Five Star 150 manual

OWNER’S MANUAL OWNER’S MANUAL DUNE 150 DUNE 150 Minimum Minimum Recommended Recommended Operator Operator Age: Age: 16 16 THIS VEHICLE IS SOLD FOR OFF-ROAD USE ONL Y . BEFORE OPERA TING THIS VEHICLE, READ ALL THE INSTRUCTIONS FOR SAFE ASSEMBL Y AND OPERA TION AS WELL AS ALL INSTRUCTION GOVERNING THE ENGINE AND OTHER POR TIONS OF THE VEHICLE.[...]

LIMITED W LIMITED W ARRANTY ARRANTY This Limited W arranty applies to those cases where the new product is unloaded from it s shipping con- tainer , set-up as described in this manual, and under normal use and service is found to have defects in part s or workmanship under the following terms and conditions: This Limited W arranty covers the frame,[...]

FOREWORD FOREWORD Congratulations on your purchase of a Baja Motorsports Of f-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 cont ains im[...]

CONTENTS CONTENTS Safety Safety Labels V echicle Assembly S pecifications Operation Controls Pre-Operation Inspection Before Y ou S tart the Engine Driving T ips Slope Guide Periodic Maintenance T ouble Shooting Wiring Diagram California Emissions W arranty Page 1 - 4 Page 5 Page 6 - 8 Page 9 - 10 Page 1 1 - 13 Page 14 - 15 Page 16 - 17 Page 18 - 1[...]

SAFETY SAFETY This off-road product IS NOT A TOY AND CAN BE HAZARDOUS TO OPERA TE. This product handles differently from other vehicles including A TV’s and motorcycles. A collision or rollover can occur quickly , even during routine maneuvers such as turning and riding on hills or over obstacles. T o help you make informed decisions about safety[...]

4. Prevailing-T orque-type locknut s 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 MA Y CAUSE I[...]

SAFETY SAFETY 13. LOOSE CLOTHING , LONG HAIR, OR ARTICLES WORN BY ANY OPERA TOR OR P ASSEN- GER MUST BE FULL Y CONT AINED, OR COVERED T O PREVENT THEM FROM POSSIBL Y BEING CAUGHT IN ROT A TING P ARTS OF THE VEHICLE OR THE SURROUNDING ENVI- RONMENT WHILE RIDING . F AILURE T O OBEY COULD ENDANGER THE PERSONAL SAFE- TY OF THE OPERA TOR OR P ASSENGER. [...]

SAFETY 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 wit[...]

SAFETY SAFETY LABELS LABELS Read and understand all of the labels on your vehicle. The labels con- tain import ant information for safe and proper operation. The labels should be considered as permanent part s of the vehicle. If a label comes off or becomes hard to read, cont act the manufacturer for replacement labels. The Engine Exhaust from this[...]

VEHICLE VEHICLE ASSEMBL ASSEMBL Y Y Step 1 Installing the R ear and F r ont W heels Place a common automobile jack under the rear axle. Using the automobile jack raise the r ear axle off the gr ound appr o ximately 12”. Slide one of the 22” rear w heels o v er the splined rear axle. Make sure the air stem valve is f acing outward. Note the groo[...]

VEHICLE VEHICLE ASSEMBL ASSEMBL Y Y Step 2 Attac hing the Bar Ca ge 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 f oam pad ding as sho wn. Figure 6 Figure 7 7[...]

VEHICLE VEHICLE ASSEMBL ASSEMBL Y Y Step 3 Attac h the F r ont Bumper Attach the front bumper as shown using the bolts provided. Note there are four attac hing points. Two on the top and two on the bottom. Fig 8. Attaching Points Step 4 Connect the W iring for the Lights Attach the wires from the Ignition to the wires found on the right side of the[...]

SPECIFICA SPECIFICA TIONS TIONS DIMENSIONS Overall Length ------------------------------------------------------------------------------86 in. (2184mm) Overall Width -------------------------------------------------------------------------------54 in. (1371mm) Overall Height --------------------------------------------------------------------------[...]

