Baja motorsports BA49 Owner's Manual
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Baja motorsports BA49 Owner's Manual

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BA49 ATV
Read this manual carefully. It contains important safety information.
Children under the age of 16 should be supervised by a responsible adult.
OWNER'S MANUAL
Minimum Age Requirement: 6
Maximum weight limit: 45Kg (100 lbs.)
For More information on ATV Safety Contact
the Baja ATV Safety Hotline at: 866-260-8630
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.
REVB
012109

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  • Page 1 BA49 ATV Read this manual carefully. It contains important safety information. Children under the age of 16 should be supervised by a responsible adult. OWNER’S MANUAL Minimum Age Requirement: 6 Maximum weight limit: 45Kg (100 lbs.) REVB For More information on ATV Safety Contact...
  • Page 2 “YOUR ATV CAN BE HAZARDOUS TO OPERATE. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. For your safety, understand and follow all the warnings contained in this owner’s manual and the labels on your vehicle.
  • Page 3 90 days from the date of purchase. During the warranty period BAJA, INC. will at its option, repair, provide replacement parts or replace your Baja Motorsports 49cc ATV at no charge. This warranty does not cover normal wear items or damage caused by neglect or misuse of the product.
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS IMPORTANT ...................3 FOREWORD ...................3 NOTICE TO THE USER ..............4 BA49 ATV ..................8 LOCATION OF LABELS ..............9 FUEL AND OIL ................10 CONTROLS AND FUNCTIONS ............11 IGNITION SWITCH ..............11 LEFT HANDLEBAR ..............11 RIGHT HANDLEBAR ...............12 EMERGENCY SAFETY TETHER ..........12 CHOKE KNOB .................12...
  • Page 6 ACCESSORY USE AND VEHICLE LOADING .......35 INSPECTION AND MAINTENANCE ..........37 SPARK PLUG ................39 VALVE CLEARANCE..............41 BATTERY INSTALLATION ............42 ADJUSTMENT OF THROTTLE LEVER ........46 THROTTLE SPEED ADJUSTMENT SCREW ......47 IDLE SPEED ADJUSTMENT ...........47 FUEL HOSE ................48 ENGINE OIL ................48 AIR CLEANER .................50 DRIVE CHAIN ................53 DRIVE CHAIN CLEANING AND OILING .........54 CLUTCH ADJUSTMENT ............55...

  • Page 7: Important

    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. WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in vehicle damage.

  • Page 8: Notice To The User

    We believe in conservation and protection of the earth’s natural resources. We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off-road recreational use. NOTICE TO PARENTS This ATV is built for use by children age 6 and older, but the users manual is written for adults who will be supervising the children, we strongly recommend , therefore, that you review this entire manual with your child and carefully explain...
  • Page 9 · Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. Never carry a passenger on an ATV. ·...
  • Page 10 · Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slipper or loose surfaces. Shift you weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.
  • Page 11 · Never modify an ATV through improper installation or use of accessories. · Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. ·...

  • Page 12: Ba49 Atv

    BA49 Parking brake Gas cap Rear brake lever Seat Front bumper Rear shock Front Tire Fuel valve Foot rest [Left] Throttle lever Key switch Carburetor Air filter Exhaust silencer Front shocks Rear wheel Oil fill plug/dipstick [Right]...

  • Page 13: Location Of Labels

    Read and follow all of the warnings labels on your ATV. Make sure you understand all the labels. Keep the labels on the ATV. 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 Motorsports.

  • Page 14: Fuel And Oil

    FUEL AND OIL FUEL The proper fuel is very important for the engine. Ensure that there is no dust or dirt, or water which has mixed in the fuel. Please use the regular unleaded gasoline with the octane number 90 or higher. ENGINE OIL Your 49cc ATV has a four-stroke engine.

  • Page 15: Controls And Functions

    CONTROLS AND FUNCTIONS Ignition switch “OFF” position - All electrical components are OFF except hazard lights. Key can be removed in this position. “ON” position - With transmission in NEUTRAL and the parking brake set, the engine will start. Key cannot be removed in this position. LEFT HANDLEBAR Headlight dimmer Parking brake...

