Baja BO250 UTV Owner's Manual
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Baja BO250 UTV Owner's Manual

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BO250 UTV
Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this UTV
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.C
021309

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Summary of Contents for Baja BO250 UTV

  • Page 1 BO250 UTV Read this manual carefully. It contains important safety information. No one under the age of 16 should operate this UTV OWNER’S MANUAL Minimum Age Requirement 16 Rev.C 021309 Always wear a helmet; It could save your Life! Please obtain, review, and follow provincial / municipal government acts and regulations...
  • Page 2 BAJA MOTORSPORTS customer service department TOLL FREE at 1-888-863- BAJA (2252) between the hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm PST. During DST hours change to MT. You will be instructed how to proceed.
  • Page 3 WARNING 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS NOTICE TO USERS..................6 BAJA 250cc UTV................... 10 LOCATION OF WARNING LABELS.............. 11 CONTROLS AND INDICATORS..............14 KEY SWITCH..................14 HEADLIGHT SWITCH................. 14 EMERGENCY SHUT OFF SWITCH............ 14 HOUR METER..................14 REVERSE INDICATOR LIGHT............14 NEUTRAL INDICATOR LIGHT............14 FORWARD INDICATOR LIGHT............
  • Page 5 TABLE OF CONTENTS PERIODIC MAINTENANCE SCHEDULE............37 PERIODIC LUBRICATION SCHEDULE..........37 AIR FILTER....................38 RADIATOR..................... 39 ENGINE OIL....................39 ENGINE OIL LEVEL CHECK............. ENGINE OIL CHANGE............... 41 TRANSMISSION OIL CHANGE............REAR DIFFERENTIAL OIL CHANGE............42 FUELING INSTRUCTIONS................43 BATTERY....................... PREPARING THE BATTERY............. HOW TO INITIALLY CHARGE THE BATTERY.........

  • Page 6: 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 attention to the messages. WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in vehicle damage.
  • Page 7 NOTICE TO USERS We believe in conservation and protection of the earth’s natural resources. We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off-road recreational use. NOTICE TO USERS THIS UTV IS NOT A TOY.
  • Page 8 NOTICE TO USERS · Never operate this UTV at excessive speeds. Always operate at a speed that is proper for the terrain, visibility, operating conditions, and the operator’s skill / experience. · Never attempt jumps or other stunts. · Always inspect the UTV each time before use to ensure it is in a safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
  • Page 9 NOTICE TO USERS · Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. ·...

  • Page 10: Baja 250Cc Utv

    BAJA 250CC UTV Forward/Reverse Headrests lever Brush guard Cargo bed latch Cargo bed Front bumper Accelerator and Brake pedals Radiator fill Parking brake lever Left Mirror Passenger Handle Seat Belts Key switch Steering wheel Cargo bed Front Rear Shocks Shocks...

  • Page 11: Location Of Warning Labels

    LOCATION OF WARNING LABELS 7 Located on left and right side panels...
  • Page 12 LOCATION OF WARNING LABELS...
  • Page 13 LOCATION OF WARNING LABELS...

  • Page 14: Controls And Indicators

    CONTROLS AND INDICATORS KEY SWITCH To start the vehicle turn key switch right (CW) and hold until engine is running smoothly. The engine should now idle. Turn key switch left (CCW) to turn engine off. NOTE: Key can only be removed when engine is off. EMERGENCY SHUT OFF SWITCH For engine to run, the Emergency shut off switch needs to be placed in the “ON”...

  • Page 15: Transmission Gear Shift Lever

    CONTROLS AND INDICATOR TRANSMISSION GEAR SHIFT LEVER The transmission gear shift lever is located between the driver and passenger seat cushion. To put the transmission in forward, place lever down. To put transmission in reverse, pull lever back. NOTE: Be sure to depress the brake pedal before shifting in any position.

