Razor DUNE BUGGY 25143511 User manual

OWNER’S MANUAL
Read and understand this entire manual before riding!
For assistance contact Razor. DO NOT RETURN TO STORE.
Item Number:
25143511
DUNE BUGGY

WARNING: Riding an electric vehicle can be a hazardous activity.
Certain conditions may cause the equipment to fail without fault of the
manufacturer. Like other electric vehicles, the Dune Buggy can and is
intended to move, and it is therefore possible to lose control, fall off and/or
get into dangerous situations that no amount of care, instruction or expertise
can eliminate. If such things occur you can be seriously injured or die, even
when using safety equipment and other precautions. RIDE AT YOUR OWN
RISK AND USE COMMON SENSE.
This manual contains many warnings and cautions concerning the
consequences of failing to maintain, inspect or properly use your electric
vehicle. Because any incident can result in serious injury or even death, we
do not repeat the warning of possible serious injury or death each time such
a possibility is mentioned.
APPROPRIATE RIDER USE AND
PARENTAL SUPERVISION
This manual contains important safety information. It is your responsibility
to review this information and make sure that all riders understand all
warnings, cautions, instructions and safety topics and assure that young
riders are able to safely and responsibly use this product. Razor USA
recommends that you periodically review and reinforce the information in
this manual with younger riders, and that you inspect and maintain your
children’s vehicle to insure their safety.
The recommended rider age of 8 years is only an estimate, and can
be affected by the rider’s size, weight or skills. Any rider unable to fit
comfortably on the Dune Buggy should not attempt to ride it.
A parent’s decision to allow his or her child to ride this product
should be based on the child’s maturity, skill and ability to follow
rules.
Keep this product away from small children and remember that this product
is intended for use only by persons who are, at a minimum, completely
comfortable and competent while operating the vehicle.
DO NOT EXCEED THE WEIGHT LIMIT OF 120lbs (54kgs). Rider weight does not
necessarily mean a person’s size is appropriate to fit or maintain control of
the Dune Buggy.
Do not touch the brakes or electric motor on your electric vehicle when in
use as they can become very hot.
Refer to the following section on safety for additional warnings.
ACCEPTABLE RIDING PRACTICES AND
CONDITIONS
Always check and obey any local laws or regulations which may
affect the locations where the Dune Buggy may be used.
Ride defensively. Watch out for potential obstacles that could catch your
wheel or force you to swerve suddenly or lose control. Be careful to avoid
pedestrians, skaters, skateboards, scooters, bikes, children or animals who
may enter your path, and respect the rights and property of others.
The Dune Buggy is meant to be used on private property and on closed
courses and not on public streets or sidewalks. Do not ride your electric
vehicle in any areas where pedestrian or vehicle traffic is present.
Do not activate the throttle unless you are on the electric vehicle and in a
safe, outdoor environment suitable for riding.
This product was manufactured for performance and durability but are not
impervious to damage. Jumping or other aggressive riding can over-stress
and damage any product, including the Dune Buggy, and the rider assumes all
risks associated with high-stress activity.
Be careful and know your limitations. Risk of injury increases as the degree
of riding difficulty increases. The rider assumes all risk associated with
aggressive riding activities.
Maintain a hold on the handlebars at all times.
Never carry passengers or allow more than one person at a time to ride the
electric vehicle.
Never use near steps or swimming pools.
Keep your fingers and other body parts away from the drive chain, steering
system, wheels and all other moving components.
Never use headphones or a cell phone when riding.
Never hitch a ride with another vehicle.
Do not ride the Dune Buggy in wet or icy weather and never immerse the
electric vehicle in water, as the electrical and drive components could be
damaged by water or create other possibly unsafe conditions.
Wet, slick, bumpy, uneven or rough surfaces may increase risks of use. Do
not drive the electric vehicle in mud, ice, puddles or water. Avoid excessive
speeds that can be associated with downhill rides. Never risk damaging
surfaces such as carpet or flooring by use of an electric vehicle indoors.
Do not ride at night or when visibility is limited.
PROPER RIDING ATTIRE
Always wear proper protective equipment such as an approved safety helmet
(with chin strap securely buckled), elbow pads and kneepads. A helmet may
be legally required by local law or regulation in your area. A long-sleeved
shirt, long pants and gloves are recommended. Always wear athletic shoes
(lace-up shoes with rubber soles), never drive barefooted or in sandals,
and keep shoelaces tied and out of the way of the wheels, motor and drive
system.
USING THE CHARGER
The charger supplied with the electric vehicle should be regularly examined
for damage to the cord, plug, enclosure and other parts, and in the event
of such damage, the bike must not be charged until the charger has been
repaired or replaced.
Use only with the recommended charger.
The charger is not a toy.
Always disconnect from the charger prior to wiping down and cleaning your
electric vehicle with liquid.
FAILURE TO USE COMMON SENSE AND HEED THE ABOVE
WARNINGS INCREASES RISK OF SERIOUS INJURY. USE WITH
APPROPRIATE CAUTION AND SERIOUS ATTENTION TO SAFE
OPERATION.
SAFETY WARNINGS
Safety Warnings ............................................................ 1
Before You Begin ........................................................... 2
Assembly and Set-Up .................................................... 2
Repair and Maintenance ............................................. 3-4
1
Troubleshooting Guide ................................................ 4-5
Dune Buggy Parts ...................................................... 7-8
Safety Reminders .......................................................... 9
Warranty ........................................................................ 9
CONTENTS

