Baja motorsports BR150-D Owner's Manual
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Baja motorsports BR150-D Owner's Manual

150cc go-kart
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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
OWNER'S MANUAL
Minimum Age Requirement 16
Always wear a helmet; It could save your Life!
Please obtain, review, and follow provincial / municipal government acts and
regulations pertaining to owning and operating an off-road vehicle.
REV. D
040209

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Summary of Contents for Baja motorsports BR150-D

  • Page 1 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 OWNER’S MANUAL Minimum Age Requirement 16 REV. D 040209 Always wear a helmet; It could save your Life! Please obtain, review, and follow provincial / municipal government acts and regulations pertaining to owning and operating an off-road vehicle.
  • Page 2 Congratulations on your purchase of a Baja 150cc Go-Kart. It is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days form the date of purchase. During the warranty period BAJA, INC. will at its option, repair, provide replacement parts or replace your Baja Go-Kart at no charge.
  • Page 3 WARNING 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 instructions which should be read carefully before operating the vehicle.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS NOTICE TO USERS..................2 BR150 GOKART..................... 9 FUEL AND OIL....................10 WARNING LABELS..................11 CONTROL PANEL AND IGNITION SWITCH..........13 THROTTLE AND BRAKE PEDAL..............14 PARKING BRAKE................. 14 SEAT ADJUSTMENT..................15 RIDING YOUR GO-KART................16 INSPECTION BEFORE RIDING..............17 SAFETY GEAR....................

  • Page 5: Notice To Users

    NOTICE TO USERS Please read this manual and follow all instructions carefully. To emphasize the special information, the symbol and the words WARNING or CAUTION have some special meanings. Pay great attention to the messages. Indicates a potential hazard that WARNING could result in death or injury.
  • Page 6 NOTICE TO USERS This off-road product IS NOT A TOY AND CAN BE HAZARDOUS TO OPER- ATE. This product handles differently from other vehicles including ATV’s and motorcycles. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles. To help you make informed decisions about safety, you will find provided in this manual operating procedures and other safety procedures which must be followed.
  • Page 7 NOTICE TO USERS IMPORTANT RULES FOR SAFE OPERATION WARNING 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.
  • Page 8 NOTICE TO USERS THE VEHICLE SHOULD NEVER BE STARTED WITHOUT FIRST CHECKING TO SEE THAT THE THROTTLE IS IN IDLE POSITION. Do not start engine without verifying proper function of the throttle. Never attempt to start this vehicle without having the operator seated in the proper position. When starting with the operator in the seat, the operator should have their left foot on the brake.
  • Page 9 NOTICE TO USERS LOOSE CLOTHING, LONG HAIR, OR ARTICLES WORN BY ANY OPERATOR OR PASSENGER MUST BE FULLY CONTAINED OR COVERED TO PREVENT THEM FROM POSSIBLY BEING CAUGHT IN ROTATING PARTS OF THE VEHICLE OR THE SURROUNDING ENVIRONMENT WHILE RIDING. FAILURE TO OBEY COULD ENDANGER THE PERSONAL SAFETY OF THE OPERATOR OR PASSENGER.
  • Page 10 NOTICE TO USERS 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 muffler, cylinder head, or any other potentially hot area on or around the engine.
  • Page 11 NOTICE TO USERS This manual, along with the other supplements provided with your vehicle, provide guidelines for the assembly, maintenance, and operation of this vehicle and is not intended as a service manual. Assembly, maintenance, and/or repair of this vehicle should only be performed by persons of sufficient mechanical skill, experience, and judgment (such as outdoor equipment dealers, motorcycle dealer/shops, or small engine dealers) so that no unsafe condition or modification is made.

  • Page 12: Br150 Gokart

    BR150-1 Brush guard bar Steering wheel Rear rack Headlight Rear wheel Front wheel [Left] Fuel tank Control panel Seat Rear shock ab- Front shock sorber absorber Safety belt [Right]...

  • Page 13: Fuel And Oil

    FUEL AND OIL FUEL The proper fuel is very important for the engine. Ensure that there is no dust, dirt, or water which has mixed in the fuel. Please use regular unleaded gasoline ENGINE OIL Your 150cc Go-kart has a four-stroke engine. Please use oil as described in the chart below.

  • Page 14: Warning Labels

    WARNING LABELS 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 difficult to read, you should get a replacement by contacting Baja...
  • Page 15 WARNING LABELS WARNING -Moving parts can crush and cut. -Keep hands clear. -Do not operate with guard removed. WARNING LOAD LIMIT WARNING 22 LBS NEVER sit here LONG HAIR WARNING ALL HAIR MUST BE TIED UP AND NO RIDING SECURED AT OR ABOVE SHOULDER LENGTH. ALL LOOSE CLOTHING MUST BE SECURED.

