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Baja Shifter 90 Model SF90 (double-seat): Owner’s Manual Version:1.0 April 2005

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Contents

1. Foreword----------------------------------------------------------------------------------------------------------------5
2. A Few Words about Safety-------------------------------------------------------------------------------------------6
3. Important Safety Information----------------------------------------------------------------------------------------8
4. Safety Labels----------------------------------------------------------------------------------------------------------12
5. Are You Ready to Drive? --------------------------------------------------------------------------- ----------------13
6. Is Your Vehicle Ready to Drive? -----------------------------------------------------------------------------------18
7. Safe Driving Precautions---------------------------------------------------------------------------------------------21
8. Operation-------------------------------------------------------------------------------------------------- ------------26
9. Service Instructions---------------------------------------------------------------------------------------------------40
10. Repairs----------------------------------------------------------------------------------------------------------------65
11. Periodical Checks and Services------------------------------------------------------------------------------------66
13. Specifications---------------------------------------------------------------------------------------------------------68
Attachment: Wiring Diagram

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Summary of Contents for Shifter 90

Page 1: ......

Page 2: ...r workmanship under the following terms and conditions This warranty covers the engine and engine related components for a period of 90 days from the date of purchase This warranty does not apply to a...

Page 3: ...e in any way so as to adversely affect its safety or reliability c Competition or racing The warranty does not cover any losses of the seller vehicle use any losses of time any inconveniences or any o...

Page 4: ...w Words about Safety 6 3 Important Safety Information 8 4 Safety Labels 12 5 Are You Ready to Drive 13 6 Is Your Vehicle Ready to Drive 18 7 Safe Driving Precautions 21 8 Operation 26 9 Service Instru...

Page 5: ...re to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and service your vehicle accordingly Preventive maintenance is...

Page 6: ...s and other information on labels in this manual This information alerts you to potential hazards that could hurt you or others It is not practical or possible to warn you against all hazards associat...

Page 7: ...ON Damages to your BUGGY and possible subsequent personal injuries or death could result from the failure to take proper precautions described within the labels Safety Headings such as Important Safet...

Page 8: ...wing are a few of the most important ones Always Wear a Helmet Facts have proven that helmets can significantly reduce the quantity and severity of head injuries so when you drive your BUGGY please al...

Page 9: ...terrain for unexpected turns drop offs rocks ruts and any other hazards Always keep your speed low enough to allow time for seeing and reacting Drive within Your Limits Pushing limits is another major...

Page 10: ...engine contains a tasteless odorless but poisonous gas called carbon monoxide For the health of your family please don t drive your BUGGY in your lovely house Keep away from Moving Parts You should ne...

Page 11: ...ice you may lose all directional controls To avoid skidding or sliding on slippery terrain surfaces you should keep your speed low and drive carefully This section presents some of the most important...

Page 12: ...seat Owner s Manual Version 1 0 April 2005 12 SAFETY LABELS The labels should be considered permanent parts of your BUGGY If a label comes off or becomes difficult to read please contact Baja Motorspo...

Page 13: ...rt conveniences and safety Before you drive your BUGGY for the first time we urge you to Carefully read this owner s manual and the labels on your BUGGY Make sure that you understand all the safety me...

Page 14: ...possible wearing proper protective apparel can reduce the chances of injuries when you drive The following suggestion will help you choose the proper driving gear 1 Helmets and Eye Protection Gear Yo...

Page 15: ...road motorcycle gloves to help protect your hands Driving pants with knee and hip pads a driving jersey with padded elbows and a chest and shoulder protector z Operating this BUGGY without wearing a...

Page 16: ...accustomed to all the controls on this BUGGY and felt comfortable with its size and weight No Alcohol or Drugs Alcohol drugs and Buggies never mix Even a small amount of alcohol can impair your abilit...

Page 17: ...oadage on the rear rack is 5kg or 11 lbs z Operating this BUGGY after consuming alcohol or drugs can seriously affect your judgments cause you to react more slowly affect your balance and perception a...

Page 18: ...ecause a breakdo wn or even a flat tire can be a major inconvenience If your BUGGY has overturned or has been involved in a collision please don t drive it until an authorized service center has inspe...

Page 19: ...eeded look for signs of damages or excessive abrasion z Nuts Bolts Check the wheels and all the accessible parts to see if the nuts bolts and fasteners are tightened use a wrench to tighten them if ne...

Page 20: ...snaps back automatically z Brakes Check if the mechanical brake system works properly inspect for the brake efficiency z Engine Stop Button When the engine is running press and hold the Engine Stop Bu...

Page 21: ...ion to drive on private property Avoid posted areas and obey no trespassing signs Never drive your BUGGY on public streets roads or highways even if they are not paved Drivers of street vehicles may h...

Page 22: ...s can reduce your ability of controlling your BUGGY z Operating your BUGGY on public streets roads or highways can cause collisions with other vehicles z Never operate your BUGGY on any public streets...

Page 23: ...r Rough Terrain Before driving in a new area always check the terrain thoroughly Don t drive fast on unfamiliar terrain or when the visibility is limited Sometimes it s difficult to gain the reaction...

