Five Star 150 User Manual
OWNER’S MANUAL
OWNER’S MANUAL
DUNE 150
DUNE 150
Minimum
Minimum
Recommended
Recommended
Operator
Operator
Age:
Age:
16
16
THIS VEHICLE IS SOLD FOR OFF-ROAD USE ONLY. BEFORE OPERATING THIS VEHICLE,
READ ALL THE INSTRUCTIONS FOR SAFE ASSEMBLY AND OPERATION AS WELLAS ALL
INSTRUCTION GOVERNING THE ENGINE AND OTHER PORTIONS OF THE VEHICLE.
LIMITED W
LIMITED W
ARRANTY
ARRANTY
This Limited Warranty applies to those cases where the new product is unloaded from its shipping container, set-up as described in this manual, and under normal use and service is found to have defects in
parts or workmanship under the following terms and conditions:
This Limited Warranty covers the frame, suspension, steering, brakes, engine and engine related components for a period of 90 days from the date of purchase on the sales receipt.
This Limited Warranty DOES NOT cover wear items like tires, batteries, belts, brake pads, chains, spark
plugs, fuses, clutch plates, sprockets, light bulbs, and other normal wear items.
This Limited Warranty DOES NOT apply to any part, which in the opinion of the seller was defective
because of improper maintenance, improper assembly, alterations, abuse, negligence, or accident.
What is not covered under this Limited War ranty
This Limited Warranty does not cover any product which has been subjected to:
1. Installation of non-original replacement parts.
2. Rental Use.
3. Disassembly, adjusting, or repairing of the product in any was so as to adversely affect its safety
and reliability.
4. Competition or racing.
This Limited Warranty does not cover loss of use of the product, loss of time, inconvenience, or other
consequential damage which includes, but is not limited to, loss or damage to persons or property or
any expense of returning any damaged / defective product to the manufacturer.
How do I get Replacement Par ts and Ser vice?
Please DO NOT TAKE THIS PRODUCT BACK TO THE RETAILER. For parts or service center locations, please call 888-863-2252. Many problems are easily repaired by the consumer. Our expert customer service representatives can lead you through most problems with ease. We also have a nationwide network of Authorized Service Centers to assist with any repair or problem.
RECORD THE MODEL NUMBER AND SERIAL NUMBER OF YOUR PRODUCT IN THE SPACES
PROVIDED BELOW FOR REFERENCE WHEN ORDERING REPLACEMENT PARTS. IT IS ALSO
RECOMMENDED TO ATTACH YOU SALES RECEIPT TO THIS PAGE.
Model
No._______________________________________________Color_________________________
Serial
No._____________________________________________________________________________
(Located on the left rear frame member near the seat belt mount)
Engine
No.____________________________________________________________________________
(Located on top of engine)
FOREWORD
FOREWORD
Congratulations on your purchase of a Baja Motorsports Off-Road Machine. It represents more than 20
years of the pursuit of excellence in the off-road recreation industry. With the purchase of this product,
you will experience the thrill of off-road recreation like thousand of other consumers.
This Owner’s Manual contains important assembly, operational, safety, and maintenance information.
The manual provides information about special techniques and skills necessary to ride your machine.
Read it carefully BEFORE YOU OR ANYONE ELSE USES THIS PRODUCT. Failure to follow the
warnings contained in this manual can result in SEVERE INJURY OR DEATH.
Be sure to follow the recommended maintenance schedule and service your Baja Motorsports product
accordingly. Preventive maintenance is extremely important its longevity.
It is important that this manual remain with the product when you sell it as the next owner will need this
manual. If you should lose or damage this Owner’s Manual, please call 888-863-2252 for a replacement.
SAFETY MESSA
GE:
READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR
MACHINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO ALL THE LABELS ON THE MACHINE.
IT IS NOT RECOMMENDED THAT THIS PRODUCT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
Assumption of Risk
The Owner / Operator and any passengers assume all risks or incidents arising fr om
the use of this product.
Failure to follow, and comply with, all warnings may cause SERIOUS INJURY OR
DEATH.