  • Page 16: Control Panel And Ignition Switch

    CONTROL PANEL AND IGNITION SWITCH Engine stop switch Ignition Key Engine stop switch - When engine is running move Stop switch to “OFF” position. The engine should stop when switch is depressed. If the switch fails to stop engine, consult your nearest service center. Ignition key switch - Insert key into ignition switch, turn key CW and release key when engine starts.

  • Page 17: Throttle And Brake Pedal

    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 fluid reservoir Parking brake...

  • Page 18: Seat Adjustment

    SEAT ADJUSTMENT 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 WARNING Before attempting to adjust the seat, ensure that the engine is not running.

  • Page 19: Riding Your Go-Kart

    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 find a good place to practice the skills. Find a flat, open area with enough space to practice the new skills.

  • Page 20: Inspection Before Riding

    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 operating condition.
  • Page 21 INSPECTION BEFORE RIDING WARNING Overloading could be hazardous. Overloading could cause changes in vehicle handling and could lead to an accident. Never exceed the stated load capacity for this Go-kart. WARNING Operating this Go-kart with improper modifications could be hazardous. Improper installation of accessories or modifications to this vehicle may cause changes in handling.

  • Page 22: Safety Gear

    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 fits snugly. Motorcycle dealers can help in selecting a good quality helmet which fits properly. WARNING Operating this Go-kart without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be hazardous.

  • Page 23: Break-In

    BREAK-IN The first month is the most important in the life of your vehicle. Proper operation during this break-in period will be helpful for assuring maximum life and performance of your new vehicle. The following guidelines explain proper break-in procedures. Maximum Throttle Opening Recommendation During the first 10 hours of operation, you should always use less than ½...

  • Page 24: Drive Select Lever

    DRIVE SELECT LEVER The drive select lever shifts 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.

  • Page 25: Carburetor Adjustment

    CARBURETOR ADJUSTMENT Never make unnecessary adjustments. The manufacturer recommended settings are correct for most applications. You will need a tachometer to make some of the adjustments. This should only be performed by a trained mechanic. Idle screw Warm up the engine for about 5-10 minutes. Connect the tachometer, and adjust the throttle idle speed (standard value is 1700 RPM).

  • Page 26: Chain And Shock Adjustment

    CHAIN AND SHOCK ADJUSTMENT CHAIN ADJUSTMENT Check the chain adjustment after the first two hours of use. Readjust if it has more than 1/2” flex. Nut #2 3/8”-1/2” Nut #1 Loosen Nuts #1. Turn Nut #2 clockwise in 1/2 turn increments, then turn Nut #1 until it becomes tight.

  • Page 27: Inspection And Maintenance

    MAINTENANCE SCHEDULE 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. ITEMS 1 WEEK MONTHLY...
  • Page 28 If you are not sure how to do the maintenance ask your authorized service or call Baja Motorsports. CAUTION If you use your Go-kart under severe conditions, it will need maintenance more often than shown in the chart.

  • Page 29: Battery Installation

    BATTERY INSTALLATION BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: Eye Protection Rubber Gloves WARNING The following procedure is very dangerous and should be performed with the utmost care and attention. Wear protective eye wear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes.
  • Page 30 BATTERY INSTALLATION Preparing the battery: · Place battery on level surface. Remove cap strip from top of battery. (see figure 20) Wear eye protection and rubber gloves for this step. Once battery strip is removed, Figure 20 locate electrolyte in bottle and place over the six openings.
  • Page 31 BATTERY INSTALLATION BATTERY INSTALLATION How to Initially Charge the battery: Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 24) Connect the black negative (-) cable to the Figure 24 black negative (-) pole of the battery. (see figure 25) Note: The red positive (+) cable has a larger diameter than the black negative y...

  • Page 32: Battery Replacement

    BATTERY REPLACEMENT · Remove old battery from under seat. The battery strap will need to be removed. Mark which cable is connected to the positive terminal (+) and which cable is connected to the negative (-) terminal. · Clean cable connectors with wire brush or sandpaper to remove oxidation. ·...

  • Page 33: Engine Oil

    ENGINE OIL To check oil level: 1. Park vehicle on level ground. Oil cap and dipstick 2. Remove dip stick and wipe off with a clean rag. Insert the dipstick in the filler hole. 3. Remove the dipstick and inspect the oil level. 4.

  • Page 34: Cleaning Oil Filter

    CLEANING OIL FILTER, TRANSMISSION OIL Cleaning oil filter 1. Drain engine oil as instructed on page 30. 2. Remove oil filter plug (located on bottom left side of engine. 3. Remove screen filter and spring assembly. 4. Clean screen with solvent. 5.
  • Page 35 ENGINE OIL WARNING 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.

