Baja motorsports SD65 Go-kart 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
Minimum Age Requirement 16
SD65 Go-kart
Read this manual carefully. It contains important safety information.
No one under the age of 16 should operate this Go-Kart
REV. A
061807

II
Congratulations on your purchase of the
Baja Motorsports Sand Dog 65 Go-Kart.
It is warranted to be free of manufacturing defects in the material
of workmanship for a period of 90 days from the date of purchase.
During the warranty period BAJA, INC. will at its option, repair, provide
replacement parts or replace your Baja Motorsports Sand Dog
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 or need to return your Baja Motorsports
Sand Dog 65 Go-kart for repair, please call the BAJA MOTORSPORTS
customer service department TOLL FREE at 1-888-863-BAJA (2252) between
the hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm
PST. During DST hours change to MT. You will be instructed how to proceed.
A COPY OF THE SALES RECEIPT IS REQUIRED.

III
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.
WARNING
!
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
!

1
TABLE OF CONTENTS
NOTICE TO USERS....................................................................... 2
SAND DOG 65 GO-KART................................................................ 9
FUEL AND OIL............................................................................. 10
WARNING LABELS..................................................................... 11
THROTTLE AND BRAKE LEVER/KILL SWITCH........................ 13
ENGINE STARTING..................................................................... 14
RIDING YOUR GO-KART............................................................. 15
INSPECTION BEFORE RIDING................................................... 16
SAFETY GEAR............................................................................. 18
BREAK-IN..................................................................................... 19
MAINTENANCE SCHEDULE....................................................... 21
ENGINE OIL.................................................................................. 23
AIR FILTER................................................................................... 25
TIRES............................................................................................ 27
BRAKE ADJUSTMENT................................................................ 28
CHAIN ADJUSTMENT.................................................................. 29
IGNITION SYSTEM CHECK.......................................................... 30
SLOPE GUIDE............................................................................... 31
TRANSPORTING........................................................................... 32
CLEANING PROCEDURE............................................................. 33
WASHING YOUR GO-KART......................................................... 34
STORAGE PROCEDURE............................................................... 35
SERIAL NUMBER LOCATION....................................................... 36
SPECIFICATIONS......................................................................... 37
EMISSION CONTROL SYSTEM WARRANTY.............................. 38

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.
WARNING
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.
TABLE OF CONTENTS
WARNING
WARNING
CAUTION

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 WARNINGS 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.
NOTE: A NOTE provides key information to make procedures easier or
clearer.
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.
NOTICE TO USERS
CAUTION
WARNING

4
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.
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.
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 servic-
ing of the vehicle, ensure that they are secured in place prior to operating the
vehicle.
NOTICE TO USERS
WARNING

5
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 com-
petition, or use on metal tracks.
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 in
decongested areas. Safe operation includes responsibility for the safety or 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 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 Founda-
tion (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.
NOTICE TO USERS

6
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 those conditions. The operator
must use mature judgment, skill, and experience to choose a speed suitable
for the 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 smok-
ing, 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 abnor-
mally, the engine should be stopped and the spark plug wire disconnected.
The vehicle should then be checked for damaged. Excessive noise or vibra-
tion is generally a warning of loose or worn parts.
NOTICE TO USERS

7
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 work-
ing 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. When turning, knobby tires amy 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, if
you fail to take proper precautions.
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.
NOTICE TO USERS

8
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 judg-
ment (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 touch-
ing 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 pos-
sibly 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 protec-
tion 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 at-
tempting 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.
NOTICE TO USERS

9
[Right]
[Left]
SAND DOG 65
Front wheel
Front shocks
Steering wheel
Headrests
Brush guards
Rear wheel
Rear shocks
Manual pull start
Seat belts
Fuel tank Gas and Brake pedals

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 6.5 HP 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.
10W-30
ENGINE
TEMP.
°C
°F
-30
-22
40
104
-20
-4
-10
14
0
32
10
50
20
68
30
86
15W-40
20W-50
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.
LOCATION OF WARNING
LABELS
1-
3-
2-
1
2
3

12
LOCATION OF WARNING
LABELS
4-
5
6
Located on
chain guard
5-
6-
4

13
ACCELERATOR AND BRAKE
PEDAL, KILL SWITCH
Brake pedal
Depressing the brake pedal draws the brake calipers against the
brake rotor and slows or stops the go-kart.
Accelerator pedal
Depressing the throttle pedal will engage the torque converter and
move the go-kart forward.
Kill Switch
The engine will shut off by pressing the kill switch button.
Brake uid reservoir-located behind driver seat
Check brake uid by making sure the uid is above the low mark.
Use only DOT3 or DOT4 brake uid. DO NOT MIX BRAKE FLUID
TYPES.
Kill switch Accelerator
pedal
Brake pedal
Brake uid
reservoir

14
MAKE SURE THE DRIVER IS SEATED IN THE GO-KART BEFORE
STARTING ENGINE
To start, turn “Engine ON/OFF”
switch to “ON” position. To turn engine off,
turn switch to “OFF” position.
To start a cold engine:
1. Place choke lever in the “ON” position.
2. Place fuel lever in the “ON” position.
3. Start the engine using the pull start
recoil.
4. Once the engine is on and warmed up
move the choke lever to “OFF” position.
Procedures for stopping the engine:
1. Release the throttle pedal to slow down
go-kart.
2. Press down the brake pedal to slowly stop the go-kart
3. Push kill switch to turn engine off.
4. Set fuel lever to “OFF” position and Choke lever to “ON” position.
CAUTION
Verify oil level prior to starting (see page 10)
Starting the engine with low or no oil will damage the engine.
WARNING
Never start the engine in a closed place as the exhausted gas from
the vehicle contains toxic carbon monoxide.
Fuel lever
Choke lever
Engine on/off switch
ENGINE STARTING
ON OFF
OFF ON

15
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 nd a good place to practice the skills. Find a at,
open area with enough space to practice the new skills.
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.

16
RIDING YOUR GO-KART
WARNING
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.
ITEM TO CHECK CONTENT
Steering Smoothness; No restriction of movement; No play or
looseness
Brakes Proper brake pedal free play; 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 inspecting Engine Oil Dip
Stick. The engine oil should be between the Minimum
and Maximum lines.
Throttle Proper free play of accelerator pedal; 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

17
INSPECTION BEFORE RIDING
WARNING
Check the condition of the Go-kart to make sure that the Go-kart does not have
mechanical problems or you could get stranded when you ride. Before riding
the Go-kart, be sure to check the above items. Be sure your Go-kart is in good
condition to ensure the safety of the rider.
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.
Operating this Go-kart with improper modications could be
hazardous.
Improper installation of accessories or modications to this vehicle
may cause changes in handling. In some situations, this could lead
to an accident.
Never modify this Go-kart through improper installation or use of
accessories.
Checking maintenance items when the engine is running could be
hazardous.
You could be severely injured if your hands or clothing get caught in
moving Go-kart parts.
Shut the engine off when performing maintenance checks, except
checking the engine stop switch and throttle.
WARNING
WARNING