DR70 Dirt Bike Read this manual carefully. It contains important safety information. OWNER’S MANUAL No one under the age of 16 should operate this Dirtbike without adult supervision. Parents should consider child’s age, size, maturity and ability before allowing to ride. Rev. G 022709 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 INC. DR70 Dirt Bike. Your bike is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days from the date of purchase. During the warranty period BAJA, INC. will at its option, repair, provide replacement parts or replace your BAJA INC. DR70 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. ! WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
TABLE OF CONTENTS NOTICE TO USER’S............................................................................................2 SAFE OPERATION ..............................................................................................3 PRE-RIDE CHECKLIST .......................................................................................4 SAFETY GEAR ....................................................................................................5 LOCATION OF WARNING LABELS.........................
Please read this manual and follow all instructions carefully. To emphasize 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. This check will insure safety, prevent mishaps, and prevent 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.
Pre-Ride Checklist Before Starting the Engine/Motor 1. Engine oil level a) Check for leaks b) Tighten filler cap securely. c) Add oil if required. 2. Fuel level a) Add fuel as necessary. b) Do not overfill (no fuel in the filler neck). c) Do not mix oil with gas. d) Replace cap tightly. e) Do not refuel a hot engine. Allow engine to cool before adding fuel. 3. Warning decals a) Make sure all warning decals are legible and securely attached. b) Replace as necessary. 4.
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 Dirt bike without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be hazardous.
LOCATION OF WARNING LABELS Read and follow all of the warning labels on your dirt bike. Make sure you understand all the labels. Keep the labels on the dirt bike. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting Baja Inc. 2 1 1 ! WARNING No one under the age of 16 should operate this vehicle without adult supervision.
MAIN DATA DESCRIPTION DATA Overall length 1562 mm (61.5 inches) Overall width 673 mm (26.5 inches) Overall height 889 mm (35 inches) Wheelbase 1105 mm (43.5 inches) Dry weight 55.79 kg (123 lbs.) Payload 75 kg (165 lbs.) Ground clearance 300 mm (11.81 inches) Max speed ≥65 km/h (40 mph) Transmission 4 gear mesh Capacity of fuel tank 3.3L Cylinder bore X stroke 47 mm X 41.4 mm Compression ratio 8.8:1 Max output 3.7 KW /8500 rpm Max torque 4.
PARTS & SUBASSEMBLIES Front brake lever On/Off switch Throttle twist grip Fuel tank cover 8
PARTS & SUBASSEMBLIES Gas Cap Fuel Valve Front Wheel Rear Wheel Carburetor Gear Shifting Pedal Side Stand Drive Chain LEFT Front Brake Lever Seat Cushion Front Shocks Exhaust Silencer Oil Cap Kick Lever Choke lever on Carburetor Rear Brake pedal RIGHT 9
OPERATION FUEL VALVE Fuel filling The capacity of the fuel tank is 3.3L . 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 15) 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 key of the ignition switch to “ 2. Put the dirt bike in the neutral gear. 3. Ensure that there is fuel in the tank. 4. Set the fuel valve handle to “ON” or “RES” position. ” position. CLOSED To start a cold engine: OPEN 1.
BREAKING IN THE ENGINE The first 600 Miles of operation should be considered the “Break-in” period and special attention shall be paid to the following points: 1. Take special care not to increase the RPM’s of the engine while climbing steep slopes. Never drive your dirt bike continuously for more than 30 miles without increasing and decreasing the throttle. 2. The engine shall be warmed up for 3-5 minutes prior to operation so all components are lubricated sufficiently. 3.
SWITCHES ON RIGHT HANDLEBAR Ignition switch The ignition switch is Located on the right handlebar. When the switch is turned to “ ” (off) position, the engine will not start. If the engine is running and the Off button is pushed the engine will turn off. When the switch is turned to “ the kick start lever.
GEAR SHIFTING Reduce throttle before shifting. Never increase the throttle while shifting gears. Depress the gear shift pedal to place the gear in 1st, lift up the lever to shift to 2nd, 3rd, 4th and 5th. Do not place your foot on the gear-shifting pedal while operating the dirt bike to avoid damaging the clutch caused by sudden gear shifting accidentally.
