Five Star 150 User's Manual

OWNER’S MANUAL DUNE 150
Minimum
Recommended
Operator Age:
16
THIS VEHICLE IS SOLD FOR OFF-ROAD USE ONLY. BEFORE OPERATING THIS VEHICLE,
READ ALL THE INSTRUCTIONS FOR SAFE ASSEMBLY AND OPERATION AS WELL AS ALL
INSTRUCTION GOVERNING THE ENGINE AND OTHER PORTIONS OF THE VEHICLE.
LIMITED WARRANTY
This Limited Warranty applies to those cases where the new product is unloaded from its shipping container, set-up as described in this manual, and under normal use and service is found to have defects in
parts or workmanship under the following terms and conditions:
This Limited Warranty covers the frame, suspension, steering, brakes, engine and engine related components for a period of 90 days from the date of purchase on the sales receipt.
This Limited Warranty DOES NOT cover wear items like tires, batteries, belts, brake pads, chains, spark
plugs, fuses, clutch plates, sprockets, light bulbs, and other normal wear items.
This Limited Warranty DOES NOT apply to any part, which in the opinion of the seller was defective
because of improper maintenance, improper assembly, alterations, abuse, negligence, or accident.
What is not covered under this Limited Warranty
This Limited Warranty does not cover any product which has been subjected to:
1.
2.
3.
4.
Installation of non-original replacement parts.
Rental Use.
Disassembly, adjusting, or repairing of the product in any was so as to adversely affect its safety
and reliability.
Competition or racing.
This Limited Warranty does not cover loss of use of the product, loss of time, inconvenience, or other
consequential damage which includes, but is not limited to, loss or damage to persons or property or
any expense of returning any damaged / defective product to the manufacturer.
How do I get Replacement Parts and Service?
Please DO NOT TAKE THIS PRODUCT BACK TO THE RETAILER. For parts or service center locations, please call 888-863-2252. Many problems are easily repaired by the consumer. Our expert customer service representatives can lead you through most problems with ease. We also have a nationwide network of Authorized Service Centers to assist with any repair or problem.
RECORD THE MODEL NUMBER AND SERIAL NUMBER OF YOUR PRODUCT IN THE SPACES
PROVIDED BELOW FOR REFERENCE WHEN ORDERING REPLACEMENT PARTS. IT IS ALSO
RECOMMENDED TO ATTACH YOU SALES RECEIPT TO THIS PAGE.
Model
No._______________________________________________Color_________________________
Serial
No._____________________________________________________________________________
(Located on the left rear frame member near the seat belt mount)
Engine
No.____________________________________________________________________________
(Located on top of engine)
FOREWORD
Congratulations on your purchase of a Baja Motorsports Off-Road Machine. It represents more than 20
years of the pursuit of excellence in the off-road recreation industry. With the purchase of this product,
you will experience the thrill of off-road recreation like thousand of other consumers.
This Owner’s Manual contains important assembly, operational, safety, and maintenance information.
The manual provides information about special techniques and skills necessary to ride your machine.
Read it carefully BEFORE YOU OR ANYONE ELSE USES THIS PRODUCT. Failure to follow the
warnings contained in this manual can result in SEVERE INJURY OR DEATH.
Be sure to follow the recommended maintenance schedule and service your Baja Motorsports product
accordingly. Preventive maintenance is extremely important its longevity.
It is important that this manual remain with the product when you sell it as the next owner will need this
manual. If you should lose or damage this Owner’s Manual, please call 888-863-2252 for a replacement.
SAFETY MESSAGE:
READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR
MACHINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO ALL THE LABELS ON THE MACHINE.
IT IS NOT RECOMMENDED THAT THIS PRODUCT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
Assumption of Risk
The Owner / Operator and any passengers assume all risks or incidents arising from
the use of this product.
Failure to follow, and comply with, all warnings may cause SERIOUS INJURY OR
DEATH.
CONTENTS
Safety
Page 1 - 4
Safety Labels
Page 5
Vechicle Assembly
Page 6 - 8
Specifications
Page 9 - 10
Operation Controls
Page 11 - 13
Pre-Operation Inspection
Page 14 - 15
Before You Start the Engine
Page 16 - 17
Driving Tips
Page 18 - 19
Slope Guide
Page 20
Periodic Maintenance
Page 21 - 30
Touble Shooting
Page 31
Wiring Diagram
Page 32
California Emissions Warranty
Page 33
SAFETY
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. In addition to the safety information in this
manual, you will find 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 (IF
DOUBLE SEAT PRODUCT), A BYSTANDER OR A PERSON INSPECTING
OR REPAIRING THE PRODUCT.
CAUTION INSTRUCTIONS ARE PROCEDURES TO PREVENT DAM-
AGE TO THE VEHICLE OR INJURY TO THE OPERATOR OR PASSENGER
(IF DOUBLE SEAT PRODUCT), A BYSTANDER OR A PERSON INSPECTING OR REPAIRING THE PRODUCT.
N O T E :
A NOTE provides key information to make procedures easier or clearer.
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 specified 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.
1
SAFETY
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 recommended inflation 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.
Modification of this vehicle or removal of any original equipment or safety decal may render the
vehicle unsafe or illegal. NEVER REMOVE ANY PROTECTIVE GUARDS, BELT GUARD,
These covers are for operator/passenger's protection. If any guards are removed for mainenance or servicing of the vehicle, ensure that they are secured in place prior to operating the
vehicle.