  • Page 16: Right Handlebar

    CONTROLS AND FUNCTIONS Front brake lever RIGHT HANDLEBAR Throttle lever Throttle lever Control the engine and ATV speed with the throttle lever. Operate this lever with your thumb. Push it forward to increase engine and ATV speed. Release it to decrease engine and ATV speed. Front brake lever Control the engine and ATV braking with the front brake lever.

  • Page 17: Fuel Valve

    CONTROLS AND FUNCTIONS Fuel valve ON: With handle of the fuel valve at “ON” position, fuel will flow to the carburetor. OFF: With handle of the fuel valve at “OFF” position, fuel will not flow to the carburetor. RES: If fuel level in fuel tank becomes too low for engine to stay running while fuel valve is at “ON”...

  • Page 18: Seat Lock

    WARNING Overfilling the fuel tank could be hazardous. If you overfill the fuel tank, fuel may overflow when it expands. Expanding is due to heat from engine or sun. Overheated fuel could easily catch fire. Stop adding fuel when the fuel level reaches the bottom of the filler neck. WARNING Improper fueling of the ATV could be hazardous.

  • Page 19: Riding Your Atv

    WHAT YOU SHOULD KNOW BEFORE RIDING Before riding, you should read all the following information carefully. If you are properly prepared, you will have a more enjoyable ride. Before riding, you should find a good place to practice the skills. Find a flat, open area with enough space to practice the new skills.

  • Page 20: Inspection Before Riding

    INSPECTION BEFORE RIDING Check the condition of the ATV to make sure that the ATV does not have mechanical problems or you could get stranded when you ride. Before riding the ATV, be sure to check the items below. Be sure your ATV is in good condition to ensure the safety of the rider.

  • Page 21: Break-In

    WARNING Checking maintenance items when the engine is running could be hazardous. You could be severely injured if your hands or clothing get caught in moving ATV parts. Shut the engine off when performing maintenance checks, except checking the engine stop switch and throttle. BREAK-IN The first month is the most important in the life of your vehicle.

  • Page 22: Starting The Engine

    STARTING THE ENGINE Before attempting to start the engine, make sure to follow these steps. Turn the key switch to the ON position. Set the engine stop switch to the “RUN“ position. Apply the rear brake lever and make sure that the rear wheels are in locking condition.
  • Page 23 WARNING Operating this ATV on paved surfaces. The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.

  • Page 24: Safety Gear

    SAFETY GEAR A DOT approved motorcycle helmet is the most important part of your 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. WARNING Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
  • Page 25 WARNING Operating this ATV after consuming alcohol or drugs. Could seriously affect your judgement. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. Never consume alcohol or drugs before or while driving this ATV. WARNING Operating this ATV at excessive speeds.
  • Page 26 WARNING Failure to inspect the ATV before operating. Failure to properly maintain the ATV. Increases the possibility of an accident or equipment damage. Always inspect your ATV each time you us it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.
  • Page 27 WARNING Failure to use extra care when operating on excessively rough, slipper or loose terrain. Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

  • Page 28: Braking

    BRAKING To stop ATV, first release the throttle lever. Apply front and rear brakes smoothly. WARNING Braking while turning the ATV could be hazardous. Use of the brake when turning could cause the ATV to slide or roll over. Use the brake to slow down before you begin to turn. WARNING Braking hard on slippery surfaces could be hazardous.

  • Page 29: Turning

    TURNING To turn the ATV, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to move straight ahead.

  • Page 30: Operation On Hills

    OPERATION ON HILLS WARNING Operating on excessively steep hills. The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the ATV on hills too steep for the ATV or for your abilities.
  • Page 31 To climb a hill with the ATV, follow the directions below. Speed up and maintain a steady speed before reaching the top of the hill. Remember that you must ride at a steady speed all the way to the top of the hill.
  • Page 32 To ride down a hill with the ATV, follow the instructions below. Check the terrain carefully for any obstacles before you go down the hill. Point the ATV straight down the hill. Transfer your body to the rear by sliding back on the seat. Ride down the hill slowly with the throttle released.

