Baja BO250 UTV Owner'S Manual Download

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TABLE OF CONTENTS

PERIODIC MAINTENANCE SCHEDULE....................................................... 37

PERIODIC LUBRICATION SCHEDULE............................................. 37

AIR FILTER.................................................................................................... 38

RADIATOR..................................................................................................... 39

ENGINE OIL................................................................................................... 39

ENGINE OIL LEVEL CHECK............................................................. 39

ENGINE OIL CHANGE....................................................................... 41

TRANSMISSION OIL CHANGE......................................................... 41

REAR DIFFERENTIAL OIL CHANGE........................................................... 42

FUELING INSTRUCTIONS............................................................................ 43

BATTERY....................................................................................................... 44

PREPARING THE BATTERY............................................................. 45

HOW TO INITIALLY CHARGE THE BATTERY................................. 46

BATTERY REPLACEMENT............................................................... 47

ADJUSTMENTS............................................................................................ 48

SUSPENSION.................................................................................... 48

SPARK PLUG..................................................................................... 48

TIRES.................................................................................................. 50

VEHICLE CLEANING.................................................................................... 51

CLEANING PROCEDURE................................................................. 51

PREPARATION FOR CLEANING...................................................... 51

TROUBLESHOOTING................................................................................... 52

SERIAL NUMBER LOCATIONS................................................................... 53

SPECIFICATIONS......................................................................................... 54

EMISSION CONTROL SYSTEM WARRANTY.............................................. 55

Summary of Contents for BO250 UTV

Page 1: ...refully It contains important safety information No one under the age of 16 should operate this UTV Always wear a helmet It could save your Life Please obtain review and follow provincial municipal go...

Page 2: ...anty 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...

Page 3: ...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 co...

Page 4: ...LEVER 15 OPERATION INSTRUCTIONS 16 STARTING THE UTV 16 STOPPING THE UTV 16 PARKING THE UTV 16 BED LATCH 16 LOADING AND UNLOADING CARGO BED 17 TOWING WITH THE UTV 18 TRANSPORTING THE UTV 18 STORING TH...

Page 5: ...L CHANGE 41 REAR DIFFERENTIAL OIL CHANGE 42 FUELING INSTRUCTIONS 43 BATTERY 44 PREPARING THE BATTERY 45 HOW TO INITIALLY CHARGE THE BATTERY 46 BATTERY REPLACEMENT 47 ADJUSTMENTS 48 SUSPENSION 48 SPARK...

Page 6: ...r user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvemen...

Page 7: ...els on the UTV carefully and follow the operations procedures as described Never operate the UTV without proper instructions Always avoid operating an UTV on paved surfaces including sidewalks paths p...

Page 8: ...you have learned and practiced the necessary skills to control the UTV on such terrain Never operate the UTV on hills that are too steep for the UTV or for the operator s ability Practice on smaller...

Page 9: ...linings dry out Always use the tires with proper size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify a UTV through improper inst...

Page 10: ...Front wheel Cargo bed Passenger Handle Key switch Accelerator and Brake pedals Brush guard Front bumper Forward Reverse lever Rear wheel Headrests Cargo bed latch Parking brake lever Mirror Radiator f...

Page 11: ...11 LOCATION OF WARNING LABELS 1 2 3 4 5 6 7 Located on left and right side panels 8 9 5 10...

Page 12: ...12 LOCATION OF WARNING LABELS 2 1 4 3...

Page 13: ...13 LOCATION OF WARNING LABELS 8 5 7 6 9 10...

Page 14: ...r located under driver seat only operates when the engine is running It tracks accumulative operating time of the engine so you know when to perform the periodic maintenance REVERSE INDICATOR LIGHT Th...

Page 15: ...he vehicles speed will increase in either forward or reverse When the pedal is released it will return to the original position and the engine will idle BRAKE PEDAL This pedal will slow or stop the ve...

Page 16: ...vehicle is completely stopped STOPPING THE UTV Driving through water may affect the brakes Check the effectiveness of the brakes after driving through water by gently depressing the brake pedal If the...

Page 17: ...ect vehicle handling and cause components to fail resulting in injury or death Reduce speed and sudden stops when in reverse to prevent the vehicle from flipping backward Do not load tailgate Tailgate...

Page 18: ...riders on the vehicle Avoid sudden starts stops and tight turns Avoid stopping on a hill If it is necessary to stop on a hill avoid sudden starts or rolling backward and sudden stopping Reduce speed T...

Page 19: ...el tank 1 inch from the top of fuel tank and add fuel stabilizer 7 Disconnect fuel tank line from fuel tank vent nipple 8 Plug the fuel tank vent line air tight 9 Disconnect battery cables making sure...

Page 20: ...or and fuel lines and the engine starts Turn the engine off NOTE Engine may smoke for awhile when running it the first time after storage 6 Adjust the tires to recommended tire pressure OPERATING YOU...

Page 21: ...all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle WARNING Operating this UTV without proper instruction could be hazardous The risk o...

