Baja motorsports BR150-D, Owner'S Manual

Page 1: ...cipal government acts and regulations pertaining to owning and operating an off road vehicle OWNER S MANUAL BR150 D BR150 1 Go Kart Read this manual carefully It contains important safety information No one under the age of 16 should operate this Go Kart Minimum Age Requirement 16 REV D 040209 ...

Page 2: ...0 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem with your vehicle please call Baja Inc custom...

Page 3: ...d carefully before operating the vehicle 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 WARNING Never operate this Go Kart at night Night is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise You may collide with another vehicle a stat...

Page 4: ...2 CHAIN AND SHOCK ADJUSTMENT 23 INSPECTION AND MAINTENANCE 24 BATTERY INSTALLATION 26 BATTERY REPLACEMENT 29 ENGINE OIL 30 CLEANING OIL FILTER 31 TRANSMISSION OIL 31 AIR FILTER 33 SPARK PLUG 35 TIRES 36 BRAKING 38 BRAKE INSPECTION 39 TROUBLESHOOTING 40 IGNITION SYSTEM CHECK 41 TRANSPORTING 42 CLEANING PROCEDURE 43 PREPARATION FOR CLEANING 43 WASHING YOUR GO KART 44 INSPECTION AFTER CLEANING 44 STO...

Page 5: ... to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the s...

Page 6: ...formation in this manual you will find safety labels on the product FOLLOW ALL WARNING BOTH IN THIS MANUAL AND ON THE PRODUCT Information which is particularly important is distinguished in this manual by the following notations FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY OR DEATH TO THE OPERATOR OR PASSENGER A BYSTANDER OR A PERSON INSPECTING OR REPAIRING THE PRODUCT CAUT...

Page 7: ...tationary 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 4 Prevailing Torque type locknuts lose their locking capability with repeated use and require replacement Ensure locknuts are functioning properly 5 The tire pressure should be checked prior to each use The recom mended infl...

Page 8: ...tice Safe operation includes responsibility for the safety of a passenger if any 10 A DOUBLE SEAT VEHICLE IS DESIGNED FOR ONE OPERATOR AND ONE PASSENGER No one should ever attempt to ride on this vehicle without being seated with the seat belt properly secured For double seat vehicles ridden without passenger the passenger seat belt must be secure to prevent it from getting caught up in operating ...

Page 9: ...skill and experience to choose a speed suitable for terrain and riding conditions 16 The governor settings for this vehicle s engine must not be tampered with altered or changed The governor is set by the engine manufacturer and limits the maximum speed of the engine and vehicle and protects the engine from damage Excessive speeds are potentially dangerous to the operator passenger and the engine ...

Page 10: ...lowed to cool before storage in any enclosure Read and keep all printed material supplied with this vehicle Timely and specific instructions and an Operator s Manual revisions are included in supplements If any printed material is unclear contact the manufacturer 22 NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATION OF ANY KIND SUCH OPERATION COULD BE DANGEROUS TO ...

Page 11: ...applicable contains sulfuric acid and must not come in contact with skin eyes or clothing since this will cause severe burns possibly causing disfigurement Also battery may generate explosive gases and must not be exposed to sparks flame cigarettes or anything flammable or an explosion may result causing severe injury Protective gloves and face protection must be worn when servicing the battery 30...

Page 12: ...9 BR150 1 Left Right Headlight Front wheel Brush guard bar Rear wheel Rear rack Rear shock ab sorber Front shock absorber Seat Safety belt Control panel Fuel tank Steering wheel ...

Page 13: ...oline ENGINE OIL Your 150cc Go kart has a four stroke engine Please use oil as described in the chart below By using the prescribe oil you will realize the best lubrication for the engine Use the chart to select a viscosity rating based on the temperature range in your area SAE 10W 30 ENGINE TEMP C F 30 22 40 104 20 4 10 14 0 32 10 50 20 68 30 86 FUEL AND OIL ...

Page 14: ...ing Wear protective eye wear and clothing Keep arms legs and feet inside kart Do not use alcohol or drugs WARNING 303115 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 supervisio...

Page 15: ...ST 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 LOAD LIMIT WARNING 22 LBS NEVER sit here WARNING NO RIDING WARNING Go Kart Must Be Stopped And Engine Speed At Idle To Shift Into Forward Or Reverse WARNING Parking Brake Must Be Set Before Exiting The Go Kart ...

Page 16: ...rn key CW and release key when engine starts Note The engine stop switch needs to be placed in the ON I position and the foot brake needs to be depressed for engine to start CAUTION Do not hold key for more than 5 seconds at a time when starting engine If engine fails to start within 5 seconds allow starter to rest for 10 seconds before trying again Allowing the starter to run for more than 5 seco...

