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Baja Shifter 90 Owner's Manual

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  • Page 2: Baja Shifter 90 Model Sf90 (Double-Seat): Owner's Manual Version:1.0 April

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Limited Warranty The warranty policy applies to those cases where the new seller vehicle unloaded from its shipping container, set up and delivered by authorized dealer and under normal use and service is found to have defects in parts or workmanship under the following terms and conditions.
  • Page 3 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 What is not covered under this warranty? This warranty does not cover any seller vehicles that have been subjected to: Renting; Disassembly, adjusting or repairing of the vehicle in any way so as to adversely affect its safety or reliability;...

  • Page 4: Table Of Contents

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Contents 1. Foreword----------------------------------------------------------------------------------------------------------------5 2. A Few Words about Safety-------------------------------------------------------------------------------------------6 3. Important Safety Information----------------------------------------------------------------------------------------8 4. Safety Labels----------------------------------------------------------------------------------------------------------12 5. Are You Ready to Drive? --------------------------------------------------------------------------- ----------------13 6. Is Your Vehicle Ready to Drive? -----------------------------------------------------------------------------------18 7.

  • Page 5: Foreword

    Beginners should drive this BUGGY in a large open area to practice handling this BUGGY. Wear protective gears all the time when driving or riding this BUGGY. We hope you will have a pleasant experience with our products and thanks again for choosing Baja Motorsports.

  • Page 6: A Few Words About Safety

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your BUGGY. To help you make informed decisions about safety, we have provided operating procedures and other information on labels in this manual.
  • Page 7 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 The meaning of these signal words: WARNING ------Physical harm may result from the failure to follow the instructions that are described within the labels; CAUTION------ Damages to your BUGGY and possible subsequent personal injuries or death could result from the failure to take proper precautions described within the labels;...

  • Page 8: Important Safety Information

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 IMPORTANT SAFETY INFORMATION Your BUGGY will provide you with many years of service and pleasure, providing you take responsibility for your own safety and understand the challenges you will meet while driving.
  • Page 9 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Take Time to Learn & Practice Even if you have driven other buggies, you still should take time to become familiar with how this BUGGY works. Practice in a safe area until you have built your skills and gotten accustomed to the size and weight of this Buggy.
  • Page 10 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Don't drink and drive, and don't let your friends drink and drive either. Don't Drive at Night At night your visibility and judgment can be greatly reduced, so driving at night is dangerous and can terribly increase chances of accidents.
  • Page 11 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 If you skid or slide on ice, you may lose all directional controls. To avoid skidding or sliding on slippery terrain surfaces, you should keep your speed low and drive carefully.

  • Page 12: Safety Labels

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 SAFETY LABELS The labels should be considered permanent parts of your BUGGY. If a label comes off or becomes difficult to read, please contact Baja Motorsports for warning label replacements.

  • Page 13: Are You Ready To Drive

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 ARE YOU READY TO DRIVE? Before each drive, you need to make sure that you and your BUGGY are both ready to drive. To help you be prepared, this section discusses how to evaluate your driving readiness, what items you should check on your BUGGY, and how to adjust your BUGGY for your comfort, conveniences and safety.
  • Page 14 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Protective Apparel For your safety, we strongly recommend that you always wear a DOT approved motorcycle helmet, approved goggles sturdy boots, durable gloves, long pants and long-sleeved shirt or jacket whenever you drive.
  • Page 15 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Always wear a face shield or a pair of goggles to protect your eyes and vision. 2. Additional Driving Gear In addition to a helmet and eye protection gear, we also recommend: •...
  • Page 16 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Driver Training Developing your driving skills is an on-going process. Even if you have driven other Buggies, you still need take time to become familiar with how this BUGGY works. Practice driving this BUGGY in a safe area to build your skills.
  • Page 17 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Operating this BUGGY after consuming alcohol or drugs can seriously affect your judgments, cause you to react more slowly, affect your balance and perception, and even could result in serious injuries or death.