Page 22: ...ing 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...

Page 23: ...he UTV does not have mechanical problems or you could get stranded when you ride Before riding the UTV be sure to check the above items Be sure your UTV is in good condition to ensure the safety of th...

Page 24: ...rom injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt WARNING Operating this UTV without wearing an approved DOT motorcycle helmet eye protectio...

Page 25: ...oid Constant Low Rotating Speed Operating the engine at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding th...

Page 26: ...is applied WARNING The UTV could start moving as soon as you start the engine Unexpected movement could cause you to lose control of the UTV Be sure to set the parking brake before you start the engin...

Page 27: ...UTV on public streets roads or highways could be hazardous You may collide with another vehicle if you ride on the public roads Never operate this UTV on any public street road or highway even dirt o...

Page 28: ...d the skills necessary to control the UTV on such terrain Always be especially cautious on this kind of terrain WARNING Failing to use extra care when operating this UTV on unfamiliar terrain could be...

Page 29: ...lose control of the UTV Make sure to apply the foot brake before you release the parking brake Release the brake pedal and slowly depress the accelerator pedal to move forward WARNING Opening the thro...

Page 30: ...the brake when turning could cause the UTV to slide or roll over Use the brake to slow down before you begin to turn BRAKING WARNING Braking hard on slippery surfaces could be hazardous The UTV could...

Page 31: ...s follow the proper procedures for climbing hills as described in this section Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surf...

Page 32: ...ause the UTV to overturn Always follow the proper procedures for going down hills as described in this section Descending a Hill OPERATING OVER OBSTACLES WARNING Operating this UTV over obstacles impr...

Page 33: ...ting this UTV through deep or fast flowing water could be hazardous The UTV tires may float losing traction and then loss of control This could lead to an accident Never operate this UTV in fast flowi...

Page 34: ...power ask your authorized service center to check them before you continue riding your UTV Water that enters the brakes may freeze after you park your UTV The frozen water can prevent wheels from tur...

Page 35: ...tion of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be p...

Page 36: ...s of control Severe injury or death could occur if you lose control of the UTV Go slowly and be careful when riding on snow covered terrain Always be alert to changing terrain conditions WARNING Ridin...

Page 37: ...Inspect and replace any worn components Annual service every 100 hours of operation Engine Check for leaks around the gaskets fill plugs etc General vehicle Check for loose hardware and tighten if ne...

Page 38: ...emove lower portion of center console that covers parking brake and allows access to air filter box There are a total of 6 screws 3 Locate air filter box and remove 4 Now you have complete access to t...

Page 39: ...excellent performance check the oil level before each use Before checking the oil place the vehicle on a level surface 1 Remove the oil fill dipstick and wipe clean 2 Insert dipstick into filler tube...

Page 40: ...se 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 your exposure to used oil wear a long sleeve sh...

Page 41: ...fter the first 30 hours of use 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 engin...

Page 42: ...ear differential case 2 Remove differential drain bolt Let drain 3 Reinstall the differential drain bolt and torque to 25 ft lbs 4 Remove differential oil fill plug and add 16 ounces of SAE80W 90 oil...

Page 43: ...recautions when refueling could result in a fire or let you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not smoke and...

Page 44: ...IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water...

Page 45: ...to drain in battery cell Fill battery to upper level mark located on front of battery Repeat step for each of the 6 cells see figure 22 After each cell is filled with electrolyte to upper level remove...

Page 46: ...egative y cable 3 Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete install securely cap strip see figure 26 Install battery into battery tray located under driver seat s...

Page 47: ...and strap WARNING DO NOT open sealed caps to add water to battery Always wear safety glasses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to...

Page 48: ...electrode insulator after vehicle operation 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...

Page 49: ...ust the gap to 0 6 0 7mm 024 028in for good ignition Use a thickness gauge to check the gap CAUTION Improper installation of the spark plug could damage your UTV An overly tight or cross threaded spar...

Page 50: ...ires are cold COLD TIRE AIR PRESSURE 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 ma...

Page 51: ...r another method to prevent water from entering engine With some care your UTV can be washed in a similar manner to washing an automobile Note Avoid spraying or allowing water to flow over the followi...

Page 52: ...enter Engine stops or looses power No fuel Replenish fuel Clogged fuel filter Replace fuel filter Water in fuel system Drain fuel system and replenish fuel Fuel vent line kinked or plugged Un kink or...

Page 53: ...ed 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 The engine serial...

Page 54: ...ting Electric Cooling system Water cool Max Power 11kw 7000rpm Max torque 17 6Nm 500rpm Bore and stroke 72x60 Compression ratio 10 1 Spark Plug NGK DPR7EA 9 0 6 0 7mm gap 024 028 in TRANSMISSION Drive...

Page 55: ...maintenance or unapproved modifications WARRANTY COVERAGE The Distributor warrants that each new 2008 and later vehicle is designed built and equipped so as to conform at the time of initial retail p...

Page 56: ...s and all other warranties LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an au...

Page 57: ...57 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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