BEFORE YOU BEGIN
2
WARNING: DO
NOT USE NON-RAZOR
PRODUCTS WITH YOUR
RAZOR DUNE BUGGY.
The Dune Buggy has been built to
certain Razor design specifications.
The original equipment supplied at
the time of sale was selected on
the basis of its compatibility with
the frame, fork and all other parts.
Certain aftermarket products may
or may not be compatible.
❑ Required Tools
Some tools may be supplied; however, we recommend the use of mechanic’s grade tools. Use the supplied tools only
as a last resort.
Need Help? Visit our web site for replacement parts, product support, live chat and a list of
authorized service centers at www.razor.com or call toll-free at 866-467-2967 Monday - Friday
8:00 AM - 5:00 PM Pacific Time.
2.5mm hexagonal wrench
(included)
Bicycle-style tire pump
for Schrader valve tires,
with pressure gauge
ASSEMBLY AND SET-UP
❑ Charging the Battery
Your Dune Buggy may not have a fully charged battery; therefore you must charge the battery prior to use.
• Initial charge time: 12 hours • Run time: up to 45 minutes
• Recharge time: up to 8 hours • Average battery life: 250 charge/discharge cycles
• Fully charge once a month when not in use • Do not store below 32 degrees - this can damage the battery.
1 Plug the charger port into
the port on the Dune Buggy. The
charger works with the power
switch in either the on or off
position.
2 Plug the charger plug into a wall
outlet.
WARNING:
Rechargeable batteries are only to
be charged under adult supervision.
Always disconnect your Dune
Buggy from the charger before
cleaning with liquid.
Note: If your charger does not
look like the one illustrated,
your unit has been supplied
with an alternative charger.
The specifications and charging
procedure would not change.
The charger has a small window
with one LED or two LEDs to
indicate the charge status. Refer
to the illustration on the charger
unit for the actual “charging” and
“charged” status indications for
your model charger.
Chargers have built-in over-charge
protection to prevent battery from
being over-charged.
Be sure to properly align the
groove on the charger input
plug with the corresponding
socket on the case; otherwise,
no charging action will occur.
Charger
Plug
Charger
Port
1 Use the 2.5mm hexagonal
wrench to make a throttle
adjustment.
❑ Adjusting the Throttle

3
REPAIR AND MAINTENANCE
❑ Inflating the Tires
Tires are inflated when shipped, but they invariably lose some pressure between the point of manufacturing and
your purchase.
1 Using a bicycle style tire pump
equipped for a Schrader-type valve,
inflate the front tire to the PSI
indicated on the sidewall of the
tire.
Note: The pressurized air supplies
found at gasoline stations are
designed to inflate high-volume
automobile tires. If you decide to
use such an air supply to inflate
your Dune Buggy tires, first make
sure the pressure gauge is working,
then use very short bursts to
inflate to the correct PSI. If you
inadvertently over-inflate the
tire, release the excess pressure
immediately.
Check the Razor web site for any updates on the latest repair and maintenance procedures.
Turn power switch off before conducting any maintenance procedures.
❑ Replacing the Fuse WARNING: To prevent
shock or short circuit, please follow
the instructions in order and do not
skip or combine any steps.
4 Close the fuse cover.
3 Remove the fuse and replace
with a new one of equal
amperage.
Note: Amperage rating is
located on top of fuse. Fuse must
be replaced with one of equal
amperage.
Amperage
number
1 Make sure the power switch is
turned off.
2 Locate fuse cover near the
battery .Open the fuse cover to
expose the fuse.
POWER
OFF