  • Page 16: Operation Instructions

    OPERATION INSTRUCTIONS STARTING THE UTV 1. Read warning and loading labels, be sure to secure load (if any). 2. Study and understand all controls and indicators. 3. Fasten seat belt including passenger (if any). 4. Depress the brake pedal, turn ignition key clockwise and hold. 5.

  • Page 17: Loading And Unloading Cargo Bed

    OPERATION INSTRUCTIONS WARNING Make certain the hydraulic stand is secure when working under the bed. Failure to do so may result in severe injury or death. WARNING Do not lower cargo bed until all persons and objects are clear from cargo bed area. Gently lower cargo bed, do not drop bed down.

  • Page 18: Towing With The Utv

    OPERATION INSTRUCTIONS TOWING WITH THE UTV • Never tow a vehicle or trailer on public streets or highways. • Speed should be reduce when towing. • Use extreme caution. • Never allow riders in or on whatever is being towed. •...

  • Page 19: Preparation For Extended Storage

    OPERATION INSTRUCTIONS WARNING Remove the key and set the parking brake. Do not charge a frozen battery or batteries with bulging cases. Discard batteries according to state and local environmental legal guidelines for battery disposal. Frozen batteries may explode. CAUTION Batteries with low charge will freeze at low temperatures.

  • Page 20: Returning Stored Utv To Service

    OPERATION INSTRUCTIONS RETURNING STORED UTV TO SERVICE 1. Restore the fueling system to operational standards. 2. Remove plug from fuel tank vent. 3. Connect fuel vent line to fuel tank vent. 4. Connect the battery cables making sure to connect the positive cable first. 5.

  • Page 21: Operating Your Utv

    OPERATING YOUR UTV WARNING Operating this UTV without proper instruction could be hazardous. The risk of riding could increase greatly if you do not know how to operate the UTV properly under different situations and in different types of terrain. Beginners and inexperienced operators should complete a certified training course.

  • Page 22: Inspection Before Riding

    OPERATING YOUR UTV INSPECTION BEFORE RIDING ITEM TO CHECK CONTENT Steering Smoothness; No restriction of movement; No play or looseness Brakes Proper brake lever free play; enough brake force; Parking brake effectiveness Tires Proper air pressure; Enough tread depth; No cracks, rips, or other damages Fuel Enough fuel for the intended trip;...
  • Page 23 OPERATING YOUR UTV WARNING Operating this UTV with improper tires, or improper tire air pressure could be hazardous. If you use improper tires or improper air pressure, you may lose control of the UTV. This will cause an accident. Always use the tires with size and type tires specified in this user’s manual. Always maintain proper tire air pressure as described in the TIRES section.

  • Page 24: Safety Gear

    OPERATING YOUR UTV 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 UTV without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be hazardous.

  • Page 25: Break-In

    OPERATING YOUR UTV BREAK-IN The first 10 hours 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 26: Starting The Engine

    OPERATING YOUR UTV STARTING THE ENGINE Before attempting to start the engine, make sure to follow these steps. 1. Any maintenance checks have been made. 2. Parking brake is applied. 3. Driver and passenger (if any) is seated with seat belt on. 4.
  • Page 27 OPERATING YOUR UTV WARNING Operating this UTV on paved surfaces, including sidewalks, paths, parking lots, driveways and streets could be hazardous. UTV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the UTV, and may cause the vehicle to lose control. Avoid operating the UTV on paved surfaces if possible.
  • Page 28 OPERATING YOUR UTV WARNING Failing to use extra care when operating on excessively rough, slippery, or loose terrain could be hazardous. Failing to use extra care could cause loss of traction. This could result in an accident, including an overturn. Do not operate under these conditions until you have learned and practiced the skills necessary to control the UTV on such terrain.
  • Page 29 OPERATING YOUR UTV WARNING The UTV may start moving as soon as you release the parking brake. Unexpected movement could cause you to lose control of the UTV. Make sure to apply the foot brake before you release the parking brake. Brake pedal Accelerator pedal Release the brake pedal and slowly...