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, or use on rental
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 sufficient age, understanding, mental capacity, and
physical capability to safely operate this vehicle. This vehicle should only be operated after
mature, supervised instruction and sufficient practice in decongested areas. 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 prop
erly secured. For double seat vehicles ridden without a passenger, the passenger seat belt must
be secure to prevent it from getting caught up in operating components. Any passenger must be
of sufficient age, understanding, mental capacity, and physical capability to act to protect him
self/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 the 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.
2
SAFETY
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 is 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 suit
able 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 be checked. The fuel tank should
never be filled while the engine is running or while the engine is hot. Do not fill tank in a closed
area such as a garage, while smoking, or in the vicinity of an open flame. Do not overfill the
tank. There should not be any fuel in the filler neck. Replace cap tightly to prevent spillage of
fuel and potential fire hazard. After filling tank, move the vehicle at least 15 feet away from spot
of filling 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.
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.
20.
Always perform a Pre-Ride Inspection before starting the engine. See Pre-Ride Inspection section in this manual.
21.
The Bar Cage assembly provided with this vehicle is not designed as a "roll bar". Do not
operate this vehicle without the cage properly installed. Vehicles with light kits are for decorative
purposes and to assist others in seeing you. Only operate this vehicle during daylight.
3
SAFETY
22.
When storing the vehicle, it must be kept in a place where gasoline fumes will not reach an open
flame or spark. For long period of 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 specific instructions and a
Operator's Manual revisions are included in supplements. If any printed material included is
unclear, contact the manufacturer.
23.
NEVER OPERATE THIS VEHICLE WHILE UNDER THE INFLUENCE OF ALCOHOL, DRUGS,
OR MEDICATION OF ANY KIND. SUCH OPERATION COULD BE DANGEROUS TO YOUR
SELF AND/OR OTHERS.
24.
Always slow down when turning. High speed turning may cause loss of control, possible turnover
of the vehicle, and/or possible injury to operator or passenger.
25.
When turning, 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 hill or over obstacles, if you fail to take proper precautions.
26.
DO NOT RACE, JUMP, PERFORM "STUNT" RIDING OR "SPINOUTS" WHEN OPERATING
THIS VEHICLE. THIS VEHICLE IS NOT DESIGNED OR INTENDED FOR SUCH OPERATION.
27.
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.
28.
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 made.
29.
Always use extreme caution when starting the engine. Avoid touching the engine, muffler, or
drive components. These areas could cause burns on contact.
30.
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 disfigurement. Also, battery may
generate explosive gases and must not be exposed to sparks, flame, cigarettes, or anything
flammable or an explosion may result causing severe injury. Protective gloves and face protection must be worn when servicing the battery
31.
ANY OPERATOR OR PASSENGER UNDER 18 YEARS OF AGE MUST ALWAYS BE APPROPRIATELY SUPERVISED BY AN ADULT AT ALL TIMES WHILE OPERATING THE VEHICLE.
32.
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.
33.
Operate only on safe and familiar terrain. Avoid loose gravel and rocks. Be careful on wet surfaces and allow for extra braking distance.
4
SAFETY LABELS
Read and understand all of the labels on your vehicle. The labels contain important information for safe and proper operation. The labels
should be considered as permanent parts of the vehicle. If a label
comes off or becomes hard to read, contact the manufacturer for
replacement labels.
The Engine Exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects, or other
reproductive harm.
5
VEHICLE ASSEMBLY
Step 1
Installing the Rear and Front Wheels
Place a common automobile jack under the rear axle. Using the automobile jack raise the rear
axle off the ground approximately 12”. Slide one of the 22” rear wheels over the splined rear
axle. Make sure the air stem valve is facing outward. Note the grooves in the rear wheel hub
must match the grooves in the axle and wheel must “seat properly”. Assemble the large washer, smaller washer, axle nut and tighten the axle nut using a socket or adjustable wrench. See
fig 1.
THE NEXT STEP IS VERY IMPORTANT. INSERT THE COTTER PIN THROUGH THE GROOVES IN
THE NUT THE THEN THROUGH THE REAR AXLE. BEND THE OPEN END OF THE COTTER PIN
TO ENSURE THE REAR AXLE NUT DOES NOT LOOSEN DURING OPERATION.
Use the automobile jack to raise the front of the go-kart off the ground. Remove the nuts
which are placed on the front wheel hubs. Install one of the front wheels by lining up the bolts
on the front wheel hub with the holes in the front wheel rim. NOTE: THE VALVE STEM (AIR FILL
TUBE) MUST BE TO THE OUTSIDE to ensure the wheel has been installed properly.. Place the
nuts on the bolts. Using socket wrench, evenly tighten the nuts in diagonal pattern. Put the
rubber covers over the front hubs. See fig 2.
Figure 1
Figure 2
Step 2
Attaching the Gas Tank
Next attached the gas tank to the rack as shown in. Fig 3. Follow the bolt, spacer, and washer
order to insure the tank is securely fastened. See fig 4.
Attach the gas line to the gas on/off valve on the gas tank as shown in Fig 5. Turn the gas
on/off value to either on or res. In the res position, half of the gas in the tank will be used during operation. Turn the value to res to use the remaining gas.
Figure 4
Figure 5
Figure 3
6
VEHICLE ASSEMBLY
Step 2
Attaching the Bar Cage
Attach the Bar cage using the bolts and nuts provided. See Fig 6. Tighten
the nuts after the bar cage is seated. Attach the light as shown. See Fig 7.
Attach the foam padding as shown.
Figure 6
Figure 7
7
VEHICLE ASSEMBLY
Step 3
Attach the Front Bumper
Attach the front bumper as shown
using the bolts provided. Note there
are four attaching points. Two on the
top and two on the bottom. Fig 8.
