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Minimum Age Requirement 16 REV.D 040209 Alwaysweara helmet;It couldsaveyourLife! Pleaseobtain,review,andfollow provincial / municipalgovernment a cts and regulations pertainingto owningand operating an off-roadvehicle.
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Congratulations on your purchase of a Baja150ccGo-Kart. It iswarrantedto be free of manufacturing defectsin materialand workmanship for a periodof 90 daysform the dateof purchase.During thewarrantyperiodBAJA,INC. will at itsoption,repair,provide replacement partsor replaceyour BajaGo-Kartat no charge. This warrantydoesnot covernormalwearitemsor damagecausedby neglector misuseof the product. Engine Warranty- 90 days FrameWarranty - 90 days Warrantyisvoid if:...
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This manual should be considered 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 instructionswhich should be read carefully before operating the vehicle.
Pleasereadthis manualand follow all instructions carefully.Toemphasize the specialinformation, t hesymbol,tand thewordsWARNING or CAUTION havesomespecialmeanings.Pay greatattentionto the messages. Indicates a potentialhazardthat couldresultin deathor injury. Indicates a potentialhazardthat CAUTION couldresultin vehicle damage. NOTE:Indicating specialinformation which isto makemaintenance easieror instructions clearer. WARNING and CAUTION are arrangedlike this: The first partwill identify a POTENTIAL HAZARD.
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This off-road product IS NOTA TOYANDCANBE HAZARDOUS TO OPER- ATE.This producthandlesdifferentlyfrom othervehiclesincluding ATV'sand motorcycles. A collisionor rollover canoccurquickly, evenduringroutine maneuvers such as turningand ridingon hills or over obstacles. To helpyou makeinformeddecisionsaboutsafety,you willfind providedin this manualoperatingprocedures and othersafetyprocedures which must befollowed. In additionto the safetyinformationin this manual, y ou willfind safetylabelson theproduct.FOLLOW ALL WARNING BOTHIN THISMANUAL AND ONTHE PRODUCT.
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IMPORTANTRULES FOR SAFE OPERATION Thisvehicleis not licensable. I T IS NOT TO BEOPERATED ONANY PUBLICROAD,STREET,HIGHWAY, PARKING LOT,SIDEWALK, O RALLEY. T o do so wouldbe in violationof local law.Thisvehiclemay be operatedonlyon privatepropertyand upon areasapprovedby locallaw.Avoidoperatingthis vehiclein any areawith stationary objectsthatthe vehiclecouldtravel under. Do not ridein areaswhere otherrecreational v ehiclesare beingoperated.Be respectful o f landowners and theenvironment.
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7. THE VEHICLESHOULDNEVERBE STARTED WITHOUTFIRST CHECKING TOSEE THATTHE THROTTLE IS IN IDLEPOSITION.Do not start enginewithoutverifyingproperfunction of the throttle.Neverattemptto start thisvehiclewithouthavingtheoperatorseatedin the properposition.When startingwith theoperatorin theseat,the operatorshouldhavetheir leftfoot on the brake. Thisvehicleis notdesignedor intended for racing,anyform of competition. The operator'sabilityto operatethis off-roadvehiclesafelyis largely dependentuponthe operator'sabilityto exerciseproperjudgment.
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LOOSECLOTHING,LONGHAIR, ORARTICLES WORNBYANY OPERATOR OR PASSENGER MUSTBE FULLYCONTAINED OR COVEREDTO PREVENTTHEMFROMPOSSIBLYBEINGCAUGHTIN ROTATING PARTSOF THEVEHICLEORTHE SURROUNDING ENVIRONMENT WHILERIDING. FAILURETO OBEYCOULDENDANGER THE PERSONAL SAFETYOFTHE OPERATOR OR PASSENGER. DO NOTPLACEHANDS,FEET,ORANY OTHERPARTOF THE BODYOR ANY CLOTHINGNEARTHE ENGINE,MUFFLER, W HEELS,CHAINAND OTHER ROTATING PARTSOFTHE VEHICLEWHILERIDINGOR RUNNING THE ENGINE.Caution must be used in performing required maintenance on or near an operating engine.Special cautionshouldbe taken after the engine has been running, sincethe engine and other drive components may be extremely...
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19. When making r epairs oradjustments tothe vehicle w hich donotinvolve adjustments tothe engine, thespark p lug wire must b edisconnected and kept away f rom thespark plugto preventaccidental s tarting.Whenworkingon or around,or whenrestartingengine,use extremecautionto avoidcontactwith the muffler,cylinderhead,or any otherpotentially hot areaon or aroundthe engine.
