Bajaj HT65, WR65, MB165, MB165-BC Mini Bike Owner's manual
HT65/WR65/MB165/MB165-BC Mini Bike
Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this Mini Bike.
OWNER’S MANUAL
Minimum Age Requirement: 16
Rev. F (US)
012209
Always wear a helmet; It could save your Life!
Do not remove this operator’s manual from this vehicle.
Please obtain, review, and follow provincial / municipal government acts and
regulations pertaining to owning and operating an off-road vehicle.
Congratulations on your purchase of the BAJA INC. Mini Bike.
Your Mini bike is warranted to be free of manufacturing defects in
material and workmanship for a period of 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. Mini Bike
at no charge. This warranty does not cover normal wear items or
damage caused by neglect or misuse of the product.
Engine Warranty – 90 days
Frame Warranty – 90 days
Warranty is void if:
Frame is bent or broken due to abuse
Wheels are bent or broken
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.
Should you experience a problem with your vehicle, please contact Baja Inc.
customer service line toll free at 1-888-863-2252 between the hours of 7am and
5pm Monday through Friday MST (Mountain Standard Time). MDT (Mountain
Daylight Time) during the daylight saving time. You will be instructed how to
proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.
ii
!
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
WARNING
the vehicle.
!
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
CALIFORNIA PROPOSITION 65
WARNING
iii
Table of Contents
SAFE OPERATION ..............................................................................................3
SAFETY GEAR ....................................................................................................4
MODIFICATION OF VEHICLE .............................................................................4
MAIN DATA ..........................................................................................................5
PARTS & SUBASSEMBLIES .............................................................................. 6
OPERATION ........................................................................................................8
FUEL VALVE ................................................................................................8
ENGINE STARTING AND STOPPING .........................................................9
SWITCHES ON THE RIGHT HANDLEBAR ................................................10
CHECK-UPS, ADJUSTMENT AND MAINTENANCE..........................................11
CHANGING THE OIL ...................................................................................12
CHECK-UP OF SPARK PLUG ....................................................................12
CHECKING & CLEANING THE AIR FILTER............................................... 13
ADJUSTING THE THROTTLE CABLE ....................................................... 14
ADJUSTING THE CARBURETOR .............................................................. 14
ADJUSTMENT OF REAR BRAKE .............................................................. 15
ADJUSTMENT OF CHAIN ...........................................................................16
GREASING PROCEDURES TO THE DRIVING CHAIN ..............................16
VEHICLE WASHING ....................................................................................17
INSTRUCTIONS FOR STORAGE ...............................................................18
RESUMPTION OF SERVICE AFTER STORAGE ....................................... 19
TABLE AND TORQUE OF FASTENERS ....................................................19
MAINTENANCE ROUTINE DIAGRAM ........................................................20
TROUBLE SHOOTING ................................................................................21
EMISSION CONTROL SYSTEM WARRANTY ............................................ 22
1
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.
NOTE: Indicating special information which is to make maintenance easier or
instructions clearer.
WARNING and CAUTION are arranged like this:
WARNING-or-CAUTION
The rst part will identify a POTENTIAL HAZARD.
The second part will describe WHAT COULD HAPPEN if you ignore
the WARNING or CAUTION.
The third part will describe HOW TO AVOID THE HAZARD.
This user’s manual contains important safety and maintenance information. Read
it carefully before riding. Failing to follow the warnings contained in this manual
could result in INJURY or DEATH.
It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
All information, illustrations, photographs and specications contained in
this manual are based on the latest product information available at the time
of publication. Due to improvements or other changes, there will be some
discrepancies in this manual. We reserve the right to make product changes at
any time, without notice and without incurring any obligation to make the same or
similar changes to the vehicle previously built or sold.
2
SAFE OPERATION
Rules for Safe Operation
· A pre-operation check must be conducted, before starting the engine, insure
safety, prevent mishaps, and damage to components.
· It is strongly suggested that all operators take a certied motorcycle rider’s
course prior to operating the vehicle.
· Full attention is required during driving; paying close attention to the
following points to avoid any injury to you by other motorized vehicles:
· Do not drive too close to other vehicles.
· Never carry a passenger. This mini bike is for one operator only
· Never operate this mini bike at night. Night is dened as the period of time 30
minutes before sunset to 30 minutes after sunrise.
· Driving at high speeds is the cause of many accidents; do not drive at a speed
that the actual situation does not permit.
· This user’s manual contains important safety and maintenance information.
Read it carefully before riding. Failing to follow the warnings contained in this
manual could result in INJURY or DEATH.
· It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
· All information, illustrations, photographs and specications contained in
this manual are based on the latest product information available at the time
of publication. Due to improvements or other changes, there will be some
discrepancies in this manual. We reserve the right to make product changes
at any time, without notice and without incurring any obligation to make the
same or similar changes to the vehicle previously built or sold
· Always avoid operating this mini bike on paved surfaces, including;
sidewalks, paths, parking lots, driveways, streets, roads, and highways.
Never operated this or any Off-Road Vehicle on a public street, road or
highway where motor vehicles are in operation.
3
SAFETY GEAR
1. Never operate this mini bike without wearing a DOT approved motorcycle
helmet which ts properly. Operators should also wear eye protection
(goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long
pants.
2. Loose clothes are not suitable for motorcycle driving or riding as they may
get caught on footrest or wheel, resulting in danger.
MODIFICATION OF THE VEHICLE
CAUTION
Never perform any unauthorized modications to this vehicle. Only use
original replacement part which can be obtained through BAJA INC. 888863-2252.
4
MAIN DATA
Description Data Description Data
Overall length 1680mm
(66.14 inches)
Overall width 800.1mm (31.5
inches)
Overall height 979.9mm
(38.58 inches)
Wheelbase 1162mm (45.75
inches)
Dead weight 64.46 kg
(142.1lbs.)
Payload 91kg (200 lbs) Displacement of
Front wheel 19 X 7 - 8
10psi
Rear wheel 19 X 7 - 8
10psi
Cylinder bore x
stroke
PTO shaft rotation Counter clockwise
Output, max 6.5hp at 3600 rpm
Torque, max 9.76 ft-lbs. at 2500 rpm
Idling speed 1400 +200
cylinder
Spark plug MEIYA -F7RTC, NGK-
Spark plug gap 0.7mm -0.79mm
6.8cm X 15.41cm
(2.68” X 2.13”)
-150
197cc
BPR6ES, Champion
- RN9YC
(.028”-.031”)
Brake Type Drum Gap of air valve IN 0.15 +- .02mm (cold)
Capacity of
gasoline tank
Capacity of oil
tank
Drive Centrifugal
4.2L (.95 gal.) Gap of air valve EX 0.20+- .02mm (cold)
.5L (.53 qt.) Ground clearance 139 mm (5.5”)
Ignition means Magneto
clutch
5
PARTS & SUBASSEMBLIES
Rear brake lever
Throttle twist
grip
6
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