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
Overloadingcouldbe hazardous.
Overloadingcouldcausechangesin vehiclehandlingandcouldleadtoan
accident.
Neverexceedthestatedloadcapacityfor thisGo-kart.
OperatingthisGo-kartwithimproper modificationscouldbehazardous.
Improperinstallationofaccessoriesor modificationstothisvehiclemay
causechangesinhandling.Insomesituations,thiscouldleadtoan
accident.
NevermodifythisGo-kartthroughimproper installation oruseof
accessories.
ChecktheconditionoftheGo-karttomakesurethattheGo-kartdoesnothave
mechanicalproblemsoryoucouldgetstrandedwhenyouride. Beforeriding
theGo-kart,besuretochecktheaboveitems. BesureyourGo-kartisingood
conditiontoensurethesafetyoftherider.
Checkingmaintenanceitemswhentheengineisrunningcouldbe
hazardous.
Youcouldbeseverelyinjuredifyourhandsor clothinggetcaughtin
movingGo-kartparts.
Shuttheengineoffwhenperformingmaintenancechecks,except
checkingtheenginestopswitchandthrottle.
18
ADOTapprovedmotorcyclehelmetisthemostimportantpartofyou safety
gear.ADOTapprovedmotorcyclehelmetcanhelppreventa serioushead
injury. Choosea helmetthatfits snugly.Motorcycledealerscanhelpin
selectinga goodquality helmetwhichfits properly.
OperatingthisGo-kartwithoutwearinganapprovedDOTmotorcycle
helmet,eyeprotection,andprotectiveclothingcouldbehazardous.
OperatingwithoutanapprovedDOTmotorcyclehelmetoreyeprotection
increasesyourchancesof asevereheadinjuryordeathinanaccident.
Operatingwithoutprotectiveclothingalsoincreasesyourchancesof
severeinjuryinanaccident.
AlwayswearanapprovedDOTmotorcyclehelmetwhichfits properly.
Alwaysweareyeprotection(gogglesorfaceshield).Youshouldalso
weargloves,boots,longsleeveshirtorjacket,andlongpants.
Youshouldweareyeprotectionwhenyou ride. Ifa rockora branchhitsyour
eyes,you couldbeseverelyinjured.Weargogglesora face shield.
Wearproperclothingwhenyou ride. The properclothescanprotectyoufrom
injury.Wearagoodpairofgloves,strongbootsthatareovertheankle,long
pants,anda longsleeveshirt.
19
Thefirst monthisthemostimportantinthelifeofyourvehicle. Proper
operationduringthisbreak-inperiodwillbehelpfulfor assuringmaximum
lifeandperformanceofyournewvehicle. Thefollowing guidelinesexplain
properbreak-inprocedures.
MaximumThrottleOpeningRecommendation
Duringthefirst 10hoursofoperation,youshouldalwaysuselessthan1/2
throttleopening.
VarytheEngineRotatingSpeed
Varytheenginerotatingspeedduringthebreak-inperiod.Thisallowsthe
partsto "load" andthen"unload" (allowingthepartsto cool).Althoughitis
essentialto placesomestressontheenginecomponentsduringbreak-in,
youmustbecarefulnottoloadtheenginetoo much.
AvoidConstantLowRotatingSpeed
Operatingtheengineat constantlowrotatingspeed(lightload)cancause
partsto glazeandnotsealproperly.Allowtheenginetoacceleratefreely
withoutexceedingthemaximumthrottlelimit.
AllowtheEngineOilto CirculateBeforeRiding
Allowenoughidlingtimeafterwarmor coldenginestarting.Thisallowsthe
lubricatingoiltoreachall criticalenginecomponents.
ObserveYourInitialandMostCriticalService
Theinitialservice(break-inmaintenance)isthemostimportantservicethat
yourvehiclewillreceive.Observinga properbreak-inoperation,willhelp
enginecomponentssealproperly.Maintenancerequiredas partofthe initial
serviceincludesproperadjustments,tighteningofall bolts&nuts,and
replacementofdirtyoil. Timelyperformanceofthisservicewillhelpyouget
thebestservicelifeandperformanceoftheengine.
20
The drive select lever shifts the Go-kart
in either forward or reverse
ToshiftGo-kartineitherforward or reverse:
1. Releasethrottle
2. Apply brakescomingtoa completestop.
4. Shiftleverdowninthereverseposition
5. Checkfor peopleorobstaclesbehindyou.
6. Depressthethrottlepedalgradually
continuingtowatchtotherearwhile
backing.
I
Notlookingbehindvehiclebeforeandwhilegoinginreversecouldbe
hazardous.
Failureto lookbehindwhilebackingcouldcausetheGo-kartto runinto
anobstacleorpersonresultinginaninjury.
Beforegoingin reverseandwhilebacking,lookbehindthevehiclefor
anyobstaclesorpeopletoavoid.
Drive select leveradjustment
1. Pressdownthelevertothe"D"
positionsothattheunitcanmove
forward.
2 Pullbacktheleverto"R"sothatthe
unitcanmovebackward.
3. AdjustingNut#1attheendofthe
cablecanadjustthemeshstatusin
sidethegearbox;rotatethenutto
adjustthecable,andmakesurethat
thecableisn'ttootightor tooloose.
4. AdjustNut#2accordingly.
Nut#2
Nut#1
21
Nevermakeunnecessaryadjustments.Themanufacturerrecommended
settingsarecorrectfor mostapplications.Youwillneeda tachometertomake
someoftheadjustments.Thisshouldonlybeperformedbya trained
mechanic.