Figure 8
Attaching
Points
Step 4
Connect the Wiring for the Lights
Attach the wires from the Ignition to
the wires found on the right side of
the bar cage. Attach wires with corresponding colors. Fig 9
Figure 9
Step 5
Insert the headrest
Insert the headrest as shown. Fig 10.
Figure 10
Refer to the Periodic Maintenance Section of this Manual for Information
on Fuel, Oil, Battery Service, and other vital information.
8
SPECIFICATIONS
DIMENSIONS
Overall Length ------------------------------------------------------------------------------86 in. (2184mm)
Overall Width -------------------------------------------------------------------------------54 in. (1371mm)
Overall Height ----------------------------------------------------------------------------55 in. (1397mm)
Wheelbase ---------------------------------------------------------------------------------71 in. (1803mm)
Ground Clearance Front ---------------------------------------------------------------6.5 in. (165mm)
Ground Clearance Rear ---------------------------------------------------------------- 10 in. (254mm)
ENGINE
Type ---------------------------------------------------------------------------Forced Air-Cooled 4-Stroke
Engine capacity ------------------------------------------------------------------------------------------150cc
Bore x Stroke ----------------------------------------------------------------------------57mm x 57.8mm
Displacement ------------------------------------------------------------------------------------------149.6cc
Corrected compression ratio --------------------------------------------------------------------------- 9.2:1
Carburetor ---------------------------------------------------------------------------------------Keihin VE49A
Output Power -------------------------------------------------------------------------9.2 hp @ 7500 RPM
Maximum Torque -------------------------------------------------------------------8.0 nm @ 4000-4500
Starting --------------------------------------------------------------------------------------------------- Electric
Ignition ----------------------------------------------------------------------------------------------------- C.D.I.
Lubrication ---------------------------------------------------------------------------- Pressure & Splash
Transmission ------------------------------------------------------------------- Automatic (C.V.T system)
Spark plug ------------------------------------------------------------------------------------- C7HSA(NGK)
Plug gap ---------------------------------------------------------------------------------------------0.6-0.7mm
Fuel Type ------------------------------------------------------------------------------------------- (Unleaded)
Lubricate oil ------------------------------------------------------------------------------------- SAE-10W/40
CAPACITIES
Maximum Load------------------------------------------------------------------------ Double Seats/400lbs
Fuel tank ------------------------------------------------------------------------------------------------1.85 Gal
Engine oil ------------------------------------------------------------------------------------------------- 30 Oz
Starting ---------------------------------------------------------------------------------------------------- 5 sec.
Battery ------------------------------------------------------------------------------------------------ 12V 10Ah
Head Light -------------------------------------------------------------------------------------------- 12V 15W
Tail Light ----------------------------------------------------------------------------------------- 12V 10W/5W
Fuse ----------------------------------------------------------------------------------------------------------- 10A
SPECIFICATIONS
Brake Track -------------------------------------------------------------------------------- < 7 m@20miles/h
Top speed ------------------------------------------------------------------------------------ 36 MPH Est.
9
SPECIFICATIONS
CHASSIS
Front Brakes --------------------------------------------------- Dual Hydraulic Disc, Left Foot Control
Front tire ------------------------------------------------------------------------------------------------ 19 x 7-8
Rear tire --------------------------------------------------------------------------------------------- 22 x 10 -10
Front Suspension --------------------------------------------------------------- Independent Dual A-Arm
Rear Suspension -------------------------------------------- Swing Arm/Double Oil Damped Shock
Restraint System -------------------------------------------------------------------- Dual 4-point Harness
Final Drive Chain ------------------------------------------------------------------- (KMC) O-Ring Chain
TIRE PRESSURE
Front -------------------------------------------------------------------------------------------------------- 2.5 psi
Rear ------------------------------------------------------------------------------------------------------- 3.0 psi
WEIGHT
Net Weight ----------------------------------------------------------------------------------------------- 528 lbs
10
OPERATION CONTROLS
Operation Controls
WARNING - Do not attempt to start or operate the engine until completely familiar with the
location and use of each control necessary to operate this vehicle and the operator is seated properly
in the vehicle. The operator must know how to stop this vehicle before operation.
A. Throttle
The right foot pedal is the throttle that controls the Kart speed. As the engine speed is increased above
idle, the clutch automatically engages and moves the vehicle forward. To disengage the clutch at any
time, allow the throttle to return to the idle position. (See Fig. 1)
Prior to starting the engine, check the throttle assembly to ensure that when the pedal
is pushed all the way forward the assembly is working smoothly and returns to idle
when released. Do not operate if pedal or engine throttle linkage fail to return to idle.
If you are unable to correct the problem through lubrication, adjustment or replacement of worn parts , contact the manufacturer for assistance.
B. Brake
The brake is located on the left side of the kart (See Fig.1). Applying pressure to the
brake pedal draws the brake caliper around the brake discs and slows or stops
the vehicle.
B. Start engine
Position then engine stop button in the run position.
Insert the key into key-switch, depress the brake pedal,
turn the key clockwise, release the key when the engine
starts. The engine will warm up within 5 minutes and the
engine choke will close automatically and operate at the
normal RPM (Warning: Don’t actuate starter more than 5
seconds at one time).
NOTE: THE BRAKE PEDAL MUST BE
DEPRESSED WHEN STARTING THE ENGINE.
THE ENGINE WILL NOT START WITHOUT THE
BRAKE BEING DEPRESSED
Engine Stop Button
Key Switch
Brake Pedal
Throttle Pedal
D. Engine stop button
Important-stop button test.
