OWNERS_MANUAL_-_RT50-R_Scooter_Owner
Contents
1. 32 STORAGE PROCEDURE 33 MAINTENANCE CHART 34 TROUBLESHOOTING 35 SPECIFICATIONS 37 ELECTRICAL DIAGRAM 38 SERIAL NUMBER LOCATION 39 EMISSION CONTROL SYSTEM WARRANTY 40 Table of Contents 2 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 attention to the messages NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this 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 to2. 8 PRE RIDE CHECK LIST 9 LOCATION OF WARNING LABEL 10 FUEL AND OIL 13 OPERATION 14 STARTING THE ENGINE 14 DRIVING SAFELY 15 SHUTTING OFF THE ENGINE 16 STOPPING THE VEHICLE 16 PARKING 16 BREAKING IN 16 IGNITION SWITCH 17 BRAKE LEVERS AND THROTTLE 17 RIGHT BRAKE SWITCH ASSEMBLY 18 KICK STARTER
3. 19 LEFT BRAKE SWITCH ASSEMBLY 19 INSTRUMENT PANEL 20 SEAT LOCK 20 FUEL TANK 21 MAINTENANCE 22 CHECKING AND CHANGING ENGINE OIL 22 CLEANING OIL FILTER 22 CHANGING TRANSMISSION OIL 23 SPARK PLUG 23 AIR FILTER 24 BRAKES 25 IDLE SPEED ADJUSTMENT FUEL HOSE INSP 26 TIRES 27 BATTERY 28 TRANSPORTING
4. THAN 5 SECONDS AT A TIME ALWAYS ALLOW AT LEAST 10 SECONDS BETWEEN STARTING ATTEMPTS 1 2 15 Operation continued Driving Safely WARNING FOLLOW ALL OF THE WARNINGS IN THIS OPERATOR S MANUAL AT ALL TIMES WHILE OPERATING THE SCOOTER IT IS YOUR RESPONSIBILITY TO KNOW AND OBEY ALL APPLICABLE LOCAL STATE AND FEDERAL LAWS WARNING NEVER OVERLOAD THE VEHICLE THE CARRYING CAPACITY IS 251 lbs 114kg After starting the engine hold rear left brake lever and gently push the scooter forward off the center stand Straddle the seat while keeping one foot on the ground for stability Slowly turn the throttle to begin driving Place your foot on the floorboard as the scooter begins moving Never attach any articles to the handlebar Stow any cargo on the luggage rack or in the under seat storage box Do not carry cargo weighing more than 10 pounds on the luggage rack Always hold the rear hand hold when lifting the scooter WARNING ALWAYS WEAR A DOT APPROVED HELMET EYE PROTECTION AND SHOES WHEN RIDING YOUR VEHICLE WARNING NEVER DRIVE THE SCOOTER WITH THE SIDE STAND EXTENDED 16 Operation continued Shutting off the engine Always shut off the engine by turning the ignition switch to OFF Stopping the vehicle WARNING WET OIL OR SANDY ROADS REDUCE BRAKING EFFECTIVENESS HARD BRAKING ON THESE SURFACES COULD LEAD TO LOSS OF CONTROL AND A SERIOUS ACCIDENT ALWAYS REDUCE SPEED AS G
5. Your scooter has a four stroke engine Please use oil as described in the chart below By using the prescribe oil you will realize the best lubrication for the engine Oil Capacity 0 5 qt 0 47 L Use the chart to select a viscosity rating based on the temperature range in your area MACHINE OIL TEMP C F 30 22 40 104 20 4 10 14 0 32 10 50 20 68 30 86 20W 50 5W 40 15W 50 10W 40 10W 50 10W 30 14 Operation Starting the Engine WARNING ALWAYS RETRACT THE SIDE STAND 2 PRIOR TO STARTING THE VEHICLE If the engine is cold Balance the scooter on its center stand 1 with the side kick stand 2 fully retracted Make sure the ignition key is OFF then rotate the throttle 5 8 times to prime the engine Squeeze the rear brake lever turn the key to RUN and push the START button Your scooter includes an automatic choke CAUTION DO NOT RUN THE STARTER FOR MORE THAN 5 SECONDS AT A TIME ALWAYS ALLOW AT LEAST 10 SECONDS BETWEEN STARTING ATTEMPTS If the engine is warm Balance the scooter on its center stand 1 with the side stand 2 fully retract ed Squeeze the rear brake lever turn the key to RUN and push the START button If the engine does not start after 5 seconds wait 10 seconds then turn the throttle 1 3 turn while pressing the START button This will override the automatic choke and help start the engine CAUTION DO NOT RUN THE STARTER FOR MORE
6. adding fuel 3 Warning decals a Make sure all warning decals are legible and securely attached b Replace as necessary 4 Tires a Ensure that both tires have at least 1 8 in tread depth at center b Both tires must be inflated to the pressure indicated on the tire sidewalls c Replace the tires if tread height is less then 1 8 in at the center of tires 5 Throttle a Check for smooth operation Make sure the throttle snaps back to idle position when released b Check for frayed cable or damaged cable housing Replace damaged cable c Check for mud debris and ice in the throttle cable mechanism Clean out any contamination 12 Pre Ride Checklist continued Before Starting the Engine Motor 6 Fasteners a Check that axle nuts are secure b Check for missing fasteners Replace as necessary c Check that all other fasteners are secure Tighten as necessary 7 Steering Make sure steering turns freely 8 Frame chassis Check for bent damaged frame chassis components Replace as necessary 9 Battery if equipped Check to make sure connections are tight and corrosion free Clean tighten as necessary 10 Lights if equipped Check for proper operation Replace bulbs as necessary 13 FUEL AND OIL FUEL The proper fuel is very important for the engine Ensure that there is no dust dirt or water which has mixed in the fuel Please use regular unleaded 89 octane or higher gasoline ENGINE OIL