Idlescrew
1. Warmuptheenginefor about5-10minutes.
2. Connectthetachometer,andadjustthethrottleidlespeed
(standardvalueis 1700RPM).
3. TurntheIdlescrewcounter-clockwiseslowlyand observetheRPMofthe
engine,andstopadjustingasthe RPMofenginereachescorrectspeed.
22
CHAINADJUSTMENT
Checkthechainadjustmentafterthefirst twohoursof
use.Readjustif ithasmorethan1/2"flex.
Nut#2
3/8"-1/2"
Nut#1
1. LoosenNuts#1.
2. TurnNut#2 clockwisein 1/2turnincrements,thenturnNut#1 untilit
becomestight.
3. Repeattheabovestepsuntil chainisadjustedtothedesiredtension.
FRONTSHOCKADJUSTMENT
Therearefive adjustablepositionsonthefront shock.Thedefaultpositionis
inthemiddleset bythemanufacturer.
Usea roundnutwrenchasyouadjusttheshock.Thetensionofshockspring
willincreaseasyouscrewtotheleftanddecreaseasyouscrewtotheright.
Spring
adjustment
cam
23
Itisveryimportantto inspectandmaintainyourGo-kartregularly.Followthe
guidelinesinthechart. Theintervalsbetweenperiodicservicesin monthsare
shown.Attheendofeachintervalbesuretoperformthemaintenancelisted.
1WEEK MONTHLY QUARTERLY YEARLY
I L I
C C I I
* I A I A
* C I R
* I I I
During running-in period, replace every 150 miles.
After running-in period, replace every 600 miles.
ITEMS
Fuellines
Aircleaner
Throttlecontrols
Sparkplug
Valveclearance
Engineoil
Gearboxoil
Filterscreenof
engineoil
Carburetor
Drivechain
Battery
Brakeshoe
Brakesystem
Electricparts
Bolt,nuts,
fasteners
Gearin gearbox
Fueltank
Tirepressurewear
Steeringsystem
Chassis
* C C I I
* C C C C
I A L
* I
* I
I
I
L I
* I I
I I
* I
* A
L I
Note:
1.A-adjust; C-clean; I- inspect,cleanor replaceifnecessary;
L-lubricate; R-replace
2.The itemswith "*" mustbeinspectedandrepairedbyprofessionals.Ifyou
yourselfarea professionalpleasefollow thisownersmanualand choose
qualified tools.
3.Drivinginunusuallydusty,sandyorrockyareasrequiresmorefrequent
services.
24
Improper maintenanceorfailing toperformrecommendedmaintenance
couldbehazardous.
Ifyouperformimpropermaintenanceor donot maintainyourGo-kart
youmayhaveanaccident.
KeepyourGo-kartingoodcondition.Askyourauthorizedservice
centerora qualified mechanictodothemaintenanceitemsmarked
withanasterisk(*). Youmayperformtheunmarkedmaintenanceitems
byreferringtotheinstructionsinthissectionifyouhavemechanical
experience.Ifyou arenotsurehowtodo themaintenanceaskyour
authorizedserviceor callBajaMotorsports.
__CAUTION
If you useyour Go-kart under severeconditions,it will need
maintenancemoreoften thanshownin the chart.
OperatingyourGo-kartundersevereconditionscausesmorewearonyour
Go-kart.Severeconditionsincludeoperatingunderfrequentfullthrottle,or
industy,wet,sandy,ormuddyareas.TheseconditionscouldcausetheGo-
karttowearmorequickly.
Performmaintenancemoreoftenthanshowninthechart. Ifyou have
anyquestions regardingmaintenanceintervals,consultyourauthorized
servicecenteror callBajaMotorsports.
,_CAUTION
Using poorquality replacementpartscoulddamageyourGo-kart.
Poorly-madereplacementpartscouldcauseyourGo-karttowearmore
quickly andshortenitsusefullife.
Whenreplacingpartsonyourvehicle,useonlygenuinereplacement
partsor theirequivalent.
25
BATTERYINSTALLATION
INITIALSERVICEAND INSTALLATIONOF BATTERY:
EyeProtection
RubberGloves
Thefollowing procedureisverydangerousandshouldbeperformed
withtheutmostcareandattention.Wearprotectiveeyewear,rubber
gloves,andhavewateravailableshouldelectrolytecomeincontactwith
skinoreyes.KEEPALLCHILDRENAWAYFROMTHEAREAWHILETHIS
PROCEDUREISBEINGPERFORMED.
POISON- CAUSESSEVEREBURNS
Containssulfuricacid.
Avoidcontactwithskin,eyes,orclothing
Topreventaccidents,rinseemptycontainerwithwater.
ANTIDOTE:
External- flush withwater
Internal- Callphysicianimmediately.Drinklargequantities ofwateror
milk.
Followwithmilkofmagnesia,beateneggsorvegetable.
Eyes- Flushwithwaterfor 15minutesandgetpromptmedicalattention.
KEEPOUTOFREACHOFCHILDREN.
26
Preparingthe battery:
Placebatteryon levelsurface.Removecap
stripfrom topofbattery.(seefigure 20)
Weareyeprotectionandrubberglovesfor
thisstep. Oncebatterystripisremoved,
locateelectrolyteinbottleandplaceoverthe
sixopenings.Pressfirmly downon bottle
allowingthebatterytopiercethesixin-line
openingsin bottle. Letelectrolytedraininto
batteryuntilbottleiscompletelyempty. (see
figure 21)
Discardemptyelectrolytecontainerina waste
areathatisinaccessibletochildrenand
animals.