Before driving this vehicle, test the Engine Stop Button to assure that it is operating properly. With the
engine running, position the Engine Stop Button to the off position. The engine should stop.
11
OPERATION CONTROLS
E. Reverse Operation
When the forward / reverse lever is in the "D" position the
vehicle will move forward when the throttle is pressed. When
the forward / reverse level is pulled back to “R” the vehicle will
move backward when the throttle is pressed. (See Fig.4)
N O T E :
Note: Push the throttle slowly
when the reverse in engaged.
When reverse lever is in the drive position, there need to be
1/2 inch of play in the reverse level. If the adjustment is not
correct, then loosen the lock nut #2, then adjust lock nut #1 to
the proper amount of play.
F. Parking Brake
See Fig 1. on page ?? for the location of the parking brake.
The to engage the parking brake pull back on the lever. THE
PARKING BRAKE SHOULD ONLY BE USED WHEN THE
VEHICLE IS NOT MOVING.
Insure the parking brake is not engaged when the vehicle is in operation. Operating
the vehicle with the parking brake engaged will wear the brake pads quickly and braking power could be lost.
G. Passengers
The vehicle allows for two riders only. Combine maximum weight of driver and the passenger should
not exceed 180kg or 400lbs.
12
OPERATION CONTROLS
H. Seat Adjustment
The seat must always be securely fastened in the
position which best affords the operator control of
the foot pedals, steering wheel, and the remote
stop button.
a. Pull seat adjustment handle upward to disengage
seat slide.
b. Move seat to desired position.
c. Be sure seat adjustment handle snaps back into
place and that seat is locked into position.
Before attempting to adjust the seat, ensure that the vehicle engine is stopped.
Never operate this vehicle when the seat is not securely fastened. To do so could
result in the possibility of severe personal injury or loss of life. Before attempting to
adjust the seat, ensure the vehicle’s engine is stopped.
I. Seat Belts
This Vehicle is equipped with a seat belt for the operator and a seat belt
for the passenger of a double seat vehicle (if applicable). No one should
ever attempt to ride the Vehicle without being seated, with the seat belt
properly secured.
After being seated in the vehicle, place your arms through the shoulder
straps. Next, buckle the lap belt and adjust the tightness of the lap belt
by pulling the loose ends outward. The shoulder harness should then be
adjusted by pulling down on the loose ends.
Operating the vehicle without the seat belt fastened properly could result in the
operator or passenger (if applicable) being ejected from the vehicle, and coming in
contact with the ground or the custom bar cage in case of collisions or rollover. This
could result in severe injury or death.
13
PRE-OPERATION INSPECTION
Before each drive, it is important to inspect your Kart and make sure any problems you find are
corrected. A pre-drive inspection is a must, not only for safety, but because having a breakdown, or even
a flat tire, can be a major inconvenience.
If your Kart has overturned or has been involved in a collision, do not drive it until your Kart has been
inspected by an authorized service center. There may be damages or other problems you cannot see.
Operating the vehicle without the seat belt fastened properly could result in the
operator or passenger (if applicable) being ejected from the vehicle, and coming in
contact with the ground or the custom bar cage in case of collisions or rollover. This
could result in severe injury or death.
Pre-drive Inspection
Check the following items before you operate the vehicle:
Engine Oil
Check the level and add oil if needed. Check for leaks. Refer to
the “Periodic Maintenance” section of this manual for the proper
amount of oil.
Fuel
Check the level and add fuel if needed. Also make sure the fuel fill cap is securely fastened.
Check for leaks. Refer to item number 17 in the “Safety” section of this manual for proper instructions
on filling the gas tank.
Tires
Use a gauge to check the air pressure. Adjust if needed. Also look for signs of damages or excessive
wear. Refer to the “Specifications” section of this manual for proper pressure measurements for each
tire.
Nuts & Bolts
Check the wheels to see that the axle nuts are tight. Use a wrench to make sure all accessible nuts,
bolts, and fasteners are tight.
Underbody & Exhaust System
Check for and remove any dirt, vegetation or other debris that could be a fire hazard or interfere with
the proper operation of the vehicle.
14
PRE-OPERATION INSPECTION
Air Cleaner Housing Drain Tube
Check for deposits in the drain tube. If necessary, clean the tube and check the air cleaner housing.
Refer to the “Periodic Maintenance” section of this manual for instructions on cleaning the air filter.
Leaks, Loose Parts
Walk around your Kart and look for anything that appears unusual, such as a leak or loose cable.
Lights
Make sure the headlight, brake light and taillight are working properly.
Throttle
Check the freeplay and adjust if needed. Press the throttle to make sure it moves smoothly without sticking, and snaps back automatically when it is released.
Brakes
Press the rear brake pedal several times, check for proper brake pedal freeplay. Make sure there is no
brake fluid leakage. Check operation of the pedal. It should move smoothly and there should be a firm
feeling when the brake is applied.
PERFORM A BRAKE TEST: Have the operator sit in the seat, then push the vehicle from behind.
Once the vehicle is rolling, have the operator apply the brake pedal. The vehicle should come to a stop.
Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes
do not provide proper braking performance, inspect the brakes for wear.
Engine Stop Button
While engine is running, press and hold the Engine Stop Button for two seconds. Make sure engine
stops.
Steering Wheel
Check that the wheels turn properly as you turn the steering wheel.
Cables
Check all cable housings for wear. Check the fittings for looseness. Replace or tighten as needed.
15
BEFORE YOU STAR T THE ENGINE
Before operating your vehicle, you need to make sure you and your vehicle are both ready for operation. To help get you prepared, this section discusses how to evaluate your driving readiness. You
should also complete a Pre-Operation inspection as described previously in this manual.