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This manual,alongwith theothersupplements providedwithyour vehicle,provideguidelinesfor the assembly, m aintenance, a nd operation of thisvehicleand is not intendedas a servicemanual. Assembly, m aintenance, a nd/orrepairof this vehicleshouldonly be performedby personsof sufficientmechanical s kill, experience, a nd judgment(suchas outdoorequipmentdealers,motorcycle dealer/shops, o r smallenginedealers)sothat no unsafeconditionor modification is made.
FUEL The properfuel is veryimportantfor the engine. Ensurethatthere is no dust,dirt,or waterwhichhas mixedin thefuel. Pleaseuseregularunleaded gasoline ENGINEOIL Your 150ccGo-karthasa four-stroke engine. Pleaseuseoil as described in the chartbelow. By usingthe prescribeoil, youwill realizethe best lubrication for the engine. ENGINE °C TEMP. 14 32 Usethe chartto selecta viscosityratingbasedon thetemperaturerangein yourarea.
Readand follow all of the warningslabelson your Go-kart. Makesure you understand all the labels. Keepthe labelson the Go-kart. Do not remove themfor anyreason. If a labelcomesoff or becomes difficultto read,you shouldgeta replacement bycontactingBaja Motorsports. "n-iisGO-RARTCAN BE HAZARDOUSTO OPERATE If driven carelessly INJURIEScan resultIf you do not follow these instructions: -BEAD OWNER'S MANUAL AND ALL LABELSBEFORE...
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-Moving parts can crushand cut. -Keep hands clear. -Do not operate with guard removed. 5- i[O7-'I D] l I_11 NEVER sit hereJ 22LBS LONG HAIR ALL HAIR MUST BETIED UP AND SECURED AT OR ABOVE SHOULDER LENGTH. ALL LOOSECLOTHING MUST BE SECURED. ALL NECKLACESAND SCARVESMUST BE SECURED.
Enginestop switch ignitionKey Engine stop switch - Whenengineis runningmoveStopswitchto "OFF"(O) position.The engine shouldstop whenswitchis depressed. If the switchfails to stop engine,consultyournearest servicecenter. Ignition key switch - Insertkey intoignitionswitch,turnkey CW and releasekey whenenginestarts. Note: The enginestopswitchneeds to beplacedin the "ON" (I) position and thefoot brake needsto be depressedfor engineto start.
Pullseatadjustmenthandleupward to disengagethe seat slide.Movethe seat to desiredposition.Be surethe handlesnapsbackintoplace and thatthe seat is lockedintoposition Seat adjustment handle Beforeattempting to adjusttheseat,ensurethatthe engine is not running. Neveroperatego-kartwhenthe seat is not securelyadjusted.It could resultin personalinjuriesor lossof life. The seat mustalwaysbesecurelyadjustedto the position whichaffords the bestcontrolof thefoot pedals,steeringwheeland enginestop switchfor theoperator.
WHAT YOU SHOULD KNOW BEFORE RIDING Beforeriding,you shouldreadall thefollowing information carefully.If you are properlyprepared, y ou will havea moreenjoyableride. Beforeriding,you shouldfind a goodplaceto practicethe skills. Finda flat, openareawith enoughspaceto practicethe newskills. Makesurethatit is legal toridein theareayouselected. R eview thelocallaws andmakesureyouarenottrespassing. Callthepoliceifyoudon'tknowwhere youcanride.
Failingto inspect the Go-kartbefore operatingcouldbe hazardous. Failingto performpropermaintenance couldalso be hazardous. Failingto inspectand maintainyourGo-kartcouldincreasesthe chances of an accidentor equipmentdamage AlwaysinspectyourGo-kart eachtimebeforeriding, andmake sureit is in a safeoperating c ondition. Refer t otheINSPECTION ANDMAINTENANCE section inthismanual. ITEMTO CHECK CONTENT Steering Smoothness; No restriction of movement; No play or looseness.
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Overloading couldbe hazardous. Overloading c ouldcausechanges in vehiclehandling and couldleadtoan accident. Neverexceedthe statedloadcapacity for this Go-kart. Operating this Go-kartwith improper modifications could behazardous. Improperinstallation of accessories or modifications to thisvehiclemay causechangesin handling. In somesituations, t his could leadto an accident. Never modifythis Go-kartthroughimproper installation or useof accessories.
The first monthisthe mostimportantin the life of yourvehicle. Proper operationduringthis break-inperiodwill be helpfulfor assuringmaximum lifeand performance of yournewvehicle. The following guidelinesexplain properbreak-inprocedures. MaximumThrottleOpeningRecommendation Duringthe first 10 hoursof operation, y ou shouldalwaysuse lessthan1/2 throttleopening. Varythe EngineRotatingSpeed Varytheenginerotatingspeedduringthe break-inperiod. Thisallowsthe partsto "load" and then "unload" (allowing the partsto cool). Althoughit is essentialto placesomestresson the enginecomponents duringbreak-in, you mustbe carefulnot to loadthe enginetoo much.
