication, the clut ch will have a t endancy to stick . This will cause the Mini-Bike to want to take o bef ore throttle is applied . T o clean and lubr ica te clu[...]

VEHICLE W ASHING Cleaning the vehicle regularly can slo w down the color fading of its body and make it easier to check if there is an y damage and any oil leakage. 1. After pre-wiping, the vehicle should be washed with clean wa ter to remo ve dirty residues so as to prev ent corrosion. P lastic subassemblies should be cleaned by wiping with a clot[...]

INSTRUC TIONS FOR ST ORAGE 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 pr event malfunction of and damage to its components which might be caused by long stor age. Befor e storing the vehicle f or a long period , proper maintenance has t o be carried in case mainten[...]

INSPEC TION AND M AINTENANCE RESUMPTION OF SER VICE AFTER ST ORAGE 1. Remove the co vering and remo ve the wooden blocks used in st oring the vehicle. Change the engine oil if the vehicle has been out of service for ov er 4 months. 2. Drain o the remaining at omized anti-rust oil from the fuel tank, follo wed by lling it with fresh gasoline t[...]

MAINTENANCE SCHEDULE Each Use 1st Month or 20 hours Every 3 Months or 50 hours Every 6 Months or 100 hours Every Y ear or 300 hours Engine Oil- Check X * Engine Oil - Change X X Air F ilter-Check X * Air F ilter-Clean X X * Air F ilter- Change X * Carburetor Sediment cup - Clean X Spark Plug- Check - Adjust X Spark plug - Replace X Idle Speed - Che[...]

23 1. F uel V alve OFF Move F uel valve lever t o ON. 2. Choke OFF Move Choke L ever to ON 3. Out of fuel Refuel 4. Bad fuel; engine stor ed without treating or draining gasoline, or r efuled with bad gasoline Drain fuel and carburetor . R efuel with fresh gasoline 5. Spark plug faulty , fouled , or improperly gapped Remove and inspect spark plug. [...]

ELEC TRICAL SCHEM A TIC Engine S witch T r ansistor Magnito Ignition C oil Spark Plug B1 B1[...]

Baja Motorspor ts , LL C 2801 So. F air Lane Ste . 101 T empe, AZ 85282 T el: 480-222-8280 T oll Free: 888-863-2252 ELEC TRICAL SCHEM A TIC B1[...]