7. 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 WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage 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 Important 3 Read and follow all instructions in this Owner s Operator s Manual any accompanying supplements Do not discard this owner s manual safety video or any other material or documentation included with this vehicle Exhaust fumes are toxic California Proposition 65 warning Gasoline engine exhaust from this vehicle contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The engine exhaust contains carbon monoxide which is tasteless odorless poisonous gas Never operate this vehicle indoors or in an enclosed area with poor ventil
8. for current weather and traffic conditions and slow down if necessary DRIVE TO ARRIVE Use extreme caution when riding on wet slippery rough or sloped terrain There is an increased risk of loss of control which can result in injury death and or property damage Always slow down when turning High speed turning can cause loss of control and or possible death injury and or property damage Practice turning in a safe area away from traffic until you are confident in your ability to control the vehicle at all times Operating this vehicle at an unsafe speed especially while turning can cause death injury and or property damage Never use this vehicle to perform any type of racing stunt riding jumps spin outs donuts or other maneuvers You could kill or injure yourself or others and or cause property damage Never operate vehicle while under the influence of alcohol drugs or medication of any kind Such operation is dangerous to yourself and or others Check the tire pressure before operating the vehicle using a properly calibrated tire air pressure gauge Stop the vehicle and shut off the engine immediately if the vehicle makes unusual noises or vibrations Check the vehicle for damage Excessive noise or vibration is a sign of loose or worn parts 6 Additional Warnings continued Engine Motor Safety Keep the engine motor free of dirt and debris especially in the throttle l
9. have any ques tions regarding your warranty rights and responsibilities you should contact BAJA INC 888 863 2252 42 BAJA INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252
10. may also result if idle speed is adjusted improperly or when the engine is not fully warmed up Adjust the idle to the correct speed Make sure the engine is fully warm before adjusting the engine idle speed Inspect the fuel hose for damage and fuel leakage If any defects are found the fuel hose must be replaced Fuel Hose Idle speed adjustment To adjust the idle speed properly you need a tachometer If you do not have one ask your authorized service center to perform this adjustment To adjust the idle speed 1 Start the engine and warm it up 2 Turn the engine idle screw in or out so that the engine idle speed is at 1450 1550 r min Engine Idle adjustment Screw Maintenance continued 27 Tires Tire Air Pressure Check the air pressure in tires before riding Improper air pressure could effect handling steering response traction tire life and rider comfort Be sure that the tires are inflated to the pressures shown below Tire pressure should only be measured or adjusted when the tires are cold Recommended pressure Front 36 psi Rear 36 psi WARNING Operating this scooter with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may loose control of the scooter Always use the size and type of tires specified Always maintain proper tire air pressure as described in this section WARNING Using worn tires cou
11. protective eye wear rubber gloves and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medical attention KEEP OUT OF REACH OF CHILDREN 30 Note The following page is for vehicles with battery s containing separate electrolyte pack Preparing the battery Place battery on level surface Remove sealing tape from top see figure 20 Take the electrolyte container out of the plastic bag Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery see figure 21 Push the container down strongly enough to break the silver seals As electrolyte starts flowing into battery air bubbles will come up from the mouths of the plastic electrolyte bottles Leave bottles upside down in battery holes until electrolyte is completely drained Never leave children unattended around battery If air bubbles cease to float to t
