Baja BR150-1 Owner's manual

Type
Owner's manual
MinimumAge Requirement16
REV.D
040209
Alwaysweara helmet;It couldsaveyourLife!
Pleaseobtain,review,andfollow provincial/ municipalgovernmentactsand
regulationspertainingtoowningandoperatinganoff-roadvehicle.
0
Congratulationsonyourpurchaseofa Baja150ccGo-Kart.
It iswarrantedtobefreeofmanufacturingdefectsinmaterialand
workmanshipfor a periodof90daysform thedateofpurchase.During
thewarrantyperiodBAJA,INC. willat itsoption,repair,provide
replacementpartsor replaceyourBajaGo-Kartat nocharge.This
warrantydoesnotcovernormalwearitemsor damagecausedby
neglector misuseoftheproduct.
EngineWarranty- 90days
FrameWarranty- 90 days
Warrantyisvoidif:
Frameisbentorbrokenduetoabuse
Wheelsarebentor broken
Fenderbentor brokenduetoabuse
Anysignofimpact,accident,jumping,spin-outsor rollover.
BAJA,INC.isnotliablefor anydamageclaimor liabilityclaimperson
orotherwiseresultingfrom theoperationofthisproductinanyway.
Shouldyouexperiencea problemwithyourvehicle,pleasecall BajaInc.
customerservicelinetollfree at 1-888-863-2252betweenthehoursof
7amand5proMondaythroughFridayMST(MountainStandardTime).
MDT(MountainDaylightTime)duringthedaylightsavingtime.Youwillbe
instructedhowtoproceed.
A COPYOFTHESALESRECEIPTISREQUIRED.
This manual should be considered a permanent part of
the vehicle and should remainwith the vehicle when
resold or otherwisetransferred to a newuser or operator.
The manual contains important safety information and
instructionswhich should be read carefullybefore
operatingthevehicle.
The engineexhaust from this productcontains
chemicalsknown to the Stateof Californiato cause
cancer,birthdefects or other reproductiveharm.
CALIFORNIA PROPOSITION65
Never operatethis Go-Kart at night. Night isdefined
asthe period oftime 30 minutesbefore sunsetto 30
minutesafter sunrise.
You may collidewith another vehicle, a stationary
object,or hazardfound inthe terrain.
NOTICETO USERS.......................................................................................2
BR150GOKART.............................................................................................9
FUELAND OIL...............................................................................................10
WARNING LABELS........................................................................................11
CONTROL PANEL AND IGNITIONSWITCH.................................................13
THROTTLE AND BRAKE PEDAL..................................................................14
PARKING BRAKE .........................................................................14
SEAT ADJUSTMENT.......................................................................................15
RIDINGYOUR GO-KART................................................................................16
INSPECTIONBEFORE RIDING.....................................................................17
SAFETY GEAR ...............................................................................................19
BREAK-IN.......................................................................................................20
DRIVESELECT LEVER..................................................................................21
CARBURETOR ADJUSTMENT......................................................................22
CHAINAND SHOCK ADJUSTMENT..............................................................23
INSPECTIONAND MAINTENANCE ...............................................................24
BATTERY INSTALLATION..............................................................................26
BATTERY REPLACEMENT. ..........................................................29
ENGINE OIL....................................................................................................30
CLEANING OILFILTER..................................................................................31
TRANSMISSIONOIL.....................................................................31
AIRFILTER.....................................................................................................33
SPARK PLUG..................................................................................................35
TIRES.........................................................................................................36
BRAKING.......................................................................................................38
BRAKE INSPECTION...................................................................39
TROUBLESHOOTING ...................................................................................40
IGNITIONSYSTEM CHECK .........................................................41
TRANSPORTING ............................................................................................42
CLEANING PROCEDURE ..............................................................................43
PREPARATION FOR CLEANING.................................................43
WASHING YOUR GO-KART...........................................................................44
INSPECTIONAFTER CLEANING.................................................44
STORAGE PROCEDURE ...............................................................................45
SERIALNUMBER LOCATION.......................................................................46
SPECIFICATIONS...........................................................................................47
WIRE DIAGRAM.............................................................................................48
EMISSIONCONTROL SYSTEM WARRANTY. ..............................................49
Pleasereadthis manualandfollow all instructionscarefully.Toemphasize
thespecialinformation,thesymbol,tandthewordsWARNINGorCAUTION
havesomespecialmeanings.Paygreatattentiontothemessages.
