Baja motorsports BR150-D User manual

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.
No one under the age of 16 should operate this Go-Kart
Minimum Age Requirement 16
REV. D
040209

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 Baja Go-Kart at no charge. This
warranty does not cover normal wear items or damage caused by
neglect or misuse of the product.
Engine Warranty – 90 days
Frame 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.
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.
Should you experience a problem with your vehicle, please call Baja Inc.
customer service line toll free at 1-888-863-2252 between the hours of
7am and 5pm Monday through Friday MST (Mountain Standard Time).
MDT (Mountain Daylight Time) during the daylight saving time. You will be
instructed how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.

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 engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
CALIFORNIA PROPOSITION 65
! WARNING
! WARNING
Never operate this Go-Kart at night. Night is dened
as the period of time 30 minutes before sunset to 30
minutes after sunrise.
You may collide with another vehicle, a stationary
object, or hazard found in the terrain.
! WARNING

1
TABLE OF CONTENTS
NOTICE TO USERS....................................................................................... 2
BR150 GOKART............................................................................................. 9
FUEL AND OIL............................................................................................... 10
WARNING LABELS........................................................................................ 11
CONTROL PANEL AND IGNITION SWITCH................................................. 13
THROTTLE AND BRAKE PEDAL.................................................................. 14
PARKING BRAKE......................................................................... 14
SEAT ADJUSTMENT.......................................................................................15
RIDING YOUR GO-KART................................................................................16
INSPECTION BEFORE RIDING..................................................................... 17
SAFETY GEAR............................................................................................... 19
BREAK-IN....................................................................................................... 20
DRIVE SELECT LEVER..................................................................................21
CARBURETOR ADJUSTMENT...................................................................... 22
CHAIN AND SHOCK ADJUSTMENT..............................................................23
INSPECTION AND MAINTENANCE...............................................................24
BATTERY INSTALLATION..............................................................................26
BATTERY REPLACEMENT........................................................... 29
ENGINE OIL.................................................................................................... 30
CLEANING OIL FILTER..................................................................................31
TRANSMISSION OIL.....................................................................31
AIR FILTER..................................................................................................... 33
SPARK PLUG..................................................................................................35
TIRES......................................................................................................... 36
BRAKING....................................................................................................... 38
BRAKE INSPECTION................................................................... 39
TROUBLESHOOTING................................................................................... 40
IGNITION SYSTEM CHECK......................................................... 41
TRANSPORTING............................................................................................ 42
CLEANING PROCEDURE.............................................................................. 43
PREPARATION FOR CLEANING................................................. 43
WASHING YOUR GO-KART...........................................................................44
INSPECTION AFTER CLEANING.................................................44
STORAGE PROCEDURE............................................................................... 45
SERIAL NUMBER LOCATION....................................................................... 46
SPECIFICATIONS...........................................................................................47
WIRE DIAGRAM............................................................................................. 48
EMISSION CONTROL SYSTEM WARRANTY............................................... 49

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 clearer.
WARNING and CAUTION are arranged like this:
This user’s manual contains important safety and maintenance information.
Read it carefully before riding. Failing to follow the warnings contained in
this manual could result in INJURY or DEATH.
It is important that this manual remain with the vehicle when you transfer it to
another user or owner.
All information, illustrations, photographs and specications contained in
this manual are based on the latest product information available at the time
of publication. Due to improvements or other changes, there will be some
discrepancies in this manual. We reserve the right to make product changes
at any time, without notice and without incurring any obligation to make the
same or similar changes to the vehicle previously built or sold.
Indicates a potential hazard that
could result in death or injury.
Indicates a potential hazard that
could result in vehicle damage.
The rst part will identify a POTENTIAL
HAZARD.
The second part will describe WHAT COULD
HAPPEN if you ignore the WARNING or
CAUTION.
The third part will describe HOW TO AVOID
THE HAZARD.
NOTICE TO USERS
WARNING
CAUTION
WARNING

