Baja Comet 90cc BC90, Owner'S Manual

Page 1: ...provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle OWNER S MANUAL Model Number BC90 Minimum Age Requirement 16 Rev A US 012709 Baja Comet 90cc Mini Bike Read this manual carefully It contains important safety information No one under the age of 16 should operate this Mini Bike ...

Page 2: ...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 Baja ...

Page 3: ...ed to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 WARNING ...

Page 4: ...14 check up of spark plug 15 Valve clearance 16 checking cleaning the air filter 17 Adjusting the throttle cable 18 adjusting the carburetor 18 adjustment of rear and front brake 19 adjustment of chain 20 greasing procedures to the driving chain 20 vehicle washing 21 instructions for storage 22 resumption of service after storage 23 table and torque of fasteners 23 maintenance routine diagram 24 T...

Page 5: ...to 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 sa...

Page 6: ...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 to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information av...

Page 7: ...ce shield gloves boots long sleeved shirt or jacket and long pants 2 Loose clothes are not suitable for motorcycle driving or riding as they may get caught on footrest or in moving parts Modification of the vehicle CAUTION Never perform any unauthorized modifications to this vehicle Only use original replacement part which can be obtained through BAJA INC 888 863 2252 ...

Page 8: ...ake sure all warning decals are legible and securely attached b Replace as necessary 4 Tires a Ensure that both tires are in safe riding condition b Both tires must be inflated to the pressure indicated on the tire sidewalls 5 Drive chain a Check condition and tension b Lubricate and adjust tension as necessary 6 Throttle a Check for smooth operation Make sure the throttle snaps back to idle b Che...

Page 9: ...y of oil tank 24L 25 qt Wheelbase 1070 mm 42 11 in Displacement of cylinder 86cc Ground clearance 189 7 mm 7 47 in Ignition means Magneto Vehicle weight 67 59 kg 149 lbs Idling speed 1500 100rpm Weight capacity 69 4 kg 153 lbs Spark plug MEIYA A7TC NGK C7HSA DENSO U22FS U CHAMPION Z10YC Front wheel 3 50 10 36psi Spark plug gap 0 6 0 7mm 024 028 Rear wheel 3 50 10 36psi Valve Clearance Intake 0 002...

Page 10: ...7 PARTS SUBASSEMBLIES Brake lever Throttle twist grip Engine stop switch ...

Page 11: ... Headlight Foot pegs Drive Chain Vehicle Identification Number Brake Drum Rear shock Kick start lever Oil fill plug dipstick Carburetor Spark plug Ignition key switch Taillight PARTS SUBASSEMBLIES Fuel tank located under seat Shift lever Oil drain bolt Foot brake Brake drum Muffler ...

Page 12: ...comes difficult to read you should get a replacement by contacting Baja Inc 1 2 3 3 No one under the age of 16 should operate this vehicle without adult supervision WARNING 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 THIS VEHICLE IS AN OFF ROAD VEHICLE AND IS NOT INTENDED FOR USE...

Page 13: ...cap by carefully aligning the threads on the cap and the tank and turning the cap clock wise Wipe any spilled fuel from the mini bike using a cloth and dispose of the cloth properly DO NOT SMOKE OR REFUEL THE VEHICLE NEAR OPEN FLAMES OR NEAR HEATING UNITS ONLY REFUEL THE VEHICLE IN OPEN AREAS TO REDUCE THE LIKELIHOOD OF THE BUILD UP OF GASOLINE FUMES DO NOT OVERFILL TANK FUEL LEVEL SHOULD BE BELOW...

Page 14: ...in the DOWN OFF position when engine has sufficiently warmed up Procedures for stopping the engine 1 Release throttle twist grip to slow engine RPM s to idle 2 Shift mini bike transmission to neutral position 3 Set ignition switch key to OFF position CAUTION Verify oil level prior to starting Starting the engine with low or no oil will damage engine CAUTION Unnecessarily increasing RPM s to a high...

Page 15: ...stop switch is provided on the left handlebar When the switch is turned to off position the engine will not start or will stop engine if running When the switch is turned to on position the engine can start and the vehicle can be driven ON button OFF button ...

Page 16: ... gear 3 3rd gear 4 4th gear Points of Attention during Drive 1 Avoid unnecessary idling of engine at high speeds Idling engine at high speeds can damage engine 2 Down shift to lower gears when there is insufficient power to climb hills or continue forward 3 As a general rule the front brake provides approximately 70 of stopping power Always use both the rear brake pedal and front brake lever simul...

Page 17: ...ting Oil Recommended The lubricating oil is an important factor affecting 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 employe...

