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.
Congratulations on your purchase of the Baja Motorsports Mini Bike. Your Mini bike is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days form the date of purchase. During the warranty period BAJA MOTORSPORTS, LLC will at its option, repair, provide replacement parts or replace your Baja Motorsports 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 safe operation................................................................................ 3 safety gear....................................................................................... 4 modification of vehicle........................................................... 4 main data............................................................................................ 5 parts & subassemblies............................................................... 6 OPERAtion...........
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.
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 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.
MAIN DATA Description Data Description Data Overall length 1624mm (64”) Cylinder bore x stroke 6.8cm X 15.41cm (2.68” X 2.13”) Overall width 737mm (29”) PTO shaft rotation Counter clockwise Overall height 914mm (36”) Output, max 6.5hp at 3600 rpm Wheelbase 1162mm (45.75”) Torque, max 9.76 ft-lbs. at 2500 rpm Dead weight 75kg (165 lbs.
PARTS & SUBASSEMBLIES Rear brake lever Throttle twist grip
Headlight Hand brake Front Shock Absorber Front Wheel Rear Wheel Clutch cover Drive Chain Foot pegs Decorative tank Seat Cushion Air Filter Brake Drum Gas Tank Pull Start Cord EPA Sticker Side Stand Vehicle Identifictaion Number
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.
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. Set the ignition switch to “ ” position. 2. Ensure that there is fuel in the tank. 3. Set the fuel valve lever to “ON” position. Choke Lever Closed ON To start a cold engine: 1. Place the choke lever in the closed position 2.
Switches on Right Handlebar Ignition switch The ignition switch is provided on the right handlebar. When the switch is turned to “ ” (off ) position, the engine will not start or stops the engine. When the switch is turned to “ driven.
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.
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.
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. 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.
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.
Adjustment of Rear Brake 1. The front brake hand grip should have free operating movement of 5-7mm (.2-.3in) . 5-7mm free play (.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 .
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.
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.
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.
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.
20 X X Every 6 Months or 100 hours X X X X X All nuts and bolts - Check for tightness Chain tension - Check *Brakes - Check * Throttle - check * Throttle cable - 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.
troubleshooting Engine will not Start 1. Fuel Valve OFF 2. Choke OPEN 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 Chock Lever to CLOSED Refuel Drain fuel and carburetor.
Baja Motorsports, LLC 2910 South Hardy Drive, Suite 103 Tempe, AZ 85282 Tel: 480-222-8280 Toll Free: 888-863-2252
