Baja Shifter 90 Model SF90 (double-seat): Owner s Manual Version:1.0 April Limited Warranty

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2 Limited Warranty The warranty policy applies to those cases where the new seller vehicle unloaded from its shipping container, set up and delivered by authorized dealer and under normal use and service is found to have defects in parts or workmanship under the following terms and conditions. This warranty covers the engine and engine related components for a period of 90 days from the date of purchase. This warranty does not apply to any parts that in the seller s opinion were defective because of improper maintenance, improper assembly, alterations, abuse, negligence, usage of non-genuine parts or accidents. Should warranty service be required on your vehicle during the 90-day warranty period, please contact your nearest authorized dealer for repairs. 2

3 What is not covered under this warranty? This warranty does not cover any seller vehicles that have been subjected to: a. Renting; b. Disassembly, adjusting or repairing of the vehicle in any way so as to adversely affect its safety or reliability; c. Competition or racing. The warranty does not cover any losses of the seller vehicle use, any losses of time, any inconveniences, or any other consequential damages which include, but are not limited to the losses or damages to any persons, property or expenses of returning damaged units to the vehicle distributor or any authorized dealers. We have the right to make changes without prior notice. 3

4 Contents 1. Foreword A Few Words about Safety Important Safety Information Safety Labels Are You Ready to Drive? Is Your Vehicle Ready to Drive? Safe Driving Precautions Operation Service Instructions Repairs Periodical Checks and Services Specifications Attachment: Wiring Diagram 4

5 FOREWORD Thank you for choosing our double -seat BUGGY. We hope you will have fun with it. Before starting operate the BUGGY, please read through this Owner's Manual carefully as it contains important safety and maintenance information. Failure to follow the warnings contained in this manual can result in serious injuries. Be sure to follow the recommended maintenance schedule and service your vehicle accordingly. Preventive maintenance is extremely important to the longevity of your BUGGY. Beginners should drive this BUGGY in a large open area to practice handling this BUGGY. Wear protective gears all the time when driving or riding this BUGGY. We hope you will have a pleasant experience with our products and thanks again for choosing Baja Motorsports. 5

6 A FEW WORDS ABOUT SAFETY In order to keep everyone safe, you must take responsibility for the safe operation of your BUGGY. To help you make informed decisions about safety, we have provided operating procedures and other information on labels in this manual. This information alerts you to potential hazards that could hurt you or others. It is not practical or possible to warn you against all hazards associated with operating or maintaining your BUGGY, so you must use your own good judgments. You will find important safety information in a variety of forms, including: Safety Labels on the BUGGY; Safety Messages preceded by a safety alert symbol and one of the two signal words WARNING or CAUTION ; 6

7 The meaning of these signal words: WARNING Physical harm may result from the failure to follow the instructions that are described within the labels; CAUTION Damages to your BUGGY and possible subsequent personal injuries or death could result from the failure to take proper precautions described within the labels; Safety Headings------such as Important Safety Reminders or Important Safety Precautions; Safety Sections------such as Buggy Safety; Instructions------about how to use this BUGGY correctly and safely. The whole manual is filled with important safety information, so please read it carefully. 7

8 IMPORTANT SAFETY INFORMATION Your BUGGY will provide you with many years of service and pleasure, providing you take responsibility for your own safety and understand the challenges you will meet while driving. There is much that you can do to protect yourself when driving your BUGGY. You'll find many helpful recommendations throughout this manual. The following are a few of the most important ones. Always Wear a Helmet Facts have proven that helmets can significantly reduce the quantity and severity of head injuries, so when you drive your BUGGY, please always wear a DOT approved motorcycle helmet. We also recommend that you wear approved goggles, sturdy boots, durable gloves and other protective gear. Drive Off-Road Only Your BUGGY is designed and manufactured only for off-road use. Its tires are not made for pavements, and it does not have turn signals or other features required for use on public roads. If you need to cross a paved or public road, please get off and walk your BUGGY across. 8

9 Take Time to Learn & Practice Even if you have driven other buggies, you still should take time to become familiar with how this BUGGY works. Practice in a safe area until you have built your skills and gotten accustomed to the size and weight of this Buggy. Be Alert to Off-Road Hazards The terrain can present a variety of challenges. Continually "read" the terrain for unexpected turns, drop-offs, rocks, ruts and any other hazards. Always keep your speed low enough to allow time for seeing and reacting. Drive within Your Limits Pushing limits is another major cause of BUGGY accidents. Never drive beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue and inattention can significantly reduce your ability to make good judgments and to drive safely. Don't Drink and Drive Alcohol and drive never mix. Even one drink can reduce your ability of responding to changing conditions, and every additional drink can lengthen and worsen your reaction time. 9

