Bajaj Electricals Bicycle HT65 MB165 User Manual

HT65/MB165 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. B  
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.  
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!
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. All operators should obtain, review,  
and follow provincial and municipal government acts and  
regulations pertaining to owning and operating an off-  
road vehicle. Children under the age of 16 should never  
operate this vehicle.  
iii  
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Table of Contents  
SAFE OPERATION............................................................................... 3  
SAFETY GEAR ...................................................................................... 4  
MODIFICATION OF vEHICLE.......................................................... 4  
MAIN DATA........................................................................................... 5  
PARTS & SUBASSEMBLIES .............................................................. 6  
OPERATION .......................................................................................... 8  
FUEL COCk.................................................................................... 8  
ENGINE STARTING...................................................................... 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 FASTNERS .................................... 19  
MAINTENANCE REOUTINE DIAGRAM................................ 20  
TROUBLE SHOOTING ................................................................ 21  
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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 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.  
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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 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:  
·
·
·
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 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.  
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  
·
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.  
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SAFETY GEAR  
1. Never operate this mini bike without wearing a DOT approved motorcycle helmet which  
fits 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 modifications to this vehicle. Only use original  
replacement part which can be obtained through Baja Motorsports 888-863-2252.  
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MAIN DATA  
Description  
Data  
Description  
Data  
Overall length  
1624mm (64”) Cylinder bore x  
stroke  
6.8cm X 15.41cm  
(2.68X 2.13”)  
Overall width  
Overall height  
Wheelbase  
737mm (29”)  
914mm (36”)  
PTO shaft rotation  
Output, max  
Counter clockwise  
6.5hp at 3600 rpm  
9.76 ft-lbs. at 2500 rpm  
1162mm  
(45.75”)  
Torque, max  
Dead weight  
Payload  
75kg (165 lbs.)  
Idling speed  
1400 +200  
-150  
91kg (200 lbs)  
Displacement of  
cylinder  
197cc  
Front wheel  
19 X 7 - 8  
10psi  
Spark plug  
MEIYA -F7RTC, NGk-  
BPR6ES, Champion  
- RN9YC  
Rear wheel  
Brake Type  
19 X 7 - 8  
10psi  
Spark plug gap  
0.7mm -0.79mm  
(.028”-.031”)  
Drum  
Gap of air valve IN  
Gap of air valve EX  
0.15 +- .02mm (cold)  
0.20+- .02mm (cold)  
Capacity of gasoline 4.2L (.95 gal.)  
tank  
Capacity of oil tank .5L (.53 qt.)  
Ground clearance  
Ignition means  
139 mm (5.5”)  
Magnito  
Drive  
Cintrifugal  
cutch  
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PARTS & SUBASSEMBLIES  
Rear brake lever  
Throttle twist grip  
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Headlight  
Hand brake  
Front Shock Absorber  
Front Wheel  
Rear Wheel  
Clutch cover  
Drive Chain  
Side Stand  
Foot pegs  
Air Filter  
Decorative tank  
Vehicle Identifictaion Number  
Seat Cushion  
Brake Drum  
Gas Tank  
Pull Start Cord  
EPA Sticker  
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OPERATION  
FUEL vALvE  
Fuel filling  
The capacity of the fuel tank is 4.2L (.95 gal) . 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. Replace the gas cap by carefully  
aligning the threads on the cap and the tank and turning the cap clock wise. Wipe any spilled  
fuel from the dirt bike using a cloth and dispose of the cloth properly. DO NOT SMOkE OR  
REFUEL THE 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.  
Filler neck  
Fuel level  
Operation of the fuel valve (the valve under the fuel tank)  
ON: With the handle of the fuel valve to “ONposition, the fuel supply will flow to the  
carburetor.  
OFF: With the handle of the fuel valve to “OFFposition, the fuel supply is cut off to the  
caburetor.  
OFF  
ON  
Fuel valve Handle  
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ENGINE STARTING  
CAUTION  
verify oil level prior to starting (see page 11)  
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.  