Page 18: ...lean and re install the Screw Plug Torque to 18 ft lb 5 Refill engine with 0 25 qt 0 24L of recommended oil recheck the amount of oil in the engine by using the oil dip stick Check up of Spark Plug 1 Remove the spark plug cap Remove spark plug by using the spark plug wrench provided 2 Clean spark plug all around or replace plug if it is corroded or there is too much deposit on it 3 Regulate gap of...

Page 19: ...haust 0 003 inch 0 0762 mm Excessive clearance will cause noise Insufficient clearance will cause loss of power and possibly damage the valves For those who are mechanically proficient and have the proper tools instructions on adjusting the valve clearance are given in the service manual If assistance is needed please contact Baja Inc to find your local service center ...

Page 20: ...ebris replace air filter CAUTION The air filter element must be intact or the engine will suck in dust and dirt resulting in a shorter service life of the engine Water should be prevented from entering into the filter when washing the vehicle The filter element shall be cleaned gently Replace the air filter element with a new one if it is broken or cracked Clamp Air filter ...

Page 21: ...the operating movement again Repeat the adjustment if necessary until the desired operating movement is obtained Adjusting Carburetor Idle speed adjustment 1 place vehicle in neutral and start engine 2 Adjust idle speed by turning the throttle stop screw to 1500 100rpm CAUTION Do not try to correct a malfunctioning carburetor by adjusting the idling speed If the carburetor is not functioning prope...

Page 22: ...rating movement of 5 7 mm 0 2 0 3 in 2 To make adjustment on brake lever loosen jam nut then turn adjusting nut counter clockwise to reduce and clockwise to increase the free operating movement of the front hand brake lever 3 To make adjustment on brake cable tension turn adjusting nut located on the front hub assembly Clockwise to increase braking and counter clockwise to decrease braking 4 Brake...

Page 23: ...ent of Chain 1 When chain adjustment is needed loosen rear axle nut 2 Turn chain adjusting nuts on the left and right sides to adjust the tension of the chain Align the marking of the chain adjuster with the engraved lines in the frame on both sides 3 After adjustment has been made torque rear axle nut to 50 60Nm 37 44 ft lb 4 Check chain tension before each ride 15 20mm 1 2 3 4 Chain tension Chai...

Page 24: ...ent solution followed by rinsing with clean water 2 After vehicle has air dried lube drive chain then run engine at idle speed for a few minutes 3 Prior to driving carefully check brake system repair or adjust if necessary CAUTION Washing the Mini Bike with over pressurized water may cause damage to some of its components Therefore do not use a pressure washer to clean the vehicle The following pa...

Page 25: ... plug pour about 15 20ml 5 68 oz of clean engine oil into t cylinder step down on kick lever repetitively several times to have the oil distributed evenly inside the engine cylinder 4 Re install spark plug 5 Wash vehicle clean wipe dry and apply an even coat of wax to painted surfaces Apply a light coat of anti rust oil to all metal parts 6 Inflate tires as required and place vehicle up on wooden ...

Page 26: ...ning atomized anti rust oil from the fuel tank Fill tank with fresh gasoline 3 Prior to driving all the required check ups must be made After checking vehicle start engine and drive slowly at first in an open area to make sure vehicle operates correctly 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 50 60Nm 37 44 f...

Page 27: ... maximum figures specified in the table maintenance should be still cycled according to the intervals of time or hours stated herein ITEM OF MAINTENANCE EA USE 1ST MO 20 HRS EVERY 3 MO 50 HRS EVERY 6 MO 100 HRS EVERY YR 300 HRS Engine oil Check X Engine oil Change X X Air filter Check X Air filter Clean X Air filter Change X Carburetor sediment cup Clean X Spark plug Check Adjust X Spark plug Repl...

Page 28: ...nspect spark plug Dry and reinstall spark plug 6 Carburetor malfunction ignition malfunction valves stuck etc Take vehicle to a qualified mechanic Replace or repair faulty components as necessary SYMPTOM POSSIBLE FIX 1 Filter element s clogged Check air filter Clean or replace 2 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carbureto...

Page 29: ...ake Light 12VDC 5 21W Fuse 10A Battery Head Light 12VAC 18W Regulator Magneto Ignition coil Spark plug CDI B Y W B B W B R B W W Y R G Y G G G G G B B G Y G G B B W R W White R Red Y Yellow G Green B W Black White Bl W Blue White B R Black Red B Y Black Yellow G Y Green Yellow ...

Page 30: ... numbers to help your authorized service center or BAJA INC order parts The Frame number is stamped on front of Mini 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 VIN ...

Page 31: ...fica tions 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 the California Air Resources Board and is free from defects in material and workmanship which cause such vehicle to fail to confirm w...

Page 32: ...MITED 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 busi ness 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 ...

Page 33: ...Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 1 888 863 2252 ...