Before you drive your Kart for the first time, we urge you to:
•
•
•
•
Read this owner's manual and the labels on your vehicle carefully.
Make sure you understand all the safety messages.
Know how to operate all the controls.
Have adult present if under 18 years old.
Before each drive, be sure:
• You wear your seat belt at all times while driving your kart or as a passenger.
• You feel well and are in good physical and mental condition.
• You are wearing an approved motorcycle helmet (with chin strap tightened securely), eye protection,
and other protective clothing.
• You don't have any alcohol or drugs in your system.
Protective Apparel
For your safety, we strongly recommend that you always wear an approved motorcycle helmet, eye protection, boots, gloves, long pants, long-sleeved shirt or jacket, and closed toe shoes or boots whenever you drive. Although complete protection is not possible, wearing proper gear can reduce the chance
of injury when you operate the vehicle.
The following suggestions will help you choose the proper driving gear.
Helmet and Eye Protection
Your helmet is your most important piece of driving gear because it offers the best protection against
head injuries. A helmet should fit your head comfortably and securely. An open-face helmet offers some
protection, but a full-face helmet offers more. Regardless of the style, look for a DOT (Department of
Transportation) sticker on any helmet you buy. Always wear a face shield or goggles to protect your eyes
and help your vision.
Operating this vehicle without wearing an approved motorcycle helmet, eye protection,and protective clothing could increase your chances of head and/or eye injury,
and the possibility of death in the event of a severe accident. Always wear an
approved motorcycle helmet that fits properly and wear eye protection
(goggles or face s held), gloves , boots , long-s leaved shirt or jacket, long pants,
and closed toe shoes or boots.
16
BEFORE YOU STAR T THE ENGINE
Additional Driving Gear
In addition to a helmet and eye protection, we also recommend:
Sturdy off-road motorcycle boots to help protect your feet, ankles, and lower legs. Off-road motorcycle
gloves to help protect your hands. Driving pants with knee and hip pads, a driving jersey with padded
elbows, and a chest/shoulder protector.
Driver Training
Developing your driving skills is an on-going process. Even if you have driven other off-road vehicles,
take time to become familiar with how this vehicle works and handles. Practice driving in a safe area to
build your skills. Do not drive in rough terrain until you get accustomed to the controls, and feel comfortable with the vehicle’s size and weight.
Age Recommendation
It is strongly recommended that no one under the age of 16 be permitted to operate this Go-Kart
without adult supervision.
Allowing a person under the age of 16 to operate this vehicle or to become a passenger could be hazardous and could result in sever injury or death. Operating, or
becoming a passenger in this vehicle, or any other vehicle, which is not recommended for his /her age could result in loss of control and could result in severe injury or
death. A minor under 18 should have adult supervision when operating this vehicle.
No Alcohol or Drugs
Alcohol, drugs and off-road vehicles don't mix. Even a small amount of alcohol can impair your ability
to operate an off-road vehicle safely. Likewise, drugs-even if prescribed by a physician, can be dangerous while operating an off-road vehicle. Consult your doctor to be sure it is safe to operate a vehicle
after taking medication.
Operating this vehicle after consuming alcohol or drugs can seriously
impair your judgement, cause you to react more slowly, affect your balance
and perception, and could result in serious injury or death.
Never consume alcohol or drugs before or while operating this vehicle.
The Exhaust System
The exhaust system on this vehicle is very hot during and following operation. To prevent burns,
avoid touching the exhaust system. Always park the vehicle in a place where pedestrians or children
can not touch it.
Touching the exhaust system during or after operation could result in sever burns.
17
DRIVING TIPS
Off-Road Use Only
Your vehicle and its tires are designed and manufactured for off-road use only, not for pavement. Driving
on pavement can affect handling and control. You should not drive your vehicle on pavement.
When driving off-road, also remember to always obey local off-road driving laws and regulations. Obtain
permission to drive on private property. Avoid posted areas and obey "no trespassing" signs.
You should never drive your vehicle on public streets, roads or highways, even if they are not paved.
Drivers of motor vehicles may have difficulty seeing and avoiding you, which could lead to a collision. It
is illegal to operate off-road vehicles on public streets, roads, or highways.
Operating this vehicle on paved surfaces may seriously affect handling and control of
the vehicle, and may cause the vehicle to go out of control. Never operate the vehicle on any paved surfaces , including sidewalks , driveways , parking lots and
streets .
In addition, operating this vehicle on public streets , roads or highways could cause a
collision with another vehicle. Never operate this vehicle on any public streets , roads
or highways ,weather it be dirt, gravel or pavement.
Keep Hands and Feet on Controls
When driving your vehicle always keep both hands on the steering wheel and both feet
on the foot controls. It is important to maintain your balance and to control the vehicle.
Removing hands or feet away from the controls can reduce your ability to react and
control the vehicle.
Removing your hands from the steering wheel or feet from foot controls during operation can reduce your ability to control the vehicle.
Always keep both hands on the steering wheel and both feet on the foot controls during operation.
18
DRIVING TIPS
Control Speed
Driving at excessive speed increases the chance of an accident. In choosing a proper speed, you
need to consider the capability of your vehicle, the terrain, visibility and other operating conditions, plus
your own skills and experience.
Roll Over
This, or any other off-road vehicle, could overturn during high speed turns, on uneven terrain, or during
sliding stops. This possibility increases on paved or hard surfaces. Take extra precautions to slow down
during turns. In addition, never perform sliding stops. Keep hands and feet inside the vehicle at all
times.
Operating this vehicle at excessive speeds increases your chances of losing control
of the vehicle, which can result in roll over or another type of accident.