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 make informed decisions about safety, you will nd provided in
this manual operating procedures and other safety procedures which must
be followed. In addition to the safety information in this manual, you will nd
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 by
the following notations:
FAILURE TO FOLLOW WARNING INSTRUCTIONS
COULD RESULT IN SEVERE INJURY OR DEATH
TO THE OPERATOR OR PASSENGER, A
BYSTANDER OR A PERSON INSPECTING OR
REPAIRING THE PRODUCT.
CAUTION INSTRUCTIONS ARE PROCEDURES TO
PREVENT DAMAGE TO THE VEHICLE OR INJURY
TO THE OPERATOR OR PASSENGER, A
BYSTANDER OR A PERSON INSPECTING OR
REPAIRING THE PRODUCT.
NOTE: A NOTE provides key information to make procedures easier or
clearer.
NOTICE TO USERS
WARNING
CAUTION

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 specied in this manual, all screws, nuts, and bolts
must be kept tight to 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.
IMPORTANT RULES FOR SAFE OPERATION
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. Avoid operating this
vehicle in any area with stationary objects that the vehicle could travel under.
Do not ride in areas where other recreational vehicles are being operated. Be
respectful of landowners and the environment.
4. Prevailing-Torque-type locknuts lose their locking capability with repeated
use and require replacement. Ensure locknuts are functioning properly.
5. The tire pressure should be checked prior to each use. The recom-
mended ination pressure is the maximum tire pressure as printed on the tire’s
sidewall. IMPROPER TIRE PRESSURE MAY CAUSE INSTABILITY AND MAY
PREVENT PROPER BRAKING OR
STEERING.
6. Modications of this vehicle or removal of any original equipment or
safety decal may render the vehicle unsafe or illegal. NEVER REMOVE ANY
PROTECTIVE GUARDS OR BELT GUARDS. These covers are for operator/
passenger’s protection. If any guards are removed for maintenance or
servicing of the vehicle, ensure that they are secured in place prior to
operating the vehicle.
NOTICE TO USERS
WARNING

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
starting with the operator in the seat, the operator should have their left foot
on the brake.
8. This vehicle is not designed or intended for racing, any form of
competition.
9. The operator’s ability to operate this off-road vehicle safely is largely
dependent upon the operator’s ability to exercise proper judgment. An
operator also must not be too small or too large for controlled operation.
The operator must be of sufcient age, understanding, mental capacity, and
physical capability to safely operate this vehicle. This vehicle should only be
operated after mature, supervised instruction and sufcient practice. Safe
operation 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 seated, with the seat belt properly secured. For double seat vehicles
ridden without passenger, the passenger seat belt must be secure to prevent
it from getting caught up in operating components. Any passenger must be
of sufcient age, understanding, mental capacity, and physical capability to
act to protect himself/herself. ALWAYS FOLLOW THE RECOMMENDED AGE
RESTRICTION OF 16 YEARS FOR OPERATORS AND PASSENGERS.
11. The engine should be stopped when the vehicle is not in use.
12 The operator and passenger (if any) of this vehicle should always wear
a helmet approved by agencies such as Department of Transportation (DOT),
Safety Helmet Council of America (SHCA), or Snell Memorial Foundation
(SNELL). Most off-road vehicle accident fatalities are due to head injuries. The
operator should also wear face shields or goggles, boots or closed-toe shoes,
gloves, and other appropriate
protective clothing.