Page 17: ...t 2 Throttle pedal Depressing the throttle pedal will engage the clutch and move the go kart forward 3 Brake fluid reservoir 4 Parking brake While starting the engine or parking the machine especially on a slope apply the parking brake by pulling lever back towards the seat 1 3 THROTTLE BRAKE PEDAL AND PARKING BRAKE LEVER 4 ...

Page 18: ... injuries or loss of life The seat must always be securely adjusted to the position which affords the best control of the foot pedals steering wheel and engine stop switch for the operator Pull seat adjustment handle upward to disengage the seat slide Move the seat to desired position Be sure the handle snaps back into place and that the seat is locked into position Seat adjustment handle ...

Page 19: ... good place to practice review the control system on your Go kart before riding Learn to find these controls without looking for them because you will not have time to look for them when you are riding Canadian residents must obtain review and follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle WHAT YOU SHOULD KNOW BEFORE RIDIN...

Page 20: ...rting Engine oil dipstick The engine oil should be between the minimum and maximum lines Throttle Smooth response quick return to idle position General Condition Bolts and nuts are tight no rattle from any parts of the engine when running no visible evidence of damage Failing to inspect the Go kart before operating could be hazardous Failing to perform proper maintenance could also be hazardous Fa...

Page 21: ...ition to ensure the safety of the rider Operating this Go kart with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may cause changes in handling In some situations this could lead to an accident Never modify this Go kart through improper installation or use of accessories Checking maintenance items when the engine is running could be...

Page 22: ...ct you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt Operating this Go kart without wearing an approved DOT motorcycle helmet eye protection and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating ...

Page 23: ...o much Avoid Constant Low Rotating Speed Operating the engine at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding the maximum throttle limit Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting This allows the lubricating oil to reach all critical engi...

Page 24: ...hifts the Go kart in either forward or reverse To shift Go kart in either forward or reverse 1 Release throttle 2 Apply brakes coming to a complete stop 4 Shift lever down in the reverse position 5 Check for people or obstacles behind you 6 Depress the throttle pedal gradually continuing to watch to the rear while backing Not looking behind vehicle before and while going in reverse could be hazard...

Page 25: ...ake some of the adjustments This should only be performed by a trained mechanic 1 Warm up the engine for about 5 10 minutes 2 Connect the tachometer and adjust the throttle idle speed standard value is 1700 RPM 3 Turn the Idle screw counter clockwise slowly and observe the RPM of the engine and stop adjusting as the RPM of engine reaches correct speed Idle screw ...

Page 26: ...ght 3 Repeat the above steps until chain is adjusted to the desired tension CHAIN ADJUSTMENT FRONT SHOCK ADJUSTMENT There are five 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 you screw to the left and decrease as you screw to the right Spring adjustm...

Page 27: ...rols I A I A Spark plug C I R Valve clearance I I I Engine oil Gearbox oil Filter screen of engine oil C C I I Carburetor C C C C Drive chain I A L Battery I Brake shoe I Brake system I Electric parts I Bolt nuts fasteners L I Gear in gearbox I I Fuel tank I I Tire pressure wear I Steering system A Chassis L I During running in period replace every 150 miles After running in period replace every 6...

Page 28: ... Go kart under severe conditions it will need maintenance more often than shown in the chart Operating your Go kart under severe conditions causes more wear on your Go kart Severe conditions include operating under frequent full throttle or in dusty wet sandy or muddy areas These conditions could cause the Go kart to wear more quickly Perform maintenance more often than shown in the chart If you h...

Page 29: ... KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush w...

Page 30: ... in bottle Let electrolyte drain into battery until bottle is completely empty see figure 21 Discard empty electrolyte container in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life After 30 minutes the battery is re...

Page 31: ...ge battery 0 7 Amps for 5 10 hours After charging is complete install securely all six battery caps see figure 26 Install battery into battery tray located behind seat see figure 27 Once battery is firmly seated in tray attach red positive wire to positive terminal on battery then attach black negative wire to negative terminal on battery see figure 27 Attach cover over battery using rubber strap ...

Page 32: ...ery to the vehicle using metal battery strap DO NOT open sealed caps to add water to battery Always wear safety glasses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to cool down Do not use fast charging unless it is an emergency At the beginning or end of charging turn off the charger first in order to prevent electric spark and explosion ...

Page 33: ...k 5 Add oil if oil is below lower mark on dipstick Do Not fill above upper mark Refer to page 10 for correct engine oil type Engine oil replacement The engine oil should be changed every 20 to 40 hours of operation It should be changed more often in dirty and dusty areas 1 Park vehicle on level ground 2 Remove engine oil drain bolt located on bottom left side of engine 3 Drain oil into a catch bas...

