Baja motorsports BV250 Owner'S Manual Download Page 40 | Manualshive

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Lower Adjustment

If the upper clutch cable adjuster has reached it’s limit or you cannot

obtain the correct free play, you may also use the lower clutch cable

adjuster.

1) Loosen the upper lock nut and rotate the upper clutch cable ad-

juster in to maximum free play.

2) Tighten the upper lock nut.

3) Loosen lower lock nut.

4) Rotate lower adjusting nut until the proper free play has been ac-

complished.

5) Tighten lower lock nut and check adjustment.

6) Start engine, hold in clutch lever and shift into gear. Make sure the

engine does not stall and the motorcycle does not move. Slowly re-

lease the clutch lever and open the throttle, your motorcycle should

accelerate gradually and move smoothly.

If you cannot accomplish the correct free play using both

adjustments, contact you local Service Center.

Clutch System

Lower lock nut

Lower adjusting nut

↔

Increase

Decrease

Upper lock

nut

Clutch cable

adjuster

«
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38
39
40
41
42
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»

Summary of Contents for BV250

Page 1: ...idered 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 REVA 073107 Minimum age requirement 16 ...

Page 2: ...your responsibilities If you have any questions comments or concerns contact Baja Motorsports at 888 863 2252 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 c...

Page 3: ...ds of safety information you will find in this manual Safety Labels On your motorcycle Safety Messages Warning Caution and Danger The meaning of Warning Caution and Danger Safety Messages WARNING DANGER CAUTION Death or serious injury CAN occur if proper instructions are not followed Death or serious injury WILL occur if proper instructions are not followed You CAN be hurt if proper instructions a...

Page 4: ...elines and Load Limits Pg 18 Starting Procedures Pg 19 Starting and Stopping Engine Pg 19 Shifting Gears Pg 21 Braking Pg 23 Parking Pg 24 Servicing your Motorcycle Pg 25 Maintenance Safety Pg 26 Maintenance Schedule Pg 28 Servicing Pg 32 Fuel Pg 32 Fuel and Engine Oil Pg 33 Air Cleaner Pg 37 Crankcase Breather and Throttle Pg 38 Clutch Pg 39 Engine Idle Speed Pg 41 Spark Plug Pg 42 ...

Page 5: ... Contents Brakes Pg 43 Tires Pg 47 Drive Chain Pg 51 Battery Pg 55 Appearance Care Pg 58 Vehicle Identification Pg 59 Specifications Pg 60 Wire Diagram Pg 63 Emission Control System Warranty Pg 64 ...

Page 6: ...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 MOTORSPORTS LLC 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 or need to return your Baja Moto...

Page 7: ...LEARN AND PRACTICE Take time to get to know this vehicle The operator s ability to operate this motorcycle safely is largely dependent upon the operator s ability to exercise proper judgment The operator must be of sufficient age understanding mental capacity and physical capability to safely operate this vehicle This vehicle should only be operated after sufficient practice in a decongested safe ...

Page 8: ...d inspect your vehicle before each ride Never modify your vehicle in any way to make it unsafe 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 Motorsports If NHTSA receives similar complaints it may open an investigation a...

Page 9: ...act Baja Motorsports for replacement COLD TIRE PRESSURES DRIVER AND PASSENGER FRONT 29psi 199kpa REAR 36psi 250kpa DRIVER ONLY FRONT 29psi 200kpa REAR 33 psi 250kpa TIRE SIZE FRONT 110 90 16 REAR 130 90 15 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 ...

Page 10: ...lve Air cleaner Shift Lever Kickstand Passenger footrest Battery Main fuse Fuel tank cap Steering lock Rear brake pedal Oil filler cap dipstick Headlight Taillight Driver footrest Brake caliper Carburetor Cargo rack Mirrors Exhaust ...

Page 11: ...meter Indicator lights Brake fluid reservoir Ignition switch Brake brake lever Horn Turn signal switch Headlight dimmer switch Clutch lever Fuel indicator Fuel fill cap Throttle grip Engine stop switch Start button Rearview mirror ...

Page 12: ...les driven Tripmeter 3 Displays the number of miles you have traveled since last reset To reset turn tripmeter reset knob Rpm 4 Shows engine s rpm s Fuel indicator 5 Shows fuel level High beam indicator 6 Illuminates when headlight is on High beam Neutral indicator 7 Illuminates when transmission is in neutral Turn signal indicator 8 Flashes when left right turn signal is on 1 2 3 4 5 6 7 8 ...

Page 13: ...ve Fuel valve Used to control the flow of gasoline from the fuel tank to the carburetor Choke Button May be used when starting engine See starting procedures using choke lever on page 19 Choke Button ON OFF ON OFF RESERVE ...