The drive select lever shifts the Go-kart in either forward or reverse Toshift Go-kartin eitherforward or reverse: 1. Releasethrottle 2. Apply brakescomingto a completestop. 4. Shift leverdownin the reverseposition 5. Checkfor peopleor obstaclesbehindyou. Depressthethrottlepedalgradually continuing to watchto the rearwhile backing. Notlookingbehindvehiclebeforeand whilegoingin reversecouldbe hazardous.
Nevermake unnecessary adjustments. T he manufacturer recommended settingsare correctfor mostapplications. Y ouwill needa tachometer to make someof theadjustments. T hisshouldonly be performedbya trained mechanic. Idle screw Warmup the enginefor about5-10 minutes. Connectthe tachometer, a nd adjustthe throttleidlespeed (standard value is 1700RPM). Turnthe Idlescrewcounter-clockwise s lowlyand observethe RPMof the engine,and stopadjustingas the RPMof enginereachescorrectspeed.
CHAIN ADJUSTMENT Checkthe chainadjustment afterthe first twohoursof use. Readjustif it hasmorethan 1/2"flex. Nut #2 3/8"-1/2" Nut#1 LoosenNuts#1. TurnNut#2 clockwisein 1/2turn increments, t henturn Nut#1 until it becomestight. Repeatthe abovestepsuntil chainisadjustedto the desiredtension. FRONT SHOCK ADJUSTMENT Thereare five adjustablepositionson thefront shock.The defaultpositionis in the middleset bythe manufacturer.
It is very important t o inspectand maintain yourGo-kartregularly.Followthe guidelinesin the chart. The intervalsbetweenperiodicservicesin monthsare shown. At the end of eachintervalbe sure to performthe maintenance listed. 1WEEK MONTHLY QUARTERLY YEARLY ITEMS Fuellines Air cleaner Throttlecontrols Sparkplug Valveclearance Engineoil During running-in period, replace every 150 miles. After running-in period, replace every 600 miles.
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Improper maintenance or failing to performrecommended maintenance couldbe hazardous. If you performimpropermaintenance or do not maintain yourGo-kart you may havean accident. Keepyour Go-kartin good condition.Askyourauthorizedservice centeror a qualified mechanicto do the maintenance itemsmarked with anasterisk(*). Youmay performthe unmarked maintenance items by referringto the instructions in this sectionif you havemechanical experience.Ifyou arenot sure how todo the maintenance ask your authorized serviceor call BajaMotorsports.
BATTERY INSTALLATION INITIALSERVICE AND INSTALLATIONOF BATTERY: Eye Protection RubberGloves The following procedure isvery dangerous and shouldbe performed with the utmostcareand attention.Wear protective eye wear,rubber gloves,and havewateravailableshouldelectrolyte come in contactwith skin or eyes.KEEPALL CHILDREN AWAYFROMTHE AREAWHILETHIS PROCEDURE IS BEINGPERFORMED. POISON - CAUSESSEVEREBURNS Containssulfuricacid.
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Preparing the battery: Placebatteryon levelsurface.Remove cap stripfrom top of battery. (seefigure 20) Wear eye protection and rubberglovesfor this step. Oncebatterystripis removed, Figure20 locateelectrolytein bottleand placeoverthe six openings. Pressfirmly downon bottle allowingthe batteryto piercethe six in-line openingsin bottle. Let electrolyte drain into batteryuntil bottleis completely empty.
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How to Initially Charge the battery: Connectthe red positive(+) cabletothe red positive(+) poleof the battery. (seefigure 24) Connectthe blacknegative(-) cableto the Figure24 blacknegative(-) poleof the battery.(see figure 25) Note:The red positive(+) cablehasa largerdiameterthan the blacknegativey cable. Chargingrate:Chargebattery@ 0.7Amps for 5 ~ 10 hours. •...
Removeold batteryfrom underseat. The batterystrapwill needto be removed. Markwhichcable is connected to thepositiveterminal(+)and whichcable is connected to the negative(-) terminal. Cleancableconnectors withwire brushor sandpaperto removeoxidation. After charging,installnewbattery.Putdielectricgreaseon thebattery terminalstoavoidcorrosion.Connectcablestothe properterminals. Positivecableto positiveterminalA and negativecableto negative terminaly. Positive(+)cable is redand largerin diameter.Negative y cableis black andsmallerof thetwo in diameter.CONNECTNEGATIVE CABLELAST.