4
❑ Battery Care and Disposal
Do not store the battery in temperatures above 75° or below -10° F.
CONTAINS SEALED LEAD BATTERY. BATTERY MUST BE RECYCLED.
Disposal: Your Razor product uses sealed lead-acid batteries which must be recycled or disposed of in an
environmentally sound manner. Do not dispose of a lead-acid battery in a fire. The battery may explode or leak. Do not
dispose of a lead-acid battery in your regular household trash. The incineration, land filling or mixing of sealed lead-
acid batteries with household trash is prohibited by law in most areas. Return exhausted batteries to a federal or state
approved lead-acid battery recycler or a local seller of automotive batteries. If you live in Florida or Minnesota, it is
prohibited by law to throw away lead-acid batteries in the municipal waste stream.
❑ Charger
The transformer/charger supplied with the Dune Buggy should be regularly examined for damage to the cord, plug,
enclosure and other parts, and, in the event of such damage, the bike must not be charged until it has been repaired or
replaced.
Use ONLY with the recommended charger.
❑ Replacement Parts
The most frequently requested replacement parts (wheels, tires, tubes, batteries and chargers) are available for
purchase at some Razor retail partners or online at www.razorama.com. For other parts contact an authorized Razor
repair center.
❑ Repair Centers
For a list of authorized Razor repair centers:
• Check online at www.razor.com.
• Send e-mail to [email protected] or call 866-467-2967 for the center nearest you.
WARNING: If a battery
leak develops, avoid contact with
the leaking acid and place the
damaged battery in a plastic bag.
Refer to the disposal instructions at
left. If acid comes into contact with
skin or eyes, flush with cool water
for at least 15 minutes and contact
a physician.
REPAIR AND MAINTENANCE
Vehicle does not run
Vehicle was running but
suddenly stopped
TROUBLESHOOTING GUIDE
Problem Possible Cause Solution
Vehicle is rolling backwards
Undercharged battery
Charger is not working
Loose wires or connectors
Burned-out fuse
Motor or electrical switch damage
Throttle will not engage if the vehicle is rolling backwards. Come to a
complete stop and then activate the throttle.
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all connectors. Make sure the charger connector is tightly
plugged into the charging port, and that the charger is plugged into
the wall.
Make sure power flow to the wall outlet is on.
You may check to see if your charger is working by using a volt meter
or asking your local Razor authorized service center to test your
charger for you.
Check all wires and connectors to make sure they are tight.
The fuse will burn out and automatically shut off the power if the
motor is overloaded.
An excessive overload, such as too heavy a rider or too steep a
hill, could cause the motor to overheat. Refer to replacing the fuse
instructions in this manual. Correct the conditions that caused the
fuse to burn out and avoid repeatedly burning out fuse.
Contact your local Razor authorized service center for diagnosis and
repair.

5
Short run time (less than
30 minutes per charge)
Vehicle runs sluggishly
Sometimes the vehicle
doesn’t run, but other
times it does
Charger gets warm
during use
Vehicle makes loud
noises or grinding
sounds
Problem Possible Cause Solution
Undercharged battery
Battery is old and will not accept
full charge
Driving conditions are too stressful
Tires are not properly inflated
Vehicle is overloaded
Loose wires or connectors
Motor or electrical switch damage
Normal response to charger use
Chain is too dry
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all wires and connectors. Make sure the battery connector is
tightly plugged into the charger connector, and that the charger is
plugged into the wall.
Make sure power flow to the wall outlet is on.
Even with proper care, a rechargeable battery does not last forever.
Average battery life is 1 to 2 years depending on vehicle use and
conditions. Replace only with a Razor replacement battery.
Use only on solid, flat clean and dry surfaces such as pavement or
level ground.
The tires are inflated when shipped, but they invariably will lose
some pressure between the point of manufacturing and your
purchase. Refer to instructions in this manual to properly inflate tires.
Make sure you do not overload the vehicle by allowing more than
one rider at one time, exceeding the maximum weight limit, going up
too steep a hill or towing objects behind the vehicle. If the vehicle is
overheated, the temperature circuit protector will slow motor down
and if the condition continues, will shut off power to the motor.
Correct the driving conditions that caused the overheating, wait
5-10 minutes and then resume riding. Avoid repeatedly overheating
the unit.
Check all wires around the motors and all connectors to make sure
they are tight.
Contact your local Razor authorized service center for diagnosis and
repair.
No action required. This is normal for some chargers and is no cause
for concern. If your charger does not get warm during use, it does not
mean that it is not working properly.
Apply a lubricant such as 3 in 1TM or Tri-FlowTM to the chain.
TROUBLESHOOTING GUIDE
Need Help? Visit our web site for replacement parts, product support, live chat and a list of
authorized service centers at www.razor.com or call toll-free at 866-467-2967 Monday - Friday
8:00 AM - 5:00 PM Pacific Time.