Indicates a potentialhazardthat
couldresultindeathor injury.
I
CAUTION
Indicatesa potentialhazardthat
I couldresultin vehicle damage.
NOTE:Indicatingspecialinformationwhichisto makemaintenanceeasieror
instructionsclearer.
WARNINGand CAUTIONarearrangedlikethis:
Thefirst partwillidentify a POTENTIAL
HAZARD.
ThesecondpartwilldescribeWHATCOULD
HAPPENifyou ignoretheWARNINGor
CAUTION.
Thethird partwilldescribeHOWTOAVOID
THEHAZARD.
Thisuser'smanualcontainsimportant safetyandmaintenanceinformation.
Readitcarefullybeforeriding.Failingtofollow thewarningscontainedin
this manualcouldresultin INJURYor DEATH.
Itisimportantthatthismanualremainwiththevehiclewhenyoutransferitto
anotheruseror owner.
Allinformation,illustrations,photographsandspecificationscontainedin
this manualarebasedonthelatestproductinformationavailableatthetime
of publication.Duetoimprovementsor otherchanges,therewillbesome
discrepanciesinthismanual.Wereservetherightto makeproductchanges
at anytime,withoutnoticeandwithoutincurringanyobligationtomakethe
sameorsimilarchangestothevehiclepreviouslybuiltor sold.
Thisoff-roadproductISNOTATOYANDCANBEHAZARDOUSTOOPER-
ATE.Thisproducthandlesdifferentlyfrom othervehiclesincludingATV'sand
motorcycles.Acollisionorrollover canoccurquickly, evenduringroutine
maneuverssuchasturningandridingonhillsoroverobstacles.
Tohelpyou makeinformeddecisionsaboutsafety,youwillfind providedin
thismanualoperatingproceduresandothersafetyprocedureswhichmust
befollowed. Inadditiontothesafetyinformationinthismanual,you willfind
safetylabelson theproduct.FOLLOWALLWARNINGBOTHINTHISMANUAL
ANDONTHEPRODUCT.
Informationwhichisparticularlyimportantisdistinguishedin thismanualby
thefollowing notations:
FAILURETOFOLLOWWARNINGINSTRUCTIONS
COULDRESULTINSEVEREINJURYORDEATH
TOTHEOPERATORORPASSENGER,A
BYSTANDERORA PERSONINSPECTINGOR
REPAIRINGTHEPRODUCT.
I
CAUTION
CAUTIONINSTRUCTIONSAREPROCEDURESTO
PREVENTDAMAGETOTHEVEHICLEORINJURY
TOTHEOPERATORORPASSENGER,A
BYSTANDERORA PERSONINSPECTINGOR
REPAIRINGTHEPRODUCT.
NOTE:ANOTEprovideskey information tomakeprocedureseasieror
clearer.
IMPORTANTRULES FORSAFE OPERATION
1. Thisvehicleisnotlicensable.ITISNOTTOBEOPERATEDONANY
PUBLICROAD,STREET,HIGHWAY,PARKINGLOT,SIDEWALK,ORALLEY.To
dosowouldbeinviolationoflocallaw.Thisvehiclemaybeoperatedonlyon
privatepropertyanduponareasapprovedbylocallaw.Avoidoperatingthis
vehicleinanyareawithstationaryobjectsthatthevehiclecouldtravelunder.
Donotridein areaswhereotherrecreationalvehiclesarebeingoperated.Be
respectfuloflandownersandtheenvironment.
2. ThisvehicleshouldNEVERbeoperatedindoors.Theexhaustfrom the
enginecontainscarbonmonoxide,whichisa tasteless,odorless,and
poisonousgas.
3. Unlessotherwisespecifiedin thismanual,allscrews,nuts,andbolts
mustbekepttighttoensurethatthevehicleisinsafeoperatingcondition.
Theenginemustbekeptfree ofalldirtandotheraccumulations,paying
particularattentiontothrottlelinkagearea.