To check oil level: 1. Parkvehicleon levelground. Oil capand dipstick 2. Remove dip stickand wipeoff with a cleanrag. Insertthe dipstickin the filler hole. 3. Removethe dipstickand inspectthe oil level. 4. Oil levelshouldbe in betweenthe Lowerindexlineand Upperindexline markson thedipstick. 5. Addoil if oil is belowlowermarkon dipstick. Do Not fill aboveuppermark. Referto page10 for correctengineoiltype.
The air filter elementmustbe keptcleanto providegoodenginepower, ifyou useyour vehicleundernormalconditions, y ou shouldservicethe air filter at the intervalsspecified.If you ridein dusty,wet,or muddyconditions, y ou will needto inspecttheair filter elementmuchmorefrequently. Usethefollowing procedures to removetheelementto inspectand clean. AIR FILTERREMOVAL Cover Air Filter 1. LocateAir FilterBox at rearof Go-kart and removecover.
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Operatingtheenginewithoutthe air filter elementin place couldbe hazardous. If theair filter elementdid not filter dirt, severeenginedamagewould occurifthe dirtenteredthe runningengine. Neverrunthe enginewithouttheair filter elementin place. _CAUTION Failing to inspect the air filter elementfrequently if the vehicle is used in dusty, wet, or muddy conditionscoulddamageyour Go-kart. The air filter elementcouldbecomecloggedundertheseconditions, a nd enginedamagemay result.
NOTE: This Go-Kartusesresistor-type sparkplug to avoidjamming electronicparts. Impropersparkplug selectionmaycauseelectronic interference with your Kartsignitionsystem,resultingin vehicleperformance problems. Use recommended sparkplugs. To installa sparkplugturn it in as far as possiblewith yourfingers, then tightenit with a wrench. Ak CAUTION Improperinstallation of the sparkplug coulddamageyourKart. An overlytightor crossthreadedspark plugwilldamagethealuminum threadsof the cylinderhead.
The Go-kart is equipped with low pressuretubeless tires of the size listed below: Front Rear Size 19x7-8 22x10-10 Operatingthis Go-kartwith improper tires,or even improper tire air pressurecould be hazardous. If youuseimproper t iresor improper t ireair pressure, you maylosecontrol of theGo-kart. Alwaysusethe sizeand typetires specified.Alwaysmaintainpropertire air pressure as describedin this section.
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Overfilling the air to the tires couldbe hazardous. If you put too muchair intothetire, mayburst,and causingsevereinjury. Checktheair pressure from timeto timewhileinflatingthe tire gradually, untilthe specifiedair pressureis obtained. Tire Replacement YourGo-karthas low-pressure tubelesstires. Air is sealedby thecontact surfacesof the innerwheelrim and the tire bead. If the innerwheelrim or tire beadis damaged, a ir may leak.
The Go-kart has Hydraulic disk brakes on all four wheels. Failingto inspectand maintain your Go-kart'sbrakesystemproperly could behazardous. Impropermaintenance of the brakeincreasesyourchanceof havingan accident. Besureto inspectthe brakebeforeridingaccording to the INSPECTION BEFORERIDINGsection. Alwaysmaintainyour brakesaccording to the MAINTENANCE SCHEDULE. Operatingthe Go-kartin harshconditions could behazardousifyou do not inspectbrakewearoften.
The following informationisprovidedto helpyou identifyprobable questions you mayhaveconcerning the operationofyou Go-kart.See your authorized servicecenterwithany additionalquestions you may have. Engineturns over but fails to start On'O'"'psw"ch I,n o _ po,,on IWa'er'n'ue' I ISparkp'u0 nginecompression 155Ibs I No fuel I Ora'ns_"e_ I r_°s_ar_'°lsoar_ IRep'en'shfue' J Nocompression [c,ogged...
1.Remove the spark p lug a nd reattach ittothe spark plug lead. 2. Turnignitionkey to the "RUN" position. Slide the enginestop switch to the "Run" position. Push the electricbutton "START "(grey button). Applythe rear brakeleverto makesure the rear wheelsare locked. If the ignitionsystemis operatingproperly,a bluesparkshouldjump acrossthe sparkplug gap.
It is best to transport the Go-kart in the normal position. Drainscrew Beforetransportinq the Go-kartdrain thefuel from thecarburetoras follows: 1. Drainfuel from carburetorintoanemptycontainerby looseningthe carburetor drainscrewlocatedon bottomof carburetor. 2. Whenthefuel has beendrained,retightenthedrain screw. Drainingfuel from thecarburetorcouldbe hazardous. Fuelcouldcatchfire if you do not handleit properly. Whendraining fuel from the carburetor, besuretoshuttheengine off.
