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. Rev. D 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 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.
! 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 offroad vehicle.
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 -----
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, 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.
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 fits snugly. Motorcycle dealers can help in selecting a good quality helmet which fits properly. WARNING Operating this Mini Bike without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be hazardous.
safety !•• LOCATION OF LABELS 4 1 3 1 5 2 3 ! WARNING -Moving parts can crush and cut. -Keep hands clear. -Do not operate with guard removed. 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.
Specifications MAIN DATA Description Data Description Data Overall length 1295mm (51 inches) Bore x stroke 52x45 Overall width 476.2mm (18.75 inches) PTO shaft rotation Counter clockwise Overall height 863.6mm (34 inches) Displacement of cylinder 97cc Wheelbase 927.1mm (36.5 inches) Spark plug NGK- 6RTF, BM4A, BMR4A Dead weight 33.57kg (74 lbs.) Spark plug gap (0.6mm -0.7mm) .024 inch - .028 inch Payload 96.
location of parts Hand brake Seat Cushion Spark plug Front Wheel Rear Wheel Oil fill plug Clutch cover Oil drain plug Kick Stand Drive Chain Off Button Throttle handle Gas Tank Air Filter Foot pegs Brake Caliber Pull Start Cord
Operation Left and right hand grip operation Throttle control grip Brake Lever Right Hand Grip Left Hand Grip OFF button Pulling in brake lever located on left hand grip will stop mini bike. Applying the hand throttle (moving throttle counter clockwise ) will cause engine rpms to increase, causing mini bike to move foreward. Depressing “OFF” Button will turn off engine. Engine pull cord operation Pull Cord Pulling the pull cord will start the engine.
Operation Fuel and fuel valve operation 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.
inspection before riding ITEM TO CHECK Steering Brakes Tires Fuel Engine stop switch Engine oil Throttle General condition CONTENT Smoothness; No restriction of movement; No play or looseness Proper brake lever free play; enough brake force. Proper air pressure; Enough tread depth; No cracks, rips, or other damages Note: Check tire pressure, spec is located on side of tire.
Engine starting and stopping CAUTION Verify fuel and oil level prior to starting (see page 12) 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. Ensure there is fuel in fuel tank and oil in crank case. 2. Set fuel valve lever to “ON” position 3. Place choke lever in “ON” position 4. Start engine with pull start cord. 5. Allow engine to idle until engine is warm 6.
inspection and maintenance CHECKING THE OIL Check engine oil each time prior to operating mini bike. The oil level should be between upper and lower lines of 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 completely in the hole to check the oil. 2. Add lubricating oil up to the edge of the fuel plug. 3.
inspection and maintenance Changing the Oil 1. Remove the “Screw Plug” located 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. Clean and replace the “Screw Plug” tighly. 4.
inspection and maintenance Checking & Cleaning the Air Filter 1. 2. 3. 4. Locate Air Filter Box at rear of engine Remove air filter cover by unscrewing phillips head screw Remove foam Air filter element. Tap Air filter element gently to remove most of the dust and dirt. 5. Wash foam element per instructions below then allow to dry thouroghly. 6. Reinstall foam air filter element. 7.
inspection and maintenance 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.
inspection and maintenance Adjustment of Rear Brake 1. The front brake hand grip should have free operating movement of 5-7mm (.2-.3in) . Adjust with free play adjustment bolt. 5-7mm free play (.2-.3in) 2. To make rear brake pad adjustment, turn rear adjusting bolt clockwise to loosen and counter clockwise to tighten brake tension. 3. Brake pads should be replaced by a qualified service technition once brake shoes are worn . 4.
inspection and maintenance Adjustment of Chain 1. When chain adjustment is needed, loosen 4 bolts under engine. 2. Move engine forward to tighten chain or backward to loosen chain. 3. Tighten bolts under engine Torque bolts to 25 ft./lbs. 4. Repetitively check tension of chain. Nut 2 Nut 1 Loosen Chain Engine adjusting bolts Loosen Chain Tighten Chain Minor chain adjustment 1. When minor chain adjustment is needed, loosen “Nut 2”.
inspection and maintenance Clutch cleaning and maintenance After every 5 hour of use, your clutch will need cleaning and lubrication. If clutch becomes too dirty or has lack of lubrication, the clutch will have a tendancy to stick. This will cause the Mini-Bike to want to take off before throttle is applied. To clean and lubricate clutch, follow the instructions below: 1. Make sure engine is turned off and engine is cool before removing clutch cover. 2. Remove Clutch Cover 3.
inspection and maintenance 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.
inspection and maintenance 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.
inspection and maintenance 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.
22 X X X Chain tension - Check *Brakes - Check * Throttle - check 2. When Mini bike has exceeded the maximum figures specified in the table, maintenance should be still cycled according to the intervals of time or hours stated herein. Notes: 1. Maintenance should be conducted more frequently when Mini Bike is driven in dusty areas. “**” means: This item can only be carried out by an authorized service center in order to ensure safety.
troubleshooting Engine will not Start 1. Fuel Valve OFF 2. Choke OFF 3. Out of fuel 4. Bad fuel; engine stored without treating or draining gasoline, or refuled with bad gasoline 5. Spark plug faulty, fouled, or improperly gapped 6. Spark plug wet with fuel (flooded engine) 7. Fuel filter clogged, carburetor malfunction, ignition malfunction, valves stuck, etc. Move Fuel valve lever to ON. Move Choke Lever to ON Refuel Drain fuel and carburetor. Refuel with fresh gasoline Remove and inspect spark plug.
Electrical Schematic Engine Switch B1 Transistor Magnito Spark Plug Ignition Coil B1
Baja Motorsports, LLC 2801 So. Fair Lane Ste.