Baja BLASTER 6.5 Manual

1
1. Remove cardboard carton from
metal frame
2. Remove operating instructions
and owners manual located on top of
Go-Kart.
E - REV - A
4. Remove bolts as indicated in photo
from both sides of metal frame
5. Carefully remove metal
frame
3. Remove hardware box
BAJA BLASTER 6.5 SET UP INSTRUCTIONS

2
Rear Rack
Rear Tire
Seat
Seat cover
Front tire
Cross Support
steering
wheel
Front bumper
Front Tire
Seat
Rear tire Cross braces
Seat cover
Left Brush
Guard
Right Brush
Guard
Left and
right Nerf
Bars
Nerf
Brace
Nerf
Brace
6. Remove parts from crate, layout
according to diagram
7. Remove parts from hardware box
and layout accordingly.
Rubber Grommets
QTY 8
Cotter Pin
QTY 2
Parts and Hardware
Rear bumper

3
Tie Rod
8. Attach Tie rod to spindle assembly
9. To attach rear axle to support bar you
must rst remove the rear bumper
Trailing arm axle support
10. Attach rear shock to axle using
bolt and nut already attached to shock.
Tie Rod and Rear Shock Assembly
Cotter pin
Axle
NOTE: The rear guard has been removed to show
detail.This assembly must be performed with
removing the rear guard.
Castle nut

4
11. Attach front wheels using 4 M10 nuts
Torque lug nuts to 33ft.lbs. Make sure the
air ll valve is facing out.
12. Attach rear wheels using M10 nuts.
Torque lug nuts to 33ft. lbs.
Front and Rear Wheel Assembly
NOTE: The front rim is not as “Deep” as the rear
rim on the side containing the air ll valve.
The rear wheels have “Deeper” rims
on the side with the air ll valve.

5
13. Attach steering support to frame
using M10x55 bolt and M10 nut.
Once assembled the steering column
can be used to adjust the steering
wheel height.
14. Attach top of steering support
bracket to steering shaft using M10x90
bolt and M10 nut.
15. Attach steering wheel to steering
support using M12 nut. Torque nut
to 39 ft.lbs.
Steering Column and Steering Wheel

4
Rubber
gromets
16. Attach seats to frame using phillips
screw driver, M6x30 screws, M6 washers,
rubber grommets and M6 nuts.
17. Put seat cover over seat and
tie down.
6
Seat Assembly

5
18. Attach Nerf bar to frame and
add nerf brace using M10x30 and
M12-25 bolts and nuts
19. Attach front bumper to front of
frame using M8x40 bolt, lockwasher
and M8 nut.
M12x25 bolt and nut
M10x30 bolt and nut
7
Nerf Bar and Front Bumper Assembly
Nerf Brace
Nerf Bar
Lock washer

6
20. Attach front of brush guards to frame
using M12x90 bolt and M12 nut.
21. You must rst remove the rear bumper
before attaching the rear of brush guards to
the frame. Use M12x105 bolt and M12 nut
to attach. Make certain that you reattach the
rear bumper.
8
Front Bar Cage Assembly

7
22. Attach cross bar behind seat
using sleeve, M12x100 bolt and
M12 nut.
23. Attach cross bar to top
mounting point of brush guard
using sleeve, M12x105 bolt and
M12 nut.
9
Cross Bar Assembly
Sleeve

8
24. Attach front of rear cargo rack to bar
cage using M12x75 and M12 nut.
25. Attach rear of cargo rack using
M10x25 bolt and M10 nut.
10
Rear Cargo Rack Assembly
26. To attach Brushguard cross support
you must loosen the attachments on the
side of the bar cage frame. Use M10-70
bolts and M10 nuts. Make sure you have
retightened all hardware.

9
27. Attach seat belt to bar cage using
M12x25 bolt and nut. Torque bolts to 39
ft.lbs.
28. Attach headrest using 6mm nut.
11
Seatbelt and Headrest Assembly

10
29. Fill engine with correct amount of oil. Refer to owners
manual for oil types and quantity.
30. Fill gas tank as specied in
owners manual.
31. Refer to owners manual for
proper starting instructions.
!!WARNING!!
This engine may be shipped with packing oil in
the engine. This oil should be drained and
replaced with new engine oil as described in the
owners manual. Never attempt to start the
engine without rst replacing the engine oil with
the proper amount and grade as described in the
owners manual.
Gas and Oil
Gas Tank
Oil Tank