Baja BR250 Owner's Manual

Text of Baja BR250 User Guide:

• Baja BR250, 22 Drive select lever adjustment: 1. Press down the lever to the “D” position so that the unit can move forward. 2 Pull back the lever to “R” so that the unit can move backward. 3. Loosen Nut #1 at the end of the cable. 4. Adjust Nut #2 accordingly to adjust the mesh status inside the gear box; rotate the nut to adjust the cable, and make sure that the cable isn’t too tight or too loose. 5. Make sure to re-tighten Nut #1 when adjustment is co

• Baja BR250, 42 1. Remove the spark plug and reattach it to the spark plug lead. 2. Turn ignition key switch CW (clockwise) to “ON” and push electric start button. Be sure the parking brake is set If the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is no spark, take your machine to your service center. COMPLAINT: Engine stalls 1. Make sure there is enough fuel in the fuel tank. 2. Check to see that the spark plug is not fouled. Remove the spark plug and clean it. Replace it,

• Baja BR250, 11 Read and follow all of the warnings labels on your Go-kart. Make sure you understand all the labels. Keep the labels on the Go-kart. Do not remove them for any reason. If a label comes off or becomes difcult to read, you should get a replacement by contacting Baja Motorsports. WARNING THIS GO-KART CAN BE HAZARDOUS TO OPERATE if driven carelessly INJURIES can result if you do not follow these instructions: -READ OWNER’S MANUAL AND ALL LABELS BEFORE YOU OPERATE THIS GO-KART. -NEVER OPERATE THIS GO-KART WITHOUT PROPER INSTRUCTIONS. Beginners require mature supervision. -NEVER OPERATE THIS GO-KART ON PUBLIC ROADS. it is

• Baja BR250, II Congratulations on your purchase of the Baja Inc. BR250/DN250 Go-Kart. It is warranted to be free of manufacturing defects in the material and workmanship for a period of 90 days from the date of purchase. During the warranty period BAJA, INC. will at its option, repair, provide replacement parts or replace your Baja Inc. BR250/ DN250 Go-Kart at no charge. This warranty does not cover normal wear items or damage caused by neglect or misuse of the product. Engine Warranty – 90 days Frame Warranty – 90 days Warranty is v

• 44 A thorough cleaning of your Go-kart is a necessary part of maintenance. It will help keep your Go-kart looking and performing best. Proper cleaning can also extend the life of your Go-kart. It is important to clean and inspect your Go-kart after every ride, especially if it is used in mud, brush, grass, water, salt water, or very dusty conditions The build-up of mud, bru

• Baja BR250, 33 Draining transmission oil 1. Drain transmission oil by removing transmission oil drain bolt (located on the bottom of transmission). 2. Drain oil into a catch basin and dispose of properly at an oil reclaim facility. Adding transmission oil 1. Add transmission oil by removing transmission oil ll plug (located on right of transmission). 2. Add 5 ounces of 80W-90 gear oil. Transmission oil ll plug Transmission oil drain bolt Running the engine without an adequate amount of engine oil could

• Baja BR250, 26 Improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your Go-kart you may have an accident. Keep your Go-kart in good condition. Ask your authorized service center or a qualied mechanic to do the maintenance items marked with an asterisk (*). You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience. If you are not sure how to do the maintenance ask your authorized service or call Baja Motorsports. If you use your Go-kart under severe conditions, it will need maintenance

• Baja BR250, 35 The air lter element must be kept clean to provide good engine power. If you use your vehicle under normal, low-tension conditions, you should service the air lter at the intervals specied. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air lter element much more frequently. Use the following procedures to remove the element and inspect it. AIR FILTER REMOVAL AND CLEANING 1. Locate Air Filter Box under rear rack on left side, remove cover. 2. Remove air lter. 3. Tap the Air lter element gently to remove most of the dust and dirt. Blow

• Baja BR250, 45 With some care, your Go-kart can be washed in a similar manner to washing an automobile. Note: Avoid spraying or allowing water to ow over the following places: · Ignition switch · Spark plug · Fuel tank cap · Carburetor Use a garden hose at low pressure to remove the majority of dirt or other debris. Hand wash your Go-kart with mild soap or detergent and water. Try to thoroughly remove all dirt and debris without excessive water pressure, even at remote areas such as between engine cooling ns, linkages or mounting brackets. Cloth rags, washing mitts or cleaning brushes can be used. Be careful with brushes as they may scratch plastic