1.  
2.  
3.  
Set the ignition switch to “ position.  
Ensure that there is fuel in the tank.  
Set the fuel valve lever to “ONposition.  
Choke Lever  
Closed  
ON  
To start a cold engine:  
OFF  
ON  
Fuel valve lever  
1.  
2.  
Place the choke lever in the closed position  
Start the engine with the pull start cord.  
3. Allow the engine to idle until the engine is warm  
4.  
Turn the carburetor choke lever to the ON position when the engine has sufficiently  
warmed up.  
CAUTION  
Unnecessarily increasing RPM’s to a high level while the Mini Bike is warming up is  
harmful to the engine.  
Procedures for stopping the engine:  
1.  
Release the throttle twist grip to slow down the engine.  
2.  
3.  
Set the ignition switch to “ position.  
Set the fuel valve lever (the fuel tank valve) handle to “OFFposition.  
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SWITCHES ON RIGHT HANDLEBAR  
Ignition switch  
The ignition switch is provided on the right handlebar.  
When the switch is turned to “ (o) position, the engine will not start or stops the engine.  
When the switch is turned to “ (on) position, the engine can start and the vehicle can be  
driven.  
ON button  
OFF button  
ꢀ0  
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CHECk-UPS, ADJUSTMENT AND MAINTENANCE  
Checking the Oil  
Check the engine oil each time prior to operating the mini bike.  
The oil level should be between the upper and lower lines of the oil gauge.  
1. Set the Mini Bike on level ground, screw off the oil gage plug, wipe the oil gage rod clean  
and then insert the gage plug into the crankcase again to check the oil level. There is no  
need to screw the oil gage plug into its hole in the crankcase.  
2. Add lubricating oil up to the edge of the fuel plug.  
3. Finally screw in the oil gage plug tightly.  
CAUTION  
Never start the engine when there is  
insufficient lubricating oil. Otherwise, it will  
cause harm to the engine.  
Oil dip stick  
Lubricating Oil Recommended  
The lubricating oil is an important factor affecting the performance and service life of  
the engine. Please refer to the chart for the correct grade of engine oil based on the  
environmental conditions in your area. Do not use any other type of oil other than what is  
recommended in the chart. DO NOT MIX OIL WITH THE GASOLINE.  
Lubricating oils of different  
viscosity shall be employed  
in different regions and at  
different temperatures.  
ꢁ0W-ꢄ0  
MACHINE  
OIL  
15W - 40  
10W-30  
°C  
°F  
-30  
-22  
-20  
-4  
-10  
14  
0
10  
50  
20  
68  
30  
86  
40  
TEMP.  
32  
104  
ꢀꢀ  
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CHANGING THE OIL*  
1.  
Remove the “Screw Pluglocated 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.  
2.  
Dispose of the used oil properly. For proper disposal procedures, contact your local oil  
recycling center.  
3.  
4.  
Clean and replace the “Screw Plugtighly.  
Refill the engine with the proper amount of oil and recheck the amount of oil in the  
engine by using the oil gauge plug.  
Screw plug for oil draining  
CHECk-UP OF SPARk PLUG  
1.  
2.  
3.  
3.  
Remove the cap of spark plug and screw off the spark  
plug using the plug wrench.  
Clean the spark plug all around or replace it if it is  
corroded or there is too much deposit on it.  
Regulate the gap of the spark plug to .7mm - .79mm  
(.028”-.031”).  
.7mm - .79mm  
(.028- .031”)  
The spark plug of the designated type should be used.  
The applicable type of spark plug: Meiya - F7RTC  
Champion- RN9YC, NGk - BPR6ES  
ꢀꢁ  
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CHECkING & CLEANING THE AIR FILTER  
1. Remove seat to access air filter. Seat is removed by  
removing nut located under seat (see photo).  