Page 14: ... start the engine When button is pressed in the start motor will crank the engine headlights will turn off but the taillight will stay on See starting procedures page 19 Engine stop switch In case of an emergency and a quick stop is necessary turn switch to the OFF position This switch must be in the RUN position in order to start the vehicle and should remain in this position even while the engin...

Page 15: ...urn signal switch Horn HI LO Turn signal switch Use this switch to signal a lane change or turn Horn The horn is used to warn other motorist Left Right Tripmeter reset knob Tripmeter reset knob Tripmeter reset knob By turning the knob counter clockwise you can reset the tripmeter to zero 0 ...

Page 16: ...lothing The proper clothes can protect you from injury Wear an approved motorcycle helmet goggles a good pair of gloves strong boots that cover the ankle long pants and a long sleeve shirt every time you ride Helmets and Eye protection A DOT approved motorcycle helmet is the most important part of your protective gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a...

Page 17: ... that the brakes are operating correctly Throttle Rotate the throttle handle to ensure it moves smoothly Leaks and Loose ends Check all hoses for leaks and cables that may be loose Lights Be sure that your Headlight Brake light Taillight and Turn signals are working properly Chain Check the condition Adjust the slack if any and lubricate if needed Tires Use an air pressure gauge to check the press...

Page 18: ...g of your motorcycle may affect your stability With the motorcycle properly loaded always ride at a reduced speed If you have questions about carrying cargo contact Baja Motorsports for advice Check the following when carrying a passenger or cargo Both tires are properly inflated Rear suspension may need adjusting Secure all cargo Balance cargo weight Do not attach large or heavy items to the fron...

Page 19: ...m engine follow procedure for High Air Temperature Normal Air Temperature 10 35 C 50 95 F Never start the engine in a closed place as the exhausted gas from the vehicle contains toxic carbon monoxide WARNING 1 Turn choke ON pull and hold button out 2 Start the engine leaving throttle closed Do not open throttle while choke is ON this will make it difficult to start 3 After engine has started turn ...

Page 20: ... choke can cause damage to the piston and cylinder wall Fast idling for more than 5 minutes at Normal Air Temperature can cause exhaust pipe discoloration Flooded Engine The engine may be flooded with extra gasoline if it does not start after several attempts Try the following to clear a flooded engine 1 Turn the engine stop switch to the OFF position 2 Close the choke OFF 3 Open the throttle comp...

Page 21: ... to loose life Emergency Engine Stop If an emergency stop is necessary use the engine stop switch Simply move the emergency stop switch to OFF Shifting Gears Tips for learning how to shift for the inexperienced rider Shift while moving a straight line Let loose on the throttle and pull in clutch lever completely before shifting improper shifting may cause damage to the engine Recognize the engagin...

Page 22: ...re the engine RPM s get too low When the engine RPM s are too high do not downshift to slow your motorcycle this could cause damage Do not coast or tow your motorcycle for a long period of time while the engine is off If your speed drops below 9mph 15km h pull in clutch lever and shift down to 1st gear or stalling can occur ...

Page 23: ...ply your brakes too abruptly you may lock the wheels slide and loose control of your motorcycle If this should happen release the brakes and steer straight until you have completely regained control Before making a turn reduce your speed Try not to brake or close the throttle too quickly while turning or you may loose control of your motorcycle When traveling down a steep grade reduce your speed b...

Page 24: ...rcycle is parked this will lock the handlebars in place Turn the handler bars left Insert ignition key into lock and turn clockwise 90 remove key Turn fuel valve OFF Theft Prevention Tips You should park your motorcycle in a garage if possible otherwise make certain to park in a well lit area Never leave the ignition key with the motorcycle Always use the steering lock even for a short period of t...

Page 25: ...cle will help protect your investment avoid break downs and have maximum performance The maintenance of your motorcycle is YOUR responsibility In the event of an accident have a Service Center inspect ALL parts even if they appear to be undamaged Type of Inspection Service Refer to page When to perform Who performs Pre ride Inspection 17 Before EVERY ride You Maintenance Schedule 29 Interval on Sc...

Page 26: ...rs Let the engine cool before touching any related parts Do not touch any moving parts while engine is running Make sure you have the tools and skills required before performing any maintenance or repairs Use the side stand or maintenance stand to prevent the motorcycle from falling over Keep cigarettes sparks and flames away from all fuel related parts Use a non flammable solvent when cleaning pa...