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 SAFETY OF THE
OPERATOR OR PASSENGER.
14. DO NOT PLACE HANDS, FEET, OR ANY OTHER PART OF THE BODY OR
ANY CLOTHING NEAR THE ENGINE, MUFFLER, WHEELS, CHAIN AND OTHER
ROTATING PARTS OF THE VEHICLE WHILE RIDING OR RUNNING THE
ENGINE. Caution must be used in performing required maintenance on or near
an operating engine. Special caution should be taken after the engine has
been running, since the engine and other drive components may be extremely
hot.
15. Wet, slippery, rough, or steep terrain is potentially dangerous and may
result in injury if proper caution in not observed. Slow speeds are required
to safely operate this vehicle under these conditions. The operator must use
mature judgment, skill, and experience 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 manufacturer and
limits the maximum speed of the engine (and vehicle) and protects the engine
from damage. Excessive speeds are potentially dangerous to the operator/
passenger, and the engine.
17. Each time before using this vehicle, the fuel supply should checked.
The fuel tank should never be lled while the engine is running or while the
engine is hot. Do not ll tank in a closed area such as a garage, while
smoking, or in the vicinity of an open ame. Do not overll the tank. There
should not be any fuel in the ller neck. Replace cap tightly to prevent
spillage of fuel and potential re hazard. After lling tank, move the vehicle at
least 15 feet away from the spot of lling before starting.
18. If the vehicle should start making unusual noise or vibrating abnormally,
the engine should be stopped and the spark plug wire disconnected. The
vehicle should then be checked for damage. Excessive noise or vibration is
generally a warning of loose or worn parts.

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 to avoid contact with
the mufer, cylinder head, or any other potentially hot area on or around the
engine.
20. Always perform a pre-ride inspection before starting the engine. See
Pre-Ride Inspection section in this manual.
21. When storing the vehicle, it must be kept in a place where gasoline
fumes will not reach an open ame or spark. For long period storage, such as
for winter, the fuel tank should be drained in an open, cool area. The engine
must be allowed to cool before storage in any enclosure. Read and keep all
printed material supplied with this vehicle. Timely and specic instructions
and an Operator’s Manual revisions are included in supplements. If any
printed material is unclear, contact the manufacturer.
22. NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF
ALCOHOL, DRUGS, OR MEDICATION OF ANY KIND. SUCH OPERATION
COULD BE DANGEROUS TO YOURSELF AND/OR OTHERS.
23. Always slow down when turning. High speed turning may cause loss of
control, possible turnover of the vehicle, and/or possible injury to the operator
or passenger.
24. While making a turn, knobby tires may increase the risk of loss of
control. ALWAYS SLOW DOWN! A collision or rollover can occur quickly,
even during routine maneuvers such as turning and riding on a hill or over
obstacles.
25. DO NOT RACE. JUMP, PERFORM “STUNT” RIDING OR “SPIN OUTS”
WHEN OPERATING THIS VEHICLE. THIS VEHICLE IS NOT DESIGNED OR
INTENDED FOR SUCH OPERATION.

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 by persons of sufcient mechanical skill, experience, and
judgment (such as outdoor equipment dealers, motorcycle dealer/shops, or
small engine dealers) so that no unsafe condition or modication is made.
28. Always use extreme caution when starting the engine. Avoid touching
the engine, mufer, or drive components. These areas could cause burns on
contact.
29. The battery (if applicable) contains sulfuric acid and must not come in
contact with skin, eyes, or clothing since this will cause severe burns
possibly causing disgurement. Also, battery may generate explosive gases
and must not be exposed to sparks, ame, cigarettes, or anything ammable
or an explosion may result causing severe injury. Protective gloves and face
protection must be worn when servicing the battery.
30. ANY OPERATOR OR PASSENGER UNDER 18 YEARS OF AGE MUST
ALWAYS BE APPROPRIATELY SUPERVISED BY AN ADULT AT ALL TIMES
WHILE OPERATING THE VEHICLE.
31. Operating this vehicle requires skills acquired through practice over a
period of time. Take the time to learn the basic techniques well before
attempting to operate the vehicle.
32. Operate only on safe and familiar terrain. Avoid loose gravel and rocks.
Be careful on wet surfaces and allow for extra braking distance.