6
SB 1918 (CALIFORNIA) DECLARATION
YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS
INVOLVING THE USE OF THIS SCOOTER/ELECTRIC VEHICLE. TO DETERMINE
IF COVERAGE IS PROVIDED, YOU SHOULD CONTACT YOUR INSURANCE
COMPANY OR AGENT.

Keep your Dune Buggy running for years with genuine Razor parts. Visit our web site or e-mail us for more information on spare part availability.
(Specifications subject to change without notice.)
DUNE BUGGY PARTS
7
01 Front Wheel Complete
01-1 17mm Hex Nylon Lock Nut - 2
01-2 Washer - 2
01-3 Bearing (6000Z) - 4
01-4 Spacer - 2
02 Spindle Arm (Right)
02-1 5mm Coupling Bolt - 1
02-2 Washer - 1
03 Steering Column
03-1 4mm Hexagonal Screw - 2
03-2 Washer - 4
03-3 8mm Open Wrench Hexagonal
Nylon Lock Nut - 2
04 Adjustable Tie-Rod
04-1 4mm Hexagonal Screw - 2
04-2 Washer - 4
04-3 8mm Open Wrench Hexagonal
Nylon Lock Nut - 2
05 Steering Axle
05-1 “C” Clip - 1
05-2 Washer - 1
05-3 5mm Hexagonal Screw- 1
06 Spindle Arm (Left)
06-1 5mm Coupling Bolt - 1
06-2 Washer - 1
07 Spindle Bushing - 4
08 Plastic Boot - 2
09 Upper/Lower Bushing
(Steering Axle) - 2
10 Main Frame - 1
11 Steering Wheel - 1
12 Brake Lever Complete - 1
13 Thumb Tab Throttle - 1
14 Rubber End Plug (Steering
Wheel) - 3
15 Selt Belt -1
15-1 Safety Plate - 2
15-2 Washer - 4
15-3 5mm Hexagonal Screw - 4
16 Platform (Left) - 1
16-1 Phillip Screw - 2
17 Platform (Right) - 1
17-1 Phillip Screw - 2
18 Footrest - 1
18-1 Phillips Screw - 3
19 Phillip Screw (Left Platform) - 4
20 Seat - 120-1 Phillip Screw - 2
21 Phillip Screw (Behind Seat) - 2
22 Swing Arm
22-1 Swing Arm Bushing - 2
22-2 6mm Hexagonal Screw - 2
23 Shock Absorber
23-1 5mm Coupling Bolt - 2
24 Rear Frame
25 Sprocket (Large)
25-1 6mm Axle Bolt - 1
25-2 Bearing - 2
25-3 Spacer - 1
25-4 (Thin) Bushing - 1
25-5 (Thick) Bushing - 1
25-6 Sprocket (Small) - 1
25-7 14mm Open Wrench Nut - 1
26 Motor Alignment Adiuster
26-1 10mm Open Wrench Nut - 1
26-2 10mm Open Wrench
Hexagonal Nylon Lock Nut - 1
27 Arm Tensioner
27-1 Tensioner Arm Bracket - 1
27-2 5mm Hexagonal Screw - 2
27-3 5mm Hexagonal Screw - 1
27-4 8mm Hexagonal Lock Nut - 1
27-5 Spring - 1
27-6 Spring End Cap - 2
27-7 Spacer - 1
27-8 Tensioner Wheel - 1
27-9 Bearing (606Z) - 1
27-10 Washer - 1
27-11 10mm Open Wrench
Hexagonal Nylon Lock Nut- 1
28 Motor(250W) - 1
28-1 Washer - 4
28-2 5mm Hexagonal Screw - 4
28-3 Lock Washer - 4
29 Bottom Battery Cover
Bracket - 1
29-1 5mm Hexagonal Screw - 3
29-2 Lock Washer - 3
29-3 Washer - 3
30 Lower Battery Cover
30-1 Phillips Screw - 1
31 Control Module -1
31-1 Phillips Screw - 2
32 Chain (Motor) - 1
33 Chain (Axle Sprocket) - 1
34 Battery (2 12V/7ah)
34-1 30A Fuse w/Black Box - 1
35 Large Foam Pad (Battery) - 1
36 Battery Bracket - 1
36-1 Phillips Screws - 2
37 Small Foam Pad (Battery) - 2
38 Rear Wheel Complete
38-1 Plastic Spacer -2
38-2 Spacer - 2
38-3 17mm Hex Nylon Lock Nut - 2
39 Upper/Lower Clamp (Rear Axle)
39-1 6mm Hexagonal Screw - 4
39-2 Washer - 4
39-3 13mm Lock Nut - 4
40 Bearing (690RS) -2
41 Rear Axle - 1
41-1 Flat Key - 4
41-2 “C” Clip - 2
42 Rear Axle Sprocket - 1
42-1 3mm Set Screw - 1
43 Brake Drum - 1
43-1 3mm Set Screw (Brake
Drum) - 1
44 Disc Brake - 1
44-1 3mm Hexagonal Screw - 3
45 Brake Calipher
45-1 5mm Hexagonal Screw - 2
45-2 Lock Washer - 2
45-3 Washer - 2
46 Upper Battery Cover
46-1 4mm Hexagonal Screw - 4
46-2 Phillip Screw - 5
47 Charger Port w/Wires - 1
47-1 Black Rubber Charger
Port - 1
47-2 19mm Lock Nut - 1
48 On/Off Switch

