Baja Motorsports BR250 User Manual
BR250/DN250 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. B
031109
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.
Congratulations on your purchase of the
Baja Inc. BR250/DN250 Go-Kart.
It is warranted to be free of manufacturing defects in the material
and workmanship for a period of 90 days from the date of
purchase. During the warranty period BAJA, INC. will at its option,
repair, provide replacement parts or replace your Baja Inc. BR250/
DN250 Go-Kart at no charge. This warranty does not cover normal
wear items or damage caused by neglect or misuse of the product.
Engine Warranty – 90 days
Frame Warranty – 90 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.
customer service line toll free at 1-888-863-2252 between the hours of
7am and 5pm Monday through Friday MST (Mountain Standard Time).
MDT (Mountain Daylight Time) during the daylight saving time. You will be
instructed how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.
II
!
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
WARNING
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
III
TABLE OF CONTENTS
FORWARD.................................................................................... 2
NOTICE TO USERS....................................................................... 3
BR250/DN250 GO-KART.............................................................. 9
FUEL AND OIL............................................................................. 10
WARNING LABELS..................................................................... 11
CONTROL PANEL AND IGNITION SWITCH............................... 14
THROTTLE AND BRAKE PEDAL................................................ 15
PARKING BRAKE......................................................... 15
SEAT ADJUSTMENT.................................................................... 16
RIDING YOUR GO-KART............................................................. 17
INSPECTION BEFORE RIDING................................................... 18
SAFETY GEAR............................................................................. 20
BREAK-IN..................................................................................... 21
DRIVE SELECT LEVER............................................................... 22
CARBURETOR ADJUSTMENT................................................... 23
CHAIN AND SHOCK ADJUSTMENT........................................... 24
MAINTENANCE........................................................................... 25
BATTERY INSTALLATION........................................................... 27
BATTERY REPLACEMENT.......................................... 30
ENGINE OIL.................................................................................. 31
CLEANING OIL FILTER............................................................... 32
TRANSMISSION OIL................................................... 33
RADIATOR................................................................................... 34
AIR FILTER................................................................................... 35
TIRES............................................................................................ 37
BRAKING...................................................................................... 39
BRAKE INSPECTION................................................... 40
TROUBLESHOOTING................................................................... 41
IGNITION SYSTEM CHECK......................................... 42
TRANSPORTING........................................................................... 43
CLEANING PROCEDURE............................................................. 44
PREPARATION FOR CLEANING................................. 44
WASHING YOUR GO-KART......................................................... 45
INSPECTION AFTER CLEANING................................. 45
STORAGE PROCEDURE............................................................... 46
SERIAL NUMBER LOCATION....................................................... 47
WIRE DIAGRAM............................................................................. 48
SPECIFICATIONS........................................................................... 49
EMISSION CONTROL SYSTEM WARRANTY................................ 50
1
FORWARD
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.
WARNING
WARNING
!
Indicates a potential hazard that could result
in death or injury.
CAUTION
!
NOTE: Indicating special information which is to make maintenance easier or
instructions clearer.
WARNING and CAUTION are arranged like this:
WARNING
!
CAUTION
!
This user’s manual contains important safety and maintenance information.
Read it carefully before riding. Failing to follow the warnings contained in
this manual could result in INJURY or DEATH.
It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
Indicates a potential hazard that could result
in vehicle damage.
The rst part will identify a POTENTIAL HAZARD.
The second part will describe WHAT COULD
HAPPEN if you ignore the WARNING or CAUTION.
The third part will describe HOW TO AVOID THE
HAZARD.
All information, illustrations, photographs and specications 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
same or similar changes to the vehicle previously built or sold.
2
NOTICE TO USERS
This off-road product IS NOT A TOY AND CAN BE HAZARDOUS TO
OPERATE. 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 nd provided in
this manual operating procedures and other safety procedures which must
be followed. In addition to the safety information in this manual, you will nd
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
WARNING
!
TO THE OPERATOR OR PASSENGER, A
BYSTANDER OR A PERSON INSPECTING OR
REPAIRING THE PRODUCT.
CAUTION INSTRUCTIONS ARE PROCEDURES
TO PREVENT DAMAGE TO THE VEHICLE OR
INJURY TO THE OPERATOR OR PASSENGER, A
BYSTANDER OR A PERSON INSPECTING OR
REPAIRING THE PRODUCT.
CAUTION
!
NOTE: A NOTE provides key information to make procedures easier or
clearer.
3
NOTICE TO USERS
IMPORTANT RULES FOR SAFE OPERATION
WARNING
!
1. 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. Avoid
operating this vehicle in any area with stationary 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.