Page 34: ...efer to page 10 for correct engine oil type Spring Oil Strainer Draining transmission oil Adding transmission oil Transmission oil fill bolt 1 Drain transmission oil by removing transmission oil drain bolt located on the bottom left of transmission 2 Drain oil into a catch basin and dispose of properly at an oil reclaim facility 1 Add transmission oil by removing transmission oil fill bolt located...

Page 35: ...es 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 use the correct oil could harm your Go kart Be sure to use the oil specified in the FUELAND OIL RECOMMENDATION section Running the engine without an adequate amount of engine oil could cause se...

Page 36: ...r Filter 1 Locate Air Filter Box at rear of Go kart and remove cover 2 Remove foam filter element 3 Inspect Air Filter element for tears or cracks if air filter is damaged replace 4 Wash and oil air filter element 5 Reinstall air filter and close cover The air filter element must be kept clean to provide good engine power If you use your vehicle under normal conditions you should service the air f...

Page 37: ...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 filter element frequently if the vehicle is used in dusty wet or muddy conditions could damage your Go kart The air filter element co...

Page 38: ... for good ignition Use a thickness gauge to check the gap CAUTION Improper installation of the spark plug could damage your Kart An overly tight or cross threaded spark plug will damage the aluminum threads of the cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about turn past finger tight If you are reusing the old spark plug ...

Page 39: ...r adjusted when the tires are cold Operating this Go kart with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the Go kart Always use the size and type tires specified Always maintain proper tire air pressure as described in this section Using worn tires could be hazardous Thetractionofthevehiclewi...

Page 40: ...red using a plug type patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your Go kart in areas where transportation or service facilities are not readily available it is strongly recommended that you bring a plug type repair kit and a tire air pump with you Overfilling the air to the tires could be hazardous If you put to...

Page 41: ...rding to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE Operating the Go kart in harsh conditions could be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brake must be...

Page 42: ...e your authorized service center do the work Inspecting and maintaining the brake shoe pads is recommended Replace the shoe pads in sets Brake hose WARNING 1 Inspect front and rear disk brake calipers for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joint for leakage 3 Check the brake fluid level in the brake fluid reservoir if lev...

Page 43: ...plenish fuel Clogged fuel filter On Off flip switch is in off position Water in fuel Drain system Spark plug No spark to spark plug Contact service center Engine compression 155 lbs No compression Engine stops or loses power No fuel Replenish fuel Fuel vent line kinked or plugged Water in fuel Drain system Spark plug fouled Air filter clogged Exhaust clogged Contact service center Engine overheate...

Page 44: ...uled Remove the spark plug and clean it Replace it if necessary 3 Make sure the fuel valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min Performing the spark test improperly could be hazardous You could get a high voltage electrical shock if you are not familiar with this procedure D...

Page 45: ...dle it properly When draining fuel from the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of the drained fuel properly Failing to secure the Go kart properly could be hazardous Failing to secure the vehicle properly may result in an accident or damage to...

Page 46: ...uce engine cooling ability conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the Go kart before any mud dries on the Go kart Block or seal the end of the exhaust pipe muffler and air filter using a piece of plastic wrap cloth rag or another method to prevent water from entering engine High pressure washers could dama...

Page 47: ...kages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Follow the procedures in the INSPECTION BEFORE RIDING section to check your Go kart for any problems that may have occurre...

Page 48: ...screw TIRES Inflate tires to the normal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire vehicle 2 Make sure that the vehicle is properly lubricated 3 Perform the INSPECTION BEFORE RIDING as listed in this manual 4 Start the vehicle...

Page 49: ...so need these numbers to help your authorized service center or Baja Motorsports order parts The Frame number is stamped on the frame behind seat 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 ...

Page 50: ...50ml 0 9 qt Starting time 15s Climbing 20 Top speed 35 mph Acceleration Noise level Custom engineered Battery type voltage capacity 12N14 BS 12V 8Ah Fuse 15A CHASSIS Front Rear brake type Hydraulic Disc Foot control Fuel type 90 or above unleaded Lubricate oil type SAE10W 30SF Lubrication Force Splash Cooling Forced Air cooled Ignition C D I Starting Electric Spark plug A7RTC Spark plug gap 0 6 0 ...

Page 51: ...48 WIRE DIAGRAM ...

Page 52: ... your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable ...

Page 53: ...ntrol system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following Fail...

Page 54: ...ot liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth herein Any emission control system war ranty implied by law including any warranty of merchan...

Page 55: ...52 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252 ...