• Baja BR250, 50 BAJA MOTORSPORTS – EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the rst purchaser other than an authorized dealer, or the date it is rst used as a demonstrator, lease, or company vehicle, whichever comes rst and continues for 60 months after that date, or 5,000km, whichever comes rst, provided there has been no abuse, neglect or improper maintenance of your vehicle. Where a warrantable condition exist

• 46 If you do not use your Go-kart for a long time, it will need special service requiring appropriate materials, equipment and skill. For this reason, we recommend that you trust this maintenance work to your authorized service center. If you wish to service the machine for storage yourself, follow the general guidelines below: VEHICLE Place the vehicle on l

• 18 INSPECTION BEFORE RIDING WARNING ! Failing to inspect the Go-kart before operating could be hazardous. Failing to perform proper maintenance could also be hazardous. Failing to inspect and maintain your Go-kart could increases the chances of an accident or equipment damage Always inspect your Go-kart each time before riding, and make sure it is in a safe operati

• Baja BR250, 17 RIDING YOUR GO-KART WHAT YOU SHOULD KNOW BEFORE RIDING Before riding, you should read all the following information carefully. If you are properly prepared, you will have a more enjoyable ride. Before riding, you should nd a good place to practice the skills. Find a at, open area with enough space to practice the new skills. Make sure that it is legal to ride in the area you selected. Review the local laws and make sure you are not trespassing. Call the police if you don’t know where you can ride. Protect your riding areas. When you are riding, remember to keep the

• Baja BR250, 36 A torn air lter could damage your Go-kart. Dirt and dust may get inside of the engine if the element is torn. Examine carefully the element for tears before and after cleaning it. Replace the element with a new one if it is torn. Failing to position the air cleaner element properly could damage your Go-kart. Air will bypass the air cleaner element if the element is not positioned properly. This will cause the engine parts to wear more rapidly. Be sure to position the air cleaner element properly. Failing to inspect the air lter element frequently if the vehicle is used in dusty, wet, or muddy conditions

• Baja BR250, 4 IMPORTANT RULES FOR SAFE OPERATION 1. This vehicle is not licensable. IT IS NOT TO BE OPERATED ON ANY PUBLIC ROAD, STREET, HIGHWAY, PARKING LOT, SIDEWALK, OR ALLEY To do so would be in violation of local law. This vehicle may be operated only on private property and upon areas approved by local law. Avoid operating this vehicle in any area with stationary objects that the vehicle could travel under. Do not ride in areas where other recreational vehicles are being operated. Be respectful of landowners and the environment. 2. This vehicle should NEVER be operated indoors. The exhaust from the engine contains carbon monoxi

• Baja BR250, 32 New and used oil could be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used oil can cause skin cancer in laboratory animals. Brief contact with the used oil may irritate the skin. Keep new and used oil away from children and pets. To minimize your exposure to used oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil. Failure to us

• Baja BR250, 20 SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear. A DOT approved motorcycle helmet can help prevent a serious head injury. Choose a helmet that ts snugly. Motorcycle dealers can help in selecting a good quality helmet which ts properly. You should wear eye protection when you ride. If a rock or a branch hits your eyes, you could be severely injured. Wear goggles or a face shield. Wear proper clothing when you ride. The proper clothes can protect you from inj

• 25 Periodic Check and Service It is very important to inspect and maintain your Go-kart regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed. The maintenance intervals in the following table are based upon average riding conditions. Note: 1. A=Adjust C=Clean I=Ins

• Baja BR250, 38 Tire Replacement Your Go-kart has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires. It is very important to use the proper tools when repairing or replacing tires in order to protect the tire bead or wheel rims. Have this work done by your authorized service center or a qualied tire repair station. When breaking the tire bead loose from the wheel, be extremely careful not to damage the inner wheel rim surface or the tire bead. Tubeless

• Baja BR250, 7 19. When making repairs or adjustments to the vehicle which do not involve adjustments to the engine, the spark plug wire must be disconnected and kept away from the spark plug to prevent accidental starting. When working on or around, or when restarting engine, use extreme caution to avoid contact with the mufer, cylinder head, or any other potentially hot area on or around the engine. 20. Always perform a pre-ride inspection before starting the engine. See Pre-Ride Inspection section in this manual. 21. When storing the vehicle, it must be kept in a place where gasoline fumes will not reach an open ame or spark. For long pe

