Baja motorsports BR150-1 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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