CONTENTS
CONTENTS
Safety
Safety Labels
V echicle Assembly
Specifications
Operation Controls
Pre-Operation Inspection
Before You Start the Engine
Driving Tips
Slope Guide
Periodic Maintenance
Touble Shooting
Wiring Diagram
California Emissions Warranty
Page 1 - 4
Page 5
Page 6 - 8
Page 9 - 10
Page 11 - 13
Page 14 - 15
Page 16 - 17
Page 18 - 19
Page 20
Page 21 - 30
Page 31
Page 32
Page 33
SAFETY
SAFETY
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 find 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 find safety labels on the product. FOLLOW ALL WARNINGS BOTH IN THIS MANUAL
AND ON THE PRODUCT.
Information which is particularly important is distinguished in this manual by the following notations:
IMPORTANT RULES FOR SAFE OPERATION
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 specified 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.
FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT
IN SEVERE INJURY OR DEATH TO THE OPERATOR OR PASSENGER (IF
DOUBLE SEAT PRODUCT), A BYSTANDER OR A PERSON INSPECTING
OR REPAIRING THE PRODUCT.
CA
UTION INSTRUCTIONS ARE PROCEDURES TO PREVENT DAM-
AGE TO THE VEHICLE OR INJURY TO THE OPERATOR OR PASSENGER
(IF DOUBLE SEAT PRODUCT), A BYSTANDER OR A PERSON INSPECTING OR REPAIRING THE PRODUCT.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
1
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 inflation 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. Modification of this vehicle or removal of any original equipment or safety decal may render the
vehicle unsafe or illegal. NEVER REMOVE ANY PROTECTIVE GUARDS, BELT GUARD,
These covers are for operator/passenger's protection. If any guards are removed for mainenance or servicing of the vehicle, ensure that they are secured in place prior to operating the
vehicle.
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, or use on rental
tracks.
9. The operator's ability to operate this off-road vehicle safely is largely dependent upon the opera-
tor'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 sufficient age, understanding, mental capacity, and
physical capability to safely operate this vehicle. This vehicle should only be operated after
mature, supervised instruction and sufficient practice in decongested areas. 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 prop
erly secured. For double seat vehicles ridden without a passenger, the passenger seat belt must
be secure to prevent it from getting caught up in operating components. Any passenger must be
of sufficient age, understanding, mental capacity, and physical capability to act to protect him
self/herself. ALWAYS FOLLOW THE RECOMMENDED AGE RESTRICTION OF 16 YEARS
FOR OPERA TORS 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 the 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.
SAFETY
SAFETY
2
SAFETY
SAFETY
13. LOOSE CLOTHING, LONG HAIR, OR ARTICLES WORN BYANY OPERATOR OR PASSEN-
GER 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 is not observed. Slow speeds are required to safely operate this vehicle under those conditions. The operator must use mature judgment, skill, and experience to choose a speed suit
able for the 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 be checked. The fuel tank should
never be filled while the engine is running or while the engine is hot. Do not fill tank in a closed
area such as a garage, while smoking, or in the vicinity of an open flame. Do not overfill the
tank. There should not be any fuel in the filler neck. Replace cap tightly to prevent spillage of
fuel and potential fire hazard. After filling tank, move the vehicle at least 15 feet away from spot
of filling 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.
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 muffler, 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 sec-
tion in this manual.
21. The Bar Cage assembly provided with this vehicle is not designed as a "roll bar". Do not
operate this vehicle without the cage properly installed. Vehicles with light kits are for decorative
purposes and to assist others in seeing you. Only operate this vehicle during daylight.
3
SAFETY
SAFETY
22. When storing the vehicle, it must be kept in a place where gasoline fumes will not reach an open
flame or spark. For long period of 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 specific instructions and a
Operator's Manual revisions are included in supplements. If any printed material included is
unclear, contact the manufacturer.
23. NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF ALCOHOL, DRUGS,
OR MEDICATION OF ANY KIND. SUCH OPERATION COULD BE DANGEROUS TO YOUR
SELF AND/OR OTHERS.
24. Always slow down when turning. High speed turning may cause loss of control, possible turnover
of the vehicle, and/or possible injury to operator or passenger.
25. When turning, 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 hill or over obstacles, if you fail to take proper precautions.
26. DO NOT RACE, JUMP, PERFORM "STUNT" RIDING OR "SPINOUTS" WHEN OPERATING
THIS VEHICLE. THIS VEHICLE IS NOT DESIGNED OR INTENDED FOR SUCH OPERATION.