CHECK-UPS, ADJUSTMENT AND MAINTENANCE Checking the Oil Check the engine oil each time prior to operating the dirt bike. The oil level should be between the upper and lower lines of the oil fill cap/ dipstick. 1. Set the motorcycle on level ground. Remove the oil fill cap/dipstick, wipe it clean and then insert the dipstick into the crankcase again to check the oil level. There is no need to screw the oil fill cap/dipstick into its hole in the crankcase. 2.
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 tightly. 4.
CHECKING & CLEANING THE AIR FILTER Air filter is located under left side plastic cowling. Cowling will need to be removed. Take the air filter out and check to see if it is dirty or torn. Tap the air filter clean. If necessary use compressed air to gently clean. Air filter 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.
ADJUSTING THE THROTTLE CABLE Make sure the throttle works properly. Check if the throttle twist grip has the required free operating movement. The required free operating movement: 2-6mm (.078” - .24”) If the grip cannot be moved freely, turn the adjusting nut located on top of the throttle twist grip 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.
ADJUSTMENT OF FRONT BRAKE 6mm (0.24 in) Lock nut Adjusting nut The front brake lever has a free operating movement of 6mm as shown. 1. Turn the adjusting nut beneath the front hub, clockwise to increase and counter clockwise to decrease the free operating movement. 2. You can also adjust the nut on the handlebar; clockwise to increase and counter clockwise to decrease the free operating movement. 3. Be sure to tighten the lock nut when adjustment has been made.
ADJUSTMENT OF CHAIN 1. 2. 3. 4. When chain adjustment is needed, loosen rear axle nut . 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. Tighten rear axle bolt by a torque of 35-50Nm (25-37 ft.lb.). Repetitively check the tension of the chain.
TIRES The Dirt bike is equipped tires of the type listed below: Size Front Rear 2.50-14 3.00-12 WARNING Operating this Dirt bike with improper tires, or with improper or uneven tire pressure. Use of improper tires on this Dirt bike, or operation of this Dirt bike with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. Always use the size and type of tires specified. Always maintain proper tire air pressure as described in this section.
Tire Tread Condition WARNING Using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident. Replace the front and rear tires when the depth on the tread is 3mm (0.12 in) or less. 3mm (0.12 in) Tire Air Pressure Check the air pressure in both tires before riding. Improper air pressure would effect handling, steering response, traction, tire life and rider comfort. Be sure that the tires are inflated to the pressures shown below.
Tire Replacement When the knobs loose their sharp edges, the tires have lost a lot of their effectiveness. Don’t wait until the knobs are worn down to rubber stubs. A good rule is to replace both tires at the same time, and keep them matching brands. WARNING Using tires that have been installed incorrectly could be hazardous. The Dirt bike may have unusual handling if the tires are installed incorrectly.
EXHAUST WARNING The hot exhaust muffler could burn you. The muffler will be hot enough to burn you after stopping the engine. Wait until the exhaust muffler cools to remove it. WARNING Running the engine indoors or in a garage could be hazardous. Exhaust gas contains carbon monoxide that is colorless and odorless. It could cause serious injury or death. Only run the engine outdoors where there is fresh air.
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.
Ignition System Check 1. Remove the spark plug and reattach it to the spark plug lead. 2. Turn engine switch to “ON”. Start the engine. If the ignition system is operating properly, a blue spark should jump across the 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 color fading. It will also make it easier to check to see if there is any damage and/or any oil leakage. ! CAUTION Washing the motorcycle with over-pressurized water may cause damage to some of its components. Therefore, do 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 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 and clean oil filter. 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.
Resumption of Service 1. Remove the covering and clean the vehicle. Change the lubricating oil if the vehicle has been off service for more than 4 months. 2. Charge the battery, if applicable, and remount it. 3. Drain off the anti-rust solution from the fuel tank, followed by filling fuel therein to the required level. 4. Prior to driving, test the vehicle at a low speed in a safe place.
INSPECTION AND MAINTENANCE It is very important to inspect and maintain your DR70 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.
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 INC. 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.
DR70 ELECTRICAL DIAGRAM Blue/White Black/Yellow Black/Red Black/White Green Black/Yellow Green Green Blue/ Green White Black/Red 33 Black/ White
BAJA INC. – EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
Your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injection system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assemblies.
o Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance • Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. • Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties.
Baja, INC. P.O. Box 61150 Phoenix, AZ.