Afterfilling letbatterystandfor atleast30
minutesbeforecharging.Thisallowsthe
electrolytetopenetrateplatesfor optimum
performanceandensureslongerbatterylife.
Figure20
Figure21
After30minutesthebatteryisreadyfor its
initialcharge.Placecapslooselyover battery
cellholes(seefigure 22)
27
Figure22
Howto Initially Charge the battery:
.
,
.
Connecttheredpositive(+) cabletothe
redpositive(+) poleofthebattery.
(seefigure24)
Connecttheblacknegative(-) cabletothe
blacknegative(-)poleofthebattery.(see
figure 25)
Note:Theredpositive(+) cablehasa
largerdiameterthantheblacknegativey
cable.
Chargingrate:Chargebattery@ 0.7Amps
for 5 ~ 10 hours.
• After chargingiscomplete,install
securelyall sixbatterycaps(see
figure 26)
• Installbatteryintobatterytraylocated
behindseat(seefigure 27).
• Oncebatteryisfirmly seatedintray,
attachredpositive(+)wiretopositive
(+)terminalonbattery,thenattachblack
negative(-)wiretonegative(-)terminal
onbattery(seefigure27)
• Attachcoveroverbatteryusingrubber
strapprovided(seefigure 28)
Rubberstrap
NEVERREMOVETHESTRIPOFCAPS
NORADDANYWATERORELECTROLYTE.
Figure24
Figure25
Figure26
Figure27
Figure28
28
Removeoldbatteryfrom underseat. Thebatterystrapwill needtobe
removed. Markwhichcableisconnectedtothepositiveterminal(+)and
whichcableisconnectedtothenegative(-) terminal.
Cleancableconnectorswithwire brushor sandpapertoremoveoxidation.
Aftercharging,installnewbattery.Putdielectricgreaseon thebattery
terminalstoavoidcorrosion.Connectcablestotheproperterminals.
PositivecabletopositiveterminalA and negativecabletonegative
terminaly.
Positive(+)cableisredand largerindiameter.Negativey cableisblack
andsmallerofthetwoindiameter.CONNECTNEGATIVECABLELAST.
Torqueterminalboltsto40 in./ Ibs.
Securelyfasten batterytothevehicleusingmetalbatterystrap.
DONOTopensealedcapsto addwatertobattery.
Alwayswearsafetyglassesand chargeina ventilatedarea.
Ifbatterygetshottothetouch,discontinuechargingandallow
batteryto
cooldown.
Donotusefast chargingunlessitisanemergency.
Atthebeginningorendofcharging,turnoffthechargerfirst, inorder
topreventelectricsparkandexplosion.
Chargeinawellventilatedarea.
DONOTsmokearoundbatteriesandkeepawayfrom openflame.
Toavoidpossibilityofexplosion,alwaysconnectbatterycablein
theorderspecified:REDfirst; BLACKlast.An explodingbatterycan
causeseriousinjuryor death.
Batteriescontainsulfuricacid.
Alwaysshieldeyeswithprotectiveeyewearwhenworkingaround
batteryacid.
Batteryacidispoisonousandcancausesevereburns.
DONOTsmokearoundbatteriesandkeepawayfrom openflame.
29
Tocheck oil level:
1. Parkvehicleon levelground.
Oilcapanddipstick
2. Removedipstickandwipeoffwitha cleanrag. Insertthedipstickinthe
filler hole.
3. Removethedipstickand inspecttheoillevel.
4. Oil levelshouldbe inbetweentheLowerindexlineandUpperindexline
marksonthedipstick.
5. Addoilifoilisbelowlowermarkon dipstick. DoNotfill aboveuppermark.
Referto page10 for correctengineoiltype.
Engine oil replacement:
Theengineoilshouldbechangedevery20to40 hoursofoperation.Itshould
bechangedmoreoftenindirtyanddustyareas.
1. Parkvehicleon levelground.
2. Removeengineoildrainbolt(locatedonbottomleftsideofengine).
3. Drainoil intoa catchbasinanddisposeofproperlyat anoilreclaimfacility.
Engine oil drain bolt
30
Cleaning oil filter
1. Drainengineoilas instructedonpage30.
2. Removeoilfilter plug(locatedon bottomleftsideofengine.
3. Removescreenfilter andspringassembly.
4. Cleanscreenwithsolvent.
5. Re-installfilter andrefillwith lqt. oil(refertopage10for correctengineoil
type.
Spring Strainer
Drainingtransmissionoil
1. Draintransmissionoilbyremovingtransmissionoildrainbolt(located
onthebottomleftoftransmission).
2. Drainoilintoa catchbasinanddisposeof properlyat anoilreclaim
facility.
Addingtransmission oil
1. Addtransmissionoilbyremovingtransmissionoilfill bolt(locatedon
bottomleftoftransmission).
2. Add8oz 80W-90gearoil.
Transmissionoilfill bolt
Transmissionoildrain
bolt
31
Newandusedoilcouldbehazardous.
Childrenandpetsmaybeharmedbyswallowingnewor usedoil.
Continuouscontactwithusedoilcancauseskincancerinlaboratory
animals.Briefcontactwiththeusedoilmayirritatetheskin.
