Baja motorsports DR49 Owner's Manual
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Baja motorsports DR49 Owner's Manual

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DR49 Dirt Bike
Read this manual carefully. It contains important safety information.
OWNER'S MANUAL
No one under the age of 16 should operate this
Dirtbike without adult supervision. Parents
should consider child's age, size, maturity and
ability before allowing to ride.
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.
Rev. C
030909

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  • Page 1 DR49 Dirt Bike Read this manual carefully. It contains important safety information. OWNER’S MANUAL No one under the age of 16 should operate this Dirtbike without adult supervision. Parents should consider child’s age, size, maturity and ability before allowing to ride.
  • Page 2 Fender bent or broken due to abuse Any sign of impact, accident, jumping, spin-outs or roll over. BAJA, INC. is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way.
  • 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.

  • Page 4: Table Of Contents

    Table of Contents SAFE OPERATION ....................3 SAFETY GEAR ....................4 LOCATION OF WARNING LABELS..............5 MAIN DATA ......................6 PARTS & SUBASSEMBLIES ................7 OPERATION ......................9 FUEL VALVE ....................9 ENGINE STARTING ..................10 BREAkING IN THE ENGINE ...............11 SWITCHES ON THE RIGHT HANDLEBAR ..........12 GEAR SHIFTING ..................13 CHECk-UPS, ADJUSTMENT AND MAINTENANCE..........14 CHANGING THE OIL ...................15...
  • Page 5 Please read this manual and follow all instructions carefully. To emphasize 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 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 vehicle. Full attention is required during driving;...
  • Page 7 Pre-Ride Checklist Before Starting the Engine/Motor 1. Engine oil level a) Check for leaks b) Tighten filler cap securely. c) Add oil if required. 2. Fuel level a) Add fuel as necessary. b) Do not overfill (no fuel in the filler neck). c) Do not mix oil with gas.

  • Page 8: Safety Gear

    SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you 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 Dirt bike without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be...

  • Page 9: Location Of Warning Labels

    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. WARNING No one under the age of 16 should operate this vehicle without adult supervision.

  • Page 10: Main Data

    MAIN DATA DESCRIPTION DATA DESCRIPTION DATA Overall length 1420mm Max torque 3.2N.m/6500 r/min (55.91 inches) Overall width 450mm Idle speed 1500r/min±150r/min (17.72 inches) Overall height 740mm Displacement of 49mL (29.13 inches) cylinder Wheelbase 1020mm Spark plug A7RTC (10.16 inches) Dry weight 60kg (132 lbs.) Front wheel 2.50-10...

  • Page 11: Parts & Subassemblies

    PARTS & SUBASSEMBLIES Front brake lever On/Off switch Throttle twist grip Fuel tank cover...
  • Page 12 Gas Cap Fuel Valve Front Wheel Rear Wheel Carburetor Gear Shifting Pedal Side Stand Drive Chain LEFT Front Brake Lever Seat Cushion Front Shocks Exhaust Silencer Choke lever on Carburetor Oil Cap Rear Brake pedal kick Lever RIGHT...

  • Page 13: Operation

    OPERATION FUEL VALVE Fuel filling The capacity of the fuel tank is 3.3L . 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.

  • Page 14: Engine Starting

    ENGINE STARTING CAUTION Verify oil level prior to starting (see page 15) Starting the engine with low or no oil will damage the engine. WARNING Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide. Set the key of the ignition switch to “...

  • Page 15: Breaking In The Engine

    BREAkING IN THE ENGINE The first 600 Miles of operation should be considered the “Break-in” period and special attention shall be paid to the following points: Take special care not to increase the RPM’s of the engine while climbing steep slopes. Never drive your dirt bike continuously for more than 30 miles without increasing and decreasing the throttle.

  • Page 16: Switches On The Right Handlebar

    SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is Located on the right handlebar. When the switch is turned to “ ” (off) position, the engine will not start. If the engine is running and the Off button is pushed the engine will turn off. When the switch is turned to “...

  • Page 17: Gear Shifting

    GEAR SHIFTING Reduce throttle before shifting. Never increase the throttle while shifting gears. Depress the gear shift pedal to place the gear in 1st, lift up the lever to shift to 2nd, 3rd, 4th. Do not place your foot on the gear-shifting pedal while operating the dirt bike to avoid damaging the clutch caused by sudden gear shifting accidentally.