2. Locate Air Filter Box under seat and remove cover.  
3. Remove air filter.  
Seat nut  
4. Remove foam cover from Air filter element.  
5. Tap the Air filter element gently to remove most of the dust  
and dirt. Blow out remaining dust with compressed air. If  
the element is damaged, replace it.  
6. Wash the foam element cover per instructions below then  
allow to dry thouroghly.  
7. Reinstall foam cover to the air filter element.  
8. Reinstall air filter and close cover.  
Foam cover  
Air Filter  
Removal of filter  
Air Filter box  
Removal of cover  
Air filter element  
Wash with mild soap  
and water  
Rinse with fresh water then  
queeze out excess.  
CAUTION  
The air filter element must be intact or the engine will suck in dust and dirt, resulting in a  
shorter service life of the engine.  
Water should be prevented from entering into the filter when washing the vehicle.  
The filter element shall be cleaned gently without twisting to prevent it from cracking.  
Never wash it with gasoline or any acid, alkaline or organic volatile oil to avoid its aging,  
which will result in reducing the effect of the air filter oil to catch particles before they  
enter the engine. Replace the filter element with a new one if it is broken or cracked.  
ꢀꢂ  
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ADJUSTING THE THROTTLE CABLE  
Make sure the throttle cable is adjusted properly. To adjust throttle cable, rotate adjustment  
nut located at the hand throttle.  
Check if the throttle twist grip has the required free operating movement.  
The required free operating movement: 2-6mm (.078 -.24in) . If the grip cannot be moved  
freely, turn the adjusting nut to ensure proper operating movement.  
After adjustment, start the engine and check for the operating movement again. Repeat the  
adjustment if necessary until the desired operating movement is obtained.  
Throttle cable adjust nut  
ADJUSTING THE CARBURETOR  
Adjusting procedures of idling speed:  
1. Support the vehicle by a stand.  
2. Adjust the idle speed by the throttle stop screw to 1400 +200 RPM  
-150.  
CAUTION  
Do not try to correct a malfunctioning carburetor by adjusting the idling speed. If the  
carburetor is not functioning properly, it should be repaired by a service center.  
Adjust idling speed only when the engine is warmed up or 10 minutes after operation.  
ꢀꢃ  
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ADJUSTMENT OF REAR BRAkE  
5-7mm free play  
(.ꢁ-.ꢂin)  
1. The front brake hand grip should have free operating  
movement of 5-7mm (.2-.3in) .  
2. To make adjustment, turn rear adjusting  
nut clockwise to reduce and counterclockwise  
to increase the free operating movement  
of the hand brake.  
3. Brake shoes should be replaced by a qualified service  
technition once brake shoes are worn .  
Rear brake arm  
Brake cable  
Rear brake adjusting nut  
ꢀꢄ  
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ADJUSTMENT OF CHAIN  
1. When chain adjustment is needed, loosen rear axle bolt .  
2. 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.  
3. Tighten rear axle bolt by a torque of 50-60Nm (37-44 ft.lb.).  
4. Repetitively check the tension of the chain.  
Rear axle bolt  
15-20mm  
1/2- 3/4”  
Chain adjusting nut  
Both Sides  
GREASING PROCEDURES TO THE DRIvING CHAIN  
1. Shut off the engine  
2. Add light amounts of machine oil or chain grease to the driving chain. (Too much machine  
oil or chain grease may cause splattering to occur.)  
Attention:  
The chain should be replaced when the adjusting limit has reached it’s maximum.  
ꢀꢅ  
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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 Mini Bike with over-pressurized water may cause damage to some of its  
components. Therefore, do use a pressure washer to clean the vehicle. The following  
parts should be cleaned using low pressure water:  
— Wheel hub  
— Exhaust pipe  
— Fuel tank and lower portion of cushion  
— Carburetor  
— Head lock and ignition switch  
— Meters  
1.  
After pre-wiping, the vehicle should be washed with clean water to remove dirty residues  
so as to prevent corrosion. Plastic subassemblies should be cleaned by wiping with a  
cloth or foam soaked in neutral detergent solution, followed by washing with clean water.  
