DX70/DX110 Dirt Bike Read this manual carefully. It contains important safety information. No one under the age of 16 should operate this dirt bike without adult supervision. OWNER’S MANUAL Minimum Recommended Age Requirement: 16 Rev. A 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 off-road vehicle.
Congratulations on your purchase of a Baja Motorsports dirt bike. Your dirt bike is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days form the date of purchase. During the warranty period BAJA MOTORSPORTS, will at its option, repair, provide replacement parts or replace your Dirt bike at no charge. This warranty does not cover normal wear items or damage caused by neglect or misuse of the product.
! 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.
TABLE OF CONTENTS safety................................................................................................................2 Safe operation.........................................................................................3 safety gear.............................................................................................4 Warning label placement.................................................................5 SPECIFICATIONS...........................................................
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.
SAFETY SAFE OPERATION Rules for Safe Operation · A pre-operation check must be conducted before starting the engine to insure safety, prevent mishaps and damage to components (see maintenance section of this manual). · It is strongly suggested that all operators take a certified motorcycle rider’s course prior to operating the vehicle.
SAFETY 9- Always avoid operating 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. 10- Always keep your dirt bike in safe operating condition. Inspect dirt bike before each ride and perform all recommended maintenance and pre ride inspections. 11- Never overload dirt bike. Maximum weight capacity is 165 lbs. (75kg).
SAFETY WARNING LABEL PLACEMENT ! WARNING OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only. It does not conform to federal motor vehicle safety standards. Operation on public streets, roads, or highways is illegal Study the owners manual carefully Always wear a helmet, eye protection and protective riding gear. Do not drive while drinking alcohol or while on medication. ! WARNING No on under the age of 16 should operate this vehicle without adult supervision.
SPECIFICATIONS SPECIFICATION 70CC 110CC Dimensions / Measurements / Weight Wheel Base 41.34 in. (1050mm) 41.73 in. (1060mm) Seat Height 24.02 in. (610mm) 25.2 in. (640mm) Grips Height 39.17 in. (995mm) 41.73 in. (1060mm) Ground Clearance 5.51 in. (140mm) 7.09 in. (180mm) Assembled Weight 130 lbs. (59kg) 137 lbs. (62.14kg) In Box Weight 174 lbs. (79kg) 185 lbs. (84kg) Passenger Capacity Operator only Operator only Maximum Weight 165lbs. (75kg) 165lbs.
SPECIFICATIONS SPECIFICATION 70CC 110CC Fuel & Lubricants Fuel Tank Capacity .92 gal / 3.5L .92 gal / 3.5L Reserve .15 gal / .57L .15gal / .
SPECIFICATIONS SPECIFICATION 70CC 110CC Torque Specifications Oil Drain Bolt 15-20 ft.lbs (20-30 NM) 15-20 ft.lbs (20-30 NM) Wheel Axles 37-44 ft.lbs (50-60 NM) 37-44 ft.lbs (50-60 NM) Front Wheel (RIM) Size 1.4 - 12 in. 1.4 - 12 in. Rear Wheel (Rim) Size 1.4 - 10 in. 1.4 - 12 in. Spokes 43mm 43mm Front Tire size 2.5 - 12 in. 2.5 - 12 in. Rear TIre size 2.75 - 10 in. 3.0 - 12 in.
PART LOCATION PARTS & SUBASSEMBLIES Clutch Lever Brake fluid reservoir Fuel Tank cap breather hose Front brake lever Throttle twist grip On/Off switch Fuel tank cap
PART LOCATION Fuel Valve Air filter Front Wheel Rear Shock Rear Wheel Carburetor Seat Cushion Muffler Drive Chain Drive Chain adjuster Rear Fork Gear Shifting Lever Side Stand Choke lever on Carburetor Front brake caliper Rear brake caliper Chain adjuster Front Shocks Oil Cap Kick Lever Rear Brake pedal 10
OPERATION FUEL FILLING The capacity of the fuel tank is 3.5L (.92gal) . Unscrew gas cap by turning counter clockwise. Fill gas tank with 86 octane or higher unleaded gasoline through opening. Do not fill gas past bottom of filler neck in gas tank. DO NOT MIX GAS AND OIL TOGETHER, THIS IS A 4-STROKE ENGINE. Replace gas cap by carefully aligning threads on cap and tank and turning cap clockwise. Wipe any spilled fuel from dirt bike using a cloth. Dispose of cloth properly.