2. This vehicle should NEVER be operated indoors. The exhaust from the
engine contains carbon monoxide, which is a tasteless, odorless, and
poisonous gas.
3. Unless otherwise specied in this manual, all screws, nuts, and bolts
must be kept tight to ensure that the vehicle is in safe operating
condition. The engine must be kept free of all dirt and other accumulations,
paying particular attention to throttle linkage area.
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 recommended
ination pressure is the maximum tire pressure as printed on the tire’s
sidewall. IMPROPER TIRE PRESSURE MAY CAUSE INSTABILITY AND MAY
PREVENT PROPER BRAKING OR STEERING.
6. Modications of this vehicle or removal of any original equipment or safety
decal may render the vehicle unsafe or illegal. NEVER REMOVE ANY
PROTECTIVE GUARDS OR BELT GUARDS. These covers are for operator
passenger’s protection. If any guards are removed for maintenance or
servicing of the vehicle, ensure that they are secured in place prior to
operating the vehicle.
4
NOTICE TO USERS
7. 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.
8. This vehicle is not designed or intended for racing, any form of
competition.
9. The operator’s ability to operate this off-road vehicle safely is largely
dependent upon the operator’s ability to exercise proper judgment. An
operator also must not be too small or too large for controlled operation.
The operator must be of sufcient age, understanding, mental capacity,
and physical capability to safely operate this vehicle. This vehicle should
only be operated after mature, supervised instruction and sufcient
practice. 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 components. Any
passenger must be of sufcient age, understanding, mental capacity, and
physical capability to act to protect himself/herself. ALWAYS FOLLOW THE
RECOMMENDED AGE RESTRICTION OF 16 YEARS FOR OPERATORS AND
PASSENGERS.
11. The engine should be stopped when the vehicle is not in use.
12. The operator and passenger (if any) of this vehicle should always wear a
helmet approved by agencies such as Department of Transportation (DOT),
Safety Helmet Council of America (SHCA), or Snell Memorial Foundation
(SNELL). Most off-road vehicle accident fatalities are due to head injuries.
The operator should also wear face shields or goggles, boots or
closed-toe shoes, gloves, and other appropriate protective clothing.
5
NOTICE TO USERS
13. 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.
14. DO NOT PLACE HANDS, FEET, OR ANY OTHER PART OF THE BODY OR
ANY CLOTHING NEAR THE ENGINE, MUFFLER, WHEELS, CHAIN AND
OTHER ROTATING PARTS OF THE VEHICLE WHILE RIDING OR RUNNING
THE ENGINE. Caution must be used in performing required maintenance
on or near an operating engine. Special caution should be taken after the
engine has been running, since the engine and other drive components
may be extremely hot.
15. Wet, slippery, rough, or steep terrain is potentially dangerous and may
result in injury if proper caution in not observed. Slow speeds are required
to safely operate this vehicle under these conditions. The operator must
use mature judgment, 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.
17. Each time before using this vehicle, the fuel supply should checked. The
fuel tank should never be lled while the engine is running or while the
engine is hot. Do not ll tank in a closed area such as a garage, while
smoking, or in the vicinity of an open ame. Do not overll the tank. There
should not be any fuel in the ller neck. Replace cap tightly to prevent
spillage of fuel and potential re hazard. After lling tank, move the
vehicle at least 15 feet away from the spot of lling before starting.
18. If the vehicle should start making unusual noise or vibrating abnormally,
the engine should be stopped and the spark plug wire disconnected. The
vehicle should then be checked for damage. Excessive noise or vibration
is generally a warning of loose or worn parts.
6
NOTICE TO USERS
19. 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 mufer, cylinder head, or any other potentially hot
area on or around the engine.
20. Always perform a pre-ride inspection before starting the engine. See
Pre-Ride Inspection section in this manual.
21. When storing the vehicle, it must be kept in a place where gasoline fumes
will not reach an open ame or spark. For long period storage, such as for
winter, the fuel tank should be drained in an open, cool area. The engine
must be allowed to cool before storage in any enclosure. Read and keep
all printed material supplied with this vehicle. Timely and specic
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 YOURSELF AND/OR OTHERS.
23. Always slow down when turning. High speed turning may cause loss of
control, possible turnover of the vehicle, and/or possible injury to the
operator or passenger.
24. While making a turn, knobby tires may increase the risk of loss of control.
ALWAYS SLOW DOWN! A collision or rollover can occur quickly, even
during routine maneuvers such as turning and riding on a hill or over
obstacles.
25. DO NOT RACE, JUMP, PERFORM “STUNT” RIDING OR “SPIN OUTS”
WHEN OPERATING THIS VEHICLE. THIS VEHICLE IS NOT DESIGNED OR
INTENDED FOR SUCH OPERATION.
