Baja DX110 Owner'S Manual Download

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SAFETY ...............................................................................................................2

SAFE OPERATION ........................................................................................3

SAFETY GEAR ............................................................................................4

WARNING LABEL PLACEMENT ................................................................5

SPECIFICATIONS ................................................................................................6

PART LOCATION.................................................................................................8

OPERATION ........................................................................................................10

FUEL FILLING .............................................................................................10

FUEL VALVE ................................................................................................10

ENGINE BREAk-IN .....................................................................................11

SWITCHES ON RIGHT HANDLE BAR .......................................................11

LEFT HANDLEBAR, CLUTCH LEVER .......................................................12

RIGHT HANDLEBAR, FRONT BRAkE LEVER AND

THROTTLE TWIST GRIP .............................................................................12

REAR FOOT BRAkE ...................................................................................12

GEAR SHIFTING .........................................................................................13

PRE-RIDE INSPECTION .............................................................................14

STARTING ENGINE .....................................................................................15

MAINTENANCE ...................................................................................................16

CHECkING ENGINE OIL ............................................................................16

CHANGING ENGINE OIL AND CLEANING SCREEN ................................17

CHECk UP OF SPARk PLUG .....................................................................17

CHECkING & CLEANING AIR FILTER .......................................................18

ADJUSTING THE THROTTLE CABLE .......................................................19

ADJUSTING THE CARBURETOR ..............................................................19

FRONT HYDRAULIC DISk BRAkE ............................................................20

REAR HYDRAULIC DISk BRAkE ..............................................................20

CLUTCH ADJUSTMENT .............................................................................21

ADJUSTMENT OF CHAIN ...........................................................................22

LUBRICATING CHAIN .................................................................................22

TORQUE SPECIFICATIONS .......................................................................23

INSPECTION AND MAINTENANCE CHART ..............................................24

TROUBLE SHOOTING ........................................................................................25

VEHICLE WASHING ............................................................................................26

INSTRUCTIONS FOR STORAGE .......................................................................28

RESUMPTION OF SERVICE AFTER STORAGE .......................................29

SERIAL NUMBER LOCATION ............................................................................30

EMISSION CONTROL SYSTEM WARRANTY ....................................................31

TABLE OF CONTENTS

Summary of Contents for DX110

Page 1: ...t acts and regulations pertaining to owning and operating an off road vehicle OWNER S MANUAL Minimum Recommended Age Requirement 16 Rev A DX70 DX110 Dirt Bike Read this manual carefully It contains important safety information No one under the age of 16 should operate this dirt bike without adult supervision ...

Page 2: ...ty is void if Frame is bent or broken due to abuse If 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 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 Motorsports dirt bi...

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 Children under the age of 16 should only ride under adult supervision WARNING The engine exhaust from this product contains chemicals known to the State of California to cause caner birth defects and o...

Page 4: ...INTENANCE 16 CHECKING ENGINE OIL 16 CHANGING ENGINE OIL AND CLEANING SCREEN 17 CHECK UP OF SPARK PLUG 17 CHECKING CLEANING AIR FILTER 18 ADJUSTING THE THROTTLE CABLE 19 ADJUSTING THE CARBURETOR 19 FRONT HYDRAULIC DISK BRAKE 20 REAR HYDRAULIC DISK BRAKE 20 CLUTCH ADJUSTMENT 21 ADJUSTMENT OF CHAIN 22 LUBRICATING CHAIN 22 TORQUE SPECIFICATIONS 23 INSPECTION AND MAINTENANCE CHART 24 TROUBLE SHOOTING 2...

Page 5: ...o 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 sam...

Page 6: ...zards be aware of unexpected turns drop offs rocks ruts and other hazards Keep speed low enough to allow time to react to hazards and changing conditions 4 Never use alcohol or drugs before or during operation Alcohol and drugs can significantly reduce your ability to make good judgements and ride safely 5 Never operate this dirt bike at night Night is defined as the period of time 30 minutes befo...

Page 7: ...vere head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident Always wear an approved DOT motorcycle helmet which fits properly Always wear eye protection goggles or face shield You should also wear gloves boots long sleeve shirt or jacket and long pants 9 Always avoid operating this dirt bike on paved surfaces including ...

Page 8: ...otective riding gear Do not drive while drinking alcohol or while on medication WARNING Must fill with motor oil before first use Please see owners manual TIRE INFORMATION Tire Pressure See tire side wall Max Weight Capacity 245lbs 111kg Tire Size Front 2 5 12in Rear 2 75 10in TIRE INFORMATION Tire Pressure See tire side wall Max Weight Capacity 245lbs 111kg Tire Size Front 2 5 12in Rear 3 0 10in ...