8
DUNE BUGGY PARTS

Tire Inflation
Periodically inspect the tires for excess wear, and regularly check
the tire pressure and re-inflate as necessary. If you get a flat tire,
the inner tube can be patched or a new tube can be purchased
from Razor or an authorized repair center.
Safety Gear
Always wear proper protective equipment such as an approved
safety helmet, elbow pads and kneepads. Always wear shoes
(lace-up shoes with rubber soles), never drive barefooted or
in sandals, and keep shoelaces tied and out of the way of the
wheels, motor and drive system.
Razor Limited Warranty
The manufacturer warranties this product to be free of manufacturing defects
for a period of 90 days from date of purchase. This Limited Warranty does
not cover normal wear and tear, tires, tubes or cables, or any damage, failure
or loss caused by improper assembly, maintenance, or storage or use of the
Razor Dune Buggy.
This Limited Warranty will be void if the product is ever
• used in a manner other than for recreation;
• modified in any way;
• rented.
The manufacturer is not liable for incidental or consequential loss or damage
due directly or indirectly to the use of this product.
Razor does not offer an extended warranty. If you have purchased an
extended warranty, it must be honored by the store at which it was
purchased.
WARRANTY
Need Help? Visit our web site for replacement parts, product support, live chat and a list of
authorized service centers at www.razor.com or call toll-free at 866-467-2967 Monday - Friday
8:00 AM - 5:00 PM Pacific Time.
Patent Pending
Printed in China for:
Razor USA LLC
PO Box 3610
Cerritos, CA 90703
© Copyright 2007 Razor USA. All rights reserved.
For your records, save your original sales receipt with this manual and write
the serial number below.
__________________________________________
Item Number:
25143511
Loose Parts
Check and secure all fasteners before every ride. There should
not be any unusual rattles or sounds from loose parts or broken
components. If you are not sure, ask an experienced mechanic to
check.
Brake
Check the brake for proper function. When you squeeze the lever,
the brake should provide positive braking action. When you apply
the brake with the speed control on, the brake cut-off switch will
stop the motor.
Frame, Fork and Handlebars
Check for cracks or broken connections. Although broken frames
are rare, it is possible for an aggressive driver to bash into a curb
or wall and wreck and bend or break a frame. Get in the habit of
inspecting yours regularly.
SAFETY REMINDERS
❑
❑
❑
❑
❑
PRE-RIDE CHECKLIST
9
08032007
DO NOT RETURN TO STORE
Do not use this vehicle for the first time until you
have inflated the tires to the correct PSI and
charged the battery for at least 12 hours.
Failure to follow these instructions may damage
your vehicle and void your warranty.