12. there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the spark plug and clean it Replace it if necessary 3 Make sure the fuel valve is not clogged and the fuel tank is not clogged 4 Check the idle speed If necessary adjust using a tachometer The correct idle speed is 1400 1600 r min 5 Make sure air filter is clean Trouble shooting Continued 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 Do not perform this check if you are not familiar with the procedure Do not point the spark plug near the spark plug hole during this test Do not do this test if you have a heart condition or wear a pacemaker Do not perform this test near any open fuel containers or near fuel which has spilled on the ground on the engine or any part of the Scooter 37 Specifications Description Data Engine type 4 stroke air cooled Overall length 1778mm 70 inches Overall width 66 4mm 26 inches Overall height 1099mm 43 25 inches Dead weight 73 94kg 163lbs Payload 114kg 251lbs Suspension Front Telescopic fork Rear Mono shock Passengers 1 Transmission Transmission oil CVT 0 12L 4oz 80W90 Clutch Auto Centrifugal Capacity of gasoline 4 9L 1 3 gal Oil capacity 0 47 L 0 5 qt Lubrication method Pressure splash Bore and s
13. 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 this scooter Minimum Recommended Age Requirement 16 Rev G 030509 RT50 R Retro SCOOTER Read this manual carefully It contains important safety information No one under the age of 16 should operate this scooter OWNER S MANUAL II Congratulations on your purchase of the BAJA INC RT50 R Retro Scooter Your Scooter 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 50cc Scooter at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the product Engine Warranty 90 days Frame Warranty 90 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem with your vehicle please call the Baja INC customer service line toll free at 1 888 863 2252 between the ho
14. BILITIES As the vehicle owner you are responsible for the performance of the required maintenance You should maintain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications WARRANTY COVERAGE The Distributor warrants that each new 2009 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency for the periods specified above Your emission control system warranty covers components whose failure would increase an engine s emission including electronic controls fuel injection system carburetor the ignition syst
15. RADUALLY AS POSSIBLE When braking always engage the rear brake first to retain maximum control of the scooter Most of your stopping power comes from the front wheel Parking Always leave the ignition key assembly in the lock position when parking the vehicle to help prevent theft Park on smooth hard surfaces use the center stand whenever possible Breaking in Following this break in procedure ensures that your scooter is functioning properly and maximizes engine life Never drive this vehicle over 25mph during the first 250 miles of operation Excessive speed could result in engine failure Always use fresh 89 octane gasoline Avoid gasoline that contains alcohol which can damage rubber gaskets and engine seals Check and adjust the brakes throttle cable tire pressure and fasteners weekly before riding This is in addition to the pre ride inspection Schedule regular maintenance with your authorized Baja Inc service center Never add oil to the gasoline your scooter has a 4 stroke engine with an internal lubricating system 17 Operation continued Ignition switch The main ignition switch contains three positions ON 2 The engine can start the key 1 cannot be removed OFF 3 This position shuts off the engine and allows the key to be removed LOCK 4 From the OFF position push inward and turn the key counterclockwise to the LOCK position while turning the steerin
16. VEHICLE AS THIS CAN HELP YOU SPOT PROBLEMS THAT COULD INTERFERE WITH SAFE VEHICLE OPERATION FAILURE TO FOLLOW THIS ENTIRE CHECKLIST BEFORE EVERY RIDE CAN CAUSE DEATH SERIOUS INJURY AND OR PROPERTY DAMAGE TO YOURSELF AND OR OTHERS Kick start lever Side stand Center stand Seat compartment lock Helmet Hook Front brake caliper Front Tire Rear Tire Rear Brake lever Battery located under floorboard Gas Cap Engine Oil fill cap Under seat storage Front Turn signals Muffler VIN Number Throttle Rear Turn signals Headlight Tail light Front Brake lever Ignition key switch Luggage rack Air filter 10 Read and follow the warning label on your Scooter Make sure you understand the label Keep the label on the Scooter Do not remove it for any reason If the label comes off or becomes difficult to read you should get a replacement by contacting BAJA INC Location of Warning Label WARNING Read and understand owners manual before operating this Scooter Always wear a helmet eye protection and protective clothing 11 Pre Ride Checklist continued 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