4. Prevailing-Torque-typeIocknutslosetheirlockingcapabilitywithrepeated
useandrequirereplacement.EnsureIocknutsarefunctioning properly.
5. Thetire pressureshouldbecheckedpriortoeachuse.Therecom-
mendedinflationpressureisthemaximumtire pressureas printedonthetire's
sidewall.IMPROPERTIREPRESSUREMAYCAUSEINSTABILITYANDMAY
PREVENTPROPERBRAKINGOR
STEERING.
6. Modificationsofthisvehicleor removalofanyoriginalequipmentor
safetydecalmayrenderthevehicleunsafeor illegal.NEVERREMOVEANY
PROTECTIVEGUARDSORBELTGUARDS.Thesecoversarefor operator/
passenger'sprotection.Ifanyguardsareremovedfor maintenanceor
servicingofthevehicle,ensurethattheyaresecuredinplacepriorto
operatingthevehicle.
7. THEVEHICLESHOULDNEVERBESTARTEDWITHOUTFIRST
CHECKINGTOSEETHATTHETHROTTLEIS INIDLEPOSITION.Donotstart
enginewithoutverifyingproperfunction ofthethrottle.Neverattemptto start
thisvehiclewithouthavingtheoperatorseatedintheproperposition.When
startingwiththeoperatorin theseat,theoperatorshouldhavetheirleftfoot
onthebrake.
8. Thisvehicleisnotdesignedor intendedfor racing,anyform of
competition.
9. Theoperator'sabilitytooperatethisoff-roadvehiclesafelyislargely
dependentupontheoperator'sabilitytoexerciseproperjudgment.An
operatoralsomustnotbetoosmallor toolargefor controlledoperation.
Theoperatormustbeofsufficientage,understanding,mentalcapacity,and
physicalcapabilitytosafelyoperatethisvehicle.Thisvehicleshouldonlybe
operatedaftermature,supervisedinstructionandsufficientpractice.Safe
operationincludesresponsibilityfor thesafetyofa passenger(ifany).
10. A DOUBLESEATVEHICLEISDESIGNEDFORONEOPERATORAND
ONEPASSENGER.Nooneshouldeverattempttorideonthisvehiclewithout
beingseated,withtheseatbeltproperlysecured.Fordoubleseatvehicles
riddenwithoutpassenger,thepassengerseatbeltmustbesecuretoprevent
itfrom gettingcaughtupinoperatingcomponents.Anypassengermustbe
ofsufficientage,understanding,mentalcapacity,andphysicalcapabilityto
acttoprotecthimself/herself.ALWAYSFOLLOWTHERECOMMENDEDAGE
RESTRICTIONOF16YEARSFOROPERATORSANDPASSENGERS.
11. Theengineshouldbestoppedwhenthevehicleisnotin use.
12 Theoperatorandpassenger(ifany)ofthisvehicleshouldalwayswear
a helmetapprovedbyagenciessuchas DepartmentofTransportation(DOT),
SafetyHelmetCouncilofAmerica(SHCA),or SnellMemorialFoundation
(SNELL).Mostoff-roadvehicleaccidentfatalities areduetoheadinjuries.The
operatorshouldalsowearface shieldsorgoggles,bootsorclosed-toeshoes,
gloves,andotherappropriate
protectiveclothing.
13. LOOSECLOTHING,LONGHAIR,ORARTICLESWORNBYANY
OPERATORORPASSENGERMUSTBEFULLYCONTAINEDORCOVEREDTO
PREVENTTHEMFROMPOSSIBLYBEINGCAUGHTINROTATINGPARTSOF
THEVEHICLEORTHESURROUNDINGENVIRONMENTWHILERIDING.
FAILURETOOBEYCOULDENDANGERTHEPERSONALSAFETYOFTHE
OPERATORORPASSENGER.
14. DONOTPLACEHANDS,FEET,ORANYOTHERPARTOFTHEBODYOR
ANYCLOTHINGNEARTHEENGINE,MUFFLER,WHEELS,CHAINANDOTHER
ROTATINGPARTSOFTHEVEHICLEWHILERIDINGORRUNNINGTHE
ENGINE.Caution must be usedin performing required maintenanceon or near
an operating engine.Special cautionshouldbe taken after theengine has
been running, sincetheengine and other drive componentsmay beextremely
hot.
