Baja motorsports DR90 Owner'S Manual Download

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DR90/WR90 Dirt Bike

Read this manual carefully. It contains important safety information.

No one under the age of 16 should operate this dirt bike.

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.

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. D

020409

Summary of Contents for DR90

Page 1: ...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 OWNER...

Page 2: ...s 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 ove...

Page 3: ...d 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 off road vehicle C...

Page 4: ...spark plug 13 checking cleaning the air filter 14 Adjusting the throttle cable 15 adjusting the carburetor 15 adjusting the air valve gap 16 adjustment of front brake 17 adjustment of rear brake 18 a...

Page 5: ...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 impr...

Page 6: ...e of many accidents do not drive at a speed that the actual situation does not permit Always avoid operating an this dirt bike on paved surfaces including sidewalks paths parking lots driveways street...

Page 7: ...If a label comes off or becomes difficult to read you should get a replacement by contacting Baja Inc 1 2 WARNING No one under the age of 16 should operate this vehicle without adult supervision WARNI...

Page 8: ...PARTS SUBASSEMBLIES Front brake lever Throttle twist grip Fuel tank cover...

Page 9: ...Front Wheel Front Shock Absorber Fuel Valve Gear Shifting Pedal Engine Number Side Stand Rear Fork Rear Wheel Seat Cushion Exhaust Silencer Kick Lever Rear Braking Pedal...

Page 10: ...EN FLAMES OR NEAR HEATING UNITS ONLY REFUEL THE VEHICLE IN OPEN AREAS TO REDUCE THE LIKELIHOOD OF THE BUILD UP OF GASOLINE FUMES Operation of the fuel valve the valve under the fuel tank ON With the h...

Page 11: ...to fully open choke after engine has sufficiently warmed up Procedures for stopping the engine 1 Release throttle twist grip to slow down engine 2 Shift to neutral position 3 Set ignition switch to O...

Page 12: ...climbing steep slopes Never drive your dirt bike continuously for more than 30 miles without increasing and decreasing the throttle 2 The engine should be warmed up for 3 5 minutes prior to operation...

Page 13: ...vided on the right handlebar When ignition switch is turned to off position engine will not start If engine is running this will stop engine When ignition switch is turned to on position engine can st...

Page 14: ...3rd gear 4 4th gear Points for Attention during Drive 1 Avoid unnecessary idling of engine at a high speeds Doing so will damage engine components seriously 2 The clutch will wear out quickly if dirt...

Page 15: ...Finally screw on oil gage plug tightly Lubricating Oil Recommended The lubricating oil is an important factor affecting performance and service life of engine Please refer to the chart for correct gr...

Page 16: ...ightly 4 Refill engine with proper amount of oil and recheck amount of oil in engine by using oil gauge plug Check up of Spark Plug 1 Remove cap of spark plug and screw off spark plug using plug wrenc...

Page 17: ...ting in a shorter service life of engine Water should be prevented from entering into filter when washing vehicle The filter element should be cleaned gently without twisting to prevent it from cracki...

Page 18: ...ck for operating movement again Repeat adjustment if necessary until desired operating movement is obtained Adjusting the Carburetor Adjusting procedures of idling speed 1 Support vehicle by a stand 2...

Page 19: ...noise if the gap is too large in air valve If gap is too small valve operation will be hindered which could result in valve malfunction and failure Therefore air valve gap must be checked periodically...

Page 20: ...fluid reservoir 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 on top of bake fluid container Add DOT3 or D...

Page 21: ...rn rear adjusting nut clockwise to reduce and counterclockwise to increase free operating movement of brake pedal 3 Brake shoes should be replaced by a qualified service technician once Wear arrow rea...

Page 22: ...loosen rear axle bolt 2 Turn chain adjusting nuts on the left and right sides to adjust tension of the chain and to align the marking of chain adjuster with the engraved lines in the similar position...

Page 23: ...tion followed by washing with clean water 2 After the cleaned vehicle is air dried grease chain and run engine at idling speed for a few minutes 3 Prior to driving carefully check braking system repea...

Page 24: ...park plug out pour about 15 20 ml 0 5 0 68 oz of clean engine oil into cylinder step down on kick lever repetitively several times so as to have machine oil distributed all over engine and finally pla...

Page 25: ...eed in an open area to test its performance before normal operation Table and Torque of Fasteners No Fastener Torque Newton m Foot lb 1 Front wheel axle nut 35 45Nm 26 33 ft lb 2 Rear wheel axle nut 5...

Page 26: ...are needed C means Cleaning is needed R means Replacement is needed A means Adjustment is needed L means Lubrication is needed means This item of maintenance should be carried out at a service center...

Page 27: ...just I Spark plug I I I I Air valve gap I I I I Engine lubricating oil R YEARLY Lubricating oil screen R YEARLY C Drive chain tension A A A A Drive chain I L I L I L I L Idle speed of carburetor I I I...

Page 28: ...Electrical DIAGRAM Gr B W Gr B Y B Y Bl W B R Gr B W Bl W Gr B R B Black W White R Red Gr Green Bl Blue...

Page 29: ...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...

Page 30: ...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 a...

Page 31: ...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...

Page 32: ...Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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Baja motorsports DR90, Owner'S Manual

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