Bajaj X250 Dirt Bike Owner's manual

X250 Dirt Bike

Read this manual carefully. It contains important safety information. No on
under the age 16 should operate this dirt bike without adult supervision.

OWNER’S MANUAL

Minimum Age Requirement: 16
Model 250cc

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.

REV. C
020509

Congratulations on your purchase of the BAJA INC. X250 Dirt Bike.

Your bike is warranted to be free of manufacturing defects in the 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 Motorsports 250cc Dirt 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 call the 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 daylight saving time. You will be instructed

how to proceed.

A COPY OF THE SALES RECEIPT IS REQUIRED.

II

!

! WARNING

This manual should be considered 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.

! WARNING

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

III

TABLE OF CONTENTS

SAFETY ...............................................................................................................2

SAFE OPERATION ......................................................................................3

SAFETY GEAR ............................................................................................4

WARNING LABEL PLACEMENT ................................................................5

SPECIFICATIONS ................................................................................................6

PART LOCATION.................................................................................................7

CRANK CASE BREATHER .................................................................................9

OPERATION ........................................................................................................10

FUEL FILLING .............................................................................................10

FUEL VALVE ................................................................................................10

ENGINE BREAK-IN .....................................................................................11

SWITCHES ON RIGHT HANDLE BAR .......................................................11

LEFT HANDLEBAR, CLUTCH LEVER ....................................................... 12

RIGHT HANDLEBAR, FRONT BRAKE LEVER AND

THROTTLE TWIST GRIP ............................................................................. 12

REAR FOOT BRAKE ...................................................................................12

GEAR SHIFTING .........................................................................................13

PRE-RIDE INSPECTION .............................................................................14

STARTING ENGINE ..................................................................................... 15

BATTERY INSTALLATION ..................................................................................16

MAINTENANCE ................................................................................................... 19

CHECKING ENGINE OIL ............................................................................19

CHANGING ENGINE OIL AND CLEANING SCREEN ................................20

CHECK UP OF SPARK PLUG .....................................................................20

VALVE CLEARANCE ...................................................................................21

CHECKING & CLEANING AIR FILTER .......................................................22

ADJUSTING THE THROTTLE CABLE ....................................................... 23

ADJUSTING THE CARBURETOR ..............................................................23

FRONT HYDRAULIC DISK BRAKE ............................................................24

REAR HYDRAULIC DISK BRAKE ..............................................................24

CLUTCH ADJUSTMENT .............................................................................25

ADJUSTMENT OF CHAIN ...........................................................................26

LUBRICATING CHAIN ................................................................................. 26

TORQUE SPECIFICATIONS .......................................................................27

INSPECTION AND MAINTENANCE CHART ..............................................28

TROUBLE SHOOTING ........................................................................................30

VEHICLE WASHING ............................................................................................31

INSTRUCTIONS FOR STORAGE ....................................................................... 32

RESUMPTION OF SERVICE AFTER STORAGE ....................................... 33

SERIAL NUMBER LOCATION ............................................................................34

EMISSION CONTROL SYSTEM WARRANTY ....................................................35

1

SAFETY

Please read this manual and follow all instructions carefully. To emphasize special
information, the symbol and the words WARNING or CAUTION have special
meaning. Pay attention to WARNINGS and CAUTIONS.

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 makes maintenance easier and/or
instructions clearer.

WARNING and CAUTION are arranged like this:

WARNING-or-CAUTION

The first 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 specifications 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

SAFETY

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; paying close attention to the following points
to avoid any injury to you by other motorized vehicles:

· Always wear an approved DOT (Department of Transportation) helmet. It is a
proven fact that helmets reduce the number of severe head injuries. Never ride, or
let a child ride without a DOT approved motorcycle helmet.

· Always wear protective riding gear, helmet, eye protection, long sleeve shirt, long
pants, riding boots and gloves.

· Always watch for off-road hazards. Be aware of unexpected turns, drop off’s,
rocks and other hazards. Keep speed low enough to allow time to react to hazards
and changing conditions.

· Never use alcohol or drugs before or during operation. Alcohol and drugs can
significantly reduce your ability to make good judgements and ride safely.

· Do not drive too close to other vehicles.

· Never carry a passenger. This dirt bike is for one operator only.

· Never operate this dirt bike at night. Night is defined 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.

· Never allow anyone under the age of 16 to operate this dirt bike. Physical, mental
and emotional maturity are requirements for safe riding. Rider must be able to
judge speed, distances and be able to react to changing conditions with good
hand, foot and eye coordination.

· Always avoid operating an this dirt 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

· Always keep your dirt bike in safe operating condition. Inspect dirt bike before
each ride and perform all recommended maintenance and pre-ride inspections.

· Never overload dirt bike. Maximum weight capacity is 250 lbs. (113 kg).