10 Don't drink and drive, and don't let your friends drink and drive either. Don't Drive at Night At night your visibility and judgment can be greatly reduced, so driving at night is dangerous and can terribly increase chances of accidents. Never Drive Indoors The exhaust from the engine contains a tasteless, odorless but poisonous gas called carbon monoxide. For the health of your family, please don t drive your BUGGY in your lovely house. Keep away from Moving Parts You should never place your hands or any other parts of your body near any moving parts of your BUGGY. Failure to adhere to this warning will cause physical harm to your body. Avoid Skidding or Sliding The terrain surface can be a major factor affecting turns. Skidding or sliding a turn is more likely to occur on slippery surfaces such as snow, ice, mud and loose gravel. 10

11 If you skid or slide on ice, you may lose all directional controls. To avoid skidding or sliding on slippery terrain surfaces, you should keep your speed low and drive carefully. This section presents some of the most important information and recommendations to help you drive your BUGGY safely. Please take a few minutes to read it. 11

12 SAFETY LABELS The labels should be considered permanent parts of your BUGGY. If a label comes off or becomes difficult to read, please contact Baja Motorsports for warning label replacements. 12

13 ARE YOU READY TO DRIVE? Before each drive, you need to make sure that you and your BUGGY are both ready to drive. To help you be prepared, this section discusses how to evaluate your driving readiness, what items you should check on your BUGGY, and how to adjust your BUGGY for your comfort, conveniences and safety. Before you drive your BUGGY for the first time, we urge you to: Carefully read this owner's manual and the labels on your BUGGY; Make sure that you understand all the safety messages; Learn how to operate all the controls on your BUGGY; Before each of your drive, we urge you to be sure that: You feel well and you are in good physical and mental conditions; You are wearing a DOT approved motorcycle helmet (with a chin strap tightened securely), approved goggles and other protective gear; You don't have any alcohol or drugs in your body system. 13

14 Protective Apparel For your safety, we strongly recommend that you always wear a DOT approved motorcycle helmet, approved goggles sturdy boots, durable gloves, long pants and long-sleeved shirt or jacket whenever you drive. Although complete protection is not possible, wearing proper protective apparel can reduce the chances of injuries when you drive. The following suggestion will help you choose the proper driving gear. 1. Helmets and Eye Protection Gear Your helmet is your most important driving gear because it offers the best protection against head injuries. Your 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 the helmet with a DOT (Department of Transportation) sticker. 14

15 Always wear a face shield or a pair of goggles to protect your eyes and vision. 2. Additional Driving Gear In addition to a helmet and eye protection gear, we also recommend: Sturdy off-road motorcycle boots to help protect your feet, ankles and lower legs; Durable 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 and shoulder protector. Operating this BUGGY without wearing a DOT approved motorcycle helmet, eye protection gear, or any protective apparel could increase your chances of head and/or eye injuries, and even possibly death in the event of severe accidents. Always wear a DOT approved motorcycle helmet, an eye protection gear (goggles or a face shield), a long-sleeved shirt or jacket, gloves, boots and long pants. 15

16 Driver Training Developing your driving skills is an on-going process. Even if you have driven other Buggies, you still need take time to become familiar with how this BUGGY works. Practice driving this BUGGY in a safe area to build your skills. Don t drive on rough terrain surfaces until you ve gotten accustomed to all the controls on this BUGGY, and felt comfortable with its size and weight. Operating this BUGGY without proper instructions could increase your risks of accidents that could lead to serious injuries, or even death. No Alcohol or Drugs Alcohol, drugs and Buggies never mix. Even a small amount of alcohol can impair your ability to operate your BUGGY safely. Likewise, drugs, even prescribed by your doctor, can be dangerous when you re operating your BUGGY. Consult your doctor for the assurance that it is safe to operate your BUGGY after taking some kind of medication. 16

17 Operating this BUGGY after consuming alcohol or drugs can seriously affect your judgments, cause you to react more slowly, affect your balance and perception, and even could result in serious injuries or death. Never consume alcohol or drugs before or while operating your BUGGY. Limited Loadage The limited loadage on the rear rack is 5kg or 11 lbs. Rear Rack 17