15. Wet,slippery,rough,or steepterrainis potentiallydangerousandmay
resultin injuryifpropercautionin notobserved.Slowspeedsarerequired
tosafelyoperatethisvehicleundertheseconditions.Theoperatormustuse
maturejudgment,skill,andexperiencetochooseaspeedsuitablefor terrain
andridingconditions.
16. Thegovernorsettingsfor this vehicle's enginemustnotbetampered
with,altered,or changed.Thegovernorissetbytheenginemanufacturerand
limitsthe maximumspeedoftheengine(andvehicle)and protectstheengine
from damage.Excessivespeedsarepotentiallydangeroustotheoperator/
passenger,andtheengine.
17. Eachtime before usingthis vehicle, thefuel supplyshouldchecked.
Thefuel tankshouldneverbefilled whiletheengineisrunningorwhilethe
engineishot.Donotfill tankina closedareasuchasa garage,while
smoking,or inthevicinityofanopenflame. Donotoverfillthetank.There
shouldnotbeanyfuel inthefiller neck.Replacecaptightlytoprevent
spillageoffuel andpotentialfire hazard.Afterfilling tank,movethevehicleat
least15feet awayfrom thespotoffilling beforestarting.
18. Ifthevehicleshouldstartmakingunusualnoiseorvibratingabnormally,
theengineshouldbestoppedandthesparkplugwiredisconnected.The
vehicleshouldthenbecheckedfor damage.Excessivenoiseorvibrationis
generallya warningoflooseorwornparts.
19. Whenmakingrepairsoradjustmentstothevehiclewhichdonotinvolve
adjustmentstotheengine,thesparkplugwiremustbedisconnectedandkept
awayfrom thesparkplugtopreventaccidentalstarting.Whenworkingon or
around,or whenrestartingengine,useextremecautiontoavoidcontactwith
themuffler,cylinderhead,oranyotherpotentiallyhotareaonor aroundthe
engine.
20. Alwaysperforma pre-rideinspectionbeforestartingtheengine.See
Pre-RideInspectionsectioninthismanual.
21. Whenstoringthevehicle,itmustbekeptina placewheregasoline
fumeswillnotreachanopenflameor spark.Forlongperiodstorage,suchas
for winter,thefuel tankshouldbedrainedinanopen,coolarea.Theengine
mustbeallowedtocoolbeforestorageinanyenclosure.Readandkeepall
printedmaterialsuppliedwiththisvehicle.Timelyandspecificinstructions
andanOperator'sManualrevisionsareincludedinsupplements.Ifany
printedmaterialisunclear,contactthemanufacturer.
22. NEVEROPERATETHISVEHICLEWHILEUNDERTHEINFLUENCEOF
ALCOHOL,DRUGS,ORMEDICATIONOFANY KIND.SUCHOPERATION
COULDBEDANGEROUSTOYOURSELFAND/OROTHERS.
23. Alwaysslowdownwhenturning.Highspeedturningmaycauselossof
control,possibleturnoverofthevehicle,and/orpossibleinjurytotheoperator
or passenger.
24. Whilemakinga turn,knobbytiresmayincreasetheriskoflossof
control.ALWAYSSLOWDOWN!A collisionor rollovercanoccurquickly,
evenduringroutinemaneuverssuchasturningandridingon a hillorover
obstacles.
25. DONOTRACE.JUMP,PERFORM"STUNT"RIDINGOR"SPINOUTS"
WHENOPERATINGTHISVEHICLE.THISVEHICLEISNOTDESIGNEDOR
INTENDEDFORSUCHOPERATION.
26. Thismanual,alongwiththeothersupplementsprovidedwithyour
vehicle,provideguidelinesfor theassembly,maintenance,andoperationof
thisvehicleandisnotintendedasa servicemanual.
27. Assembly,maintenance,and/orrepairofthisvehicleshouldonlybe
performedbypersonsofsufficientmechanicalskill,experience,and
judgment(suchas outdoorequipmentdealers,motorcycledealer/shops,or
smallenginedealers)sothatnounsafeconditionor modificationismade.