Page 9: ...ht 165lbs 75kg 165lbs 75kg Cargo Capacity No Cargo No Cargo Gears 4 Neutral 4 Neutral Clutch Manual Manual Final Drive Frt 420 14T Rr 420 42T Frt 420 14T Rr 420 42T Engine Type 4 stroke aircooled 4 stroke aircooled Displacement 72cc 107cc Bore Stroke 1 85 X 1 63 inch 47mm x 41 4mm 2 06 X 1 93 inch 52 4mm x 49 5mm Compression Ratio 8 8 1 9 8 1 Power HP 5 10 hp 6 97 hp Valve Train OHV Two valve OHV ...

Page 10: ...SA Denso U22FS U Champion Z10YC AC S102F Autolite 2795 Torch A7TC NGK C7HSA Denso U22FS U Champion Z10YC AC S102F Autolite 2795 Spark Plug Gap 02 03 inch 6 7mm 02 03 inch 6 7mm Idle Speed 1500 100rpm 1500 100rpm Drive Chain Size 08MA 08MA Drive Chain links QTY 98 98 Chassis Steel Painted Steel Painted Front Suspension 1 inch 26mm Spring Hydraulic Alluminum black coatiing Double clamps 24 4 in 620m...

Page 11: ... Rear Wheel Rim Size 1 4 10 in 1 4 12 in Spokes 43mm 43mm Front Tire size 2 5 12 in 2 5 12 in Rear TIre size 2 75 10 in 3 0 12 in Tire PSI See sidewall of tire See sidewall of tire Front Hydraulic Disc 220mm Hydraulic Disc 220mm Rear Hydrualic Disc 190mm Hydrualic Disc 190mm Torque Specifications Wheels Tires Brakes SPECIFICATION 70CC 110CC SPECIFICATIONS ...

Page 12: ... PARTS SUBASSEMBLIES Throttle twist grip Front brake lever Fuel tank cap Brake fluid reservoir Clutch Lever On Off switch Fuel Tank cap breather hose PART LOCATION ...

Page 13: ...hifting Lever Side Stand Rear Fork Rear Wheel Drive Chain Rear Shock Air filter Carburetor Seat Cushion Muffler Kick Lever Rear Brake pedal Choke lever on Carburetor Rear brake caliper Front Shocks Front brake caliper Oil Cap PART LOCATION Chain adjuster ...

Page 14: ...uel valve to OFF position after riding prevents the flow of fuel from fuel tank to carburetor RES Turning the fuel valve to RES position allows fuel to flow from the reserve fuel supply to the carburetor When engine runs out of gas at ON position set fuel valve to RES when on RES refuel as soon as possible ON OFF RESERVE WARNING Engines give off carbon monoxide an odorless colorless poison gas Bre...

Page 15: ...ERATION engine break in The first 10 hours of operation should be considered the Break in period and special attention shall be paid to the following points 1 Do not throttle past half throttle during the first 10 hours of operation Fluctuate the throttle during this period to break in engine components Do not put excessive load on engine by climbing steep hills or having fast starts 2 Warm up eng...

Page 16: ...along with speed of dirt bike Front brake lever Squeeze lever toward hand grip to apply front brakes REAR FOOT BRAKE The foot brake is located on right hand side of dirt bike Foot brake applies rear brake Front brake lever Throttle twist grip Rear foot brake Clutch lever When clutch lever is pulled toward hand grip clutch is applied Clutch lever Left HANDLEBAR clutch lever OPERATION RIGHT HANDLEBA...

Page 17: ...ear Points for Attention during Drive 1 Avoid unnecessary idling of engine at high speeds Idling engine at high speeds will damage engine components 2 The clutch will wear out quickly if clutch is in a semi engaged position Clutch should be pulled in and release once desired gear is achieved do not hold clutch half in or half out of engagement 3 Shift to lower gears when there is insufficient powe...

Page 18: ...Oil Check engine oil level add oil if needed Nuts and Bolts Check nuts and bolts for tightness Refer to proper Torque specifications in this manual Throttle Check throttle free play and adjust if needed Rotate throttle to make sure it moves smoothly without sticking and snaps back automatically when released in all steering positions Brakes Squeeze front brake lever and step on rear brake pedal to...

Page 19: ...tle to warm engine 8 Once engine has sufficiently warmed up place choke lever in down Open position CAUTION Verify oil level prior to starting Starting the engine with low or no oil will damage engine WARNING Never start the engine in a closed place as the exhausted fumes from vehicle contains toxic carbon monoxide WARNING Never start engine without first performing a pre ride inspection see page ...

Page 20: ...rt bike is in neutral is harmful to the engine Procedures for stopping engine 1 Release throttle twist grip to slow down engine 2 Shift to neutral position once stopped 3 Set the ignition switch key to OFF position 4 Set the fuel valve handle to OFF position OPERATION ...