  • Page 18: Is Your Vehicle Ready To Drive

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 IS YOUR VEHICLE READY TO DRIVE? Before each of your drive, it is important to inspect your BUGGY and make sure that any problems you’ve found have been corrected. A pre-drive inspection is a must, not only for safety, but also because a breakdo- wn, or even a flat tire, can be a major inconvenience.
  • Page 19 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Pre-Drive Inspection Please check the following items before getting on your BUGGY: Engine Oil: Check the level and add oil if needed; check for leaks; don’t let any water go into the engine, otherwise the engine can’t start.
  • Page 20 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Throttle: Check the free play and adjust the throttle if needed; press the throttle to make sure it moves smoothly without sticking, and release it to make sure it snaps back automatically.

  • Page 21: Safe Driving Precautions

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 SAFE DRIVING PRECAUTIONS Off-Road Use Only Your BUGGY and its tires are designed and manufactured for off-road use only, not for pavements. Driving on pavements can affect your handling and controlling. Don’t drive your BUGGY on pavements.
  • Page 22 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Operating your BUGGY on public streets, roads or highways can cause collisions with other vehicles. Never operate your BUGGY on any public streets, roads or highways. Keep Your Hands and Feet on Controls Always keep both of your hands on the steering wheels ,and both of your feet on the foot controls when driving your BUGGY.
  • Page 23 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Control Speed Driving at excessively high speed increases the chances of accidents. When choosing a proper speed, you need to consider the capability of your BUGGY, terrain, visibility and other operating conditions, plus your own skills and experiences.
  • Page 24 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 When driving your BUGGY on unfamiliar terrain, failure to be especially careful could cause your BUGGY to go out of control or overturn. When operating your BUGGY on unfamiliar terrain, always drive slowly, always be especially careful, and always be alert to changing terrain conditions.
  • Page 25 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Don’t Perform Stunts You should always operate your BUGGY in a safe and reasonable manner. When driving, always keep all of the four wheels on the ground. Attempting wheelies, jumps, and any other stunts increases the chances of accidents, including an overturn.

  • Page 26: Operation

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 OPERATION A. Operation Controls Don’t attempt to start or operate the engine until you’ve been completely familiar with the location and use of each control that is necessary to operate your BUGGY. You must know how to stop your BUGGY before starting and driving.
  • Page 27 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Each time before starting the engine, check the throttle assembly to ensure that when you push the pedal all the way forward, the throttle assembly is working smoothly, and when you release the pedal, the throttle assembly returns to idle.
  • Page 28 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Control Panel Engine Stop Button Important-----the Engine Stop Button test. Before driving your BUGGY, test the Engine Stop Button to assure that it is operating properly .When the engine is running, move the Stop Button to the “OFF”...
  • Page 29 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Key Switch Insert the key into the key switch, turn the key clockwise, and release the key when the engine starts. The engine will warm up within 5 minutes, and the engine choke will close automatically and operate at formal RPM.
  • Page 30 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Tires: Check the tire conditions and pressures. Front Tire Pressure: 4 P.S.I. Rear Tire Pressure: 7 P.S.I. Drive Chain: Check for the chain conditions and tension; lubricate it if necessary.
  • Page 31 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Locations of Parts: Seat Double-Seat Brush Guard Safety Belt Steering Wheel Rear Rack Control Panel Rear Wheel Front Wheel Front Shock Absorber Throttle Pedal Brake Pedal...
  • Page 32 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Rear Rack Fuel Tank Cap Fuel Tank Air Cleaner Reverse lever Engine Muffler Drive Chain...
  • Page 33 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 C. Preparations before Starting the Engine Check the engine fasteners before starting; Fill in the fuel and lubrication oil as specified; Oil Capacity Crankcase: 0.7~0.9L; Transmission Box: 0.2 L;...
  • Page 34 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Pull the seat adjustment handle left to disengage the seat slide; Move the seat to a desired position; Be sure that the seat adjustment handle snaps back into place and that the seat is locked into position.
  • Page 35 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 F Gearshift Lever Adjustment Press down the gearshift lever to the “N” position, then the vehicle is in the neutral gear; Push the gearshift lever to the “D” position so that the vehicle can move forward in the first /second gear;...
  • Page 36 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 G. Starting and Operating Instructions Before starting the engine, be sure that you’ve properly sat in your BUGGY and tightened the seat belt; Test your BUGGY in the beginning to learn how to start, turn and stop;...
  • Page 37 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Fuel Tank Cock Note: Before starting the engine, the fuel tank cock must be in the “ON” position, and the carburetor oil-inlet switch must be in the “ON” position;...
  • Page 38 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Release the button and cut the power of the starting motor immediately after starting the engine. Don’t press the starting button after starting the engine. Otherwise it may cause damages to the engine.
  • Page 39 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Rotate the throttle slowly after starting the engine; don’t speed up or speed down suddenly; Drive on smooth roads; don’t drive uphill or on rough roads for a long time;...

