Bajaj Electricals DB30 User Manual

DB30 Doodle Bug Mini Bike

Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this Mini Bike without adult supervision.

OWNER’S MANUAL

Minimum Age Requirement: 16
Weight capacity: 200 lbs.

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 o-road vehicle.

Rev. D

Congratulations on your purchase of the Baja
Motorsports DB30 Doodle Bug Mini Bike.

Your Mini bike is warranted to be free of manufacturing defects in
the material of workmanship for a period of 90 days from the date
of purchase. During the warranty period BAJA MOTORSPORTS, LLC
will at its option, repair, provide replacement parts or replace your
Baja Motorsports DB30 Doodle Bug 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
If wheels are bent or broken
Fender bent or broken due to abuse
Any sign of impact, accident, jumping, spin-outs or roll over.

Should you experience a problem or need to return your Baja Motorsports DB30 Doodle Bug

Mini Bike for repair, please call the BAJA MOTORSPORTS customer service department TOLL

FREE at 1-888-863-BAJA (2252) between the hours of 7am and 5pm Monday thru Friday PST

and Saturday 8am to 4pm PST. During DST hours change to MT. 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 the vehicle. All operators should obtain, review,
and follow provincial and municipal government acts and
regulations pertaining to owning and operating an o­road vehicle. Children under the age of 16 should never
operate this vehicle.

WARNING

iii

TABLE OF CONTENTS

SAFETY ----------------------------------------------------- 2
Safe Operation ------------------------------------ 3
Safety Gear ----------------------------------------- 4
Location of Labels -------------------------------- 5
SPECIFICATIONS ----------------------------------------- 6
LOCATION OF PARTS ----------------------------------- 7
OPERATION ----------------------------------------------- 8
Left and Right Hand Grip ----------------------- 8
Engine ON/ OFF switch and Pull Cord ------ 8
Fuel Fill ---------------------------------------------- 9
Fuel Valve ------------------------------------------- 9
INSPECTION BEFORE RIDING ------------------------- 10
ENGINE STARTING AND STOPPING ----------------- 11
INSPECTION AND MAINTENANCE ------------------ 12
Checking Oil --------------------------------------- 12
Changing Oil --------------------------------------- 13
Checking and cleaning Air Filter -------------- 14
Adjusting Throttle Cable ------------------------ 15
Adjusting Carburetor ---------------------------- 15
Adjustment of Rear Brake ---------------------- 16
Adjustment of Chain ----------------------------- 17
Clutch cleaning and maintenance ----------- 18
Vehicle Washing ----------------------------------- 19
Instruction for Storage -------------------------- 20
Resumption of Service after Storage -------- 21
MAINTENANCE SCHEDULE ---------------------------- 22
TROUBLE SHOOTING ------------------------------------ 23
ELECTRICAL SCHEMATIC ------------------------------- 24

1

SAFETY

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 specications 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, insure safety,
prevent mishaps, and damage to components.

· It is strongly suggested that all operators take a certied 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 dened 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 specications 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 O-Road
Vehicle on a public street, road or highway where motor vehicles are in operation.

3

SAFETY

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
ts snugly. Motorcycle dealers can help in selecting a good quality helmet which ts properly.

WARNING

Operating this Mini 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 a 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 ts properly. Always wear
eye protection (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.

CAUTION

Never perform any unauthorized modications to this vehicle. Only use original
replacement part which can be obtained through Baja Motorsports 888-863-2252.

4

!••

WARNING

-Moving parts
can crush and
cut.

-Keep hands
clear.

-Do not operate
with guard
removed.

!

WARNING

!

THIS VEHICLE CAN BE HAZARDOUS TO OPERATER IF
DRIVEN CARELESSLY. SERIOUS INJURIES OR DEATH CAN
RESULT IF YOU DO NOT FOLLOW THESE INSTRUCTIONS:

• Read and familiarize yourself with owners manual and all labels
before operating this vehicle.

• Always wear an approved motorcycle helmet, eye gear and
protective clothing.

• Long hair, loose clothing or items worn by the operator must be
covered to prevent them from getting caught in moving parts of
the vehicle or surroundings while riding.

• All fenders and guards must be in place at all times while the
vehicle is in use or serious injury may occure

• Hands, Feet and loose articles must be kept away from the engine,
chain and drive components.

• Check that the throttle and brake controls work freely before
starting the engine.

• Before starting the engine, operator must be seated with
kickstand up.

• NO PASSENGERS

• This vehicle is not made for use on public streets, roads or
highways and is not intended to be used in such places.

• Do not speed on this vehicle, your risk of loosing control increases
if you ride at speeds too fast for specific terrains.

• No person under the age of 16 should operate this vehicle without
adult supervision.

• Do not jump, pop wheelies or try to perform any other stunts as
they can result in serious injury or death.

1. Check oil before starting

2. Adjust chain as necessary

3. Clean clutch assembly every 5 hours as needed

4. Check tire pressure.

5. Lubricate chain.

6. For further help, refer to trouble shooting chart.

Do not return to retailer. Call 888-863-BAJA

IMPORTANT

• Improper tire pressure can cause loss of
control resulting in serious injury or death.

• Check pressures on all tires only when
tires are cold.

• Remove air from tires before demounting.

• Only use replacement tires specified by
manufacture.

WARNING

!

TIRE PRESSURES

REGULAR SERVICE PROCEDURES

STOP!

DO NOT RETURN THIS
PRODUCT TO STORE.

FOR TECHNICAL SUPPORT

TO OUR WEBSITE
WWW.bajamotorsports.net
OR CALL TOLL FREE
888-863-2252

FOR THE LATEST PRODUCT INFO

GO!

4 psi (27.6 kpa)

LOCATION OF LABELS

1

SAFETY

4

5

1

2

3

2

3

4

5

SPECIFICATIONS

MAIN DATA

Description Data Description Data

Overall length 1295mm

(51 inches)

Overall width 476.2mm

(18.75 inches)

Overall height 863.6mm

(34 inches)

Wheelbase 927.1mm

(36.5 inches)

Dead weight 33.57kg (74 lbs.) Spark plug gap (0.6mm -0.7mm)

Payload 96.7kg (200lbs) Ground clearance 127mm (5 inches)

Front wheel 145/70-6

See specied
pressure on tire

Rear wheel 145/70-6

See specied
pressure on tire

Bore x stroke 52x45

PTO shaft rotation Counter clockwise

Displacement of
cylinder

Spark plug NGK- 6RTF, BM4A,

Ignition system Non contact transitor

Tire Pressure 24 psi Max. to seat bead

97cc

BMR4A

.024 inch - .028 inch

magneto

4 psi Operating pressure

Brake Type Disc

Capacity of gasoline
tank

Capacity of oil tank 0.45L (.40 qt)

Drive Auto clutch

1.4L (.36 gal))

6