  • Page 30: Braking

    OPERATING YOUR UTV BRAKING Brake pedal Accelerator pedal To stop the UTV, first release the accelerator pedal, then depress the brake pedal smoothly. WARNING Braking while turning the UTV could be hazardous. Use of the brake when turning could cause the UTV to slide or roll over. Use the brake to slow down before you begin to turn.

  • Page 31: Operation On Hills

    OPERATING YOUR UTV OPERATION ON HILLS WARNING Operating this UTV on hills (over 15 degrees) could be hazardous. The UTV could overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the UTV on hills which are too steep for the UTV or for your abilities.

  • Page 32: Operating Over Obstacles

    OPERATING YOUR UTV DESCENDING A HILL WARNING Going down a hill improperly could be hazardous. Going down a hill improperly could cause loss of control or cause the UTV to overturn. Always follow the proper procedures for going down hills as described in this section.

  • Page 33: Operating Through Water

    OPERATING YOUR UTV OPERATING THROUGH WATER You can ride the UTV through shallow water. Make sure it is not more than 10cm (4 inches) deep and is not moving fast. Choose a good place to cross before you ride through the water. Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard.

  • Page 34: Operating In Cold Weather

    OPERATING YOUR UTV OPERATING IN COLD WEATHER Pre-ride Inspection Check that the gas, brake pedal move freely. Move the UTV forward and backward to check that the wheels roll freely. If you cannot move the UTV, the tires may be frozen to the ground, or the brakes may be frozen to the wheels. If the tires are frozen to the ground, pour warm water around them to melt the ice.

  • Page 35: Dressing For Cold Weather Riding

    OPERATING YOUR UTV DRESSING FOR COLD WEATHER RIDING WARNING Operating your UTV in cold weather without proper clothing could be hazardous. Continued exposure in the cold weather could lead to hypothermia. Hypothermia is a condition where your body’s inner temperature drops low enough to cause injury or death.

  • Page 36: Operating Your Utv On Snow And Ice

    OPERATING YOUR UTV OPERATING YOUR UTV ON SNOW AND ICE WARNING Riding on snow-covered terrain, even with care, could be hazardous. The snow may be covering rocks, holes, ice or other hazards that can cause loss of control. Severe injury or death could occur if you lose control of the UTV.

  • Page 37: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE REGULAR INTERVAL SERVICE Monthly service by owner or Check engine oil level; change if trained technician necessary (see periodic lubrication schedule) Check engine cooling air intake; visually inspect Engine unshrouded area around engine exhaust for gases and debris and clean if necessary Tires Check air pressure and adjust as...

  • Page 38: Air Filter

    AIR FILTER The air filter 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 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 39: Radiator

    RADIATOR FLUID/ENGINE OIL RADIATOR FILL The Radiator fill is located behind the passenger seat. Fill radiator with antifreeze. Radiator fill RADIATOR DRAIN 1. Place approved container under radiator drain plug. 2. Remove drain plug and let drain completely. 3. Reattach drain plug. ENGINE OIL LEVEL CHECK Change the engine oil monthly and for excellent performance check the oil level before each use.
  • Page 40 ENGINE OIL -20˚C -10˚C 10˚C 20˚C 30˚C 40˚C 0˚C Use the chart to select a viscosity rating based on the SAE 40 temperature range in your area. NOTE: Using multi-grade oils SAE 30 will increase oil consumption. Be sure to check the oil level SAE 10W-30/SAE 10W-40/15w-40 more frequently when using these oils.

  • Page 41: Engine Oil Change

    ENGINE OIL ENGINE OIL CHANGE 1. Turn engine on and let it idle for at least 5 minutes to warm up, turn engine off and remove key. 2. Place oil pan or any suitable container under engine to drain oil. 3.

