Baja BR250 Go-Kart Owner'S Manual Download

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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 information.

No one under the age of 16 should operate this Go-Kart

OWNER’S MANUAL

REV. B

031109

Summary of Contents for BR250 Go-Kart

Page 1: ...icipal 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 inf...

Page 2: ...rame Warranty 90 days Warranty 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 B...

Page 3: ...d 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 c...

Page 4: ...CHAIN AND SHOCK ADJUSTMENT 24 MAINTENANCE 25 BATTERY INSTALLATION 27 BATTERY REPLACEMENT 30 ENGINE OIL 31 CLEANING OIL FILTER 32 TRANSMISSION OIL 33 RADIATOR 34 AIR FILTER 35 TIRES 37 BRAKING 39 BRAKE...

Page 5: ...nother 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 impro...

Page 6: ...ormation in this manual you will find safety labels on the product FOLLOW ALL WARNING BOTH IN THIS MANUAL AND ON THE PRODUCT Information which is particularly important is distinguished in this manual...

Page 7: ...o 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 4 Prevailing Torque type...

Page 8: ...on 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...

Page 9: ...nce to choose a speed suitable for 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 manuf...

Page 10: ...ore storage in any enclosure Read and keep all printed material supplied with this vehicle Timely and specific instructions and an Operator s Manual revisions are included in supplements If any printe...

Page 11: ...ns 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 exp...

Page 12: ...50 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 bra...

Page 13: ...line 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 you will realize the best lubrication for the engine Use the chart...

Page 14: ...INSTRUCTIONS Beginners require mature supervision NEVER OPERATE THIS GO KART ON PUBLIC ROADS it is intened off road use only NEVER OPERATE THIS GO KART AT EXCESSIVE SPEEDS NEVER ATTEMPT WHEELIES JUMP...

Page 15: ...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 Lo...

Page 16: ...TH 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: ...Light switch When switch is in ON position lights will illuminate Engine stop switch When engine is running move Stop switch to OFF position The engine should stop when switch is depressed If the swi...

Page 18: ...e the go kart forward Brake fluid reservoir Contains brake fluid which helps to stop the go kart Use DOT3 or DOT4 brake fluid Drive select Lever This lever allows you to drive the vehicle in forward o...

Page 19: ...injuries or loss of life The seat must always be securely adjusted to the position which affords the best control of the foot pedals steering wheel and engine stop switch for the operator Pull seat ad...

Page 20: ...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 destroy plants trees or other vegetation Don t litter and don t bother...

Page 21: ...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...

Page 22: ...Never exceed the stated load capacity for this Go kart Operating this Go kart with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may c...

Page 23: ...t you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt Operating this Go kart without wearing an approved DOT motorcycle helmet eye protec...

Page 24: ...much Avoid 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 exce...

Page 25: ...in either forward or reverse To shift Go kart in either forward or reverse 1 Release throttle 2 Apply brakes coming to a complete stop 4 Shift lever in the reverse or forward position 5 Check for peop...

Page 26: ...ications 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 and adjust...

Page 27: ...the correct free play has been achieved tighten nut 2 then nut 1 FRONT SHOCK ADJUSTMENT There are five adjustable positions on the front shock The default position is in the middle set by the manufact...

Page 28: ...ourself are a professional follow this owners manual and use qualified tools 3 Driving in unusually wet or dusty areas requires more frequent services Driving in sandy or rocky areas especially requir...

Page 29: ...conditions it will need maintenance more often than shown in the chart Operating your Go kart under severe conditions causes more wear on your Go kart Severe conditions include operating under frequen...

Page 30: ...LL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty conta...

Page 31: ...tles Leave bottles upside down in battery holes until electrolyte is completely drained Never leave children unattended around battery If air bubbles cease to float to the top of the electrolyte bottl...

Page 32: ...irmly with both hands to seat the caps Do not pound or hammer The battery is now sealed see figure F Install battery into battery compartment The battery terminals should be facing the front see figur...

Page 33: ...ng metal battery strap 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 batter...

Page 34: ...if oil is below lower mark on dipstick Do Not fill above upper mark Refer to page 10 for correct engine oil type Engine oil replacement The engine oil should be changed every 20 to 40 hours of operati...

Page 35: ...il If oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil Recycle or properly dispose of used oil Failure to use the correct oil could harm your Go...

Page 36: ...Add transmission oil by removing transmission oil fill plug located on right of transmission 2 Add 5 ounces of 80W 90 gear oil Transmission oil fill plug Transmission oil drain bolt Running the engin...

Page 37: ...line if needed Coolant over flow bottle Draining the radiator 1 Remove hose and allow fluid to drain completely 2 When radiator has completely drained replace hose Remove hose to drain radiator fluid...

Page 38: ...air filter element much more frequently Use the following procedures to remove the element and inspect it AIR FILTER REMOVAL AND CLEANING 1 Locate Air Filter Box under rear rack on left side remove co...

Page 39: ...he air filter element frequently if the vehicle is used in dusty wet or muddy conditions could damage your Go kart The air filter element could become clogged under these conditions and engine damage...

Page 40: ...old Recommended pressure Front 14psi Rear 14psi Operating this Go kart with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure...

Page 41: ...ng a plug type patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your Go kart in areas where transportation or service fac...

Page 42: ...the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE Operating the Go kart in harsh conditions could be hazardous if you do not inspect brake wear oft...

Page 43: ...WARNING 1 Inspect the front disk brake caliper for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks damage and the joint for leakage 3 Check the...

Page 44: ...enish fuel Clogged fuel filter On Off flip switch is in off position Water in fuel Drain system Spark plug No spark to spark plug Contact service center Engine compression 155 lbs No compression Engin...

Page 45: ...ake sure the fuel valve is not clogged and the fuel tank is not clogged either 4 Check the idle speed If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min Performing the...

Page 46: ...ing fuel from the carburetor be sure to shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazar...

Page 47: ...bility conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the Go kart before any mud dries on the Go kart Block or seal...

Page 48: ...shes as they may scratch plastic or painted surfaces Rinse the Go kart thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wr...

Page 49: ...ormal pressure EXTERNAL 1 Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERV...

Page 50: ...p 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 side of the engine housing Write...

Page 51: ...ture switch Pilot light Kill switch Headlight Rectifier CDI Ignition coil Spark plug Tail light Ignition switch Starting relay Starting relay Fuse 15A Magneto Magneto Magneto Resistor Battery Br G G B...

Page 52: ...Fuel type SAE 90 or above unleaded Lubricate oil SAE 10W 30SF Ignition C D I Starting Electric Spark plug DPR7EA Drive system Chain drive Carburetor Vacuum diaphragm Air cleaner Paper element Transmis...

Page 53: ...RANTY COVERAGE The Distributor warrants that each new 2009 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of t...

Page 54: ...The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business dur...

Page 55: ...52 Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252...

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