Page 24: ...o out of control or overturn z When operating your BUGGY on unfamiliar terrain always drive slowly always be especially careful and always be alert to changing terrain conditions z Failure to use your...

Page 25: ...should always operate your BUGGY in a safe and reasonable manner When driving always keep all of the four wheels on the ground z Attempting wheelies jumps and any other stunts increases the chances o...

Page 26: ...use of each control that is necessary to operate your BUGGY You must know how to stop your BUGGY before starting and driving 1 Throttle Pedal The right foot pedal is the throttle pedal that controls...

Page 27: ...time before starting the engine check the throttle assembly to ensure that when you push the pedal all the way forward the throttle assembly is working smoothly and when you release the pedal the thr...

Page 28: ...erating properly When the engine is running move the Stop Button to the OFF position z Neutral Indicator Lamp Button Press the neutral indicator lamp button then after the engine has started the neutr...

Page 29: ...ction 1 Engine Oil Check for the engine oil level and add oil if required check for oil leaks don t let any water go into the engine otherwise the engine can t start 2 Fuel Check for the fuel level an...

Page 30: ...Stop Button Perform the engine stop button test repair it if necessary 8 Nuts Bolts Fasteners Check all the nuts bolts and other fasteners to see if they have been tightened to the specified conditio...

Page 31: ...0 double seat Owner s Manual Version 1 0 April 2005 31 Locations of Parts Double Seat Brush Guard Steering Wheel Control Panel Seat Safety Belt Rear Rack Throttle Pedal Brake Pedal Front Shock Absorbe...

Page 32: ...Baja Shifter 90 Model SF90 double seat Owner s Manual Version 1 0 April 2005 32 Rear Rack Drive Chain Fuel Tank Engine Fuel Tank Cap Muffler Air Cleaner Reverse lever...

Page 33: ...Capacity Crankcase 0 7 0 9L Transmission Box 0 2 L D Passengers The vehicle allows for two riders only for the double seat unit The combined maximum weight of the driver and passenger for the double s...

Page 34: ...handle snaps back into place and that the seat is locked into position z Before attempting to adjust the seat ensure that the engine of your BUGGY has stopped z Never operate your BUGGY when the provi...

Page 35: ...neutral gear 2 Push the gearshift lever to the D position so that the vehicle can move forward in the first second gear 3 Pull back the gearshift lever to the R position so that the vehicle can move...

Page 36: ...ing at high speed You d better slow down to a more controllable speed to prevent your BUGGY from rolling over 5 To prevent your vehicle from rolling over when turning be sure to only turn your vehicle...

Page 37: ...riching device starts working push the handle downwards to the lowest position the enriching device stops working If the engine cannot get started easily push the manual choke handle upwards to the hi...

Page 38: ...the throttle slightly opened 6 In cold weather warm up the engine for several minutes at the idle speed then speed up once the operation temperature has reached the requirements specified In hot weath...

Page 39: ...up suddenly or running the engine at a high speed without loading 6 Maintain your vehicle according to the service intervals and if necessary repair it as soon as possible 7 After the running in perio...

Page 40: ...more often when running under dusty conditions 1 Remove the air cleaner cover 2 Remove the air cleaner element 3 Fill the non flammable cleaning agent into a basin and dip the element in it 4 Dry it...

Page 41: ...ar 1 Remove the filler plug located on the rear side of engine remove the drain plug tip the vehicle backwards slightly by blocking up the front end drain the oil into a suitable container 2 Place the...

Page 42: ...xcess oil will greatly reduce the proper engine performance If possible check the spark plug gap area between the electrodes With a wire feeler gauge This specification is 0 6 0 7mm 2 Before installin...

Page 43: ...e adjustment 1 Warm up the engine for about 5 10 minutes 2 Tighten the airscrew gently and back out 2 3 8 turns anticlockwise 3 Connect the tachometer and adjust the throttle to limit the idle speed t...

Page 44: ...ep the engine clean of foreign objects Make sure the cylinder and cylinder head cooling fins are clean F Vehicle Lubrication Lubricate your vehicle every 90 days of use Apply several drops of oil in t...

Page 45: ...r one ounce of clean cylinder lubricating oil through the spark plug hole into the cylinder and crank the engine slowly to spread the oil so as to lubricate the cylinder better replace the spark plug...

Page 46: ...ine oil and add some if necessary Note The oil level should be between the upper index line and the lower index line of the gauge 2 50 Hour Maintenance 2 1 Finish the daily maintenance 2 2 Remove the...

Page 47: ...bolt z Drain out all the engine oil Note When draining the oil the engine should be at some temperature which can ensure the quick and complete draining 2 6 Clean up all the dirt on the cylinder body...

Page 48: ...he fixed screw of the generator stator is loose 3 5 Keep the connectors and electric parts dry and clean 4 150 Hour Maintenance 4 1 Finish 100 hour maintenance 4 2 Clean the crankcase and replace oil...