  • Page 42: Rear Differential Oil Change

    REAR DIFFERENTIAL OIL Rear differential drain plug BOTTOM VIEW REAR DIFFERENTIAL OIL CHANGE 1. Place oil pan or any suitable container under rear differential case. 2. Remove differential drain bolt. Let drain. 3. Reinstall the differential drain bolt and torque to 25 ft.lbs. 4.

  • Page 43: Fueling Instructions

    FUELING INSTRUCTIONS WARNING Overfilling the fuel tank could be hazardous. If you overfill the fuel tank, fuel may overflow when it expands. Expanding is due to heat from engine or sun. Overheated fuel could easily catch fire. Stop adding fuel when the fuel level is one inch from the top of the fuel tank. WARNING Improper fueling of the UTV could be hazardous.

  • Page 44: Battery

    BATTERY BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: 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. KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.

  • Page 45: Preparing The Battery

    BATTERY Note: The following page is for vehicles with battery’s containing separate electrolyte pack. Preparing the battery: · Place battery on level surface. Remove cap strip from top of battery. (see figure 20) · Remove Vent cap from battery vent located on Figure 20 top side portion of battery.

  • Page 46: How To Initially Charge The Battery

    BATTERY How to Initially Charge the battery: 1. Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure 24) 2. Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure 25) Figure 24 Note: The red positive (+) cable has a larger...

  • Page 47: Battery Replacement

    BATTERY Battery Replacement: · Remove old battery. 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. · After charging, install new battery. Put dielectric grease on the battery terminals to avoid corrosion.

  • Page 48: Adjustments

    A brown color indicates that the plug is correct. A white or dark insulator indicates that the engine may need adjustment, or another plug type may be needed. Consult your authorized dealer or Baja Motorsports if your plug insulator is not a light brown color. CAUTION Failing to use the proper spark plug could damage your UTV.
  • Page 49 ADJUSTMENTS NOTE: This UTV uses resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interference with your UTVs ignition system, resulting in the 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, do not over tighten.

  • Page 50: Tires

    ADJUSTMENTS TIRES The UTV is equipped with low pressure tubeless tires of the size and type listed below: Front Rear Size AT22x7-10 AT23x8.5-12 WARNING Operating this UTV 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 UTV. Always use the size and type tires specified.

  • Page 51: Vehicle Cleaning

    Be careful with brushes as they may scratch plastic or painted surfaces. Rinse the UTV thoroughly with clean water. Dry all areas using a chamois or soft absorbent cloth. NOTE: If warning labels are damaged contact Baja Motorsports or your local service center for replacement.

  • Page 52: Troubleshooting

    TROUBLESHOOTING PROBLEM CAUSE SOLUTION Engine turns over but No fuel Replenish fuel won’t start Clogged fuel filter Replace fuel filter Water in fuel system Drain fuel system and replenish fuel No spark Contact local service center Engine stops or looses No fuel Replenish fuel power...

  • Page 53: Serial Number Locations

    SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your UTV. You also need these numbers to help your authorized service center or Baja Motorsports order parts. The frame/vin number is stamped on the frame under the driver seat as shown in the photograph.

  • Page 54: Specifications

    SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length..............2600mm (102 in) Overall width...............1450mm (57 in) Overall height..............1720mm (68 in) Ground clearance...............270mm (11 in) Vehicle weight..............430Kg (948 lbs) Weight capacity..............385Kg (850 lbs) ENGINE Type..................4-stroke Ignition.................CDI Displacement...............244cc Horsepower.................14Hp Air cleaner................Paper element Starting................Electric Cooling system..............Water cool Max Power................11kw/7000rpm Max torque................17.6Nm/500rpm Bore and stroke..............72x60...

  • Page 55: Emission Control System Warranty

    EMISSION CONTROL SYSTEM WARRANTY 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 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 10,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle.
  • Page 56 No dealer is authorized to modify this Emission Control System Warranty. If you have any questions regarding your warranty rights and responsibilities, you should contact BAJA MOTORSPORTS.
  • Page 57 Baja, INC. P.O. Box 61150 Phoenix, AZ 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

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