Page 27: ...or any damage that may have occurred Check the rims and spokes for any possible damage Fluids Check the level of engine oil Check the level of the brake fluid Add the correct fluids if necessary Lights Check the headlight brake light taillight and turn signals Make certain they all work properly Free play Check the clutch lever rear brake pedal and throttle grip Drive Chain Check the condition adj...

Page 28: ...ase a Service Manual from Baja Motorsports Every maintenance item requires some mechanical knowledge some parts require more technical information and tools than others Unless you have the proper tools and service information have your local Service Center perform these tasks For safety reasons ONLY your local Service Center should perform these tasks NOTES 1 Repeat the frequency interval at highe...

Page 29: ... Air Cleaner 2 R R Crankcase Breather 3 C C C C C C Spark plug I R I R I R Valve Clearance I I I I I I I Engine Oil R R R R R R R Engine Oil strainer screen C C C Engine idle speed I I I I I I I Evaporative emission control system 5 I I x 1 000mi 0 6 4 8 12 16 20 24 x 1 000km 1 0 6 4 12 8 19 2 25 6 32 38 4 Refer to page Frequency Item Note Emission related items Odometer reading Note 1 ...

Page 30: ...I Brake System I I I I Brake light switch I I I Headlight aim I I I Clutch System I I I I I I I Side stand I I I Suspension I I I Nut Bolts Fasteners I I I I Wheels Tires I I I I I I I Steering head bearings I I I I x 1 000mi 0 6 4 8 12 16 20 24 x 1 000km 1 0 6 4 12 8 19 2 25 6 32 38 4 Refer to page Frequency Item Note Non Emission related items Odometer reading Note 1 1 L Every 500mi 800km ...

Page 31: ...r performs these tasks you will be charged Please use the tables below to keep track of all maintenance performed Miles km Odometer Date Performed By Notes 600 1 000 4 000 6 400 8 000 12 000 12 000 19 200 16 000 25 600 20 000 32 000 Miles km Odometer Date Performed By Notes 24 000 38 400 28 000 44 800 32 000 51 200 36 000 57 600 40 000 64 000 44 000 70 400 48 000 76 800 52 000 83 200 56 000 89 600...

Page 32: ...e sure to only use an octane number of 86 or higher Using a lower octane gasoline can cause severe damage to the engine Never use stale or contaminated gasoline or an oil gasoline mixture Fuel Capacity Fuel tank capacity including reserve 3 07 US gal After using the reserve tank you should refill the gas tank immediately Then turn the fuel valve to the ON position so you do not run out of fuel in ...

Page 33: ...p 4 After refueling push cap into the filler neck until it snaps and locks 5 Turn the fuel valve back to the ON position if it was in the RESERVE position By using checking adding and changing the recommended engine oil you can prolong the life of your engine Changing your engine oil helps get rid of dirt or debris that can damage the engine Always be sure to keep the right amount of oil in the en...

Page 34: ...with molybdenum additives Do not use castor based racing oil vegetable oil or non detergent oil Checking and Adding Oil API classification SE or SG Viscosity weight SAE 15W 40 0 20 40 60 80 100 F 20 10 0 10 20 30 40 C SAE 20W 50 SAE 20W 40 SAE 10W 40 SAE 10W 30 Oil fill plug dipstick Lower level mark Upper level mark ...

Page 35: ...oil is at or near the upper level mark there is no need to add oil If the oil is at or near the lower level mark add the recommended oil until it reaches the upper level mark and do not overfill 8 Screw in the oil fill plug dipstick 9 Check for any leaks Changing Engine Oil This procedure will require some mechanical skill and special tools such as a torque wrench If you are not capable of perform...

Page 36: ...ondition if not replace You should replace every other time you change the oil Adding Engine Oil 7 Install the engine oil drain bolt and torque to 18lbf ft 25N m 2 5kgf m 8 Fill crankcase with recommended oil 1 12 US qt 9 Reinstall the oil fill plug dipstick 10 Start engine and let idle for 3 5 minutes 11 Turn engine off and let stand for 2 3 minutes 12 Hold the motorcycle in a upright position an...

Page 37: ... engine wear or poor performance Replacing Air Cleaner 1 Remove left side cover 2 Remove air cleaner cover 3 Remove foam air cleaner 4 Wash foam air cleaner 5 Replace foam air cleaner 6 Replace left side cover Wash the element as the following 1 Fill a washing pan large enough to hold the element with a nonflammable cleaning solvent Immerse the element in the solvent and wash it 2 Squeeze the elem...