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 snug. 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 hazardous.

Operating without an approved DOT motorcycle helmet or eye protection
increases your chances of severe head injury or death in an accident.
Operating without protective clothing also increases your chances of severe
injury in an accident.

Always wear an approved DOT motorcycle helmet which fits properly.
Always wear eye protections (goggles or face shield). You should also wear
gloves, boots, long sleeve shirt or jacket and long pants.

You should wear eye protection when you ride. If a rock or a branch hits your
eyes, you could be severely injured. Wear goggles or a face shield.

Wear proper clothing when you ride. The proper clothes can protect you from
injury. Wear a good pair of gloves, strong boots that are over the ankle, long
pants and a long sleeve shirt.

Loose clothes are not suitable for motorcycle driving or riding as they may
get caught on the operating lever, kick lever, footrest or wheel, resulting in
danger.

MODIFICATION OF THE VEHICLE

CAUTION

!

Never perform any unauthorized modifications to this vehicle. Only use
original replacement part which can be obtained through Baja Inc.
888-863-2252.

4

WARNING LABEL PLACEMENT

OFF ROAD USE ONLY

This vehicle is manufactured and
designed for off road use only. It does
not conform to federal motor vehicle
safety standards.
Operation on public streets, roads, or
highways is illegal

5

SPECIFICATIONS

Description Data Description Data

Overall Length 1920mm

( 75 1/2 in.)

Overall Width 820mm

(32 1/4 in.)

Overall Height 1060mm

(41 3/4 in.)

Wheelbase 1320mm

(52 in.)

Dead weight
G.W/N.W

Payload 113kg

Ground
Clearance

Max Speed ≤ 90KM/H

Transmission 5 gear mesh Ignition CDI

Fuel capacity
and type

116.5kg/97kg
(257 lbs./213 lbs.)

(250 lbs.)

250mm
(9.84 in.)

(56 MPH)

3.35L
(.88 gal.)
92 octane or
higher

Cylinder bore X
Stroke

Compression
Ratio

Output Max 11.5kw / 6500 RPM

Displacement 244cc

Idle Speed 1500 r/min ±

Spark Plug A7TC (Torch)

Front Wheel 70/10-19

Rear wheel 90/100-16

67mm X 65mm

9.2:1

15.2hp / 6500 RPM

100 r/min

D8EA (NGK)
Gap .6mm - .7mm
(.024” - .028” )

22psi

28psi

6

PART LOCATION

PARTS & SUBASSEMBLIES

Clutch Lever

On/Off switch

Electric start
button

Brake fluid reservoir

Front brake lever

Throttle twist
grip

Fuel tank cap

Ignition key switch

7

PART LOCATION

Ignition Key

Front Shock Absorber

Front Wheel

Front brake
caliper

Exhaust Silencer

Gear Shifting

Choke lever
on Carburetor

Seat Cushion

Air filter compartment

Gas Cap

Fuel Valve

Pedal

Side Stand

Battery
compartment

Rear Shock

Drive

Drive Chain

Rear Wheel

Rear Fork

Front Shocks

Rear brake
caliper

Kick Lever

Oil Cap

Rear Brake pedal

8

Carburetor

Crank case
breather

CRANKCASE CREATHER

When shipped from the factory, the crankcase breather is tied up with a zip tie.
Before starting engine for the first time, make sure the zip tie is removed from
breather. Remove zip tie using a pair of shears or sharp knife, dispose of zip tie
properly.

CAUTION

!

Zip tie on breather hose needs to be removed before engine is started for
the first time.

Failure to remove zip tie from crank case breather hose before starting
engine the first time could result in damage to engine, breather hose and
breather.

Starting engine with low or no oil will damage the engine.

Breather

Crank case breather

Remove zip tie

9

OPERATION

FUEL FILLING

The capacity of the fuel tank is 3.33L (.88 gal) . Unscrew gas cap by turning
counter clockwise and carefully fill tank with unleaded gasoline through
opening. DO NOT MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE
ENGINE. Replace gas cap by carefully aligning the threads on cap and the
tank and turning the cap clock wise. Wipe any spilled fuel from dirt bike using
a cloth. Dispose of cloth properly. DO NOT SMOKE OR REFUEL VEHICLE
NEAR OPEN FLAMES OR NEAR HEATING UNITS. ONLY REFUEL THE
VEHICLE IN OPEN AREAS TO REDUCE THE LIKELIHOOD OF THE BUILD UP
OF GASOLINE FUMES.

FUEL VALVE

ON: Turn fuel valve to ON” position before attempting to start engine.
Turning fuel valve to “ON” position allows fuel to flow to the carburetor..
OFF: Turning fuel valve to “OFF” position, prevents the flow of fuel from fuel
tank to carburetor

10

Fuel Valve