28. Alwaysuseextremecautionwhenstartingtheengine.Avoidtouching
theengine,muffler,or drivecomponents.Theseareascouldcauseburnson
contact.
29. The battery(ifapplicable)containssulfuricacidandmustnotcomein
contactwithskin,eyes,orclothingsincethiswillcausesevereburns
possiblycausingdisfigurement.Also,batterymaygenerateexplosivegases
andmustnotbeexposedtosparks,flame,cigarettes,or anythingflammable
oranexplosionmayresultcausingsevereinjury.Protectiveglovesandface
protectionmustbewornwhenservicingthebattery.
30. ANYOPERATORORPASSENGERUNDER18YEARSOFAGEMUST
ALWAYSBEAPPROPRIATELYSUPERVISEDBYANADULTATALLTIMES
WHILEOPERATINGTHEVEHICLE.
31. Operatingthisvehiclerequiresskillsacquiredthroughpracticeovera
periodoftime.Takethetimetolearnthebasictechniqueswellbefore
attemptingtooperatethevehicle.
32. Operateonlyonsafeandfamiliar terrain.Avoidloosegravelandrocks.
Becarefulonwetsurfacesandallowfor extrabrakingdistance.
Brushguardbar
Steeringwheel
Headlight
Rearrack
/
Frontwheel
Rearwheel
[Left]
Fueltank
Controlpanel
Rearshockab-
sorber
Frontshock
absorber
Safetybelt
[Right]
FUEL
Theproperfuel isveryimportantfor theengine. Ensurethatthereisno
dust,dirt,or waterwhichhasmixedinthefuel. Pleaseuseregularunleaded
gasoline
ENGINEOIL
Your150ccGo-karthasa four-stroke engine. Pleaseuseoilas described
inthechartbelow. Byusingtheprescribeoil,youwill realizethebest
lubricationfor theengine.
ENGINE
TEMP.
°C
Oa
oF
-30 -20 -10 0 10 20 30 40
-22 -4 14 32 50 68 86 104
Usethe charttoselectaviscosityratingbasedonthetemperaturerangein
yourarea.
10
Readandfollow allofthe
warningslabelsonyour
Go-kart.Makesureyou
understandallthe labels.
Keepthelabelsonthe
Go-kart.Donotremove
themfor anyreason. Ifa
labelcomesofforbecomes
difficultto read,you
shouldgeta replacement
bycontactingBaja
Motorsports.
lm
m
"n-iisGO-RARTCAN BEHAZARDOUSTOOPERATE
If driven carelessly
INJURIEScan resultIfyou do not follow these
instructions:
-BEAD OWNER'S MANUAL AND ALL LABELSBEFORE
YOU OPERA'_ THIS GO=KART.
-NEVER OPERATE1HIS GO-KART WI1HOUT PROPER
INSTRUCTIONS. Beginners require mature supervision.
-NEVER OPERATE1HIS GO-KABT ON PUBLIC ROADS.
it isintened off-road use only,
-NEVER OPERATE1HIS GO-KA_r AT EXCESSIVESPEEDS,
NEVERAI"i_MPT WHEELIES,JUMPS, OR CriER STUNTS,
1
Seat Belt Must Be Worn At All Times
"mlSVEHKIE MAHUFAGURED
FOROFF-ROADUSEONLY.
DO NOTO_KII_ ON PUBLIC
11
.
-Moving parts
can crushand
cut.
-Keep hands
clear.
-Do not operate
with guard
removed.
.
NO
LONG
HAIR
ALL HAIR MUST BETIED UP AND
SECUREDAT ORABOVE SHOULDER LENGTH.
ALL LOOSECLOTHING MUST BESECURED.
ALL NECKLACESAND SCARVESMUST BE
SECURED.
5- i[O7-'I D] l I_11
k 22LBS NEVERsithereJ
.
.
.
Forwa rd Or Reverse"
12
ignitionKey
Enginestopswitch
Enginestop switch - WhenengineisrunningmoveStopswitchto
"OFF"(O) position.Theengine shouldstopwhenswitchisdepressed.
Iftheswitchfails tostopengine,consultyournearest servicecenter.
