Baja BLASTER 6.5 Setup Instructions

1

1. Remove cardboard carton from

metal frame

2. Remove operating instructions

and owners manual located on top of

Go-Kart.

E - REV - A

4. Remove bolts as indicated in photo

from both sides of metal frame

5. Carefully remove metal

frame

3. Remove hardware box

BAJA BLASTER 6.5 SET UP INSTRUCTIONS

2

Rear Rack

Rear Tire

Seat

Seat cover

Front tire

Cross Support

steering

wheel

Front bumper

Front Tire

Seat

Rear tire

Cross braces

Seat cover

Left Brush

Guard

Right Brush

Guard

Left and

right Nerf

Bars

Nerf

Brace

Nerf

Brace

6. Remove parts from crate, layout

according to diagram

7. Remove parts from hardware box

and layout accordingly.

Rubber Grommets

QTY 8

Cotter Pin

QTY 2

Parts and Hardware

Rear bumper

3

Tie Rod

8. Attach Tie rod to spindle assembly

9. To attach rear axle to support bar you

must rst remove the rear bumper

Trailing arm axle support

10. Attach rear shock to axle using

bolt and nut already attached to shock.

Tie Rod and Rear Shock Assembly

Cotter pin

Axle

NOTE: The rear guard has been removed to show

detail.This assembly must be performed with

removing the rear guard.

Castle nut

4

11. Attach front wheels using 4 M10 nuts

Torque lug nuts to 33ft.lbs. Make sure the

air ll valve is facing out.

12. Attach rear wheels using M10 nuts.

Torque lug nuts to 33ft. lbs.

Front and Rear Wheel Assembly

NOTE: The front rim is not as “Deep” as the rear

rim on the side containing the air ll valve.

The rear wheels have “Deeper” rims

on the side with the air ll valve.

5

13. Attach steering support to frame

using M10x55 bolt and M10 nut.

Once assembled the steering column

can be used to adjust the steering

wheel height.

14. Attach top of steering support

bracket to steering shaft using M10x90

bolt and M10 nut.

15. Attach steering wheel to steering

support using M12 nut. Torque nut

to 39 ft.lbs.

Steering Column and Steering Wheel

4

Rubber

gromets

16. Attach seats to frame using phillips

screw driver, M6x30 screws, M6 washers,

rubber grommets and M6 nuts.

17. Put seat cover over seat and

tie down.

6

Seat Assembly

5

18. Attach Nerf bar to frame and

add nerf brace using M10x30 and

M12-25 bolts and nuts

19. Attach front bumper to front of

frame using M8x40 bolt, lockwasher

and M8 nut.

M12x25 bolt and nut

M10x30 bolt and nut

7

Nerf Bar and Front Bumper Assembly

Nerf Brace

Nerf Bar

Lock washer

6

20. Attach front of brush guards to frame

using M12x90 bolt and M12 nut.

21. You must rst remove the rear bumper

before attaching the rear of brush guards to

the frame. Use M12x105 bolt and M12 nut

to attach. Make certain that you reattach the

rear bumper.

8

Front Bar Cage Assembly

7

22. Attach cross bar behind seat

using sleeve, M12x100 bolt and

M12 nut.

23. Attach cross bar to top

mounting point of brush guard

using sleeve, M12x105 bolt and

M12 nut.

9

Cross Bar Assembly

Sleeve

8

24. Attach front of rear cargo rack to bar

cage using M12x75 and M12 nut.

25. Attach rear of cargo rack using

M10x25 bolt and M10 nut.

10

Rear Cargo Rack Assembly

26. To attach Brushguard cross support

you must loosen the attachments on the

side of the bar cage frame. Use M10-70

bolts and M10 nuts. Make sure you have

retightened all hardware.

9

27. Attach seat belt to bar cage using

M12x25 bolt and nut. Torque bolts to 39

ft.lbs.

28. Attach headrest using 6mm nut.

11

Seatbelt and Headrest Assembly

10

29. Fill engine with correct amount of oil. Refer to owners

manual for oil types and quantity.

30. Fill gas tank as specied in

owners manual.

31. Refer to owners manual for

proper starting instructions.

!!WARNING!!

This engine may be shipped with packing oil in

the engine. This oil should be drained and

replaced with new engine oil as described in the

owners manual. Never attempt to start the

engine without rst replacing the engine oil with

the proper amount and grade as described in the

owners manual.

Gas and Oil

Gas Tank

Oil Tank

Baja BLASTER 6.5 Setup Instructions

Baja BLASTER 6.5 Setup Instructions

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