Keepnewandusedoilawayfrom childrenand pets. Tominimizeyour
exposureto usedoil,weara long-sleeveshirtandmoisture-proofgloves
(suchasdishwashinggloves)whenchangingoil. Ifoilcontactsyour
skin,washthoroughlywithsoapandwater. Launderanyclothingor
ragsifwetwithoil. Recycleor properlydisposeofusedoil.
__ CAUTION
FailuretousethecorrectoilcouldharmyourGo-kart.
BesuretousetheoilspecifiedintheFUELANDOILRECOMMENDATION
section.
_, CAUTION
Runningthe enginewithout an adequateamount of engineoil could
causesevereenginedamage.
Runningthe enginewithout anyengineoil couldcauseengine
overheating.
Alwayschecktheamount of engineoil beforestartingthe engine.
32
Theair filter elementmustbekeptcleantoprovidegoodenginepower, ifyou
useyourvehicleundernormalconditions,youshouldservicetheairfilter at
theintervalsspecified.Ifyou rideindusty,wet,or muddyconditions,youwill
needtoinspecttheair filter elementmuchmorefrequently. Usethefollowing
procedurestoremovetheelementto inspectandclean.
AIR FILTERREMOVAL
Cover AirFilter
1. LocateAirFilterBox at rearof Go-kart
and removecover.
2. Removefoam filter element
3. InspectAirFilterelementfor tearsor
cracks, ifair filter isdamaged,replace.
4. Washandoilairfilter element.
5. Reinstallairfilter andclose
cover.
Airfilter element
Washing and oiling the filter element:
1.Washairfilter elementwithwarmsoapy
water,thenrinse.
@
@
2.Squeezetheelementbypressingit
betweenthepalmsofbothhandsto
removeexcesswater(A). Donottwist
orwringtheelementor itwilldevelop
cracks.
3.Immersetheelementina panfilled with
Airfilter oil(B). Squeezetheelementto
removeexcessoil. Makesurethatthe
elementremainsdampwithoil(butnot
soaked).
33
Operatingtheenginewithouttheairfilter elementinplacecouldbe
hazardous.
If theair filter elementdidnotfilter dirt,severeenginedamagewould
occurifthedirtenteredtherunningengine.
Neverruntheenginewithouttheair filter elementin place.
_CAUTION
Failing to inspect theair filter elementfrequently if the vehicle is used in
dusty, wet,or muddy conditionscoulddamageyour Go-kart.
Theairfilter elementcouldbecomecloggedundertheseconditions,and
enginedamagemayresult.
Alwayschecktheairfilter elementafterridinginsevereconditions.
Cleanor replacetheelementsasnecessary.Ifwatergetsintheairfilter
case,immediatelycleantheelementandtheinsideofthecase.
__CAUTION
Atorn airfilter coulddamageyourGo-kart.
Dirtanddustmaygetinsideoftheengineiftheelementistorn.
Examinecarefullytheelementfor tearsbeforeandaftercleaningit.
Replacetheelementwitha newone ifitistorn.
_,CAUTION
Failing to position theair cleanerelementproperly coulddamageyour
Go-kart.
Airwillbypasstheair cleanerelementiftheelementisnotpositioned
properly.Thiswillcausetheenginepartstowearmorerapidly.
Besuretopositiontheaircleanerelementproperly.
34
NOTE:ThisGo-Kartusesresistor-typesparkplugtoavoidjamming
electronicparts. Impropersparkplugselectionmaycauseelectronic
interferencewithyourKartsignitionsystem,resultinginvehicleperformance
problems.Userecommendedsparkplugs.
Toinstalla sparkplugturnitinas far aspossiblewithyourfingers, then
tightenitwithawrench.
Ak CAUTION
ImproperinstallationofthesparkplugcoulddamageyourKart.
Anoverlytightorcrossthreadedsparkplugwilldamagethealuminum
threadsofthecylinderhead.
Carefullyturn the sparkplugby handinto thethreads. Ifthe sparkplug
isnew,tightenitwithawrenchabout1/2turnpastfinger tight. Ifyou are
reusingtheoldsparkplug,tightenitwitha wrenchabout1/8turnpast
finger tight.
,_CAUTION
Dirt coulddamageyourkart ifit enteredanopensparkplug holeof cylinder
head.
Dirt coulddamageengine parts that move.
Coverthe sparkplug hole while thesparkplug isout of the hole.
Spark plugtypes
MeijaA7RTC, NGK CR7HS,
Champion RZl0YC
Tomaintaina properfunctioning sparkplug,keepthe plugfreeof carbon.
Removecarbonfrom theplugwitha wireor pin,andadjustthegapto0.24
- 0.28inch(0.6~0.7ram)for goodignition.Usea thicknessgaugeto checkthe
gap.
35
The Go-kart isequippedwith low pressuretubeless tires ofthe
size listedbelow:
Front Rear
Size 19x7-8 22x10-10
OperatingthisGo-kartwith impropertires,orevenimpropertireair
pressurecould
behazardous.
Ifyouuseimpropertiresorimpropertireairpressure,youmaylosecontrol
oftheGo-kart.
Alwaysusethesizeandtypetiresspecified.Alwaysmaintainpropertire
air pressureas describedinthissection.
Tire TreadCondition
,_,.i_3.0 mm(0.12in)
_,--_ _ J _--S _>_-_<o- i
.Ji \_,.
ii ;
,_CAUTION
Usingworntirescouldbehazardous.