SPECIFICA SPECIFICA TIONS TIONS CHASSIS Front Brakes --------------------------------------------------- Dual Hydraulic Disc, Left Foot Control Front tire ------------------------------------------------------------------------------------------------ 19 x 7-8 Rear tire -------------------------------------------------------------------------------[...]

OPERA OPERA TION CONTROLS TION CONTROLS O O p p e e r r a a t t i i o o n n C C o o n n t t r r o o l l s s WARNI NG - 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 s[...]

OPERA OPERA TION CONTROLS TION CONTROLS E. R e verse Oper ation 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) When reverse lever is in the[...]

OPERA OPERA TION CONTROLS TION 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 handl[...]

PRE-OPERA PRE-OPERA TION INSPECTION TION 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 [...]

PRE-OPERA PRE-OPERA TION INSPECTION TION INSPECTION Air Cleaner Housing Drain T ube 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 Par ts W alk around your Kart and look fo[...]

BEFORE BEFORE YOU ST YOU ST AR AR T T THE ENGINE THE ENGINE Before operating your vehicle, you need to make sure you and your vehicle are both ready for opera- tion. T o help get you prepared, this section discusses how to evaluate your driving readiness. Y ou should also complete a Pre-Operation inspection as described previously in this manual. B[...]

BEFORE BEFORE YOU ST YOU ST AR AR T T THE ENGINE THE ENGINE Additional Driving Gear In addition to a helmet and eye protection, we also recommend: S turdy off-road motorcycle boot s to help protect your feet, ankles, and lower legs. Off-road motorcycle gloves to help protect your hands. Driving pant s with knee and hip pads, a driving jersey with p[...]

DRIVING DRIVING TIPS TIPS Of f-R oad Use Onl y Y our vehicle and its tires are designed and manufactured for of f-road use only , not for pavement. Driving on pavement can af fect handling and control. Y ou should not drive your vehicle on pavement. When driving off-road, also remember to always obey local of f-road driving laws and regulations. Ob[...]

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. R oll Over This, or any other off-road vehicle, could overturn during high speed turns, on uneven [...]

SLOPE GUIDE SLOPE GUIDE 20[...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Model Identification ENGINE NUMBER The engine number is located on the lower front left side of the engine cases. Fuel and Oil R ecommendations 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[...]

PERIODIC MAINTENANCE 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 careful- ly 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[...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Batter y Installation (cont.) Note: The follo wing page is for v ehic les with batter y’s containing separate electrol yte pack. Most batter y’s will come with the electrol yte alr eady sealed into the bat- ter y . Preparing the batter y: • Place battery on level surface. Remove sealing tape from top.[...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Ho w to Initiall y Charge the batter y: 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 [...]

• Then att ach 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 – out s. Finally , secure the battery with the wide black rubber strap using the hooks on both ends. (see figure 31 and 32). BA TTER Y REPLACEME[...]

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 of f with a clean cloth. ?[...]

PERIODIC MAINTENANCE 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 lef [...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Inspecting and Changing the Final Gear Oil Inspect final gear oil level monthly and change final gear oil every 3 months. T o check level, remove level screw on the left rear engine case. If gear oil does not come out of hole, add until it does. T o drain gear oil, remove the drain plug at the rear bottom o[...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Chain Adjustment Adjustment of F r ont and R ear 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 ri[...]

PERIODIC MAINTENANCE PERIODIC MAINTENANCE Maintenance Char t 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 R ecor d 30[...]

TROUBLESHOOTING 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 WIRING DIAGRAM 32[...]

CALIFORNIA CALIFORNIA EMISSIONS W EMISSIONS W ARRANTY ARRANTY 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 of f-ro[...]

Baja Motorspor ts,a division of The Godfrey Group, LLC 2910 South Hardy Drive, Suite 103 • T empe, A Z 85282 Phone 888-863-BA JA (2252) •Fax 866-316-4602 Copyright 2004 The Godfrey Group, LLC Oct 2004[...]