27. 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.
28. 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.
29. Always use extreme caution when starting the engine. Avoid touching the engine, muffler, or
drive components. These areas could cause burns on contact.
30. 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 disfigurement. Also, battery may
generate explosive gases and must not be exposed to sparks, flame, cigarettes, or anything
flammable or an explosion may result causing severe injury. Protective gloves and face protection must be worn when servicing the battery
31. ANY OPERATOR OR PASSENGER UNDER 18 YEARS OF AGE MUSTALWAYS BE APPRO-
PRIATELY SUPERVISED BY AN ADULT ATALL TIMES WHILE OPERATING THE VEHICLE.
32. 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.
33. Operate only on safe and familiar terrain. Avoid loose gravel and rocks. Be careful on wet sur-
faces and allow for extra braking distance.
4
SAFETY
SAFETY
LABELS
LABELS
Read and understand all of the labels on your vehicle. The labels contain important information for safe and proper operation. The labels
should be considered as permanent parts of the vehicle. If a label
comes off or becomes hard to read, contact the manufacturer for
replacement labels.
The Engine Exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects, or other
reproductive harm.
5
VEHICLE
VEHICLE
ASSEMBL
ASSEMBL
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Y
Step 1
Installing the R
ear and Front Wheels
Place a common automobile jack under the rear axle. Using the automobile jack raise the rear
axle off the ground approximately 12”. Slide one of the 22” rear wheels over the splined rear
axle. Make sure the air stem valve is facing outward. Note the grooves in the rear wheel hub
must match the grooves in the axle and wheel must “seat properly”. Assemble the large washer, smaller washer, axle nut and tighten the axle nut using a socket or adjustable wrench. See
fig 1.
THE NEXT STEP IS VERY IMPORTANT. INSERT THE COTTER PIN THROUGH THE GROOVES IN
THE NUT THE THEN THROUGH THE REAR AXLE. BEND THE OPEN END OF THE COTTER PIN
TO ENSURE THE REAR AXLE NUT DOES NOT LOOSEN DURING OPERATION.
Use the automobile jack to raise the front of the go-kart of f the ground. Remove the nuts
which are placed on the front wheel hubs. Install one of the front wheels by lining up the bolts
on the front wheel hub with the holes in the front wheel rim. NOTE: THE VALVE STEM (AIR FILL
TUBE) MUST BE TO THE OUTSIDE to ensure the wheel has been installed properly.. Place the
nuts on the bolts. Using socket wrench, evenly tighten the nuts in diagonal pattern. Put the
rubber covers over the front hubs. See fig 2.
Figure 1
Figure 2
Step 2
Attaching the Gas Tank
Next attached the gas tank to the rack as shown in. Fig 3. Follow the bolt, spacer, and washer
order to insure the tank is securel y fastened. See fig 4.
Attach the gas line to the gas on/off valve on the gas tank as shown in Fig 5. Tur n the gas
on/off value to either on or res. In the res position, half of the gas in the tank will be used during operation. Turn the value to res to use the remaining gas.
Figure 3
Figure 4
Figure 5
6
VEHICLE
VEHICLE
ASSEMBL
ASSEMBL
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Y
Step 2
Attac
hing the Bar Cage
Attach the Bar cage using the bolts and nuts provided. See Fig 6. Tighten
the nuts after the bar cage is seated. Attach the light as shown. See Fig 7.
Attach the foam padding as shown.
Figure 6
Figure 7
7
VEHICLE
VEHICLE
ASSEMBL
ASSEMBL
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Y
Step 3
Attach the Front Bumper
Attach the front bumper as shown
using the bolts provided. Note there
are four attaching points. Two on the
top and two on the bottom. Fig 8.
Attaching
Points
Step 4
Connect the Wiring for the Lights
Attach the wires from the Ignition to
the wires found on the right side of
the bar cage. Attach wires with corresponding colors. Fig 9
Step 5
Insert the headr est
Insert the headr est as shown. Fig 10.
Refer to the Periodic Maintenance Section of this Manual for Information
on Fuel, Oil, Battery Service, and other vital information.
Figure 8
Figure 9
Figure 10
8
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