Thetractionofthevehiclewillbedecreased.Thisincreasesyourriskofhavingan
accident.
Replacethefrontandreartireswhenthedepthonthetreadis4.0mm(0.16in)orless.
TireAir Pressure
Checktheairpressurein alltiresbeforeriding. Improperair pressurewould
effecthandling,steeringresponse,traction,tirelifeandridercomfort.Be
surethatthetiresareinflatedtothepressuresshownbelow.Tirepressure
shouldonlybemeasuredor adjustedwhenthetiresarecold.
Recommendedpressure
Front 96kpa(14psi)
Rear 96kpa(14psi)
36
Overfillingtheairtothetirescouldbehazardous.
Ifyouputtoomuchair intothetire,mayburst,andcausingsevereinjury.
Checktheair pressurefrom timetotimewhileinflatingthetiregradually,
untilthespecifiedairpressureisobtained.
Tire Replacement
YourGo-karthaslow-pressuretubelesstires. Airissealedbythecontact
surfacesoftheinnerwheelrimandthetirebead. Iftheinnerwheelrimor
tire beadisdamaged,air mayleak. Beextremelycarefulnotto damagethese
sectionswhenreplacingtires.
It isveryimportanttousethepropertoolswhenrepairingor replacingtires
inordertoprotectthetirebeadorwheelrims. Havethisworkdonebyyour
authorizedservicecenteror a qualified tirerepairstation.
Whenbreakingthetirebeadloosefrom thewheel,beextremelycarefulnotto
damagetheinnerwheelrimsurfaceorthetirebead.
Usingtiresthathavebeeninstalledincorrectlycouldbehazardous.
TheGo-kartmayhaveunusualhandlingifthetiresareinstalled
incorrectly.
Thetiresareintendedtorotateina specificdirection,asindicatedbythe
arrowsonthesidewallofeachtire. Installtirescorrectlysotheyrotatein
theproperdirection.
TubelessTire Repair
Ifa leakorflat tire occursduetoa puncture,thetiremayberepairedusing
a plugtypepatch.Ifthedamageisfrom a cut,or ifthepuncturecannotbe
repairedusinga plug,thetireshouldbereplaced.WhenoperatingyourGo-
kartinareaswheretransportationorservicefacilities arenotreadilyavailable,
itisstronglyrecommendedthatyoubringa plugtyperepairkitanda tireair
pumpwithyou.
37
The Go-karthas Hydraulic disk brakes on all fourwheels.
FailingtoinspectandmaintainyourGo-kart'sbrakesystemproperly
couldbehazardous.
Impropermaintenanceofthebrakeincreasesyourchanceofhavingan
accident.
Besureto inspectthebrakebeforeridingaccordingtotheINSPECTION
BEFORERIDINGsection. Alwaysmaintainyourbrakesaccordingto the
MAINTENANCESCHEDULE.
OperatingtheGo-kartin harshconditionscouldbehazardousifyou do
notinspectbrakewearoften.
Operatingin mud,water,sand,orotherextremeconditionscancause
acceleratedbrakewear. Thiscouldleadtoanaccident.
Ifyouoperateyourvehicleundertheseconditions,thebrakemust
beinspectedmoreoftenthanrecommendedintheMAINTENANCE
SCHEDULE.
38
Brakefluid reservoir
Brakefluid cap
Brakefluid level
Brakehose
Frontdiskbrake
caliper
Brakedisk
Brakehose
1.
,
3.
.
Brakehose
Brake
Reardisk
Disk
brakecaliper
Inspectfront andreardiskbrakecalipersfor leakage.If brakefluid
leaks,thesafetyofridingcouldbeaffected.
Inspectthebrakehosefor cracks,andthejointfor leakage.
Checkthebrakefluid levelin thebrakefluid reservoir,iflevelisat
or belowtheLOWERmark,inspectbrakepadsfor wearandhydraulic
systemfor leaks.
Toaddbrakefluid, unscrewscrewsontopofthebrakefluid
container.AddDOT3or DOT4brakefluid. Donotmixbrakefluid types.
Failingto maintainthebrakeshoesor padscouldbehazardous.
Ridingwithwornbrakeshoes,pads,or shoesthatareseriouslyworn,
willincreaseyourchanceof havinganaccident.
Ifyouneedtoreplacebrakeshoepads,haveyourauthorizedservice
centerdothework. Inspectingandmaintainingthebrakeshoepadsis
recommended.Replacetheshoepadsinsets.
39
Thefollowing informationisprovidedtohelpyouidentifyprobable
questionsyou mayhaveconcerningtheoperationofyou Go-kart.See
yourauthorizedservicecenterwithanyadditionalquestionsyou may
have.
I No fuel
I
IRep'en'shfue'I
I
[c,oggedfue,fi,terl
Engineturns overbutfailsto start
On'O'"'psw"chI,no_po,,onIWa'er'n'ue'I ISparkp'u0I,
IOra'ns_"e_I r_°s_ar_'°lsoar_o,uo
I nginecompressionI
155Ibs
I
J Nocompression
/\
IContact service center I
Enginestops or loses power
No fuel
I
Replenish fuel
I
Fuel vent line kinked 01
plugged
I
I Waterin fuel I
l
Drainsystem
I Sparkplugfouled I
I
i A'rf"terc'oggedi
I
iExhaustc'oggedi
I Engine overheated I
I
IO,°anraO,a,orscr°°ni
I
I Clean engine exterior I
ontact service center I
40
1.Removethesparkplugandreattachittothesparkpluglead.