• Baja BR250, 49 DIMENSIONS Overall length............................................................2450mm (96.46 in.) Overall width.............................................................1427mm (56.18 in.) Overall height............................................................1512mm (59.53 in.) Wheelbase.................................................................1865mm (73.43 in.) Dry weight .................................................................250kg (551 lbs.) Weight limit................................................................150kg (330 lbs.) ENGINE Type.....................................................

• Baja BR250, III This manual should be considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator. The manual contains important safety information and instructions which should be read carefully before operating the vehicle. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING ! !

• Baja BR250, 47 You need to know the frame and engine serial numbers to get title documents for your Go-kart. You also need these numbers to help your authorized service center or Baja Motorsports order parts. The Frame number is stamped on the frame behind the gas tank. The engine number is located on the left side of the engine housing. Write down the serial numbers here for your future reference Frame No.: Engine No.: Engine serial number Frame number SERIAL NUMBER LOCATION

• Baja BR250, 13 WARNING LABELS WARNING ALL HAIR MUST BE TIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH. ALL LOOSE CLOTHING MUST BE SECURED. ALL NECKLACES AND SCARVES MUST BE SECURED. NO LONG HAIR ! WARNING NO RIDING ! WARNING -Moving parts can crush and cut. -Keep hands clear. -Do not operate with guard removed. ! WARNING LOAD LIMIT 22lbs (10kg ) NEVER sit here 7 8 9 10 7 8 9 10 Located on the fuel tank

• Baja BR250, 15 THROTTLE, BRAKE PEDAL AND PARKING BRAKE LEVER Brake pedal Depressing the brake pedal draws the brake calipers against the brake rotor and slows or stops the go-kart. Throttle pedal Depressing the throttle pedal will engage the clutch and move the go-kart forward. Brake uid reservoir Contains brake uid which helps to stop the go-kart. Use DOT3 or DOT4 brake uid. Drive select Lever This lever allows you to drive the vehicle in forward or reverse. Parking brake While starting the engine or parking the machine, especially on a slope, apply the parking brake by pulling lever up. Forward Reverse Drive select lever Parking Brake lever Brake uid reser

• 31 To check oil level: 1. Park vehicle on level ground. 2. Remove dip stick and wipe off with a clean rag. Insert the dipstick in the ller hole. 3. Remove the dipstick and inspect the oil level. 4. Oil level should be in between the Lower index line and Upper index line marks on the dipstick. 5. Add oil if oil is below lower mark on dipstick . Do Not ll above upper mark.

• Baja BR250, 28 BATTERY INSTALLATION Note: The following page is for vehicles with battery’s containing separate electrolyte pack. Most battery’s will come with the electrolyte already sealed into the battery. Preparing the battery: · Place battery on level surface. Remove sealing tape from top. (see gure A) · Take the electrolyte container out of the plastic bag. · Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six ller holes of the battery. (see gure B) · Push the

• Baja BR250, 40 Failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, or shoes that are seriously worn, will increase your chance of having an accident. If you need to replace brake shoe pads, have your authorized service center do the work. Inspecting and maintaining the brake shoe pads is recommended. Replace the shoe pads in sets. FRONT AND REAR HYDRAULIC DISK BRAKE INSPECTION WARNING ! 1. Inspect the front disk brake caliper for leakage. If brake uid leaks, the safety of riding could be affected. 2. Inspect the brake hose for cracks/damage and the joint for leakage. 3. Check the brake uid

• Baja BR250, 24 CHAIN ADJUSTMENT Check the chain adjustment after the rst two hours of use. Readjust if it has more than 1/2” ex. 1. Loosen nut 1. 2. Loosen nut 2. 3. Tighten or loosen adjusting cap accordingly to obtain the correct free play. 4. Once the correct free play has been achieved, tighten nut 2 then nut 1. FRONT SHOCK ADJUSTMENT There are ve adjustable positions on the front shock. The default position is in the middle set by the manufacturer. Use a round nut wrench as you adjust the shock. The tension of shock spring will increase as

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