Baja BR250 Go-Kart Owner's Manual
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Baja BR250 Go-Kart Owner's Manual

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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
Minimum Age Requirement 16
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.
REV. B
031109

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  • Page 1 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 Minimum Age Requirement 16 REV. B 031109 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.
  • Page 2 Fender bent or broken due to abuse Any sign of impact, accident, jumping, spin-outs or roll over. BAJA, INC. is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way.
  • Page 3 WARNING 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS FORWARD..................NOTICE TO USERS............... BR250/DN250 GO-KART.............. FUEL AND OIL................WARNING LABELS..............CONTROL PANEL AND IGNITION SWITCH....... THROTTLE AND BRAKE PEDAL..........PARKING BRAKE............SEAT ADJUSTMENT..............RIDING YOUR GO-KART............. INSPECTION BEFORE RIDING........... SAFETY GEAR................BREAK-IN..................DRIVE SELECT LEVER............... CARBURETOR ADJUSTMENT...........

  • Page 5: Forward

    FORWARD 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. WARNING Indicates a potential hazard that could result WARNING in death or injury.

  • Page 6: Notice To Users

    NOTICE TO USERS 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 informed decisions about safety, you will find provided in this manual operating procedures and other safety procedures which must be followed.
  • Page 7 NOTICE TO USERS IMPORTANT RULES FOR SAFE OPERATION WARNING 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 law.
  • Page 8 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 starting with the operator in the seat, the operator should have their left foot on the brake.
  • Page 9 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.
  • Page 10 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 to avoid contact with the muffler, cylinder head, or any other potentially hot area on or around the engine.
  • Page 11 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 by persons of sufficient mechanical skill, experience, and judgment (such as outdoor equipment dealers, motorcycle dealer/shops, or small engine dealers) so that no unsafe condition or modification is...

  • Page 12: Br250/Dn250 Go-Kart

    BR250/DN250 Brush guard bar Rear rack Steering wheel Radiator Headlights Rear wheel Front wheel Forward/Reverse shifter [Left] Fuel tank Seats Control panel Rear shock absorber Front shock absorber Exhaust pipe Oil fill plug Parking brake [Right]...

  • Page 13: Fuel And Oil

    FUEL AND OIL 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.

  • Page 14: Warning 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 LOSS OF CONTROL, COLLISION, OR GETTING CAUGHT IN MOVING PARTS...
  • Page 15 WARNING LABELS Located on brush guard near control panel 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 Reverse Lever Parking Brake...
  • Page 16 WARNING LABELS Located on the fuel tank WARNING WARNING LOAD LIMIT LONG NEVER sit here 22lbs (10kg ) HAIR 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 WARNING SECURED.

  • Page 17: Control Panel And Ignition Switch

    CONTROL PANEL AND IGNITION SWITCH Light switch Engine stop switch Water temperature indicator light Ignition key switch 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).

  • Page 18: Throttle And Brake Pedal

    THROTTLE, BRAKE PEDAL AND PARKING BRAKE LEVER Brake fluid reservoir Brake Pedal Throttle Pedal Parking Forward Drive select lever Brake lever Reverse 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.

  • Page 19: Seat Adjustment

    SEAT ADJUSTMENT Pull seat adjustment handle upward to disengage the seat slide. Move the seat to desired position. Be sure the handle snaps back into place and that the seat is locked into position Seat adjustment handle WARNING Before attempting to adjust the seat, ensure that the engine is not running.

  • Page 20: Riding Your Go-Kart

    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 space to practice the new skills.

  • Page 21: Inspection Before Riding

    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; Fuel hose connected securely;...
  • Page 22 INSPECTION BEFORE RIDING WARNING 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. WARNING Operating this Go-kart with improper modifications could be hazardous. Improper installation of accessories or modifications to this vehicle may cause changes in handling.

  • Page 23: Safety Gear

    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. WARNING Operating this Go-kart without wearing an approved DOT motorcycle helmet, eye protection, and protective clothing could be hazardous.

  • Page 24: Break-In

    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 Recommendation During the first 10 hours of operation, you should always use less than ½...

  • Page 25: Drive Select Lever

    DRIVE SELECT LEVER The drive select lever shifts the Go-kart 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.

  • Page 26: Carburetor Adjustment

    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. Idle speed adjustment screw Warm up the engine for about 5-10 minutes. Connect the tachometer, and adjust the throttle idle speed (standard value is 1700 RPM).

  • Page 27: Chain And Shock Adjustment

    CHAIN AND SHOCK ADJUSTMENT 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.

  • Page 28: Maintenance

    MAINTENANCE SCHEDULE 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. Periodic Check and Service The maintenance intervals in the following table are based upon average riding conditions.
  • Page 29 If you are not sure how to do the maintenance ask your authorized service or call Baja Motorsports. WARNING If you use your Go-kart under severe conditions, it will need maintenance more often than shown in the chart.