2. Turnignitionkey to the"RUN" position. Slidetheenginestopswitchtothe
"Run" position.Push theelectricbutton"START"(grey button).Applytherear
brakeleverto makesuretherearwheelsare locked. Iftheignitionsystemis
operatingproperly,abluesparkshouldjump acrossthesparkpluggap. Ifthere
is nospark,takeyour machinetoyour servicecenter.
Performingthesparktestimproperlycouldbe hazardous.
Youcouldgeta highvoltageelectricalshockifyouarenotfamiliarwiththisprocedure.
Donotperformthischeckifyou arenotfamiliar withthe procedure.Donotpoint
thespark plugnearthe sparkplugholeduringthis test. Donotdothistest ifyou
havea heartconditionorweara pacemaker.Donotperformthistestisanynear
anyopenfuel containersfor nearfuel whichhasspilledonthe ground,onthe
engine,or anypartof theGo-kart.
COMPLAINT:Enginestalls
1. Makesurethereisenoughfuel inthefuel tank.
2. Checkto seethatthesparkplugisnotfouled. Removethesparkplugandclean
it. Replaceit,if necessary.
3. Makesurethefuel valveisnotclogged,andthefuel tankis notclogged,either.
4. Checkthe idlespeed. Ifnecessary,adjustitusinga tachometer.The correctidle
speedis1400-1600 r/rain.
41
It is bestto transport the Go-kart inthe normalposition.
Drainscrew
BeforetransportinqtheGo-kartdrainthefuel from thecarburetorasfollows:
1. Drainfuel from carburetorintoanemptycontainerbylooseningthe
carburetordrainscrewlocatedon bottomofcarburetor.
2. Whenthefuel hasbeendrained,retightenthedrainscrew.
Drainingfuel from thecarburetorcouldbehazardous.
Fuelcouldcatchfire ifyoudonot handleitproperly.
Whendrainingfuelfromthecarburetor,besuretoshuttheengineoff. Do
notsmoke,andneverdrainorrefuelinanareawherethereareopenflames
orsparks.Donotspillthefueloryoumaycreateafire hazard.Disposeof
thedrainedfuelproperly.
_1=CAUTION
FailingtosecuretheGo-kartproperlycouldbehazardous.
Failingtosecurethevehicleproperlymayresultinanaccidentor
damagetothevehicle.
WhentransportingtheGo-kart,locktheparkingbrakeleverandtie
downthevehiclesecurelywithstraps,rope,or someothersuitable
means. Useextratiedownswhenyoutransportthevehicleinthe
standingposition.
42
AthoroughcleaningofyourGo-kartisa necessarypartofmaintenance.Itwill
helpkeepyourGo-kartlookingandperformingbest. Propercleaningcanalso
extendthelifeofyourGo-kart.
Itisimportantto cleanandinspectyourGo-kartaftereveryride,especiallyif
itisusedinmud,brush,grass,water,saltwater,or verydustyconditions
Thebuild-upof mud,brush,grass,etc.especiallyontheengineandexhaust
system,canreduceenginecoolingability,concealdamage,or increasewear
ofcertainparts. Itisimportantto removealldebrisduringcleaning.
PREPARATIONFOR CLEANING
WashtheGo-kartbeforeanymuddriesontheGo-kart.
Blockor sealtheendoftheexhaustpipe(muffler)andairfilter usinga piece
ofplasticwrap,clothragoranothermethodto preventwaterfrom entering
engine.
__ CAUTION
HighpressurewasherscoulddamageyourGo-kart.
Highpressurewasherssuchasthosefound at coin-operatedcar
washeshaveenoughpressuretodamagethepartsofyourGo-kart.It
maycauserust,corrosionand increasewear.
DonotusehighpressurewasherstocleanyourGo-kart.
43
Withsomecare,yourGo-kartcanbewashedina similarmannertowashing
anautomobile.
Note: Avoidsprayingorallowingwatertoflow overthefollowing places:
• Ignitionswitch
• Sparkplug
• Fueltankcap
• Carburetor
• Airfilter
Usea gardenhoseat low pressuretoremovethemajorityofdirtor other
debris. HandwashyourGo-kartwithmildsoapordetergentandwater. Try
tothoroughlyremovealldirtanddebriswithoutexcessivewaterpressure,
evenat remoteareassuchas betweenenginecoolingfins, linkagesor
mountingbrackets.Clothrags,washingmittsor cleaningbrushescan
beused. Becarefulwithbrushesastheymayscratchplasticorpainted
surfaces.RinsetheATVthoroughlywith cleanwater. Dryall areasusinga
chamoisorsoftabsorbentcloth.
INSPECTIONAFTERCLEANING
FollowtheproceduresintheINSPECTIONBEFORERIDINGsectiontocheck
yourGo-kartfor anyproblemsthatmayhaveoccurredduringyourlastride.
OperatingtheGo-kartwithwetbrakescouldbehazardous.
Wetbrakesmaynotprovideas muchstoppingpoweras drybrakes.
Thiscouldleadtoanaccident.
TestyourbrakesafterwashingtheGo-kart,ridingat a slowspeed. If
necessary,applybrakeseveraltimestoletthefriction dryoutthe linings.