OPERATION engine break-in The first 10 hours of operation should be considered the “Break-in” period and special attention shall be paid to the following points: 1. Do not throttle past half throttle during the first 10 hours of operation. Fluctuate the throttle during this period to break in engine components. Do not put excessive load on engine by climbing steep hills or having fast starts. 2. Warm up engine 3-5 minutes prior to operation so all components are lubricated sufficiently.
OPERATION Left HANDLEBAR - clutch lever Clutch lever Clutch lever When clutch lever is pulled toward hand grip, clutch is applied. RIGHT HANDLEBAR - FRONT BRAKE LEVER AND throttle twist grip Front brake lever Throttle twist grip Throttle twist grip Controls engine and dirt bike speed. When twist grip is turned back CCW (counter clockwise) engine speed is increased along with speed of dirt bike. When twist grip is turned forward CW (clockwise) engine speed is decreased along with speed of dirt bike.
OPERATION Gear Shifting Reduce throttle before shifting. Never increase throttle while shifting gears. Pull in clutch lever and depress shift lever to place in 1st gear. Lift up shift lever to shift to 2nd, 3rd and 4th. Before shifting into any gear, pull in clutch lever. Once in gear, release clutch lever. Do not rest your foot on the gear-shift lever while operating dirt bike, doing so could cause unwanted shifting without applying clutch. Shifting without the clutch could cause damage to transmission.
OPERATION Pre- ride inspection Before each ride it is important to inspect your dirt bike. Make sure any problems found are corrected before starting engine. A pre-ride inspection is a must for off-road riding because off road riding can provide excessive wear and tear on components. Tires: Use a tire gauge to check air pressure Adjust air pressure if needed. Look for signs of damage or excessive wear. Spokes and Rims: Make sure all spokes are tight, check rims for damage.
OPERATION WARNING Never start engine without first performing a pre-ride inspection (see page 14 of this manual). Failure to perform a pre ride inspection could result in severe injury or death. Always perform pre-ride inspection before every ride and correct any problems CAUTION Verify oil level prior to starting Starting the engine with low or no oil will damage engine. WARNING Never start the engine in a closed place as the exhausted fumes from vehicle contains toxic carbon monoxide.
OPERATION Procedures for stopping engine: 1- Release throttle twist grip to slow down engine. 2- Shift to neutral position once stopped. 3- Set the ignition switch key to “ ” (OFF) position. 4- Set the fuel valve handle to “OFF” position. CAUTION Unnecessarily increasing RPM’s to a high level while dirt bike is in neutral is harmful to the engine.
MAINTENANCE cHECKING ENGINE OIL Checking Oil Check engine oil each time prior to operating the dirt bike. The oil level should be between the upper and lower lines of the oil cap dip stick 1- Set dirt bike on level ground. 2- Remove dip stick to check oil level. 3- Add oil if low but do not overfill. Unit requires 1 qt. (1L) 4- Re-install dip stick plug and cinch finger tight. Oil fill cap and dip stick CAUTION Never start the engine when there is insufficient lubricating oil.
MAINTENANCE CHANGING ENGINE OIL 1. If engine is cold, start engine and allow to warm up 3 - 5 minutes. 2. Turn engine off allowing oil to settle to bottom of oil case. 3. With warm engine, NOT HOT, remove oil drain plug located at bottom of engine and let oil drain into an approved collection container. DO NOT PERFORM THIS PROCEDURE WHILE ENGINE IS HOT. SERIOUS BURNS COULD RESULT FROM CONTACT WITH HOT OIL. 4. Dispose of used oil properly.
MAINTENANCE Checking & Cleaning Air Filter 1- Locate air filter which is attached to carburetor under gas tank. 2- Remove air filter by loosening clamp holding filter in place 3- Once foam filter is removed, remove outer foam filter sleeve, check filter for damage or tears. If filter is damaged or torn, replace. 5- Gently wash foam air filter and outer foam sleeve with clean, nonflammable (high flash point) solvent such as kerosene.