  • Page 18: Check-Ups, Adjustment And Maintenance

    CHECk-UPS, ADJUSTMENT AND MAINTENANCE Checking the Oil Check the engine oil each time prior to operating the dirt bike. The oil level should be between the upper and lower lines of the oil fill cap/ dipstick. Set the motorcycle on level ground. Remove the oil fill cap/dipstick, wipe it clean and then insert the dipstick into the crankcase again to check the oil level.

  • Page 19: Changing The Oil

    CHANGING THE OIL 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. Dispose of the used oil properly.

  • Page 20: Valve Inspection

    Therefore, air valve gap must be checked periodically. If you have the proper tools and are mechanically proficient, instructions on adjusting the valve clearance are given in the service manual. If assistance is needed please contact Baja Inc. to find your local service center.

  • Page 21: Checking & Cleaning The Air Filter

    CHECkING & CLEANING THE AIR FILTER Air filter is located under left side plastic cowling. Cowling will need to be removed. Take the air filter out and check to see if it is dirty or torn. Tap the air filter clean. If necessary use compressed air to gently clean. Air filter CAUTION The air filter element must be intact or the engine will suck in dust and...

  • Page 22: Adjusting The Throttle Cable

    ADJUSTING THE THROTTLE CABLE Make sure the throttle works properly. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078” - .24”) If the grip cannot be moved freely, turn the adjusting nut located on top of the throttle twist grip to ensure proper operating movement.

  • Page 23: Adjustment Of Front Brake

    ADJUSTMENT OF FRONT BRAkE 10-20mm Adjusting nut The front brake lever has a free operating movement of 10-20mm as shown. 1. Turn the adjusting nut beneath the front hub, clockwise to increase and counter clockwise to decrease the free operating movement. 2.

  • Page 24: Adjustment Of Chain

    ADJUSTMENT OF CHAIN When chain adjustment is needed, loosen rear axle nut . Turn the chain adjusting nuts on the left and right sides to adjust the tension of the chain and to align the marking of the chain adjuster with the engraved lines in the similar position on both sides.

  • Page 25: Exhaust

    EXHAUST WARNING The hot exhaust muffler could burn you. The muffler will be hot enough to burn you after stopping the engine. Wait until the exhaust muffler cools to remove it. WARNING Running the engine indoors or in a garage could be hazardous. Exhaust gas contains carbon monoxide that is colorless and odorless.

  • Page 26: Troubleshooting

    Failing to troubleshoot a problem correctly would damage your Dirt Bike. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty. If you are not sure about the proper action, consult your authorized service center or BAJA INC. about the problem. Fuel Supplying Check Make sure there is adequate fuel in the fuel tank.
  • Page 27 Ignition System Check Remove the spark plug and reattach it to the spark plug lead. Turn engine switch to “ON”. Start the engine. If the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is no spark, take your machine to your service center.

  • Page 28: Vehicle Washing

    VEHICLE WASHING Cleaning the vehicle regularly can slow down color fading. It will also make it easier to check to see if there is any damage and/or any oil leakage. CAUTION Washing the motorcycle with over-pressurized water may cause damage to some of its components. Therefore, do use a pressure washer to clean the vehicle.

  • Page 29: 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 maintenance has to be carried in case maintenance is not completed when the vehicle is put back into use after storage.

  • Page 30: Resumption Of Service After Storage

    RESUMPTION OF SERVICE AFTER STORAGE 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. Drain off the remaining atomized anti-rust oil from the fuel tank, followed by filling it with fresh gasoline therein.

  • Page 31: Resumption Of Service

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

  • Page 32: Inspection And Maintenance

    INSPECTION AND MAINTENANCE It is very important to inspect and maintain your DR49 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.

  • Page 33: Serial Number Location

    You need to know the frame and engine serial numbers to get title documents for your Dirt Bike. You also need these numbers to help your authorized service center or BAJA INC. order parts. The Frame number is stamped on front of Dirt bike frame. The engine number is located on the left side of the engine housing.

  • Page 34: Electrical Diagram

    DR49 ELECTRICAL DIAGRAM Blue/White Black/Yellow Black/Red Black/White Green Black/Yellow Green Black/ Green White Blue/ Green White Black/Red...
  • Page 35 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...
  • Page 36 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.

  • Page 37: Emission Control System Warranty

    NOT APPLY IF IT IS INCONSISTENT WITH THE CONTROLLING STATE LAW. NO DEALER IS AuTHORIZED TO MODIFy THIS EMISSION CONTROL SySTEM WARRANTY. IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES, YOU SHOULD CONTACT BAJA INC. (888) 863-2252.
  • Page 38 Baja, INC. P.O. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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