Athorough cleaning of yourGo-kart isa necessary partof maintenance. Itwill helpkeepyourGo-kart looking andperforming best. Proper cleaning canalso extend thelifeofyourGo-kart. It is importantto cleanand inspectyour Go-kartaftereveryride,especiallyif it is used in mud,brush,grass,water,salt water,or verydustyconditions The build-upof mud,brush,grass,etc.especiallyon the engineand exhaust system,canreduceenginecoolingability,concealdamage,or increasewear of certainparts. It is importantto removeall debrisduringcleaning. PREPARATIONFOR CLEANING Washthe Go-kartbeforeany muddrieson the Go-kart.
Withsomecare,yourGo-kartcanbe washedin a similarmannerto washing an automobile. Note: Avoidsprayingor allowingwaterto flow over thefollowing places: • Ignitionswitch • Spark plug • Fueltank cap • Carburetor • Air filter Use a gardenhoseat low pressureto removethe majorityof dirtor other debris. HandwashyourGo-kartwith mildsoap or detergentand water. Try to thoroughly removeall dirtand debriswithoutexcessive water pressure, evenat remoteareassuchas betweenenginecoolingfins, linkagesor mountingbrackets.
If you do notplanon usingyourGo-kartfor an extendedperiodof time, the kartwill needspecialservicerequiring appropriatematerials, e quipmentand skill. Forthis reason,we recommend thatyou trust this maintenance work to yourauthorized servicecenter. If you wish to servicethe machinefor storage yourself,follow the generalguidelines below: VEHICLE Placethe vehicleon level groundand washthe entirevehicle. FUEL Drainthefuel from thefuel tank bya handpump.
You needto knowtheframe and engineserialnumbersto get titledocuments for yourGo-kart.You also needthesenumbersto helpyourauthorized servicecenteror BajaMotorsports order parts. The Framenumberisstampedon the frame behindseat. The enginenumber is locatedon the leftside of the enginehousing. Engineserial Framenumber number Writedownthe serialnumbersherefor yourfuture reference FrameNo.: EngineNo.:...
DIMENSIONS Overalllength ....................93.5in. Overallwidth....................54.75 In. Overallheight ....................60 in. Wheelbase ....................74 in. Groundclearance ..................5.75in. Dryweight ....................515 Ibs. ENGINE Model ......................DZ1P57QMJ Type......................ForcedAir-cooled,single cylinder,4-Stroke Displacement ....................149.6cc BoreX Stroke ....................57.4mm X 57.8mm Max power .
BAJAINC.- EMISSION CONTROL SYSTEMWARRANTY YOURWARRANTY RIGHTSANDOBLIGATIONS The emissioncontrolsystemwarrantyperiodfor thisvehiclebeginson the date thevehicleisdeliveredto thefirst purchaserotherthanan authorized dealer,or the dateit isfirst used as a demonstrator, lease,or company vehicle,whichever comesfirst and continuesfor 60 monthsafterthatdate,or 5,000kin, w hichevercomesfirst, providedthere hasbeenno abuse,neglector impropermaintenance ofyour vehicle. Wherea warrantableconditionexists, the Distributor will repairyour vehicleat no costto you,includingdiagnosis, partsand labor.
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Youremissioncontrolsystemwarrantycoverscomponents whosefailure wouldincreasean engine'semission,including electroniccontrols, f uel injec- tionsystem,carburetor, t he ignitionsystem,catalyticconverter, o r any other systemutilizedin this vehicleto controlemissionif it is originallyequipped. Alsoincludedmay be hoses,connectors and otheremission-related assem- blies. Replacing or repairingothercomponents (including parts,labor,and othercosts)not coveredby thisemissioncontrolsystemwarrantyor the standard warrantyisthe responsibility ofthe owner. Coverage of repairsunderthis warrantyappliesonlywhen repairsare com- pletedat an authorized dealeror repairfacility.
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o Useof replacement p artsor accessories not conforming to the originalspecifications whichadverselyaffect performance • Physicaldamage,corrosion, o r defectscausedby fire, explosionsor similarcausesbeyondthe controlof theDistributor. • Failuresnot causedby a defectin materialor workmanship. Useof thevehiclein any typeof competitive racingor relatedeventsimmedi- atelyand completely voidsthis and all otherwarranties. LIMITEDLIABILITY The liabilityof the Distributor underthis EmissionControlSystemWarranty is limitedsolelyto the remedying of defectsin materialworkmanship by an...