44
If youdo notplanon usingyourGo-kartfor anextendedperiodof time,the
kartwillneedspecialservicerequiringappropriatematerials,equipmentand
skill. Forthisreason,we recommendthatyoutrustthismaintenanceworkto
yourauthorizedservicecenter.Ifyouwishtoservicethemachinefor storage
yourself,follow thegeneralguidelinesbelow:
VEHICLE
Placethevehicleon levelgroundandwashtheentirevehicle.
FUEL
Drainthefuel from thefuel tankbya handpump. Drainthefuel from the
carburetorbyreleasingthecarburetordrainscrew.
Drainingthefuel couldbehazardous.
Fuelcouldcatchfire ifyoudo nothandleitproperly.
Whendrainingthefuelfromthefueltank,besuretoshuttheengineoff.
Donotsmoke,andneverdrainfuelinanareawherethereareopenflames
orsparks.Keeppetsandchildrenawayfrom thefuel,anddisposeofthe
drainedfuelproperly.
TIRES
Inflatetirestothenormalpressure.
EXTERNAL
1. Sprayallvinylandrubberpartswithrubberprotection.
2. Sprayunpaintedsurfaceswithrustpreventative.
3. Coatpaintedsurfaceswithcarwax.
PROCEDUREFORRETURNINGTOSERVICE
1. Cleantheentirevehicle.
2. Makesurethatthevehicleisproperlylubricated.
3. PerformtheINSPECTIONBEFORERIDINGaslistedinthismanual.
4. Startthevehicleasoutlinedinthismanual.
45
Youneedto knowtheframe andengineserialnumberstogettitledocuments
for yourGo-kart.Youalsoneedthesenumberstohelpyourauthorized
servicecenteror BajaMotorsportsorderparts.
The Framenumberisstampedontheframe behindseat. Theenginenumber
islocatedontheleftsideoftheenginehousing.
Engineserial
Framenumber number
Writedowntheserialnumbersherefor yourfuture reference
FrameNo.:
I
EngineNo.:
I
46
DIMENSIONS
Overalllength..............................................................................................93.5in.
Overallwidth...............................................................................................54.75In.
Overallheight..............................................................................................60in.
Wheelbase...................................................................................................74in.
Groundclearance.......................................................................................5.75in.
Dryweight ..................................................................................................515Ibs.
ENGINE
Model.............................................................................................................DZ1P57QMJ
Type.............................................................................................................ForcedAir-cooled,single
cylinder,4-Stroke
Displacement..............................................................................................149.6cc
BoreX Stroke..............................................................................................57.4mmX 57.8mm
Max power.....................................................................................................9.2hp/ 7500rpm
MaxTorque...................................................................................................7.75Ib-ft/ 6500rpm
Idlespeed......................................................................................................1700+100rpm
Mainfueltankcapacity......................................................................................1.5gallons
EngineOil............................................................................................................850ml(0.9qt)
Startingtime..................................................................................................<15s
Climbing.........................................................................................................>20°
Topspeed.....................................................................................................35 mph
AccelerationNoiselevel.............................................................................Custom-engineered
Batterytype,voltage,capacity..........................................................................12N14-BS/12V8Ah
Fuse.....................................................................................................................15A
CHASSIS
Front/Rearbraketype..........................................................................................HydraulicDisc,Footcontrol
Fueltype...............................................................................................................#90orabove(unleaded)
Lubricateoiltype..................................................................................................SAE10W/30SF
Lubrication............................................................................................................Force&Splash
Cooling..................................................................................................................ForcedAir-cooled
Ignition..................................................................................................................C.D.I.
Starting..................................................................................................................Electric
Sparkplug.............................................................................................................A7RTC
Sparkpluggap......................................................................................................0.6-0.7ram
Transmission.........................................................................................................Chaindrive
TransmissionRatio...............................................................................................F1:1R1:1.45
Compressionratio.................................................................................................9.5:1
Shockabsorber.....................................................................................................Spring&Dampingtype
FrontSuspension...................................................................................................ExtendeduprightdualA-arm
TIRES
SizeFront...............................................................................................................19x7-8
SizeRear...............................................................................................................22x10-10
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BAJAINC.- EMISSIONCONTROLSYSTEMWARRANTY
YOURWARRANTYRIGHTSANDOBLIGATIONS
Theemissioncontrolsystemwarrantyperiodfor thisvehiclebeginson the
datethevehicleisdeliveredtothefirst purchaserotherthananauthorized
dealer,orthedateit isfirst usedasa demonstrator,lease,or company
vehicle,whichevercomesfirst andcontinuesfor 60monthsafterthatdate,or
5,000kin,whichevercomesfirst, providedtherehasbeennoabuse,neglector
impropermaintenanceofyourvehicle.Whereawarrantableconditionexists,
theDistributorwillrepairyourvehicleat nocosttoyou,includingdiagnosis,
partsandlabor.Ifanemission-relatedpartonyourvehicleisdefective,the
partwillberepairedor replacedbytheDistributor.Thisisyouremission
controldefectswarranty.
OWNER'SWARRANTYRESPONSIBILITIES
Asthevehicle owner,youareresponsiblefor the performanceoftherequired
maintenance.Youshouldmaintaina recordofall maintenanceperformedon
yourvehicleandretainall receiptscoveringmaintenanceonyourvehicle.
Youmaynotbedenieda warrantyclaimsolelybecauseofyourfailure to
ensuretheperformanceofallscheduledmaintenanceor lackofmaintenance
recordsor receipts.Youareresponsiblefor presentingyourvehicletoan
authorizeddealerassoonasa problemexists.Thewarrantyrepairsshouldbe
completedina reasonableamountoftime,nottoexceed30 days.