17. at or your surrounding environment Remove or tie back anything loose that can reach below and behind the seat before riding Moving Parts Never place hands feet any body parts or clothing near the engine wheels chain and other rotating parts of the vehicle while riding or running the engine Use extreme caution when performing required maintenance while the engine is running Keep guards and pads in place at all times Prevent accidental contact by any person whenever the vehicle is running The guards over the brake clutch torque converter axle and drive sprockets also help prevent mud and debris from contacting those components Traffic Safety ALWAYS FOLLOW THE ENTIRE PRE RIDE CHECKLIST PRIOR TO STARTING OR RIDING THE SCOOTER Your safety while riding this vehicle depends entirely on your ability to exercise proper judgement You must be of sufficient age understanding mental capacity and physical capability to safely operate this vehicle 5 Additional Warnings continued Traffic Safety continued Always obtain mature supervised instruction and sufficient practice in an decongested area before operating this vehicle on any public thoroughfare Excessive vehicle speed is a leading cause of accidents which can cause death or serious harm to you other people and or property Always obey all applicable traffic safety laws while operating this vehicle being sure to account
18. ation This vehicle may have been supplied to you completely assembled To prevent possible injury or death read and follow the assembly instructions to make sure the vehicle was assembled properly Always perform the daily pre ride inspection specified in this manual before operating this vehicle Modifying the vehicle and or removing original equipment and or safety decals could make this vehicle unsafe for operation Replace any safety decals that become unreadable or detached from the vehicle Decals provide critical warnings about potential hazards or safety requirements Never use this vehicle for stunt riding spin outs donuts racing or any form of competition WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH CAUTION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO RESULT IN DAMAGE TO THE VEHICLE AND OR OTHER PROPERTY General Precautions 4 Additional Warnings Protective Clothing Equipment Most accident fatalities are due to preventable head injuries Always wear a properly fitting motorcycle type helmet approved by agencies such as the Department of Transportation DOT Safety Helmet Council of America SHCA or Snell Memorial Foundation SNELL Always wear face shields or goggles boots gloves and other appropriate protective clothing Long hair loose clothes or jewelry can get caught in moving parts below and behind the se
19. commend time allowance for the war ranty repair and the geographically appropriate hourly labor rate The owner may reasonably be required to keep receipts and failed parts in order to receive compensation This Emission Control System Warranty is in addition to the standard Limited 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 inter val for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts Replacements of parts and other services and adjustments for required maintenance Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or replacements as a result of o Accident o Misuse 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 th
20. e of engine Remove screen filter 3 from spring assembly Clean screen with solvent Re install filter and refill with 0 5 qt oil Refer to page 13 for correct engine oil type 1 2 3 CAUTION Never start the engine when there is insufficient lubricating oil Otherwise it will cause harm to the engine 23 Maintenance continued Changing Transmission oil Draining transmission oil Drain transmission oil by removing drain screw 1 located on bottom of transmission 2 Drain oil into a catch basin and dispose of properly at oil reclaim facility Adding Transmission oil Add transmission oil by removing transmission oil fill cap 3 located on the side of transmission 2 Add 12L 4oz 80W 90 gear oil Spark Plug CHECK UP OF SPARK PLUG 1 Remove the cap of spark plug and spark plug 2 Clean spark plug all around or replace it if it is corroded or there is too much deposit on it 3 Regulate the gap of the spark plug to 0 6 0 7mm 024 028 3 The spark plug of the designated type should be used The applicable type of spark plug DR7HSA NGK A7RTC TORCH 1 2 3 0 6 0 7mm 024 028 The transmission oil was filled at the factory before shipment Drain and refill transmission oil every 5000km 3100 miles 24 Maintenance continued Air filter Checking Air filter The air filter 1 is located on the left side of the scooter Remove air filter cover by removing sc
21. e the key in the lock Seat lock 5 2 1 4 3 21 Operation continued Fuel tank The gas cap is located under the seat To open unlock and lift seat WARNING GASOLINE IS FLAMMABLE AND EXPLOSIVE USE EXTREME CAUTION WHEN FUELING YOUR SCOOTER ONLY FILL THE TANK IN WELL VENTILATED AREAS SHUT OFF THE ENGINE AND PLACE THE SCOOTER ON ITS CENTER STAND TO ENSURE PROPER FILLING WHILE ELIMINATING THE RISK OF STATIC IGNITION CAUSED BY IMPROPER GROUNDING NEVER SMOKE NEAR GASOLINE NEVER OVERFILL THE GAS TANK ALWAYS MAKE SURE THE FUEL CAP IS SECURELY FASTENED AFTER EACH FUELING WARNING DO NOT SPLASH OR SPILL GASOLINE WHILE FUELING IF A SPILL OCCURS IMMEDIATELY WIPE OFF ALL SURFACES PRIOR TO STARTING THE ENGINE AVOID SKIN CONTACT WITH GASOLINE AND DO NOT BREATHE GASOLINE FUMES KEEP GASOLINE AWAY FROM FLAMES OR ELECTRIC SPARKS Gas Cap 22 Maintenance Checking and Changing engine oil Checking engine oil Remove engine oil dip stick cap 1 Check oil level on dipstick Add oil if below 3 4 full Refer to page 13 for correct engine oil type Changing engine oil To drain old engine oil place catch basin under engine and unscrew drain plug 2 located on bottom left side of engine Drain engine oil into proper catch basin Dispose of oil properly at oil reclaim facility Cleaning oil filter Drain engine oil per instructions above Remove oil filter plug 2 located at bottom right sid