  • Page 40: Service Instructions

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 SERVICE INSTRUCTIONS Remove Air Cleaner Cover A. Air Cleaner Service the air cleaner every 20 hours of usage. Note: Service more often when running under dusty conditions. Remove the air cleaner cover;...
  • Page 41 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 B. Engine Lubrication After the new engine has operated for the first 5 hours and for every 10 hours thereafter, change the oil in the crankcase to insure the proper lubrication of internal parts and to prevent costly repairs due to the excessive wear.
  • Page 42 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 C. Spark Plug Remove the spark plug and inspect it with a spark plug wrench each time you change the oil; Note: The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will greatly reduce the proper engine performance.
  • Page 43 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 D. Carburetor Adjustment Never make unnecessary adjustments. The manufacturer recommended settings are correct for most applications. It's not necessary to disassemble the screw unless the carburetor needs to be replaced. Prepare a 50r/w tachometer before the adjustment.
  • Page 44 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 E. Cleaning Instructions Use a clean rag to wipe off the dirt and oil from the controls, and any spilled fuel and oil from the vehicle. Keep the engine clean of foreign objects. Make sure the cylinder and cylinder head cooling fins are clean.
  • Page 45 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 I. Storage Instructions In the event your vehicle isn’t to be operated for periods in excess of 30 days or at the end of each driving season, prepare for the storage as follows: Drain (or use a fuel stabilizer) all the fuel out of the fuel tank and carburetor;...
  • Page 46 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 1.2) Check all the exterior fasteners at the joints, and fasten or replace them if necessary; 1.3) Check for the oil leakage, and check the compression at the mating surface;...
  • Page 47 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 2.3) Remove the carbon on the spark plug; 2.4) Clean the crankcase and replace the oil; 2.5) Clean the transmission box and replace the engine oil; Remove the oil-drain bolt;...
  • Page 48 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 3.3) Clean the inner part of the crankcase, and rotate the crankshaft during the cleaning to clean the main bearing and connecting rod big end needle bearing; 3.4) Check if the fixed screw of the generator stator is loose;...
  • Page 49 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 500-Hour Maintenance: 6.1) Finish 300-hour maintenance; 6.2) Disassemble the engine (except the crankshaft connecting rod); check the parts for wear, and repair or replace the parts if necessary; K. Battery Maintenance...
  • Page 50 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 The following procedure is very dangerous and should be performed with utmost care and attention. Wear protective eyewear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes. KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
  • Page 51 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 2) 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. 2.1) Place battery on level surface;...
  • Page 52 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 2.4) Push the container down strongly enough to break the silver seals; 2.5) As electrolyte starts flowing into battery, air bubbles will come up from the mouths of the plastic electrolyte bottles;...
  • Page 53 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 2.9) Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals; 2.10) 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);...
  • Page 54 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 3.2) Connect the black negative (-) cable to the black negative (-) pole of the battery; Note: The red positive (+) cable has a larger diameter than the black negative y cable.
  • Page 55 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE. 3.5) Install battery into battery tray making sure that the rubber mat is in place; Note: The warning label on the battery should be facing the warning label on the gray tray.
  • Page 56 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 3.7) Then attach the black negative wire to the black negative terminal on the battery; 3.8) Place grey plastic battery cover on top of the battery and 3.7) threadwires through the cover cuts – outs. Finally, secure the battery with the wide black rubber strap using the hooks on both ends.
  • Page 57 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 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.
  • Page 58 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 4.3) After charging, install new battery; Put dielectric grease on the battery terminals to avoid corrosion; 4.4) Connect cables to the proper terminals: positive cable to positive terminal, and negative cable to negative terminal;...
  • Page 59 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 L. Chain Adjustment 1) Loosen the 4 bolts M8*16 on the rear wheel axle holder, and lift up the engine support so as to raise the rear wheel above the ground;...
  • Page 60 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 M. Brake Cable Adjustment 1) If the brake cable is too loose, adjust the adjust nut of the brake cable clockwise; If the brake cable is too tight, adjust the adjust nut of the brake cable counterclockwise;...
  • Page 61 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 N. Brake Shoe Replacement 1) Loosen the connecting clip on the chain; Remove the chain; Chain 2) Loosen the adjust nut on the brake cable; Take out the brake cable;...
  • Page 62 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 3) Remove the cotter pin on the bracket of the brake caliper; Bracket Cotter Pin Castle Nut Remove the cotter pin, castle nut, left rear tire, right rear tire and rear wheel hub in order;...
  • Page 63 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Bolt Rear Wheel Axle Holder Loosen the 4 bolts on the left/right holder of the rear wheel axle; Remove the left/right holder of the rear wheel axle; Remove the rear wheel axle together with the brake caliper assy.;...
  • Page 64 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 O. Idle Speed Adjustment If the rotate speed of the engine is not stable (either too low or too high) after the engine has started, adjust the idle speed adjust screw on the carburetor.