Page 38: ...nto the pan 3 Reinstall the crankcase breather tube plug Throttle Inspection Check the free play at the throttle grip Free play 1 16 1 4in 2 6mm If needed adjust to specified free play Adjustment 1 Loosen lock nut 2 Turn the adjuster 3 After the adjustment has been made check the full rotation of throttle grip from all steering positions Throttle Inspection 1 Make sure that all nuts and bolts are ...

Page 39: ...eck free play if needed adjust to specified adjustment Free play 3 8 13 16in 10 20mm Upper Adjustment Always adjust using the upper clutch cable adjuster before using the lower adjustment 1 Loosen upper lock nut 2 Rotate the upper clutch cable adjuster until the proper free play has been accomplished 3 Tighten the upper lock nut and check that the free play is correct Clutch System Upper lock nut ...

Page 40: ...ut until the proper free play has been ac complished 5 Tighten lower lock nut and check adjustment 6 Start engine hold in clutch lever and shift into gear Make sure the engine does not stall and the motorcycle does not move Slowly re lease the clutch lever and open the throttle your motorcycle should accelerate gradually and move smoothly If you cannot accomplish the correct free play using both a...

Page 41: ...dle Speed Adjustment 1 If the engine is cold start it and run for ten minutes of Stop and Go riding Turn the engine off 2 Park the motorcycle on level surface using the side stand 3 Connect tachometer to the engine 4 Shift into neutral and start the engine 5 Adjust the idle speed with throttle stop screw Idle speed in neutral 1500 50rpm Throttle stop screw Increase Decrease ...

Page 42: ...lug for corrosion and deposits if it has great corrosion replace the plug 5 Using a wire type feeler check the gap on every new spark plug If an adjustment is needed bend the electrode carefully the gap should be 0 024 0 028in 0 60 0 70mm 6 Thread spark plug in by hand so there is no cross threading 7 Tighten old but still good spark plug 1 8 1 4 turn after it seats Tighten new spark plug 1 2 turn...

Page 43: ...mediately If the pads are still in good condition there may be air in the brake system You will need to bleed the brakes visit your local Service Center for help Brake Fluid Recommendation We recommended that you use DOT3 brake fluid or any brake fluid of the same quality Always use a fresh new container of brake fluid never use an opened container that may be contaminated Brake Fluid Level Inspec...

Page 44: ...ash thoroughly Contact with eyes wash thoroughly and see a doctor immediately Brake Pad Wear Brake pad wear depends on how much you use the brakes the type of riding and road conditions Normally brake pads tend to wear quicker on wet and dirty roads Be sure to check the pads for wear during each maintenance interval You can inspect the wear on pad by using the wear indicator mark If the pads are w...

Page 45: ... specified range Adjustment 1 Turn the rear brake adjusting nut clockwise to increase free play and counter clockwise to decrease the cut out should be seated on the brake arm pin 2 Depress and release the brake Spin the wheel and make sure that it rotates smoothly Repeat procedure several times Check free play If you are unable to adjust free play correctly see your local Service Center Adjusting...

Page 46: ...o disassemble the rear end There is an external brake wear indicator By depressing the brake pedal the brake arm arrow moves toward a reference mark on the brake panel 1 Park your motorcycle and use the side stand for support 2 Depress the brake pedal and check the movement of the arrow on the brake arm If the arrow aligns with the reference mark on the brake panel have your local Service Center r...

Page 47: ...de and check the pressure each month by using an air pressure gauge 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 WARNING Operating this motorcycle with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the m...

Page 48: ...as nails embedded in the tire Excessive wear Pull to the side of the road if you drive over a pothole or any hard objects to inspect the tire for possible damage You should replace the tires if the tread wear reaches the following limits Replace tire immediately if the wear indicators are visible Front from center of tread 0 06in 1 5mm Rear from center of tread 0 08in 2 0mm Wear indicator location...

Page 49: ...If you replace only the tube and not the tire do not exceed 50mph for the first 24hrs and 80mph anytime after Tire Replacement When tire replacement is needed always replace them with the same size load range and speed rating Recommended Tire Size Front 110 90 16 Rear 130 90 15 When replacing a tire Have the wheel balanced after installation If possible have tire replaced by your local Service Cen...

Page 50: ... by your local Service Center Replace the tube Safety Reminders Do not replace tire with a Radial tire Using a different type of tire may affect stability and handling Do not replace with Car tires The tire may forcefully separate from the rim during installing causing serious injury or death Tires ...

Page 51: ...o maintain and service the chain more often that usual Before any servicing to the chain occurs be sure the engine is off and in neutral You do not need to remove the chain to perform service in the Maintenance Schedule Inspection 1 Check the slack of the lower drive chain right between the two sprockets Slack allowing vertical movement by hand 9 16in 15 30mm 2 The slack should remain consistent a...