22. e vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The Distributor is not liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control sys tem warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limita tions may not apply if it is inconsistent with the controlling state law No dealer is authorized to modify this Emission Control System Warranty If you
23. em 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 as semblies Replacing or repairing other components including parts labor and other costs not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility The Distributor will not cover repairs performed outside of an authorized dealer or repair facility except in an emergency situation The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied 41 If an emergency situation exists when a warranted part or a dealer is not reasonably available to the owner repairs may be performed at any available service establishment or by the owner us ing any replacement part The Distributor shall reimburse the owner for the expenses including diagnostic charges not to exceed the Distributor s suggested retail price for all warranted parts replaced and labor charges based on the Distributor s re
24. en W G 39 SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get warranty work theft recovery and consumer safety information You also need these numbers to help your authorized service center or BAJA INC order parts The Frame number is stamped on front of scooter just above the front floor base A small cap will need to be removed to see the number The engine number is located on the bottom left side of the engine housing Write down the serial numbers here for your future reference Frame No Engine No Engine serial number Frame number 40 Emission Control System Warranty 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 12 000km whichever comes first provided there has been no abuse neglect or improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or replaced by the Distributor This is your emission control defects warranty OWNER S WARRANTY RESPONSI
25. g column to the left and shaking it lightly to engage the steering lock Remove key Brake Levers and Throttle Rear brake 5 When stopping the scooter squeeze the rear brake smoothly and firmly Always engage the rear brake first Front brake 6 Squeeze the lever gently at first to avoid locking the front wheel Most of your stopping power comes from the front wheel which should always be used to supplement the rear wheel WARNING USE EXTREME CAUTION WHEN ENGAGING THE FRONT BRAKE TO AVOID LOCKING THE FRONT WHEEL LOCKING THE FRONT WHEEL CAN CAUSE A SERIOUS ACCIDENT Throttle grip 7 The rotary throttle grip is on the right handlebar Accelerate by rotating the throttle towards you Gently apply the throttle to avoid engine from stalling Decelerate by rotating the throttle away from you The throttle includes a safety spring that snaps the throttle back to idle when released 4 1 2 3 5 6 7 18 Operation continued Right switch assembly On Off Safety stop Switch 1 The On Off safety stop switch needs to be at on position before scooter will start The safety stop switch is available in case of an emergency Electric starter switch 2 The electric starter switch is located directly under On Off safety stop switch In order for scooter to start the key will need to be turned to on position as well as the safety stop switch Depress the electric starter switch to start
26. he top of the electrolyte bottles tap lightly on top DO NOT remove container from battery while it is draining Never cut or pierce electrolyte container After all the electrolyte has drained from the bottles into the battery pull plastic electrolyte bottles gently out of the battery Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life After 30 minutes the battery is ready for its initial charge Place cap strip loosely over the filling holes as shown in the picture see figure 22 Figure 20 Figure 21 Figure 22 31 WARNING NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE How to Initially Charge the battery 1 Connect the red positive cable to the red positive pole of the battery see figure 23 2 Connect the black negative cable to the black negative pole of the battery see figure 24 Note The red positive cable has a larger diameter than the black negative cable 3 After charging is complete press down firmly with both hands to seat the caps Do not pound or hammer The battery is now sealed see figure 25 Locate battery compartment on scooter The battery compartment is located under the f