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

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, you will realize the best
lubrication for the engine.
Use the chart to select a viscosity rating based on the temperature range in
your area.
SAE 10W-30
ENGINE
TEMP. °C
°F
-30
-22
40
104
-20
-4
-10
14
0
32
10
50
20
68
30
86
FUEL AND OIL

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
difcult to read, you
should get a replacement
by contacting Baja
Motorsports.
WARNING LABELS
1
1-
2
2-
3-
3
WARNING
LOSS OF CONTROL, COLLISION, OR GETTING CAUGHT IN MOVING PARTS
CAN RESULT IN SERIOUS INJURIES
Adult supervision for under 16 years olds
wear a D.O.T. approved motorcycle helmet
Secure long hair and loose clothing
Wear protective eye wear and clothing
Keep arms, legs and feet inside kart
Do not use alcohol or drugs
!
WARNING
303115
THIS GO-KART CAN BE HAZARDOUS TO OPERATE
if driven carelessly
INJURIES can result if you do not follow these
instructions:
-READ OWNER’S MANUAL AND ALL LABELS BEFORE
YOU OPERATE THIS GO-KART.
-NEVER OPERATE THIS GO-KART WITHOUT PROPER
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, JUMPS, OR OTHER STUNTS.
!
Seat Belt Must Be Worn At All Times
THIS VEHICLE MANUFACTURED
FOR OFF-ROAD USE ONLY.
DO NOT OPERATE ON PUBLIC
STREETS, ROADS OR HIGHWAYS.
WARNING CAUTION
!

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.
NO
LONG
HAIR
!LOAD LIMIT WARNING
!
22 LBS NEVER sit here
WARNING
NO RIDING
!
!WARNING
“Go Kart Must Be Stopped And
Engine Speed At Idle To Shift Into
Forward Or Reverse”
!WARNING
“Parking Brake Must Be Set
Before Exiting The Go Kart”

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 key CW and
release key when engine starts. Note: The engine stop switch needs
to be placed in the “ON” (I) position and the foot brake needs to be
depressed for engine to start.
CAUTION
Do not hold key for more than 5 seconds at a time when starting engine.
If engine fails to start within 5 seconds, allow starter to rest for 10
seconds before trying again.
Allowing the starter to run for more than 5 seconds at a time could cause
damage to the starter motor.
Engine stop switch
Ignition Key
(O)

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 uid reservoir
4 - Parking brake
While starting the engine or parking the machine, especially on a slope,
apply the parking brake by pulling lever back towards the seat
1
3
THROTTLE, BRAKE PEDAL AND
PARKING BRAKE LEVER
4

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 control of the foot pedals, steering wheel and engine stop
switch for the operator.
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

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 destroy plants, trees or other vegetation. Don’t litter
and don’t bother wildlife. With your help, your riding area can remain open for
use in the future.
After you have found a good place to practice, review the control system on
your Go-kart before riding. Learn to nd these controls without looking for
them, because you will not have time to look for them when you are riding.
Canadian residents must obtain, review, and follow all provincial and municipal
government acts and regulations pertaining to owning and operating an off-road
vehicle.
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 nd a good place to practice the skills. Find a at,
open area with enough space to practice the new skills.

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; Fuel hose
connected securely; No damage to fuel tank or cap;
Fuel tank cap closed securely.
Engine Stop Switch Proper operation.
Engine Oil Proper level- Check oil by inserting Engine oil
dipstick. The engine oil should be between the
minimum and maximum lines.
Throttle Smooth response; quick return to idle position.
General Condition Bolts and nuts are tight; no rattle from any parts
of the engine when running; no visible evidence of
damage.
Failing to inspect the Go-kart before operating could be hazardous.
Failing to perform proper maintenance could also be hazardous.
Failing to inspect and maintain your Go-kart could increases the
chances of an accident or equipment damage
Always inspect your Go-kart each time before riding, and make sure it is in a
safe operating condition. Refer to the INSPECTION AND MAINTENANCE section
in this manual.
WARNING