2.  
3.  
After the cleaned vehicle is air dried, grease the chain and run the engine at idling speed  
for a few minutes.  
Prior to driving, carefully check the braking system repeatedly and repair or adjust it if  
necessary.  
ꢀꢆ  
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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.  
1. Change engine oil.  
2. Drain off fuel from the fuel tank and carburetor, spray atomized anti-rust oil onto the  
inside wall of the tank and then close the tank. Dispose of any drained fuel properly so as  
not to adversely affect the environment.  
Carburetor Drain screw  
Attention:  
If the storage will last for more than one month, fuel in the carburetor must be fully  
drained. This will help ensure that the carburetor maintains its normal performance after  
the storage.  
WARNING  
Gasoline is flammable and may cause fire and even an explosion under certain  
conditions. Therefore, do not smoke, make a fire or have any fire around while draining  
off fuel.  
3. Take out the spark plug, pour about 15-20ml (.5 - .68 oz.) of clean engine oil into the  
cylinder, step down on the kick lever repetitively several times so as to have machine oil  
distributed all over the engine and finally fit the spark plug back on.  
4. Wash the vehicle clean, wipe it dry and apply an even coat of wax to the painted surface  
and a coat of anti-rust oil on the chrome-plated surfaces.  
5. Inflate the tires as required and put the vehicle up on wooden blocks with the two wheels  
clearing the ground.  
6. Put the vehicle in a shady and cool place free from humidity and direct sunlight and cover  
it properly (not with plastic or other painted materials). If there is a garage, store it within.  
ꢀꢇ  
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RESUMPTION OF SERvICE AFTER STORAGE  
1. 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.  
2. Drain off the remaining atomized anti-rust oil from the fuel tank, followed by filling it with  
fresh gasoline therein.  
3. Prior to driving, all the required check-ups must be made. It is better to drive it at a low  
speed in an open area to test its performance before normal operation.  
TABLE AND TORQUE OF FASTENERS  
Ser. No.  
Fastener  
Torque (Newton/m)  
(Foot/lb)  
1
2
3
Front wheel axle nut  
Rear wheel axle nut  
Front Fork Bolts  
35-45Nm (26-33 ft.lb.)  
50-60Nm (37-44 ft.lb.)  
45-47.5Nm (33-35  
ft.lb)  
ꢀꢈ  
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ꢁ0  
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TROUBLESHOOTING  
Engine will not Start  
1. Fuel valve OFF  
2. Choke OPEN  
3. Out of fuel  
Move Fuel valve lever to ON.  
Move Chock Lever to CLOSED  
Refuel  
4. Bad fuel; engine stored  
without treating or draining  
gasoline, or refuled with bad  
gasoline  
Drain fuel and carburetor. Refuel with  
fresh gasoline  
5. Spark plug faulty, fouled,  
or improperly gapped  
Remove and inspect spark plug. Clean,  
gap, or replace  
6. Spark plug wet with fuel  
(flooded engine)  
Remove and inspect spark plug. Dry and  
reinstall spark plug.  
7. Fuel filter clogged,  
carburetor malfunction,  
ignition malfunction, valves  
stuck, etc.  
Take the engine to a qualified mechanic.  
Replace or repair faulty components as  
necessary  
Engine Lacks Power  
1. Filter element(s) clogged  
Check air filter  
Cean or replace.  
2. Bad fuel; engine stored  
without treating or draining  
gasoline, or refueled with  
bad gasoline.  
Drain fuel tank and carburetor. Refuel with  
fresh gasoline.  
3. Fuel filter clogged,  
carburetor malfunction,  
ignition malfunction , valves  
stuck, etc.  
Take engine to a qualified mechanic.  
Replace or repair faulty components as  
necessary.  
ꢁꢀ  
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Baja Motorsports, LLC  
2910 South Hardy Drive, Suite 103  
Tempe, AZ 85282  
Tel: 480-222-8280  
Toll Free: 888-863-2252  
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