Ignitionkey switch - Insertkeyintoignitionswitch,turnkeyCWand
releasekeywhenenginestarts. Note: Theenginestopswitchneeds
to beplacedinthe"ON" (I)positionandthefoot brakeneedsto be
depressedfor enginetostart.
CAUTION
Donotholdkeyfor morethan5secondsata timewhenstartingengine.
Ifenginefails tostartwithin5 seconds,allow startertorestfor 10
secondsbeforetryingagain.
Allowingthestartertorunfor morethan5 secondsat a timecouldcause
damagetothestartermotor.
13
Q Brakepedal
Depressingthebrakepedaldrawsthebrakecalipersagainstthebrakerotor
andslowsorstopsthego-kart.
® Throttlepedal
Depressingthethrottlepedalwillengagetheclutchandmovethego-kart
forward
Brakefluid reservoir
Q Parkingbrake
Whilestartingtheengineorparkingthe machine,especiallyona slope,
applytheparkingbrakeby pullingleverbacktowardsthe seat
14
Pullseatadjustmenthandleupward
todisengagetheseatslide.Movethe
seattodesiredposition.Besurethe
handlesnapsbackintoplaceand
thattheseatislockedintoposition
Seatadjustmenthandle
Beforeattemptingtoadjusttheseat,ensurethattheengineisnot
running.
Neveroperatego-kartwhentheseatisnotsecurelyadjusted.Itcould
resultinpersonalinjuriesor lossof life.
Theseatmustalwaysbesecurelyadjustedtothepositionwhichaffords
thebestcontrolofthefoot pedals,steeringwheelandenginestop
switchfor theoperator.
15
WHATYOU SHOULD KNOW BEFORE RIDING
Beforeriding,youshouldreadall thefollowing information carefully.Ifyou
areproperlyprepared,youwillhavea moreenjoyableride.
Beforeriding,youshouldfind a goodplaceto practicetheskills. Finda flat,
openareawithenoughspaceto practicethenewskills.
Makesurethatit islegaltoridein theareayouselected.Reviewthelocallaws
andmakesureyouarenottrespassing.Callthepoliceifyoudon'tknowwhere
youcanride.
Protectyourridingareas.Whenyouareriding,remembertokeeptheterrain
ingoodcondition.Don'tdestroyplants,treesor othervegetation.Don'tlitter
anddon'tbotherwildlife.Withyourhelp,yourridingareacanremainopenfor
useinthefuture.
After you havefound a goodplacetopractice,reviewthecontrolsystemon
yourGo-kartbeforeriding.Learntofind thesecontrolswithoutlookingfor
them,becauseyouwillnothavetimetolookfor themwhenyouareriding.
Canadianresidentsmustobtain,review,andfollowallprovincialandmunicipal
governmentactsandregulationspertainingtoowningandoperatinganoff-road
vehicle.
16
Failingtoinspect theGo-kartbeforeoperatingcouldbe hazardous.
Failingtoperformpropermaintenancecouldalsobehazardous.
FailingtoinspectandmaintainyourGo-kartcouldincreasesthe
chancesofanaccidentorequipmentdamage
AlwaysinspectyourGo-karteachtimebeforeriding,andmakesureitisina
safeoperatingcondition.RefertotheINSPECTIONANDMAINTENANCEsection
inthismanual.
ITEMTOCHECK CONTENT
Steering Smoothness;Norestrictionofmovement;Noplayor
looseness.
Brakes Enoughbrakeforce; Parkingbrakeeffectiveness.
Tires Properairpressure;Enoughtreaddepth;Nocracks,
ripsor otherdamages.
Fuel Enoughfuelfor theintendedtrip;Fuelhose
connectedsecurely;Nodamagetofuel tankor cap;
Fueltankcapclosedsecurely.
EngineStopSwitch Properoperation.
EngineOil Properlevel-CheckoilbyinsertingEngineoil
dipstick.Theengineoilshouldbebetweenthe
minimumandmaximumlines.
Throttle Smoothresponse;quickreturntoidleposition.
GeneralCondition Boltsandnutsaretight;norattlefrom anyparts
oftheenginewhenrunning;novisibleevidenceof
damage.
17
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Baja BR150-1 Owner's manual

Type
Owner's manual

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