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Baja motorsports BR150-1 Owner's Manual

Other manuals for BR150-1: Owner's Manual, Setup Instructions
Manual is about: 150cc Go-Kart

Summary of BR150-1

  • 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. Owner’s manual br150-d, br150-1 go-kart read this manual carefully. It contains important safety information...

  • Page 2

    Ii 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 ...

  • Page 3: Operating The Vehicle.

    Ii 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. ! The ...

  • Page 4: Table of Contents

    1 table of contents notice to users....................................................................................... 2 br150 gokart............................................................................................. 9 fuel and oil..........................................................

  • Page 5: Notice to Users

    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: Notice to Users

    3 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 ma...

  • Page 7: Notice to Users

    4 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 co...

  • Page 8: Notice to Users

    5 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 sta...

  • Page 9: Notice to Users

    6 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 safet...

  • Page 10: Notice to Users

    7 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...

  • Page 11: Notice to Users

    8 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 b...

  • Page 12: Br150-1

    9 br150-1 [left] [right] headlight front wheel brush guard bar rear wheel rear rack rear shock ab- sorber front shock absorber seat safety belt control panel fuel tank steering wheel.

  • 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 150cc 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 labels 1 ...

  • Page 15: Warning Labels

    12 warning labels 4- 4 5 6 5- 6- 9 8 8- 9- 7- 7 warning -moving parts can crush and cut. -keep hands clear. -do not operate with guard removed. ! 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. N...

  • Page 16: Engine Stop Switch

    13 control panel and ignition switch 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 k...

  • Page 17: Throttle, Brake Pedal And

    14 2 1 - brake pedal depressing the brake pedal draws the brake calipers against the brake rotor and slows or stops the go-kart. 2 - throttle pedal depressing the throttle pedal will engage the clutch and move the go-kart forward 3 - brake fluid reservoir 4 - parking brake while starting the engine ...

  • Page 18: Seat Adjustment

    15 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 best...

  • Page 19: Riding Your Go-Kart

    16 riding your go-kart make sure that it is legal to ride in the area you selected. Review the local laws and make sure you are not trespassing. Call the police if you don’t know where you can ride. Protect your riding areas. When you are riding, remember to keep the terrain in good condition. Don’t...

  • Page 20: Inspection Before Riding

    17 inspection before riding item to check content steering smoothness; no restriction of movement; no play or looseness. Brakes 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; fu...

  • Page 21: Inspection Before Riding

    18 inspection before riding 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. Check the condition of the go-kart to make sure that the go-kart does not have mechanical problems or...

  • Page 22: Safety Gear

    19 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 23: Break-In

    20 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 24: Drive Select Lever

    21 drive select lever 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. Adjusting nut #1 at the end of the cable can adjust the mesh status in side the gear box; rotate the ...

  • Page 25: Carburetor Adjustment

    22 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. 1. Warm up the engine for about 5-10 minutes. 2. Conn...

  • Page 26: Chain And Shock Adjustment

    23 chain and shock adjustment check the chain adjustment after the first two hours of use. Readjust if it has more than 1/2” flex. 1. Loosen nuts #1. 2. Turn nut #2 clockwise in 1/2 turn increments, then turn nut #1 until it becomes tight. 3. Repeat the above steps until chain is adjusted to the des...

  • Page 27: Maintenance Schedule

    24 maintenance schedule note: 1. A- adjust; c- clean; i- inspect, clean or replace if necessary; l- lubricate; r- replace 2. The items with “*” must be inspected and repaired by professionals. If you yourself are a professional please follow this owners manual and choose qualified tools. 3. Driving ...

  • Page 28: Maintenance Schedule

    25 maintenance schedule 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...

  • Page 29: Battery Installation

    26 battery installation 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...

  • Page 30: Preparing The Battery:

    27 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, locate electrolyte in bottle and place over the six openings. Press firmly down on bottle allowing t...

  • Page 31: Battery Installation

    28 battery installation battery installation 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) note: the red po...

  • Page 32: Battery Replacement

    29 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. · a...

  • Page 33: Engine Oil

    30 engine oil 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 dip...

  • Page 34: Cleaning Oil Filter,

    31 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. Re-install filter and refill with 1qt. Oil (refer...

  • Page 35: Engine Oil

    32 engine oil ! ! 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 Removal

    33 washing and oiling the filter element : 1. Wash air filter element with warm soapy water, then rinse. 2. Squeeze the element by pressing it between the palms of both hands to remove excess water (a). Do not twist or wring the element or it will develop cracks. 3. Immerse the element in a pan fill...

  • Page 37: Air Filter

    34 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. ! A torn air filter could damage y...

  • Page 38: Caution

    35 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...

  • Page 39: Tires

    36 tires front rear size 19x7-8 22x10-10 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 an...

  • Page 40: Tires

    37 tires 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 imp...

  • Page 41: Braking

    38 braking 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 ins...

  • Page 42: Front And Rear Hydraulic

    39 front and rear hydraulic disk brake inspection brake hose front disk brake caliper brake disk brake fluid level brake fluid cap brake hose brake fluid reservoir rear disk brake caliper brake disk failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, o...

  • Page 43: Engine Stops Or Loses Power

    40 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 44: Ignition System Check

    41 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

    42 transporting drain screw 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. Wh...

  • Page 46: Cleaning Procedure

    43 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 ...

  • Page 47: Washing Your Go-Kart

    44 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 ● carburetor ● air filter use a garden hose at low pressure to rem...

  • Page 48: Storage Procedure

    45 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. If you wish to ...

  • Page 49: Serial Number Location

    46 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 locat...

  • Page 50: Specifications

    47 specifications dimensions overall length ..............................................................................................93.5 in. Overall width ...............................................................................................54.75 in. Overall height ......................

  • Page 51: Wire Diagram

    48 wire diagram.

  • Page 52

    49 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,...

  • Page 53

    50 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 origin...

  • Page 54

    51 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 ...

  • Page 55: Baja, Inc.

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