Page 52: ... the front and rear sprocket teeth for excessive wear or damage If needed replace the sprocket NOTICE The use of a new chain with a worn sprocket will cause quick wear to the chain Adjustment Every 500 miles you should check and adjust if needed the slack of the drive chain If you are riding at high speeds the chain may need adjusting for often Replace Replace Good Drive chain adjusting nut Index ...

Page 53: ...ent by hand 0 375 inches 0 750 inches 10 20mm 4 You can check the rear axle alignment by making sure the index marks align with the rear edge of the adjusting slots Both marks should at the same point If they do not match up turn the left or right adjusting nut until the marks correspond and recheck the chain slack 5 Torque the rear axle nut to 65lbf ft 88N m 9 0kgf m If you do not have a torque w...

Page 54: ...o not use a Steam cleaner high pressure washer or certain solvents These products can damaged the o rings 1 Use a dry cloth to clean the side surface of the chain Use a high flash point solvent not gasoline Do not use a solvent or brush to clean the o rings 2 Check to make sure the chain is not damaged or worn If needed replace the chain Replacement chain 520 ...

Page 55: ... frequently You should remove the battery or disconnect the battery cables if you do not plan to ride for two weeks or more Battery Storage We recommended that you remove the battery from your motorcycle if you are planning to store it for a long period of time In order to maintain the life of the battery while storing you should slow trickle charge the battery every 30 days If you do not remove t...

Page 56: ...ate location off of floor and out of reach of children 7 Clean battery box before storing 8 Use a slow trickle charger every 30 days to maintain the life of the battery To avoid possibility of explosion always connect battery cable in the order specified Negative first Positive last An exploding battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with prote...

Page 57: ...attery For home charging we suggest you use a trickle charger A trickle charger can be left connected for a long period of time without causing damage to the battery Do not leave the battery connected to the charger longer than the recommended amount of time Do not use an automotive battery charger as this can cause permanent damage to your battery Battery Trickle charger ...

Page 58: ...r a mild cleaner degreaser Do not use products that contain chemical solvents or harsh deter gents Before cleaning make sure the engine is cool Wash your motorcycle in a shady area Direct sunlight can cause water spots and fading Do not use a high pressure washer to clean we suggest you use a garden hose NOTICE High pressure washers can cause damage to certain parts of your motorcycle When you are...

Page 59: ...er your motorcycle You may also need this informa tion when ordering parts make sure to keep these numbers in a safe spot Frame number VIN Vehicle Identification Number can be found on the left side of the front forks stamped into a metal plate Engine number can be found stamped into the left side of the crankcase ...

Page 60: ... 86 or higher Fuel tank capacity 3 12US gal Fuel tank reserve capacity 0 47US gal Engine oil recommendation API service classification SF or SG SAE 15W 40 Engine oil capacity 1 5US qt 1 42L Drive chain lubricant SAE 80 or 90 gear oil Fuel and Lubrication Passenger Operator and one passenger Maximum weight 331 US lbs 150kg Includes rider passenger cargo and accessories Max cargo rack weight 11 US l...

Page 61: ...28in 0 60 0 70mm Valve clearance 0 03x0 05mm Idle speed 1500 50 Engine Specification Front Tire size 110 90 16 Front Tire pressure COLD 29psi 200kpa Rear Tire size 130 90 15 Rear Tire pressure COLD 36psi 250kpa Tires Primary transmission ratio 3 631 1st gear ratio 2 84 2nd gear ratio 1 777 3rd gear ratio 1 333 4th gear ratio 1 083 5th gear ratio 0 913 Final drive chain 520 Transmission Power ...

Page 62: ...62 Battery 12V 9AH Headlight 12V35W 35 Brake Taillight 12V20W 8 Turn signal light 12V2W Neutral indicator 12V2W Lights Main 15A Fuses Specifications ...

Page 63: ...signal light 12V 10W Right small light 12V 5W Headlight 12V 35W 35 Neutral pilot 12V 2W Turn signal light 12V 2W High beam pilot 12V 2W Speed meter pilot 12V 2W Fuel meter pilot 12V 2W Right front turn signal light 12V 10W Y Y Y R L G W B W Y B N R G Y R L B G B R Br G Y B R Br B P L Dg Lb B Gr L P G G Br W O G G L Lb G Lb B G G G Lb G Br B Y B G Br W B B BrDg B W G Y Y W B W G B R G Y B G W Y B G...

Page 64: ...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 Distributo...

Page 65: ...eipts 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 o...

Page 66: ...y 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 system 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 t...

Page 67: ...Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252 ...

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