Page 21: ...cting the performance and service life of the engine Please refer to the chart for the correct grade of engine oil based on the environmental conditions in your area Do not use any other type of oil other than what is recommended in the chart DO NOT MIX OIL WITH THE GASOLINE Lubricating oils of different viscosity shall be employed in different regions and at different temperatures MACHINE OIL TEM...

Page 22: ...isposal procedures contact your local oil recycling center 5 Re install oil Plug 6 Refill engine with proper amount of oil and recheck amount by using dip stick Check up of Spark Plug 1 Remove spark plug cap and screw out spark plug using plug wrench 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 with a feeler g...

Page 23: ...it is seated correctly and that outer foam sleeve is back place 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 The filter element shall be cleaned gently without twisting to prevent it from cracking Never wash it with gasoline or...

Page 24: ...ovement again Repeat the adjustment if necessary until the desired operating movement is obtained Adjusting the Carburetor Adjusting procedures of idling speed 1 Support the vehicle by a stand 2 Adjust the idling speed by the throttle stop screw to 1500 rpm 100 rpm CAUTION Do not try to correct a malfunctioning carburetor by adjusting the idling speed If the carburetor is not functioning properly ...

Page 25: ...ervoir 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 the brake fluid container Add DOT3 or DOT4 brake fluid Do not mix brake fluid types 1 Inspect the rear disk brake caliper for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joint...

Page 26: ...lutch adjustment cover from right side of engine housing 2 Loosen clutch adjuster cinch nut and move adjuster screw in or out to obtain correct clutch tension 3 Turn Clutch adjustment screw in Clockwise to increase clutching ability or out Counterclockwise to reduce 4 After correct adjustment tighten cinch nut and re install cover 5 Recheck clutch lever free distance Readjust it if it is not withi...

Page 27: ...ension of chain To keep wheel straight adjustment marks are marked on both sides of rear swing arm Make sure adjustment is even with corresponding mark on opposite side of wheel 3 Tighten rear axle bolt by a torque of 50 60Nm 37 44 ft lb 4 Repetitively check tension of chain Replace drive chain if it has damaged rollers loose pins or kinks that can not be freed Lubricate drive chain if it appears ...

Page 28: ...et 2ea 8mm 15 18 ft lb 20 25 Nm 6 Engine mounting top bolt 8mm 15 18 ft lb 20 25 Nm 7 Engine mounting bottom bolt 8mm 15 18 ft lb 20 25 Nm 8 Rear shock mount bolts 2ea 10mm 24 25 ft lb 32 34 Nm 9 Seat mount bolts 2ea 6mm 6 8 ft lb 8 11 Nm 10 Shift lever mount bolt 6mm 6 8 ft lb 8 11 Nm 11 Swing arm Bolt 10mm 24 25 ft lb 32 34 Nm 12 Main triple tree mounting bolt 26 33 ft lb 35 45 Nm TORQUE SPECIFI...

Page 29: ...ont and rear suspension I Steering system I I I Steering shaft lubrication use Li grease L Fittings and Fasteners T T T I Inspect and clean adjust lubricate or replace if necessary C Clean R Replace T Tighten Should be completed by an authorized service center MAINTENANCE INSPECTION AND MAINTENANCE It is very important to inspect and maintain your dirt bike regularly Follow the guidelines in the c...

Page 30: ...ew 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 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 re...

Page 31: ... valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min 5 Make sure the air filter is clean 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 ...

Page 32: ...by washing with clean water 2 After the cleaned vehicle is air dried grease the chain and run the engine at idling speed for a few minutes 3 Prior to driving carefully check the braking system repeatedly and repair or adjust it if necessary CAUTION Washing the dirt bike with over pressurized water may cause damage to some of its components Therefore do not use a pressure washer to clean the vehicl...

Page 33: ...he kick lever repetitively several times so as to have oil distributed all over inside engine components Attention The ignition switch must be set to OFF position before stepping down on kick lever To protect ignition system from damage the spark plug should be inserted in its cap and grounded 4 Wash the vehicle clean wipe it dry and apply an even coat of wax to the painted surface and a coat of a...

Page 34: ... months 2 Drain off any remaining unused gas in tank follow by filling with fresh gasoline 3 Make sure all bolts are tight See torque specs 3 Prior to riding all the required check ups must be made Ride at a low speed in an open area to test performance before normal operation INSTRUCTIONS FOR STORAGE ...

Page 35: ...e numbers to help your authorized service center or Baja Motorsports 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 Write down the serial numbers here for your future reference Frame No Engine No Engine serial number Frame number SERIAL NUMBER LOCATION ...

Page 36: ... to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and id free from defects in material and workmanship which cause such vehicle to fail to conform with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board for the ...

Page 37: ...he 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 ...

Page 38: ...35 Baja Motorsports LLC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252 ...

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