27. head or any potentially hot area on or around the engine when working on around or restarting the engine 8 Additional Warnings continued Maintenance continued Store this vehicle in a place where gasoline fumes cannot reach an open flame spark or other source of ignition Drain the fuel tank in a cool well ventilated area prior to any long term storage Never store this vehicle in a close proximity to appliances such as water heaters or furnaces Engine exhausts and other components can become extremely hot during operation Use caution when near hot components Never adjust repair or clean the vehicle while it is in motion NHTSA Safety Notice If you believe that your vehicle has a defect which could cause serious injury or death you should immediately contact the National Highway Traffic Safety Administration NHTSA in addition to notifying BAJA INC If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or BAJA INC To contact NHTSA you may call the Auto Safety Hotline toll free within the United States on 1 800 424 9393 or write to NHTSA 400 Seventh Street SW Washington DC 20590 9 Pre Ride Checklist WARNING ALWAYS PERFORM THE ENTIRE PRE RIDE CHECKLIST BEFORE USING THE
28. ing appropriate materials equipment and skill For this reason we recommend that you trust this maintenance work to your authorized service center If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE Place the vehicle on level ground and wash the entire vehicle FUEL Drain the fuel from the fuel tank by a hand pump Drain the fuel from the carburetor by releasing the carburetor drain screw TIRES Inflate tires to the normal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted metal surfaces with rust preventative 3 Coat painted and plastic surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire vehicle 2 Make sure that the vehicle is properly lubricated 3 Perform the INSPECTION BEFORE RIDING as listed in this manual 4 Start the vehicle as outlined in this manual WARNING Draining the fuel could be hazardous Fuel could catch fire if you do not handle it properly When draining the fuel from the fuel tank be sure to shut the engine off Do not smoke and never drain fuel in an area where there are open flames or sparks Keep pets and children away from the fuel and dispose of the drained fuel properly Storage Procedure 34 Item Each use Initial 150 Initial 500 Initial 1000 Every 1000 Air Filter I Every 1000 miles more often in dusty areas Carburetor I I E
29. inkage area Never start the engine motor without checking to see that the throttle control is in the idle position Never start the engine motor unless you are properly seated with your hands firmly on the controls Never tamper with alter or change the vehicle s engine motor settings The engine motor governor is factory set and protects the engine motor from damage Excessive engine motor speed is potentially dangerous to the operator bystanders and the engine motor itself All guards must be in place prior to starting the engine Operating the vehicle in conditions where water mud snow dirt sand or other debris can get into the throttle cable conduit and or the throttle mechanism can cause the cable or throttle mechanism to bind which may lead to throttle sticking loss of control and possible death injury and or property damage Fasteners Make sure that all screws nuts and bolts are properly tightened Never over tighten hardware that is designed to move such as front and rear wheels Restricting moving parts can cause a loss of control and possible injury or death Always replace torque type locknuts with new locknuts of the same type after removing the old locknuts 7 Additional Warnings continued Fueling Check the fuel supply before each use Never fill the fuel tank while the engine is running or hot Always allow at least 1in of expansion space at the top of
30. ld 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 3 0 mm 0 12 in or less Front Rear Size 3 00 x 10 3 00 x 10 Maintenance continued Tire Tread Condition 3 0 mm 0 12 in 28 Maintenance continued Battery gas scooter Your scooter uses a sealed maintenance free lead acid battery rated 12V3AH The battery is located underneath the floorboard Charging new batteries Fill the battery with the acid in the pre packed bottles and allow to rest for 30 minutes prior to sealing the battery After sealing Charging rate Charge battery 0 7 Amps for 5 10 hours Recharging batteries For best results charge the battery at a low current see above You can fast charge the battery at 2A for up to 1hr You may wish to use a trickle charger lt 5A to keep the battery charged if you use your scooter is not used frequently or for short trips You can attach a trickle charger for up to a week WARNING BATTERY ACID IS EXTREMELY CORROSIVE ALWAYS WEAR GLOVES AND EYE PROTECTION WHEN HANDLING ACID IF YOUR SKIN OR EYE CONTACTS THE ACID IMMEDIATELY FLUSH WITH WATER FOR AT LEAST 15 MINUTES IF SWALLOWED DO NOT INDUCE VOMITING CALL YOUR LOCAL POISON CONTROL CENTER 29 WARNING The following procedure is very dangerous and should be performed with utmost care and attention Wear
