Bajaj Electricals HT65/MB165 manual

HT65/MB165 M ini Bike Read this manual carefully . It contains impor tant safety information. No one under the age of 16 should operate this Mini Bike. Alway s wear a helmet; It could sav e your Lif e! Do not remove this opera tor ’ s manual from this vehicle . Please obtain, review , and follow provincial / municipal government acts and regulati[...]

Cong ratulations on y our purchase of the Baja Motorspor ts M ini Bike . Y our Mini bike is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 day s form the date of purchase . During the warranty period BA JA MO T ORSPORTS, LL C will at its option, repair , provide replac ement par ts or replac e your B[...]

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 safety information and instructions which should be read carefully bef ore operating the v ehicle. All oper ators should obtain, r eview , and fol[...]

SA F E O P ER A T IO N ............................................................................... 3 SA F E T Y G E AR ...................................................................................... 4 MO D IF I C A TI ON O F VE HI C LE .......................................................... 4 MA IN DA T A .............................[...]

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 to the messages . NO TE: Indicating special information which is to make maintenanc e easier or instructions clearer . W ARNING and CA UTION are arra[...]

SAFE OPERA TION Rules for Saf e Operation · A pre- operation check must be conducted, bef ore starting the engine, insure saf ety , preven t mishaps, and damage to componen ts. · It is strongly suggested that all operators take a c er tied motorcycle rider ’ s course prior to operating the vehicle . · F ull attention is required during driv[...]

SAFE T Y GEAR 1. Never operat e this mini bike without wearing a DO T approv ed motorcycle helmet which ts properly . Operators should also wear ey e protection (goggles or face shield), glov es, boots, long-sleev ed shir t or jacket, and long pants. 2. Loose clothes ar e not suitable for motor c ycle driving or riding as they may get caugh t on[...]

MA I N D A T A Description Data Description Data Overall length 1624mm (64”) Cylinder bor e x stroke 6.8cm X 15.41cm (2.68” X 2.13”) Overall width 737mm (29”) PT O shaft rotation Count er clockwise Overall height 914mm (36”) Output, max 6.5hp at 3600 rpm Wheelbase 1162mm (45.75”) T or que, max 9.76 ft-lbs. at 2500 rpm Dead weight 75kg ([...]

P ARTS & SUBASSEMBLIES Rear brake lever Throttle twist grip 6[...]

F ront Wheel F ront Shock Absorber EP A Sticker Side Stand Rear Wheel Seat Cushion 7 Pull Start Cord Hand brake Air F ilter Headlight Clutch cov er Gas T ank F oot pegs Decorative tank Drive Chain V ehicle Identictaion Number Brake Drum[...]

OPERA TION F U E L V A L V E 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 NOT MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE ENGINE. Replace the gas cap by carefully aligning the threads on the cap and [...]

ENGINE ST ARTING 1. Set the ignition switch to “ ” position. 2. Ensure that ther e is fuel in the tank. 3. Set the fuel valve lever t o “ON” position. T o start a cold engine: 1. Place the choke lev er in the closed position 2. Star t the engine with the pull start cord. 3. Allow the engine t o idle until the engine is warm 4. T urn the car[...]

SWIT CHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is pr ovided on the right handlebar . When the switch is turned to “ ” (o ) position, the engine will not start or stops the engine. When the switch is turned to “ ” (on) position, the engine can start and the vehicle can be driven. ON button 10 OFF button[...]

CHECKUPS, ADJUSTMENT AND M AINTENANCE Checking the Oil Check the engine oil each time prior to operating the mini bike . The oil level should be between the upper and lo wer lines of the 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 into the cr ankcase [...]

CHANGING THE OIL * 1. Remove the “Screw Plug ” locat ed at the bottom of the engine and let the oil drain in to an approv ed collection container . DO NO T PERFORM THIS PROCEDURE WHILE THE ENGINE IS HO T . SERIOUS BURNS C OULD RESUL T FROM CONT ACT WITH HO T OIL. 2. Dispose of the used oil properly . F or proper disposal proc edures, con tact y[...]

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 ter service life of the engine . W ater should be prevented fr om entering into the lt er when washing the vehicle . The lter element shall be cleaned gen tly without twisting to prevent it fr[...]

ADJUSTING THE THRO T TLE CABLE Make sure the throttle cable is adjusted pr operly . T o adjust thr ottle 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 operating mo vement: 2-6mm (.078 -.24in) . If the grip cannot be moved freely , turn the[...]

ADJUSTMENT OF REAR BRAKE 1. The fron t brake hand grip should have fr ee operating movemen t of 5-7mm (.2-.3in) . 2. T o make adjustmen t, turn rear adjusting nut clockwise to reduce and count erclockwise to increase the fr ee operating mov ement of the hand brake. 3. Brake shoes should be replac ed by a qualied ser vice technition once brake sh[...]

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. 16 ADJUSTMENT OF CHAIN 1. When chain ad[...]

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 w ater to remo ve dirt y residues so as to prev ent corrosion. Plastic subassemblies should be cleaned b y wiping with a clo[...]

INSTRUC TIONS FOR ST OR A GE 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 maint[...]

RESUMPTION OF SER VICE AFTER ST ORAGE 1. Remove the co vering and remo ve the wooden blocks used in storing the v ehicle. 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 therein. 3. Prior to driving ,[...]

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[...]

“*” means: This item of maintenance should be carried out at a service center . It may be also done by the user with ref erence to this manual provided special t ools and authorized spare parts are used. The user must also be capable of completing the proc edure. “**” means: This item can only be carried out by an authorized ser vice cent e[...]

Baja Motorspor ts, LL C 2910 South Hardy Drive , Suite 103 T empe , AZ 85282 T el: 480-222-8280 T oll F ree: 888-863-2252[...]