MAINTENANCE Adjusting the Throttle Cable 2-4mm 1/16 - 3/16 in Make sure the throttle works normally. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-4mm (1/16-3/16 in) If the grip cannot be moved freely, turn adjusting nut located on top of the throttle twist grip to ensure proper operating movement. Adjust nut After adjustment, start the engine and check for the operating movement again.
MAINTENANCE 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- Inspect the brake hose for cracks, and the joint for leakage. 3- Check the brake fluid level in the brake fluid reservoir, if level is at or below the LOWER mark, inspect brake pads for wear and hydraulic system for leaks.
MAINTENANCE CLUTCH ADJUSTMENT 3.0 - 5.0mm play (0.12”-0.20”) Clutch lever adjustment nut Adjustment Cover To adjust the clutch lever play: 1- Remove adjuster cover (slide back on cable). 2- Loosen adjuster nut and move adjuster in or out to obtain the correct play. Correct free play should be 0.12-0.20 inch (3.0-5.0mm) 3- Tighten adjuster nut 4- Recheck the clutch lever free distance. Readjust if it is not within the correct limits.
MAINTENANCE Adjustment of Chain 1- When chain adjustment is needed, loosen rear axle bolt . 2- Turn chain adjusting nuts on left and right sides to adjust tension of chain. To keep wheel straight, adjustment marks are marked on both sides of rear swing arm. Make sure adjustment is even with corresponding mark on opposite side of wheel. 3- Tighten rear axle bolt by a torque of 50-60Nm (37-44 ft.lb.). 4- Repetitively check tension of chain.
MAINTENANCE TORQUE SPECIFICATIONS 1 Front wheel axle bolt 12mm 37-44 ft.lb. (50-60 Nm) 2 Rear wheel axle bolt 13mm 37-44 ft.lb. (50-60 Nm) 3 Handle bar clamp bracket 4 ea. 8mm 15-18 ft.lb. (20-25 Nm) 4 Top fork tube bolts 2 ea. 10 mm 24-25 ft.lb. (32-34 Nm) 5 Bottom triple tree shock bracket 2ea. 8mm 15-18 ft.lb. (20-25 Nm) 6 Engine mounting top bolt 8mm 15-18 ft.lb. (20-25 Nm) 7 Engine mounting bottom bolt 8mm 15-18 ft.lb. (20-25 Nm) 8 Rear shock mount bolts 2ea. 10mm 24-25 ft.lb.
MAINTENANCE INSPECTION AND MAINTENANCE It is very important to inspect and maintain your dirt bike 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 perform the maintenance listed.
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. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty.
TROUBLESHOOTING Ignition System Check 1- Remove the spark plug and reattach it to the spark plug lead. 2- Turn ignition stop switch to the “RUN” position. Have someone work the kick start lever. If the ignition system is operating properly, a blue spark should jump across spark plug gap. If there is no spark, take your machine to your service center. WARNING Performing the spark test improperly could be hazardous. You could get a high voltage electrical shock if you are not familiar with this procedure.
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 dirt bike with over-pressurized water may cause damage to some of its components. Therefore, do not use a pressure washer to clean the vehicle.
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 vehicle for a long period , proper maintenance should be completed. 1- Change engine oil and clean oil filter. 2- Drain off fuel from the fuel tank and carburetor. Dispose of any drained fuel properly so as not to adversely affect the environment.
INSTRUCTIONS FOR STORAGE RESUMPTION OF SERVICE AFTER STORAGE 1. Change engine oil if vehicle has been out service for over 4 months. 2. Drain off any remaining unused gas in tank, follow by filling with fresh gasoline. 3. Make sure all bolts are tight. See torque specs. 3. Prior to riding, all the required check-ups must be made. Ride at a low speed in an open area to test performance before normal operation .
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 Motorsports 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. Frame number Engine serial number Write down the serial numbers here for your future reference Frame No.: Engine No.
EMISSION CONTROL SYSTEM WARRANTY BAJA MOTORSPORTS - EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the the date the vehicle is delivered to the first purchaser other than an authorized dealer, or the date it is first used a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 10,000km, whichever comes first, provided there has been no abuse, neglect or imp
EMISSION CONTROL SYSTEM WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not cover the following: ● Failures or malfunctions of the emission control systems caused by abuse, alteration, accident, misuse, the use of leaded gasoline. ● Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use, and the first required replacement interval for the item has not been reached.
Baja Motorsports, LLC P.O.