7
NOTICE TO USERS
26. 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.
27. Assembly, maintenance, and/or repair of this vehicle should only be
performed by persons of sufcient mechanical skill, experience, and
judgment (such as outdoor equipment dealers, motorcycle dealer/shops,
or small engine dealers) so that no unsafe condition or modication is
made.
28. Always use extreme caution when starting the engine. Avoid touching
the engine, mufer, or drive components. These areas could cause burns
on contact.
29. The battery (if applicable) contains sulfuric acid and must not come in
contact with skin, eyes, or clothing since this will cause severe burns
possibly causing disgurement. Also, battery may generate explosive
gases and must not be exposed to sparks, ame, cigarettes, or anything
ammable or an explosion may result causing severe injury. Protective
gloves and face protection must be worn when servicing the battery.
30. ANY OPERATOR OR PASSENGER UNDER 18 YEARS OF AGE MUST
ALWAYS BE APPROPRIATELY SUPERVISED BY AN ADULT AT ALL TIMES
WHILE OPERATING THE VEHICLE.
31. Operating this vehicle requires skills acquired through practice over a
period of time. Take the time to learn the basic techniques well before
attempting to operate the vehicle.
32. Operate only on safe and familiar terrain. Avoid loose gravel and rocks. Be
careful on wet surfaces and allow for extra braking distance.
8
Headlights
BR250/DN250
Brush guard bar
Steering
wheel
Rear rack
Radiator
Front wheel
Rear shock
absorber
Exhaust pipe
Forward/Reverse shifter
Fuel tank
[Left]
Seats
Rear wheel
Control panel
Front shock
absorber
Oil ll plug
[Right]
9
Parking brake
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 250cc 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.
ENGINE
°C -30 -20 -10 0 10 20 30 40
TEMP.
°F -22 -4 14 32 50 68 86 104
Use the chart to select a viscosity rating based on the temperature range in
your area.
SAE 10W-30
10
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 difcult to read, you
should get a replacement by contacting Baja Motorsports.
1
2
3
1
!
LOSS OF CONTROL, COLLISION, OR GETTING CAUGHT IN MOVING PARTS
Adult supervision for under 16 years olds
wear a D.O.T. approved motorcycle helmet
Wear protective eye wear and clothing
2
!
WARNING
THIS GO-KART CAN BE HAZARDOUS TO OPERATE
if driven carelessly
INJURIES can result if you do not follow these
-READ OWNER’S MANUAL AND ALL LABELS BEFORE
YOU OPERATE THIS GO-KART.
-NEVER OPERATE THIS GO-KART WITHOUT PROPER
INSTRUCTIONS. Beginners require mature supervision.
-NEVER OPERATE THIS GO-KART ON PUBLIC ROADS.
it is intened off-road use only.
-NEVER OPERATE THIS GO-KART AT EXCESSIVE SPEEDS.
NEVER ATTEMPT WHEELIES, JUMPS, OR OTHER STUNTS.
instructions:
WARNING
CAN RESULT IN SERIOUS INJURIES
Secure long hair and loose clothing
Keep arms, legs and feet inside kart
Do not use alcohol or drugs
3
!
WARNING
Seat Belt Must Be Worn At All Times
CAUTION
THIS VEHICLE MANUFACTURED
FOR OFF-ROAD USE ONLY.
DO NOT OPERATE ON PUBLIC
STREETS, ROADS OR HIGHWAYS.
11
WARNING LABELS
Located on brush guard
near control panel
4
5
4
Never attempt to switch gears while vehicle is moving!
This will result in severe damage to reverse mechanism.
Only switch gears when vehicle is completely still.
5
Parking
WARNING!
6
6
R
D
Parking Brake
Reverse Lever
12
WARNING LABELS
Located on the fuel tank
7
9
8
10
7
!
WARNING
NO
LONG
9
LOAD LIMIT
22lbs (10kg )
WARNING
NEVER sit here
HAIR
ALL HAIR MUST BE TIED UP AND
SECURED AT OR ABOVE SHOULDER LENGTH.
ALL LOOSE CLOTHING MUST BE SECURED.
ALL NECKLACES AND SCARVES MUST BE
SECURED.
8
!
WARNING
NO RIDING
10
!
WARNING
-Moving parts
can crush and
cut.
-Keep hands
clear.
-Do not operate
with guard
removed.
13
CONTROL PANEL AND IGNITION SWITCH
Light switch
Water temperature
indicator light
Water temperature indicator light - This light will illuminate when the engine is
too hot.
Ignition key switch - To start vehicle insert key into ignition switch and turn
CW (clockwise).
Light switch- When switch is in “ON” position lights will illuminate.
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
Engine stop switch
14
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