31. loorboard see figure 26 Attach red positive cable to positive terminal on battery Then attach black negative cable to negative terminal on battery Figure 23 Figure 24 Figure 25 Figure 26 32 It is best to transport the scooter in the normal upright position Before transporting the scooter drain the fuel from the carburetor as follows 1 Drain fuel from carburetor into an empty container by loosening the carburetor drain screw 1 The carburetor drain screw is located at the bottom of the engine 2 When the fuel has been drained re tighten the drain screw WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire if you do not handle it properly When draining fuel from the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of the drained fuel properly CAUTION Failing to secure the Scooter properly could be hazardous Failing to secure the vehicle properly may result in an accident or damage to the vehicle When transporting the Scooter tie down the vehicle securely with straps rope or some other suitable means Use extra tie downs when you transport the vehicle in the standing position 1 Transporting 33 If you do not use your scooter for a long period of time it will need special service requir
32. nder the carburetor Drain the fuel from the carburetor into a container b Tighten the drain screw c Run the engine for a few seconds Shut off engine d Loosen the drain screw and check that the carburetor is filled back up with fuel e If fuel is reaching the carburetor the ignition system should be checked next CAUTION Failing to troubleshoot a problem correctly can damage your Scooter Improper repairs or adjustments may damage the vehicle Such damage may not be covered under warranty If you are not sure about the proper action consult your authorized service center or BAJA INC about the problem WARNING Draining fuel from the carburetor could be hazardous Fuel could catch fire if you do not handle it properly When draining the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of drained fuel properly Troubleshooting 36 Ignition System Check 1 Remove the spark plug and reattach it to the spark plug lead 2 Turn ignition key to the RUN position Slide the engine stop switch to the Run position Push the electric button START 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 COMPLAINT Engine stalls 1 Make sure
33. rews 2 If filter is dirty follow cleaning instructions below Cleaning Air filter 1 Remove foam element 3 from air filter housing 1 2 Wash foam element 3 in water or a mild non flammable solvent 3 Squeeze water out of foam element and let dry 4 Re install foam element 3 in air filter housing 1 2 3 25 1 Inspect front disk brake caliper 1 for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose 2 for cracks and the joint for leakage 3 Check the brake fluid level through the sight gauge on front of brake fluid reservoir 3 If level is at or below the LOWER mark inspect brake pads for wear and hydraulic system for leaks 4 To add brake fluid unscrew the 2 screws 4 on top of the brake fluid container located on right handlebar Add DOT3 or DOT4 brake fluid Do not mix brake fluid types Maintenance continued ADJUSTMENT OF REAR BRAKE 1 1 To make rear break adjustment turn rear adjusting nut 1 clockwise to increase and counterclockwise to reduce tension on the brake cable 2 Brake shoes should be replaced by a qualified service technician once worn 1 2 Brakes FRONT HYDRAULIC DISK BRAKE INSPECTION 3 4 26 WARNING Improper adjustment of the idle speed could be hazardous An idle speed that is too high could cause the scooter to move forward when you start the engine This may cause an accident Excessive engine wear
34. the engine Never run the starter for more than 5 seconds at a time Allow at least 10 seconds between each starting attempt 1 2 OFF ON 19 Operation continued Kick starter Use the kick starter to start the engine if the battery is drained Once started leave the engine running until the battery recharges sufficiently to restart the scooter Left switch assembly High low beam light switch 1 To activate the high beam move the switch to position 2 For low beam use position 3 Turn signal switch 4 Slide the switch plate left for a left signal and right for a right signal Press the center of the switch to cancel the turn signal Horn 5 Press the bottom button to sound the horn 5 4 1 2 3 Kick starter 20 Operation continued Instrumental panel Speedometer 1 Indicates the current driving speed in both mph and km h High beam indication lamp 2 Illuminates when high beam is selected Turn signal lamp 3 Indicates that the turn signal is activated Fuel indicator 4 Indicates the fuel level Odometer 5 Indicates the total distance the vehicle has traveled in km Seat lock To open Insert the key just below the seat on the left side of the vehicle Press the seat down slightly while turning the key clockwise to release the latch Lift the seat To close Press down the seat until locked then remove the key Never leav