Always drive at a speed that is proper for your vehicle, the terrain, visibility and other
operating conditions , and your experience.
Use Care on Unfamiliar or Rough Terrain
Before driving in a new area, always check the terrain thoroughly. Don't drive fast on unfamiliar terrain
or when visibility is limited.(it's sometimes difficult to see obstructions like hidden rocks,bumps, or
holes in time to react.)
Never drive past the limit of visibility. Maintain a safe distance between your vehicle and other off-road
vehicles. Always exercise caution and use extra care on rough, slippery and loose terrain.
Failure to use extra care when Operating this vehicle on unfamiliar terrain could result
in the vehicle overturning or going out of control. Go slowly and be extra careful when
operating on unfamiliar, rough, slippery, or loose terrain. Always be alert to changing
terrain conditions when operating the vehicle.
Do Not Perform Stunts
You should always operate your vehicle in a safe and reasonable manner. When driving, always keep
all four wheels on the ground.
Attempting wheelies, jumps, and other stunts increases the chance of an accident,
including a rollover. Never attempt stunts , such as wheelies or jumps.
19
SLOPE GUIDE
20
PERIODIC MAINTENANCE
Model Identification
ENGINE NUMBER
The engine number is located on the
lower front left side of the engine cases.
Fuel and Oil Recommendations
In order to ensure proper operation of the kart only the specified fuel and oil should be used.
Fuel
• Gasoline should be 85 to 93 octane or higher.
• Only use unleaded gasoline.
• To avoid serious burn or injury, always take caution when working with gasoline.
• DO NOT refuel when engine is hot.
• Always refuel with the engine stopped and outdoors or in a well-ventilated area.
• Be sure to tighten fuel cap after refueling.
• Avoid all spilling.
• If you get gasoline on your skin or clothing immediately wash it off with soap and
water and change clothing.
• DO NOT smoke around gas container or go kart and keep away from open flame.
• Follow all gasoline producer directions.
Engine Oil
• API Classification SF – SG (SAE 10W – 40) motor oil should be used.
Gear Oil
• API Classification GL – 5, GL – 4, GL – 3 (SAE 80W – 90) gear oil should be used.
Note: SAE is an oil weight viscosity classification standard.
21
PERIODIC MAINTENANCE
ENGINE BREAK-IN
The most critical time in your engine's life is the first 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load
on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear
and polish themselves to the correct operating clearance. In the first 20 hours of the engine's operation
it is critical to avoid excessive engine heating. However, momentary (2~3 seconds maximum) full throttle operation under load does not harm the engine. Each full throttle acceleration sequence should be
followed with a substantial rest period for the engine by cruising at lower rpm (revolutions per minute)
so the engine can rid itself of the temporary build up of heat.
1.
0~10 hours:
Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after
every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one
set throttle position.
2.
10~20 hours:
Avoid prolonged operating above ¾ throttle. Rev the machine freely but do not use full throttle at any
time.
3.
After break-in:
Avoid prolonged full throttle operation. Vary speeds occasionally.
Battery Installation
INITIAL SERVICE AND INSTALLATION OF BATTERY:
The following procedure is very dangerous and should be performed with utmost care and
attention. Wear protective eyewear, 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.
POISON – CAUSES SEVERE BURNS
Contains sulfuric acid.
Avoid contact with skin, eyes, or clothing
TO prevent accidents, rinse empty container with water.
ANTIDOTE:
External – flush with water
Internal – Call physician immediately. Drink large quantities of water or milk.
Follow with milk of magnesia, beaten eggs or vegetable.
Eyes – Flush with water for 15 minutes and get prompt medical attention.
KEEP OUT OF THE REACH OF CHILDREN
22
PERIODIC MAINTENANCE
Battery Installation (cont.)
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 20)
• Take the electrolyte container out of the plastic bag.
• Place electrolyte container upside down with the sealed silver
mouths of the electrolyte bottles in line with the six filler holes of
the battery. (see figure 21)
• Push the container down strongly enough to break the silver seals.
(see figure 22)
• As electrolyte starts flowing into battery, air bubbles will come up
from the mouths of the plastic electrolyte bottles.
• Leave bottles upside down in battery holes until electrolyte is
completely drained.
• Never leave children unattended around battery.
• If air bubbles cease to float to the top of the electrolyte bottles,
tap lightly on top.
• DO NOT remove container from battery while it is draining.
• Never cut or pierce electrolyte container.
• After all the electrolyte has drained from the bottles into the battery, pull plastic electrolyte bottles gently out of the battery.
• Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals.
• After filling let battery stand for at least 30 minutes before charging.This allows the electrolyte to penetrate plates for optimum
performance and ensures longer battery life.
• After 30 minutes the battery is ready for its initial charge. Place cap strip loosely over the filling holes
as shown in the picture.(see figure 23)
23
PERIODIC MAINTENANCE
How to Initially Charge the battery:
1. Connect the red positive (+) cable to the red positive (+) pole of
the battery. (see figure 24)
2. Connect the black negative (-) cable to the black negative (-) pole
of the battery. (see figure 25)
Note: The red positive (+) cable has a larger diameter than the
black negative y cable.
3. Charging rate: Charge battery @ 0.7 Amps for 5 ~ 10 hours.
• After charging is complete, press down firmly with both hands to
seat the caps. (Do not pound or hammer.) The battery is now
sealed. (see figure 26 and 27)
NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR
ELECTROLYTE.