Asthevehicleowner,youshouldbeawarethatyoumaybedeniedyour
warrantycoverageifyourvehicleora parthasfailed duetoabuse,neglect,
impropermaintenance,or unapprovedmodifications.
WARRANTYCOVERAGE
The Distributorwarrantsthateachnew2009andlatervehicle:
• isdesigned,built,andequippedsoas toconformatthetimeofinitial
retailpurchasewithallapplicableregulationsoftheUnitedStatesEnviron-
mentalProtectionAgency,andtheCaliforniaAir ResourcesBoard;and
• isfree from defectsinmaterialandworkmanshipwhichcausesuch
vehicletofail to confirmwithapplicableregulationsoftheUnitedStatesEn-
vironmentalProtectionAgencyortheCaliforniaAir ResourcesBoardfor the
periodsspecifiedabove.
49
Youremissioncontrolsystemwarrantycoverscomponentswhosefailure
wouldincreaseanengine'semission,includingelectroniccontrols,fuel injec-
tionsystem,carburetor,theignitionsystem,catalyticconverter,oranyother
systemutilizedinthisvehicleto controlemissionifitisoriginallyequipped.
Alsoincludedmaybehoses,connectorsandotheremission-relatedassem-
blies. Replacingorrepairingothercomponents(includingparts,labor,and
othercosts)notcoveredbythisemissioncontrolsystemwarrantyor the
standardwarrantyistheresponsibilityoftheowner.
Coverageof repairsunderthiswarrantyappliesonlywhenrepairsarecom-
pletedat anauthorizeddealeror repairfacility. TheDistributorwillnotcover
repairsperformedoutsideofanauthorizeddealeror repairfacility. The useof
replacementpartsnotequivalentto theoriginalpartsmayimpairtheeffective-
nessofyourvehicle'semissioncontrolsystem. Ifsucha replacementpartis
usedandanauthorizeddealerdeterminesitisdefectiveor causesafailure of
awarrantedpart,yourclaimfor repairtobringyourvehicleintocompliance
withapplicablestandardsmaybedenied.
ThisEmissionControlSystemWarrantyisinadditiontothestandardLimited
Warranty.
EXCLUSIONSANDLIMITATIONS
Thiswarrantydoesnotcoverthefollowing:
• Failuresor malfunctionsoftheemissioncontrolsystemscausedby
abuse,alteration,accident,misuse,theuseofleadedgasoline.
• Replacementofexpendablemaintenanceitemsunlesstheyare
originalequipmentdefectiveinmaterialorworkmanshipundernormaluse,
andthefirstrequiredreplacementintervalfortheitemhasnotbeenreached.
Expendablemaintenanceitemsincludebut notlimitedtosparkplugs,filters,
coolant,lubricants,gaskets,hoses,andbelts.
• Replacementsofpartsandotherservicesandadjustmentsfor
requiredmaintenance.
• Anyvehicleequippedwithanodometerorhourmeterwherethe
readingisalteredsothatactualmileagecannotbereadilydetermined.
• Repairsor replacementsasa resultof:
oAccident
oMisuse
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oUseof replacementpartsor accessoriesnotconformingtothe
originalspecificationswhichadverselyaffectperformance
• Physicaldamage,corrosion,or defectscausedbyfire, explosionsor
similarcausesbeyondthecontroloftheDistributor.
• Failuresnotcausedbya defectin materialor workmanship.
Useofthevehicleinanytypeofcompetitiveracingorrelatedeventsimmedi-
atelyandcompletelyvoidsthisandall otherwarranties.
LIMITEDLIABILITY
TheliabilityoftheDistributorunderthisEmissionControlSystemWarranty
islimitedsolelytotheremedyingofdefectsinmaterialworkmanshipbyan
authorizeddealerat itsplaceofbusinessduringcustomarybusinesshours.
Thiswarrantydoesnotcoverinconvenienceor lossof useofthevehicleor
transportationofthevehicleto/fromtheauthorizeddealer.The Distributoris
notliabletoanypersonfor incidental,consequentialor specialdamagesof
anydescription,whetherarisingoutofexpressor impliedwarrantyorany
othercontract,negligenceorothertortorotherwise.
NoexpressemissioncontrolsystemwarrantyisgivenbytheDistributor
exceptasspecificallysetforth herein.Anyemissioncontrolsystemwar-
rantyimpliedbylaw,includinganywarrantyofmerchantabilityorfitness for a
particularpurposeislimitedtotheexpressemissioncontrolsystemwar-
rantytermsstatedin thiswarranty.Theforegoing statementsofwarrantyare
exclusiveandin lieuofallotherremedies.Allexpresswarrantiesnotstated
inthiswarrantyaredisclaimed.Somestatesdonotallowlimitationson how
longan impliedwarrantylasts,sotheabovelimitationsmaynotapplyif itis
inconsistentwiththecontrollingstatelaw.
Nodealerisauthorizedto modifythisEmissionControlSystemWarranty.If
youhaveanyquestions regardingyourwarrantyrightsandresponsibilities,
youshouldcontactBAJAINC.(888)863-2252.
51
0
Baja, INC.
P.O.Box 61150
Phoenix,AZ. 85082
Tel: 602-443-9180
Toll Free: 888-863-2252
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en otros idiomas
- English: Baja BR150-1 Owner's manual
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