Table of Contents
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DR125/DR150 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.
Max. Weight Limit: 250lbs. (113kg)
Always wear a helmet; It could save your Life!
Please obtain, review, and follow the municipal, provincial and government
acts and regulations pertaining to owning and operating an off-road vehicle.
Rev. D (US)
031109
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Table of Contents
Related Manuals for Baja motorsports DR125
Summary of Contents for Baja motorsports DR125
- Page 1 DR125/DR150 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 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 INC. DR125/ DR150 Dirt bike at no charge. This warranty does not cover normal wear items or damage caused by neglect or misuse of the product.
- 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS NOTICE TO USER’S ....................2 SAFE OPERATION ....................3 PRE-RIDE CHECkLIST ..................4 SAFETY GEAR ....................5 LOCATION OF WARNING LABELS..............6 MAIN DATA ......................7 PARTS & SUBASSEMBLIES ................9 OPERATION ......................11 FUEL VALVE ....................11 ENGINE STARTING ..................12 BREAkING IN THE ENGINE ...............13 SWITCHES ON THE RIGHT HANDLEBAR ..........14 GEAR SHIFTING ..................15 CHECk-UPS, ADJUSTMENT AND MAINTENANCE..........16... -
Page 5: Notice To User's
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
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
LOCATION OF WARNING LABELS Read and follow all of the warnings labels on your Dirtbike. Make sure you understand all the labels. keep the labels on the 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. -
Page 10: Main Data
MAIN DATA DR125 DESCRIPTION DATA DESCRIPTION DATA Overall length 1930mm (76 inches) Cylinder bore X 56.5mm X 49.5mm stroke Overall width 100mm (43.3 inches) Compression 8.9:1 ratio Overall height 1199mm (47.2 inches) Max output 7.5kW/8500rpm (11.4hp) Wheelbase 1320mm (51.97 inches) Max torque 8.0kW/6500r/min... - Page 11 MAIN DATA DR150 DESCRIPTION DATA DESCRIPTION DATA Overall length 1930mm (76 inches) Cylinder bore X 69mm X 53mm stroke Overall width 100mm (43.3 inches) Compression 9.0:1 ratio Overall height 1199mm (47.2 inches) Max output 8.5kW/9500rpm (11.4hp) Wheelbase 1320mm (51.97 inches) Max torque 8.2N.m/7500r/min Dead weight...
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Page 12: Parts & Subassemblies
PARTS & SUBASSEMBLIES Brake fluid reservoir Clutch Lever Front brake lever On/Off switch Throttle twist grip Fuel tank cover... - Page 13 DR125/DR150 Gas Cap Exhaust Silencer Seat Cushion Front Shocks Rear Fork Rear Wheel Carburetor Oil Cap Front brake Rear brake kick start lever Side Stand caliper caliper Front Wheel...
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Page 14: Operation
OPERATION FUEL VALVE Fuel filling The capacity of the fuel tank is 5.7L (1.5gal) . 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 15: 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 16: 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: 1. Take special care not to increase the RPM’s of the engine while climbing steep slopes. -
Page 17: 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 18: Gear Shifting
GEAR SHIFTING Reduce throttle before shifting. Never increase the throttle while shifting gears. Clutch lever Pull in the clutch lever, located on the left hand grip. Depress the Shift lever to place the gear in 1st, lift up the lever to shift to 2nd, 3rd, 4th and 5th. -
Page 19: 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 sight gauge located on the right cover of the crankcase. The level can also be checked on the dip stick. -
Page 20: Changing The Oil, Cleaning Oil Filter Screen
CHANGING THE OIL, CLEANING OIL FILTER SCREEN 1. Remove the oil drain plug, spring and oil filter screen 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. -
Page 21: Valve Inspection
VALVE INSPECTION REFER TO MAINTENANCE SCHEDULE IN THIS OWNER’S MANUAL FOR VALVE ADJUSTMENT INSPECTION INTERVALS. Valve clearance should be: Intake: 0.002 inch (0.051 mm) Exhaust: 0.002 inch (0.051 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 22: 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. Remove foam element and wash with water and allow it to dry per instructions below. -
Page 23: Adjusting The Throttle Cable
ADJUSTING THE THROTTLE CABLE Make sure the throttle works normally. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078 inches - .24 inches) 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 24: Inspection Of Front Hydraulic Brake
FRONT HYDRAULIC DISk BRAkE INSPECTION Brake fluid reservoir Brake fluid cap Brake hose Lower mark Brake fluid level Front disk brake caliper 1. Inspect the front disk brake caliper for leakage. If brake fluid leaks, the safety of riding could be affected. 2. -
Page 25: Clutch Adjustment
CLUTCH ADJUSTMENT Clutch lever adjustment nut 3.0 - 5.0mm play (0.12 inches-0.20 inches) To adjust the clutch lever play: Remove the adjuster cover (slide back on cable). Loosen adjuster nut and move adjuster in or out to obtain the correct play. -
Page 26: Adjustment Of Chain
ADJUSTMENT OF CHAIN When chain adjustment is needed, loosen rear axle nut . Turn the chain adjusting brackets 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 27: 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 Dirt Bike. - Page 28 Ignition System Check Remove the spark plug and reattach it to the spark plug lead. Turn ignition key to the “RUN” position. Slide the engine stop switch to the “Run” position. Push the electric button “START “(grey button). If the ignition system is operating properly, a blue spark should jump across the spark plug gap.
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Page 29: Vehicle Washing
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. CAUTION Washing the motorcycle with over-pressurized water may cause damage to some of its components. Therefore, do not use a pressure washer to clean the vehicle. -
Page 30: 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 done. -
Page 31: 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 32: Resumption Of Service
INSPECTION AND MAINTENANCE It is very important to inspect and maintain your DR125/DR150 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... -
Page 33: Maintenance Schedule
MAINTENANCE SCHEDULE Item Initial Initial Every Every months/ Months/ Months/ Months/ 20 hrs 50 hrs 50 hrs 100 hrs * Valves Spark Plug Valve clearance-Check-Adjust Air Filter Every 20 - 40 hours (more often in dusty areas) * Carburetor * Exhaust system Spark arrester Fuel hose Engine Oil... -
Page 34: Serial Number Location
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 35: Electrical Diagram
DR125/DR150 wire diagram Engine stop switch B/W G G G BL/W Ignition coil B-Black W-White Magneto R-Red G-Green BL-Blue Y-Yellow... -
Page 36: 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... - Page 37 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 38 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 CAUSED By A DEFECT IN MATERIAL OR WORkMANSHIP.
- Page 39 Baja INC. P.O. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...
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