  • Page 65: Repairs

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 REPAIRS A. Front Wheels Replacement Remove the 3 lock bolts and lock nuts on the front wheel; Remove the front wheel; Assemble the new front wheel Front Wheel Fasten the 3 lock bolts and lock nuts.

  • Page 66: Periodical Checks And Services

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 PERIODICAL CHECK AND SERVICE The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent services. Interval Service in 1...
  • Page 67 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Interval Service in 1 Week Daily Monthly Quarterly Yearly Items Valve clearance of engine Throttle cable Absorber Note: X：inspect，clean or replace if necessary A: adjust; C: clean; L: lubricate;...

  • Page 68: Specifications

    Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 SPECIFICATIONS DIMENSIONS DOUBLE-SEAT Overall Length 1500mm Overall Width 1100mm Overall Height 1230mm Wheelbase 1100mm Ground Clearance 120mm Accord With GMVR A01-01 Statutory Plate& Safety Labels Accord With GB 7258-1997...
  • Page 69 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Max. Torque 5.0N.m /5000 rpm Idle Speed 1500±100r/M Idle Speed CO Pollutant ≤3.8% Idle Speed HC Pollutant ≤800 Ppm Fuel Type SAE 90# or Above (Unleaded) Min. Fuel Consumption 367g/KW.H...
  • Page 70 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Primary Reduction Ratio 4.058 Clutch Wet, Multi-plate (Automatic, Single) Carburetor PZ19 Air Cleaner Filter Sponge Element Gear-Shifting Hand Control Valve Gap 0.05±0.02mm Engine Size (Length×Width×Height) 430mm×320mm×270mm Engine Net Weight...
  • Page 71 Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005 Battery 12V 3Ah CHASSIS Brake System Rear Disk *1 Front Suspension Single A-arm 30 Travel Rear Suspension Swing Arm 30 Travel Front Tire 145/70–6 Rear Tire 16X8.0–7 TIRE PRESSURE Front 4 P.S.I.
  • Page 72 BAJA INC. – 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 de- livered to the first purchaser other than an authorized dealer, or the date it is first used as a dem-...
  • Page 73 Your emission control system warranty covers components whose failure would increase an en- gine’s emission, including electronic controls, fuel injection system, carburetor, the ignition sys- tem, catalytic converter, or any other system utilized in this vehicle to control emission if it is origi- nally equipped.
  • Page 74 No dealer is authorized to modify this Emission Control System Warranty. If you have any ques- tions regarding your warranty rights and responsibilities, you should contact BAJA INC. (888) 863-2252.
  • Page 75 Baja Inc. P.O. Box 61150 Phoenix, Az. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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