Page 49: ...Version 1 0 April 2005 49 6 500 Hour Maintenance 6 1 Finish 300 hour maintenance 6 2 Disassemble the engine except the crankshaft connecting rod check the parts for wear and repair or replace the part...

Page 50: ...EEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED z POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing TO prevent accidents rinse empt...

Page 51: ...e electrolyte pack Most battery s will come with the electrolyte already sealed into the battery 2 1 Place battery on level surface Remove sealing tape from top 2 2 Take the electrolyte container out...

Page 52: ...2 6 Leave bottles upside down in battery holes until electrolyte is completely drained Note Never leave children unattended around battery 2 7 If air bubbles cease to float to the top of the electroly...

Page 53: ...et battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life 2 11 After 30 minutes the battery is re...

Page 54: ...black negative pole of the battery Note The red positive cable has a larger diameter than the black negative y cable 3 3 Charging rate Charge battery 0 7 Amps for 5 10 hours 3 4 After charging is com...

Page 55: ...the rubber mat is in place Note The warning label on the battery should be facing the warning label on the gray tray 3 6 Once battery is firmly seated in gray tray with rubber mat under it attach the...

Page 56: ...Then attach the black negative wire to the black negative terminal on the battery 3 8 Place grey plastic battery cover on top of the battery and threadwires through the cover cuts outs Finally secure...

Page 57: ...per to remove oxidation z DO NOT open sealed caps to add water to battery z Always wear safety glasses and charge in a ventilated area z If battery gets hot to the touch discontinue charging and allow...

Page 58: ...of the two in diameter CONNECT NEGATIVE CABLE LAST 4 5 Torque terminal bolts to 40 in lbs 4 6 Place rubber pad in bottom of battery tray Securely fasten battery to the vehicle using cover and strap z...

Page 59: ...upport so as to raise the rear wheel above the ground 2 If the chain is too loose adjust the left and right rear wheel bearing holders counterclockwise at the same time If the chain is too tight adjus...

Page 60: ...If the brake cable is too tight adjust the adjust nut of the brake cable counterclockwise If the adjustment doesn t work go on with the next step 2 Loosen the nut M6 at the adjust bolt of the brake ca...

Page 61: ...ble seat Owner s Manual Version 1 0 April 2005 61 N Brake Shoe Replacement 1 Loosen the connecting clip on the chain Remove the chain 2 Loosen the adjust nut on the brake cable Take out the brake cabl...

Page 62: ...s Manual Version 1 0 April 2005 62 3 Remove the cotter pin on the bracket of the brake caliper 4 Remove the cotter pin castle nut left rear tire right rear tire and rear wheel hub in order Cotter Pin...

Page 63: ...ht holder of the rear wheel axle Remove the rear wheel axle together with the brake caliper assy 6 Remove the lower right connecting bush bearing seat of the right rear wheel axle and bearing Remove t...

Page 64: ...engine is not stable either too low or too high after the engine has started adjust the idle speed adjust screw on the carburetor If the engine rotate speed is too high turn the adjust screw counterc...

Page 65: ...lock nuts on the front wheel 2 Remove the front wheel 3 Assemble the new front wheel 4 Fasten the 3 lock bolts and lock nuts B Rear Wheel Replacement 1 Remove the 4 lock bolts and lock nuts on the rea...

Page 66: ...Riding in unusually dusty areas requires more frequent services Interval Items 1st Service in 1st Week Daily Monthly Quarterly Yearly Air cleaner X X C R R Spark plug X C A R R Carburetor A A A C Gea...

Page 67: ...Version 1 0 April 2005 67 Interval Items 1st Service in 1st Week Daily Monthly Quarterly Yearly Valve clearance of engine A A A Throttle cable A A A A Absorber X X X R Note X inspect clean or replace...

Page 68: ...Overall Length 1500mm Overall Width 1100mm Overall Height 1230mm Wheelbase 1100mm Ground Clearance 120mm VIN Accord With GMVR A01 01 Statutory Plate Safety Labels Accord With GB 7258 1997 ENGINE Model...

Page 69: ...lutant 800 Ppm Fuel Type SAE 90 or Above Unleaded Min Fuel Consumption 367g KW H Lubricate Oil Type SAE 10W 40SF Lubrication Pressure Splash Cooling Air Cooled Ignition C D I Starting Electric Spark P...

Page 70: ...plate Automatic Single Carburetor PZ19 Air Cleaner Filter Sponge Element Gear Shifting Hand Control Valve Gap 0 05 0 02mm Engine Size Length Width Height 430mm 320mm 270mm Engine Net Weight 20kg CAPA...

Page 71: ...Version 1 0 April 2005 71 Battery 12V 3Ah CHASSIS Brake System Rear Disk 1 Front Suspension Single A arm 30 Travel Rear Suspension Swing Arm 30 Travel Front Tire 145 70 6 Rear Tire 16X8 0 7 TIRE PRESS...

Page 72: ...your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance o...

Page 73: ...er determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied This Emission Control System W...

Page 74: ...l damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the...

Page 75: ...Baja Inc P O Box 61150 Phoenix Az 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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