• Install battery into battery tray making sure that the rubber mat is
in place. The warning label on the battery should be facing the
warning label on the gray tray. (see figure 28)
• Once battery is firmly seated in gray tray with rubber mat under it,
attach the red positive wire to the red positive terminal on the
battery. (see figure 29)
24
PERIODIC MAINTENANCE
• Then attach the black negative wire to the black negative terminal
on the battery. (see figure 30)
• Place grey plastic battery cover on top of the battery and thread
wires through the cover cuts – outs. Finally, secure the battery
with the wide black rubber strap using the hooks on both ends.
(see figure 31 and 32).
• DO NOT open sealed caps to add water to battery.
• Always wear safety glasses and charge in a ventilated area.
• If battery gets hot to the touch, discontinue charging and allow battery to cool down.
• Do not use fast charging unless it is an emergency.
• At the beginning or end of charging, turn off the charger first, in order to prevent electric spark and explosion.
• Charge in a well ventilated area.
• DO NOT smoke around batteries and keep away from open flame.
BATTERY REPLACEMENT:
• Remove old battery. 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.
• After charging, install new battery. Put dielectric grease on the battery terminals to avoid corrosion.
Connect cables to the proper terminals. Positive cable to positive terminal Å and negative cable
to negative terminal y.
• Positive (+) cable is red and larger in diameter. Negative y cable is black and smaller of the two in
diameter. CONNECT NEGATIVE CABLE LAST.
• Torque terminal bolts to 40 in. / lbs.
• Place rubber pad in bottom of battery tray.
• Securely fasten battery to the vehicle using cover and strap.
• To avoid possibility of explosion, always connect battery cable in the order specified:
RED first; BLACK last. An exploding battery can cause serious injury or death.
• Batteries contain sulfuric acid.
• Always shield eyes with protective eyewear when working around battery acid.
• Battery acid is poisonous and can cause severe burns.
• DO NOT smoke around batteries and keep away from open flame.
25
PERIODIC MAINTENANCE
Changing the Oil
The engine oil must be changed the first 5 hours of operation of your new vehicle engine. The engine
oil should then be changed every 10 hours of use thereafter.
ENGINE OIL: API Classification SF – SG (SAE 10W – 40)
Checking the Engine Oil
• Place unit on flat surface.
• Remove dipstick and wipe off with a clean cloth.
• Put dipstick in hole without screwing it in.
• Check oil level to see if it is between min and max indicators.
• Add oil as necessary to reach required level.
Changing the Engine Oil
• Run unit for at least 5 minutes or until warm, shut off.
• Place suitable container for draining oil beneath engine.
• Container should be capable of holding at least 1 gallon.
• Remove the engine drain plug, oil filter cap, spring, and oil filter
screen. Drain the oil completely.
•
•
•
•
•
Check condition of O-ring and filter screen for foreign material before installing.
Install the drain plug and torque to 12 ft. / lbs.
Fill with 25 to 31 oz. of API classification SF – SG (SAE 10W – 40) oil.
Start engine and check for leaks.
Shut off engine and check the oil level with dipstick, do NOT screw the dipstick in when making
this check. Add oil if necessary to reach safe amount.
26
PERIODIC MAINTENANCE
Cleaning the Air Filter
It is very important that the air filter be cleaned on a regular basis. The air filter should be cleaned every
10 -20 hours or more often if the vehicle is driven in extremely dusty conditions. If the air filter is clogged
with dust, performance will be adversely affected and if left unserviced, engine damage can occur.
Check and clean in the following manner:
• Remove the 5 screws on air filter and remove the cover. Remove
the 3 screws of the air filter and remove element.
• Clean the air filter cover with mild, sudsy water. Rinse and allow to dry.
• Install a new air filter element and reattach cover. Tighten screws
Before and during service, inspect the element for rips. A torn element must be replaced. Make sure that the element is
seated properly and no foreign material can pass by it.
27
PERIODIC MAINTENANCE
Inspecting and Changing the Final Gear Oil
Inspect final gear oil level monthly and change final gear oil every 3 months.
To check level, remove
level screw on the left
rear engine case. If gear
oil does not come out of
hole, add until it does.
To drain gear oil, remove
the drain plug at the rear
bottom of the engine
case. It is recommended
to warm the engine for
10 minutes or more
before draining final gear
oil.
Note:
API Service Standard GL-5, GL-4,
GL-3 SAE 80W 90 gear oil is
recommended in the final drive case.
However, in extreme cold weather
conditions it is then advised to use
lighter viscosity oil, such as 75 wt.
Final drive capacity: 80cc (3 oz.)
SPARK PLUG - NGK C7HSA
• Clean up the carbon around the spark plug to prevent the carbon from dropping into the cylinder
when removing the spark plug.
• Remove the spark plug.
• Clean up carbon accumulation on the spark plug with a steel brush or a
blade.
• Inspect the spark plug gap, in general it should be about
Spark plug gap: .024 in. ~ .028 in. (0.6 ~ 0.7mm).
Note: If the carbon accumulation and wear on the spark plug appear to be
excessive, replace it with a spark plug of the same specification.
BRAKE PERFORMANCE
• Always check that there is plenty of brake fluid in the brake
fluid reservoir.
• Ensure that the rear brake pads are in good condition.
• Check the brake rotor for abnormal wear.
• DOT 3 – 4 brake fluid
28
PERIODIC MAINTENANCE
Chain Adjustment
Loosen the jam nuts
Turn adjustment nut clockwise
to remove deflection in chain
Leave 3/8 - 3.4 in. deflection in
chain. Tighten jam nuts to 40ft /
lbs.
Adjustment of Front and Rear Shocks
There are five adjustable positions on each shock. The default position is in the middle set by
manufacture. Use a round nut wrench as you adjust the shock, the tension of shock spring will
increase as you screw to left, decrease as you screw to the right. Adjust according to the
weight of the riders.