  • Page 30: Battery Installation

    BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY: WARNING 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 CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED.
  • Page 31 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 BATTERY INSTALLATION How to Initially Charge the battery: Connect the red positive (+) cable to the red positive (+) pole of the battery. (see figure D) Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure E) Note: The red positive (+) cable has a larger Figure D...

  • Page 33: Battery Replacement

    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.

  • Page 34: Engine Oil

    ENGINE OIL To check oil level: 1. Park vehicle on level ground. Oil cap and dipstick 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.

  • Page 35: Cleaning Oil Filter

    ENGINE OIL Cleaning oil filter 1. Drain engine oil as instructed on page 31. 2. Remove oil filter plug (located on bottom right 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 to page 10 for correct engine oil type).

  • Page 36: Transmission Oil

    TRANSMISSION OIL WARNING Running the engine without an adequate amount of engine oil could cause severe engine damage. Running the engine without any engine oil could cause engine overheating. Always check the amount of engine oil before starting the engine. Draining transmission oil 1.

  • Page 37: Radiator

    RADIATOR WARNING Removing radiator cap while engine is hot can be hazardous. You can be seriously burned or injured by removing radiator cap while engine is hot. NEVER open radiator cap while engine is hot. Radiator Coolant over- flow bottle Radiator cap Coolant over- flow bottle...

  • Page 38: Air Filter

    AIR FILTER 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 more frequently.
  • Page 39 AIR FILTER WARNING 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. CAUTION Failing to inspect the air filter element frequently if the vehicle is used in dusty, wet, or muddy conditions could damage your Go-kart.

  • Page 40: Tires

    TIRES The Go-kart is equipped with low pressure tubeless tires of the size listed below: Front Rear Size 19x7-8 22x10-10 CAUTION Using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident.
  • Page 41 TIRES WARNING Overfilling the air to the tires could be hazardous. If you put too much air into the tire, may burst, and causing severe injury. Check the air pressure from time to time while inflating the tire gradually, until the specified air pressure is obtained. Tire Replacement Your Go-kart has low-pressure tubeless tires.

  • Page 42: Braking

    BRAKING The Go-kart has Hydraulic disk brakes on all four wheels. WARNING 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 BEFORE RIDING section.

  • Page 43: Brake Inspection

    FRONT AND REAR HYDRAULIC DISK BRAKE INSPECTION Brake fluid reservoir Brake hose Front disk brake caliper Brake disk Brake hose Brake disk Rear disk brake caliper Brake hose 1. Inspect the front disk brake caliper for leakage. If brake fluid leaks, the safety of riding could be affected.

  • Page 44: Troubleshooting

    TROUBLESHOOTING 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 Engine compression Spark plug On/Off flip switch...

  • Page 45: Ignition System Check

    IGNITION SYSTEM CHECK Remove the spark plug and reattach it to the spark plug lead. 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.

  • Page 46: Transporting

    TRANSPORTING It is best to transport the Go-kart in the normal position. Drain screw Before transporting the Go-kart drain the fuel from the carburetor as follows: Drain fuel from carburetor into an empty container by loosening the carburetor drain screw located on bottom of carburetor. When the fuel has been drained, retighten the drain screw.

  • Page 47: Cleaning Procedure

    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 used in mud, brush, grass, water, salt water, or very dusty conditions The build-up of mud, brush, grass, etc.

  • Page 48: Washing Your Go-Kart

    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 ·...

  • Page 49: Storage Procedure

    STORAGE PROCEDURE 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 the general guidelines below: VEHICLE Place the vehicle on level ground and wash the entire vehicle.

  • Page 50: 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 the gas tank. The engine number is located on the left side of the engine housing.

  • Page 51: Wire Diagram

    WIRE DIAGRAM...

  • Page 52: Specifications

    SPECIFICATIONS DIMENSIONS Overall length............2450mm (96.46 in.) Overall width.............1427mm (56.18 in.) Overall height............1512mm (59.53 in.) Wheelbase..............1865mm (73.43 in.) Dry weight ..............250kg (551 lbs.) Weight limit..............150kg (330 lbs.) ENGINE Type................Forced water-cooled,single cylinder,4-Stroke Displacement.............244.3ml Bore X Stroke............72mm X 60mm Max power..............11kw/7000rpm Fuel type................SAE 90# or above (unleaded) Lubricate oil..............SAE 10W/30SF Ignition................C.D.I.

  • Page 53: Emission Control System Warranty

    EMISSION CONTROL SYSTEM WARRANTY 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...
  • Page 54 No dealer is authorized to modify this Emission Control System Warranty. If you have any ques- tions regarding your warranty rights and responsibilities, you should contact BAJA MOTORSPORTS.
  • Page 55 Baja, INC. P.O. Box 61150 Phoenix, AZ 85082 Tel: 602-443-9180 Toll Free: 888-863-2252...

This manual is also suitable for:

Dn250 go-kart

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