  • Page 33: Riding Over Obstacles

    WARNING Stalling, rolling backwards or improperly dismounting while climbing a hill. Could result in ATV overturning. Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply brakes. Lock parking brake, after you are stopped. If you begin rolling backwards: Keep weight uphill.

  • Page 34: Skidding Or Sliding

    If you come to an obstacle that you cannot avoid, you may be able to cross over it by using the following procedure. If the obstacle is in front of you, approach at walking speed. Rise up slightly on the footrests. Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle.

  • Page 35: Riding Through Water

    RIDING THROUGH WATER You can ride the ATV through shallow water. Make sure it is not more than 10cm (4 inches) deep and is not moving fast. Choose a good place to cross before you ride through the water. Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard.

  • Page 36: Riding In Cold Weather

    RIDING IN COLD WEATHER Pre-ride Inspection Check that the throttle and all control levers move freely. Make sure that the footrests are free of ice or snow. Move the ATV forward and backward to check that the wheels roll freely. If you cannot move the ATV, the tires may be frozen to the ground, or the brakes may be frozen to the wheels.

  • Page 37: Dressing For Cold Weather Riding

    DRESSING FOR COLD WEATHER RIDING WARNING Operating your ATV in cold weather without proper clothing could be hazardous. Continued exposure in the cold weather could lead to hypothermia. Hypothermia is a condition where your body’s inner temperature drops low enough to cause injury or death. Always dress for the worst weather conditions you might encounter.

  • Page 38: Riding Your Atv On Snow And Ice

    RIDING YOUR ATV ON SNOW AND ICE WARNING Riding on snow-covered terrain, even with care, could be hazardous. The snow may be covering rocks, holes, ice or other hazards that can cause loss of control. Severe injury or death could occur if you lose control of the ATV.

  • Page 39: Accessory Use And Vehicle Loading

    Practice riding your ATV in an open snow- or ice-covered area, at slow speeds, before handling out on snow- or ice-covered trails. Learn how your ATV responds to steering and braking on the type of terrain you will encounter on your ride. Your eyes may be sensitive to sunlight when you ride over snow or ice on a bright, sunny day.
  • Page 40 Allow enough stopping distance. Stopping distance increases if you carry loads. Use engine braking as much as possible. BA49 WEIGHT LIMITS Never exceed the weight limit shown 1. Total weight limit is 45.4Kg (100 lbs), this limit includes rider and...

  • Page 41: Inspection And Maintenance

    INSPECTION AND MAINTENANCE It is very important to inspect and maintain your ATV regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed. MAINTENANCE SCHEDULE Interval Initial 1 month /...
  • Page 42 WARNING Improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your ATV you may have an accident. Keep your ATV in good condition. Ask your authorized service center or a qualified mechanic to do the maintenance items marked with an asterisk (*).

  • Page 43: Spark Plug

    A white or dark insulator indicates that the engine may need adjustment, or another plug type may be needed. Consult your authorized dealer or Baja Motorsports if your plug insulator is not a light brown color. CAUTION Failing to use the proper spark plug could damage your ATV.
  • Page 44 To maintain a proper functioning spark plug, keep the plug free of carbon. Remove carbon from the plug with a wire or pin, and adjust the gap to 0.6~0.7mm (.024”~ .028”) for good ignition. Use a thickness gauge to check the gap.

  • Page 45: Valve Clearance

    VALVE INSPECTION refer to maintenance schedule in this owner’s manual for valve adjustment inspection intervals. Valve clearance should be: Intake: 0.002 inch (0.05 mm) Exhaust: 0.003 inch (0.0762 mm) The engine will make excess noise if the gap is too large in air valve. If gap is too small valve operation will be hindered which could result in valve malfunction and failure.

