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Baja BR250 Owner's Manual

Summary of BR250

  • Page 1

    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. Minimum age requirement 16 br250/dn250 go-kart read this manual carefully. It contains important safety info...

  • Page 2

    Ii 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...

  • Page 3: The Vehicle.

    Iii 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. Wa...

  • Page 4: Table of Contents

    1 forward.................................................................................... 2 notice to users....................................................................... 3 br250/dn250 go-kart.............................................................. 9 fuel and oil......................

  • Page 5: Warning

    2 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. Note: indicating special information which is to make maintenance easier or instructions...

  • Page 6: Warning

    3 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...

  • Page 7: Warning

    4 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 la...

  • Page 8: Notice to Users

    5 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 o...

  • Page 9: Notice to Users

    6 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 operato...

  • Page 10: Notice to Users

    7 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 contac...

  • Page 11: Notice to Users

    8 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 suf...

  • Page 12: [Left]

    9 [left] [right] br250/dn250 radiator rear rack rear wheel brush guard bar headlights front wheel steering wheel forward/reverse shifter front shock absorber fuel tank rear shock absorber exhaust pipe oil fill plug parking brake seats control panel.

  • Page 13: Fuel And Oil

    10 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,...

  • Page 14: Warning Labels

    11 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 motorsports. Warning this go-k...

  • Page 15: Warning Labels

    12 warning ! 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. Parking brake parking r reverse lever d 4 5 6 warning labels 5 6 4 located on brush guard near control panel.

  • Page 16: Warning Labels

    13 warning labels warning 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. No long hair ! Warning no riding ! Warning -moving parts can crush and cut. -keep hands clear. -do not operate with guard removed...

  • Page 17

    14 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 runn...

  • Page 18: Brake Lever

    15 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 contains br...

  • Page 19: Seat Adjustment

    16 seat adjustment warning ! Before attempting to adjust the seat, ensure that the engine is not running. Never operate go-kart when the seat is not securely adjusted. It could result in personal injuries or loss of life. The seat must always be securely adjusted to the position which affords the be...

  • Page 20: Riding Your Go-Kart

    17 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 ...

  • Page 21: Inspection Before Riding

    18 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-...

  • Page 22: Inspection Before Riding

    19 inspection before riding warning ! Warning ! Check the condition of the go-kart to make sure that the go-kart does not have mechanical problems or you could get stranded when you ride. Before riding the go-kart, be sure to check the above items. Be sure your go-kart is in good condition to ensure...

  • Page 23: Safety Gear

    20 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. You should wea...

  • Page 24: Break-In

    21 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 recommendat...

  • Page 25: Drive Select Lever

    22 drive select lever adjustment: 1. Press down the lever to the “d” position so that the unit can move forward. 2 pull back the lever to “r” so that the unit can move backward. 3. Loosen nut #1 at the end of the cable. 4. Adjust nut #2 accordingly to adjust the mesh status inside the gear box; rota...

  • Page 26: Carburetor Adjustment

    23 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. 1. Warm up the engine for about 5-10 minutes. 2. Connect the tachometer, an...

  • Page 27: Chain And Shock Adjustment

    24 chain adjustment check the chain adjustment after the first two hours of use. Readjust if it has more than 1/2” flex. 1. Loosen nut 1. 2. Loosen nut 2. 3. Tighten or loosen adjusting cap accordingly to obtain the correct free play. 4. Once the correct free play has been achieved, tighten nut 2 th...

  • Page 28: Maintenance Schedule

    25 periodic check and service 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. The maintenance intervals in the ...

  • Page 29: Maintenance Schedule

    26 improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your go-kart you may have an accident. Keep your go-kart in good condition. Ask your authorized service center or a qualified mechanic to do the maintenanc...

  • Page 30: Battery Installation

    27 initial service and installation of battery: battery installation the following procedure is very dangerous and should be performed with 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 chil...

  • Page 31: Battery Installation

    28 battery installation note: the following page is for vehicles with battery’s containing separate electrolyte pack. Most battery’s will come with the electrolyte already sealed into the battery. Preparing the battery: · place battery on level surface. Remove sealing tape from top. (see figure a) ·...