35. the fuel tank There should not be any fuel in the filler neck Replace the fuel cap tightly after refueling to prevent a fuel spillage fire or explosion hazard Always use an original gas cap or an approved OEM replacement Never fill fuel tank while the vehicle is inside a building Gasoline vapors can cause injury or death and can pose a fire or explosion risk Move the vehicle at least 10 ft before starting the engine Use extreme caution when starting the engine Hot engine muffler or drive components can cause serious burns on contact Maintenance Do not modify the vehicle from the manufacturer s original design and configuration Never wash or operate the vehicle in freezing temperatures Water can freeze in the throttle cable conduit and or on the throttle mechanism possibly resulting in throttle sticking which can cause the engine to continue to run and result in loss of control Assembly maintenance and or repair of this vehicle should only be performed by designated dealers or authorized repair centers to ensure quality work and safe vehicle condition Always disconnect the spark plug wire gasoline vehicles or disconnect the battery before commencing any work in the engine vicinity or where there is a possibility that the vehicle could move unexpectedly Keep the spark plug cable away from the spark plug to avoid accidental starting Avoid contacting the muffler cylinder
36. troke 39mm x 41 4mm Horsepower HP 3 74hp Displacement 49 5cc Starter Electric with supplement kick start Brake Front Hydraulic Rear Drum Rear wheel 3 0 10 36 psi Front wheel 3 0 10 36 psi Spark plug CR7HSA NGK A7RTC TORCH Gap 0 6mm 0 7mm 0 024in 0 028in Ignition means CDI Battery 12V 3AH YTX7A BS 38 Electrical Diagram M Tailight Rear turn signal light RIGHT Rear turn signal light LEFT Alarm Battery 12V 3Ah Magneto CDI Ignition coil Regulator Fuel sensor Starting Motor Starting relay Fuel Indicator Horn Ignition switch Headlight Speedometer light ON OFF Flash Brake switch Starting switch Fuse ON ON OFF OFF Right switch assembly ON ON OFF OFF OFF Left switch assembly Horn switch Turn signal switch Brake assembly High Low beam switch R L HI LOW Right turn signal Lock B G Y G Y Y R Y W G W B1 W B1 Y W YRG W G B Y B W G Y W B R W R G Y B1Y W G B W B1 Y W G LB1 G G R G Y B Y R LR G G G Y G B R B G BLRG B R G R G B Left turn signal License plate light Red R Yellow Y White W Gray GR Light green Lg Green G Light blue LB1 Black B Blue B1 Brown BR Light red LR Green Yellow G Y Black Red B R Black White BW White Red W R White Blue LB1 Black Yellow B Y Green Red G R Red Green R G White Gre
37. urs of 7am and 5pm Monday through Friday MST Mountain Standard Time MDT Mountain Daylight Time during daylight saving time You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED III 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 on road vehicle Children under the age of 16 should never operate this vehicle WARNING It is the operators responsibility to know and obey all applicable local state and federal laws at all times while operating this vehicle including but not limited to traffic safety vehicle registration emissions and noise The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 WARNING WARNING 1 IMPORTANT 2 GENERAL PRECAUTIONS WARNINGS 3 NHTSA SAFETY NOTICE
38. xhaust system I I I Fuel hose I I Engine Oil I R R Engine Oil filter C C Transmission oil R Brake Fluid level I I I I I Brake Hose and joints I I I I I Brakes I I I I I Wheels I I Wheel bearings I Brake caliper linings I I I I Front and rear suspension I Steering system I I I I I Steering shaft lubrication use Li grease I Fittings and Fasteners I T T T T Valve Gap I I I Inspect and clean adjust lubricate or replace if necessary C Clean R Replace T Tighten Should be completed by an authorized service center Change Transmission oil every 3100 miles Interval miles Maintenance Chart It is very important to inspect and maintain your scooter regularly Follow the guidelines in the chart The intervals between periodic services in miles are shown At the end of each interval be sure to perform the maintenance listed MAINTENANCE SCHEDULE 35 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 Fuel Supply Check 1 Make sure there is adequate fuel in the fuel tank 2 Check that the ignition switch is in the RUN position 3 Make sure there is enough fuel reaching the carburetor from the fuel tank a Loosen the drain screw which is located u
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