  • Page 36: Air Filter

    AIR FILTER 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 filter at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air filter element much more frequently.
  • Page 37 AIR FILTER WARNING Operating the engine without the air filter element in place could be hazardous. If the air filter element did not filter dirt, severe engine damage would occur if the dirt entered the running engine. Never run the engine without the air filter element in place. CAUTION Failing to inspect the air filter element frequently if the vehicle is used in dusty, wet, or muddy conditions could damage your Go-kart.

  • Page 38: Spark Plug

    SPARK PLUG NOTE: This Go-Kart uses resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interference with your Karts ignition system, resulting in vehicle performance problems. Use recommended spark plugs. To install a spark plug turn it in as far as possible with your fingers, then tighten it with a wrench.

  • Page 39: Tires

    TIRES The Go-kart is equipped with low pressure tubeless tires of the size listed below: Front Rear Size 19x7-8 22x10-10 WARNING 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.

  • Page 40: Tire Replacement

    TIRES WARNING Overfilling the air to the tires could be hazardous. If you put too much air into the tire, may burst, and causing severe injury. Check the air pressure from time to time while inflating the tire gradually, until the specified air pressure is obtained. Tire Replacement Your Go-kart has low-pressure tubeless tires.

  • Page 41: Braking

    BRAKING The Go-kart has Hydraulic disk brakes on all four wheels. WARNING Failing to inspect and maintain your Go-kart’s brake system properly could be hazardous. Improper maintenance of the brake increases your chance of having an accident. Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section.

  • Page 42: Brake Inspection

    FRONT AND REAR HYDRAULIC DISK BRAKE INSPECTION Brake fluid cap Brake fluid reservoir Brake fluid level Brake hose Front disk brake caliper Brake disk Brake hose Brake Rear disk Brake hose Disk brake caliper 1. Inspect front and rear disk brake calipers for leakage. If brake fluid leaks, the safety of riding could be affected.

  • Page 43: Troubleshooting

    TROUBLESHOOTING The following information is provided to help you identify probable questions you may have concerning the operation of you Go-kart. See your authorized service center with any additional questions you may have. Engine turns over but fails to start Engine compression On/Off flip switch Spark plug...

  • Page 44: Ignition System Check

    IGNITION SYSTEM CHECK 1. Remove the spark plug and reattach it to the spark plug lead. 2. Turn ignition key to the “RUN” position. Slide the engine stop switch to the “Run” position. Push the electric button “START “(grey button). Apply the rear brake lever to make sure the rear wheels are locked.

  • Page 45: Transporting

    TRANSPORTING It is best to transport the Go-kart in the normal position Drain screw Before transporting the Go-kart drain the fuel from the carburetor as follows: 1. Drain fuel from carburetor into an empty container by loosening the carburetor drain screw located on bottom of carburetor. 2.

  • Page 46: Cleaning Procedure

    CLEANING PROCEDURE 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, brush, grass, etc.

  • Page 47: Washing Your Go-Kart

    WASHING YOUR GO-KART With some care, your Go-kart can be washed in a similar manner to washing an automobile. Note: Avoid spraying or allowing water to flow over the following places: ● Ignition switch ● Spark plug ● Fuel tank cap ●...

  • Page 48: Storage Procedure

    STORAGE PROCEDURE If you do not plan on using your Go-kart for an extended period of time, the kart 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.

  • Page 49: Serial Number Location

    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 seat. The engine number is located on the left side of the engine housing.

  • Page 50: Specifications

    SPECIFICATIONS DIMENSIONS Overall length ....................93.5 in. Overall width ....................54.75 In. Overall height ....................60 in. Wheelbase ....................74 in. Ground clearance ..................5.75 in. Dry weight ....................515 lbs. ENGINE Model......................DZ1P57QMJ Type ......................Forced Air-cooled, single cylinder, 4-Stroke Displacement ....................149.6 cc Bore X Stroke ....................57.4mm X 57.8mm Max power.....................9.2 hp / 7500rpm Max Torque....................7.75 lb-ft / 6500rpm Idle speed......................1700+100rpm...

  • Page 51: Wire Diagram

    WIRE DIAGRAM...

  • Page 52: Emission Control System Warranty

    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 delivered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
  • Page 53 Your emission control system warranty covers components whose failure would increase an engine’s emission, including electronic controls, fuel injec- tion system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assem- blies.
  • Page 54 o Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance • Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. • Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immedi- ately and completely voids this and all other warranties.
  • Page 55 Baja, INC. P.O. Box 61150 Phoenix, AZ. 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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Br150-1

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