  • Page 32: Warning

    29 how to initially charge the battery: 1. Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure d) 2. Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure e) note: the red positive (+) cable has a larger diameter than ...

  • Page 33: Battery Replacement

    30 · 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. · after charging, insta...

  • Page 34: Engine Oil

    31 to check oil level: 1. Park vehicle on level ground. 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. Oil level should be in between the lower index line and upper index line marks on the dipstick. 5. A...

  • Page 35: Engine Oil

    32 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. To minimize y...

  • Page 36: Transmission Oil

    33 draining transmission oil 1. Drain transmission oil by removing transmission oil drain bolt (located on the bottom of transmission). 2. Drain oil into a catch basin and dispose of properly at an oil reclaim facility. Adding transmission oil 1. Add transmission oil by removing transmission oil fil...

  • Page 37: Radiator

    34 filling the radiator 1. Remove cap and fill radiator with radiator fluid until full. 2. Remove cap and fill coolant over-flow bottle up to the max. Line 3. After engine has been turned on and ran for awhile check coolant over-flow bottle and fill to max. Line if needed. Coolant over- flow bottle ...

  • Page 38: Air Filter

    35 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 ...

  • Page 39: Air Filter

    36 a torn air filter could damage your go-kart. Dirt and dust may get inside of the engine if the element is torn. Examine carefully the element for tears before and after cleaning it. Replace the element with a new one if it is torn. Failing to position the air cleaner element properly could damage...

  • Page 40: Tires

    37 the go-kart is equipped with low pressure tubeless tires of the size listed below: tire tread condition tire air pressure check the air pressure in all tires before riding. Improper air pressure would effect handling, steering response, traction, tire life and rider comfort. Be sure that the tire...

  • Page 41: Tires

    38 tire replacement your go-kart has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires. It is very important...

  • Page 42: Braking

    39 the go-kart has hydraulic disk brakes on all four wheels. 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 ...

  • Page 43: Brake Inspection

    40 failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, or shoes that are seriously worn, will increase your chance of having an accident. If you need to replace brake shoe pads, have your authorized service center do the work. Inspecting and maintainin...

  • Page 44: Engine Stops Or Looses Power

    41 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 no fuel replenish fuel clogged fuel filter on/off...

  • Page 45: Ignition System Check

    42 1. Remove the spark plug and reattach it to the spark plug lead. 2. Turn ignition key switch cw (clockwise) to “on” and push electric start button. Be sure the parking brake is set if the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is no spa...

  • Page 46: Transporting

    43 it is best to transport the go-kart in the normal position. 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. When the fuel has been drain...

  • Page 47: Cleaning Procedure

    44 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,...

  • Page 48: Washing Your Go-Kart

    45 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 · carburetor use a garden hose at low pressure to remove the majority of dirt or other ...

  • Page 49: Storage Procedure

    46 if you do not use your go-kart for a long time, it 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. If you wish to service the machine for storage yourself, follow ...

  • Page 50: Serial Number Location

    47 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 the gas tank. The engine number is located on the left ...

  • Page 51: Wire Diagram

    48 wire diagram h eadligh t temp eratur e switch ligh t swit ch fan gener at or temp eratur e switch pilot ligh t k ill swit ch h eadligh t r ec tifier cdi ignition c oil spar k plug tail ligh t ignition swit ch star ting rela y star ting r ela y fuse 15a + - m agnet o m agnet o m agnet o r esist or...

  • Page 52: Specifications

    49 dimensions overall length............................................................2450mm (96.46 in.) overall width.............................................................1427mm (56.18 in.) overall height............................................................1512mm (59.53 in.) wheelba...

  • Page 53

    50 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,...

  • Page 54

    51 exclusions and limitations this warranty does not cover the following: • failures or malfunctions of the emission control systems caused by abuse, alteration, accident, misuse, the use of leaded gasoline. • replacement of expendable maintenance items unless they are original equipment defective i...

  • Page 55: Baja, Inc.

    52 baja, inc. P.O. Box 61150 phoenix, az 85082 tel: 602-443-9180 toll free: 888-863-2252.