  • Page 46: Battery Installation

    BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: WARNING The following procedure is very dangerous and should be performed with utmost care and attention. Wear protective eye wear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes. KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
  • Page 47 Note: The following page is for vehicles with battery’s containing separate electrolyte pack. Most battery’s will come with the electrolyte already sealed into the battery. Preparing the battery: · Place battery on level surface. Remove sealing tape from top. (see figure 20) ·...
  • Page 48 How to Initially Charge the battery: Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 23) Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure 24) Figure 23 Note: The red positive (+) cable has a larger...
  • Page 49 Battery Replacement: · Remove old battery. Mark which cable is connected to the positive terminal (+) and which cable is connected to the negative (-) terminal. · Clean cable connectors with wire brush or sandpaper to remove oxidation. · After charging, install new battery. Put dielectric grease on the battery terminals to avoid corrosion.

  • Page 50: Adjustment Of Throttle Lever

    THE ADJUSTMENT OF THROTTLE LEVER To adjust the throttle lever free distance: Remove the cover. Loosen the nut Turn the adjuster in or out to obtain the correct play. Tighten the nut. Recheck the throttle lever free distance. Readjust it if it is not within the correct limits. Throttle lever adjuster...

  • Page 51: Throttle Speed Adjustment Screw

    THROTTLE SPEED ADJUSTMENT SCREW The ATV is set by the factory to limit speed of ATV to 10 mph (16km/h) directly out of crate. The adjustment screw can be adjusted to allow the ATV to travel up to 15 mph (24 km/h). Any adjustment should be performed by a respon- sible adult.

  • Page 52: Fuel Hose

    FUEL HOSE Fuel hose Inspect the fuel hose for damage and fuel leakage. If ay defects are found, the fuel hose must be replaced. ENGINE OIL The engine oil should be changed every 20 to 40 hours of operation. It should be changed more often in dirty and dusty areas.
  • Page 53 WARNING New and used oil could be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used oil can cause skin cancer in laboratory animals. Brief contact with the used oil may irritate the skin.

  • Page 54: Air Cleaner

    AIR CLEANER The air cleaner element must be kept clean to provide good engine power. If you use your vehicle under normal, low-tension conditions, you should service the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air cleaner element much more frequently.
  • Page 55 REMOVAL Air filter cap Air filter Locate air filter under right side Remove air filter cap by panel. removing the two screws Air filter element 3. Remove the air filter element WASHING THE ELEMENT Wash the element as the following: 1.
  • Page 56 CAUTION A torn air filter could damage your ATV. Dirt and dust may get inside of the engine if the element is torn. Examine carefully the element for tears before and after cleaning it. Replace the element with a new one if it is torn. WARNING Oil and solvent could be hazardous.

  • Page 57: Drive Chain

    DRIVE CHAIN The condition and adjustment of the drive chain should be checked before riding. Always follow the guidelines below for inspecting and servicing the chain. WARNING Failing to maintain the chain properly before each riding could be hazardous. Riding with the chain in poor condition could lead to an accident. Be sure to inspect and maintain the chain before riding, according to these guidelines.

  • Page 58: Drive Chain Cleaning And Oiling

    DRIVE CHAIN CLEANING AND OILING Clean and oil the chain as the following: Wash the chain with water. Dry the chain, and then oil the links with Chain lube or equivalent. Adjusting the Drive Chain 10~20 mm (0.4~0.8 in) The drive chain should be adjusted and make sure there is 10~20 mm (0.4~0.8 in) of slack, as shown above.

  • Page 59: Clutch Adjustment

    CLUTCH ADJUSTMENT 1. Loosen locknut (1). 2. Slowly turn adjusting bolt (2) counter-clockwise using phillips head screwdriver until resistance is felt. Then, turn it 1/8 turn clockwise. 3. Tighten locknut (1) to 15 N•m (11 ft.lb.) NOTE: Turn adjusting bolt counter-clockwise to decrease clutch free play. Turn adjusting bolt clockwise to increase clutch free play.
  • Page 60 WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
  • Page 61 Tire Tread Condition WARNING Using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident. Replace the front and rear tires when the depth on the tread is 3mm (0.12 in) or less.
  • Page 62 Tire Replacement Your ATV has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires.