STORAGE
In the event your vehicle is not to be operated for a period in excess of 30 days and at the end of riding
season prepare for storage as follows:
WARNING - Do not drain fuel while engine is hot. Be sure to move vehicle outside before draining fuel.
1. Drain fuel tank and remove all fuel remaining in the tank by using a suction device or by soaking up the fuel
with a clean rag or towel. Remove all fuel remaining in the carburetor by allowing engine to run out of fuel. Do not
perform any fuel removal procedure while smoking or near an open flame. Dispose of any rags or towels properly.
2. Lubricate engine cylinder by removing the spark plug and pouring an ounce of lean lubricating oil through the
spark plug hole into the cylinder. Crank the engine slowly to spread oil and replace spark plug.
3. Do not save or store gasoline over winter. Using old gasoline that has deteriorated from storage will cause hard
starting and affect engine performance.
4. When the vehicle is removed from storage re-read the owner’s manual, perform any assembly required, and
perform a pre-ride inspection. See Pre-Ride Inspection section of this manual.
29
PERIODIC MAINTENANCE
Maintenance Chart
The maintenance intervals in the following table are based upon average riding conditions. Operation
in unusually dusty areas require more frequent servicing.
A: Adjust
C: Clean
I: Inspect
L: Lubricate R: Replace
Maintenance Record
30
TROUBLESHOOTING
The following information is provided to help you identify probable question you may have out the
operation of your go kart. See your authorized service center with any additional questions you may
have.
31
WIRING DIAGRAM
32
CALIFORNIA EMISSIONS WARRANTY
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Baja Motorsports (hereinafter Baja Mspt.) are pleased to explain the emission control system warranty
on your small off-road engine. In California, new small off-road engines must be designed, built and equipped to meet the State's stringent anti-smog
standards. Baja Mspt. must warrant the emission control system on your small off-road engine for the period of time listed below provided there has been
no abuse, neglect or improper maintenance of your small off-road engine.
Your emission control system may include parts such as the carburetor, the ignition system, exhaust system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Baja Mspt. will repair your small off-road engine at no cost to you including diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE
The 1995 and later small off-road engines are warranted for two years as specified by this California Emission Control Warranty Statement. If any emission-related part on your engine is defective, the part will be repaired or replaced by Baja Mspt.
OWNER'S WARRANTY RESPONSIBILITIES
As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Baja Mspt. recommends that you retain all receipts covering maintenance on your small off-road engine, but Baja Mspt. cannot deny warranty solely for the lack of
receipts or for your failure to ensure the performance of all scheduled maintenance.
As a small off-road engine owner, you should however be aware that Baja Mspt. may deny you warranty coverage if your small off-road engine or a part
has failed due to abuse, neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your small off-road engine to a Baja Mspt. distribution center or service center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should contact Baja Mspt., 2910 South Hardy Drive, Suite 103, Tempe,
AZ 85282. Phone: (888) 863-2252.
EMISSION CONTROL SYSTEM (ECS) WARRANTY
This warranty shall apply to 1995 and later model year California small off-road engines (for other states, 1997 and later model year engines)
The Emission Control System (ECS) Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use
purchaser, and shall continue for 24 consecutive months thereafter.
(1) Any warranted, emission related parts which are not scheduled for replacement as required maintenance in the Owner’s manual shall be
warranted for the ECS warranty period. If any such part fails during the ECS period of warranty coverage, it shall be repaired or replaced by
Baja Mspt. according to Subsection 4 below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder
of the ECS Warranty Period.
(2) Any warranted, emission related parts that are scheduled only for regular inspection as required maintenance in the Owner’s manual shall
be warranted for the ECS Warranty period. A statement in the written instructions to the effect of "repair or replace as necessary" will not
reduce the period of ECS Warranty coverage. Any such part repaired or replaced under the ECS Warranty must be warranted for the remaining
ECS warranty period.
(3) Any warranted, emission related part which is scheduled for replacement as required maintenance in the Owner’s manual shall be
warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Baja Mspt. according to Subsection 4 below. Any such emission-related part repaired or
replaced shall be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a
Baja Mspt. Authorized Service Center.
(5) The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact
defective, provided that such diagnostic work is performed at a Baja Mspt. Authorized Service Center.
(6) Baja Mspt. shall be liable for damages to other original engine components or approved modifications proximately caused by failure under
warranty of an emission-related part covered by the ECS warranty.
(7) Throughout the ECS Warranty period, Baja Mspt. shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.
(8) Any Baja Mspt. authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repair and will be proved without charge to the owner. Such use shall not reduce Baja Mspt. ECS warranty obligations
(9)Unapproved add-on or modified parts may not be used to modify or repair a Baja Mspt. engine. Such use voids this ECS Warranty and shall
be sufficient grounds for disallowing and ECS Warranty claim. Baja Mspt. shall not be liable hereunder for failures of any warranted parts of a
Baja Mspt. engine caused by the use of such an unapproved add-on or modified part.
ECS Warranty Parts List
Carburetor, Air Cleaner Element, Intake Manifold, Spark Plug; Champion, Ignition coil and magneto assembly, Hose, connectors and
Assemblies
33
Baja Motorsports,a division of The Godfrey Group, LLC
2 9 1 0 S o u t h H a r d y D r i v e , S u i t e 1 0 3 • Te m p e , A Z 8 52 8 2
Phone 888-863-BA JA (2252) •Fax 866-316-4602
Copyright 2004 The Godfrey Group, LLC
Oct 2004