  • Page 63: Brakes

    BRAKES The ATV has front drum brakes and a rear hydraulic disc brake. WARNING Failing to inspect and maintain your ATV’s brake system properly could be hazardous. Improper maintenance of the brake increases your chance of having an accident. Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section.

  • Page 64: Rear Hydraulic Disc Inspection

    REAR HYDRAULIC DISC INSPECTION Brake fluid reservoir Brake fluid hose Brake fluid cap Brake caliper Disc Lower mark Bake fluid hose 1. Inspect the rear disk brake caliper and brake fluid reservoir for leakage. If brake fluid leaks, the safety of riding could be affected. 2.

  • Page 65: General Lubrication

    WARNING Riding an ATV with improperly tightened drain nuts could be hazardous. Running the engine with a loose drain nut or without a drain nut will let hot carbon particles to escape. This can cause a fire. Tighten the drain nuts securely. GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and long life of your vehicle.

  • Page 66: Troubleshooting

    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. CAUTION Failing to troubleshoot a problem correctly would damage your ATV.
  • Page 67 Ignition System Check Remove the spark plug and reattach it to the spark plug lead. Push the electric button “START “(yellow button). Apply the rear brake lever to make sure the rear wheels are locked. If the ignition system is operating properly, a blue spark should jump across the spark plug gap.

  • Page 68: Transporting

    TRANSPORTING It is best to transport the ATV in the normal position. Carburetor Drain screw Before transporting the ATV turn the fuel valve to the “OFF” position then drain the fuel from the carburetor as follows: Drain fuel from carburetor into an empty container by loosening the carburetor drain screw.

  • Page 69: Cleaning Procedure

    CLEANING PROCEDURE A thorough cleaning of your ATV is a necessary part of maintenance. It will help keep your ATV looking and performing best. Proper cleaning can also extend the life of your ATV. It is important to clean and inspect your ATV after every ride, especially if it is used in mud, brush, grass, water, salt water, or very dusty conditions The build-up of mud, brush, grass, etc.

  • Page 70: Washing Your Atv

    WASHING YOUR ATV With some care, your ATV can be washed in a similar manner to washing an automobile. Note: Avoid spraying or allowing water to flow over the following places: · Ignition switch · Spark plug · Fuel tank cap ·...

  • Page 71: Storage Procedure

    STORAGE PROCEDURE If you do not use your ATV for a long time, it will need special service requiring appropriate materials, equipment and skill. For this reason, we recommend that you trust this maintenance work to your authorized service center. If you wish to service the machine for storage yourself, follow the general guidelines below: VEHICLE Place the vehicle on level ground and wash the entire vehicle.

  • Page 72: Serial Number Location

    You need to know the frame and engine serial numbers to get title documents for your ATV. You also need these numbers to help your authorized service center or Baja Motorsports order parts. The frame number is stamped on the front of the frame as shown in the photograph.

  • Page 73: Specifications

    SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length.............1180mm (46.45 inches) Overall width..............680mm (26.77 inches) Overall height.............709.9mm (27.95 inches) Wheelbase..............809.8mm (31.88 inches) Ground clearance............59.94mm (2.36 inches) Seat height..............527.6mm (20.77 inches) Dry weight..............73.94Kg (163 lbs) Weight capacity............59.87kg (132 lbs) ENGINE Type................Four stroke, air cooled Bore X Stroke............39mm X 41.4mm Displacement............49.5cc Corrected Compression ratio.........9.4:1...

  • Page 74: Emission Control System Warranty

    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, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
  • Page 75 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 originally equipped. Also included may be hoses, connectors and other emission-related assemblies.
  • Page 76 6. Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. 7. Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties.
  • Page 77 Baja, INC. P.O. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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