18 IS YOUR VEHICLE READY TO DRIVE? Before each of your drive, it is important to inspect your BUGGY and make sure that any problems you ve found have been corrected. A pre-drive inspection is a must, not only for safety, but also because a breakdown, or even a flat tire, can be a major inconvenience. If your BUGGY has overturned or has been involved in a collision, please don t drive it until an authorized service center has inspected it. There may be damages or other problems you can t see. Improperly maintaining your BUGGY or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or even killed. Always perform a pre-drive inspection before each of your drive, and correct any problems. 18

19 Pre-Drive Inspection Please check the following items before getting on your BUGGY: Engine Oil: Check the level and add oil if needed; check for leaks; don t let any water go into the engine, otherwise the engine can t start. Fuel: Check the level and add fuel if needed, and make sure the fuel-filling cap is securely fastened; check for leaks. Tires: Use a gauge to check the air pressure, adjust the tires if needed; look for signs of damages or excessive abrasion. Nuts & Bolts: Check the wheels and all the accessible parts to see if the nuts, bolts, and fasteners are tightened; use a wrench to tighten them if needed. Underbody & Exhaust System: Check for any dirt, vegetation or any other debris that could cause fire hazards or interfere with the proper operation of your BUGGY, and remove them. Air Cleaner Housing Drain Tube: Check for carbon deposits in the drain tube; if necessary, clean the tube and check the air cleaner housing. Leaks & Loose Parts: Walk around your BUGGY and look for anything that appears unusual, such as a leak or a loose cable; repair or replace the concerned parts if needed. 19

20 Throttle: Check the free play and adjust the throttle if needed; press the throttle to make sure it moves smoothly without sticking, and release it to make sure it snaps back automatically. Brakes: Check if the mechanical brake system works properly; inspect for the brake efficiency. Engine Stop Button: When the engine is running, press and hold the Engine Stop Button for two seconds to see if the engine stops. Steering Wheel: Turn the steering wheel to see if it turns properly. Cable: Check the cable housing for wear and check the fittings for looseness; replace or tighten the concerned parts if needed. 20

21 SAFE DRIVING PRECAUTIONS Off-Road Use Only Your BUGGY and its tires are designed and manufactured for off-road use only, not for pavements. Driving on pavements can affect your handling and controlling. Don t drive your BUGGY on pavements. Operating your BUGGY on paved surfaces may seriously affect your handling and controlling of your BUGGY, and may even cause your BUGGY to go out of control. Never operate your BUGGY on any paved surfaces, including sidewalks, driveways, parking lots and streets. 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. Never drive your BUGGY on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty in seeing and avoiding you, which could easily lead to collisions. In many states, it is illegal to operate BUGGIES on public streets, roads and highways. 21

22 Operating your BUGGY on public streets, roads or highways can cause collisions with other vehicles. Never operate your BUGGY on any public streets, roads or highways. Keep Your Hands and Feet on Controls Always keep both of your hands on the steering wheels,and both of your feet on the foot controls when driving your BUGGY. It is important to maintain your balance and control your BUGGY. Removing your hands or feet away from the controls can reduce your ability of controlling your BUGGY. Removing your hands from the steering wheels, or your feet from the foot controls during operation, can reduce your ability of controlling your BUGGY, or cause you to lose your balance and fall off your BUGGY. During operation, always keep your both hands on the steering wheels, and your both feet on the foot controls of your BUGGY. 22

23 Control Speed Driving at excessively high speed increases the chances of accidents. When choosing a proper speed, you need to consider the capability of your BUGGY, terrain, visibility and other operating conditions, plus your own skills and experiences. Operating your BUGGY at excessively high speed increases your chances of losing control, which can easily result in an accident. Always drive at a speed that is proper for your BUGGY, terrain, visibility and other operating conditions, plus your own skills and experiences. Be Careful 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 the visibility is limited. (Sometimes it s difficult to gain the reaction time before you see obstructions like hidden rocks, bumps, or holes in time to react.) 23

24 When driving your BUGGY on unfamiliar terrain, failure to be especially careful could cause your BUGGY to go out of control or overturn. When operating your BUGGY on unfamiliar terrain, always drive slowly, always be especially careful, and always be alert to changing terrain conditions. Never drive past the limit of visibility. Maintain a safe distance between your BUGGY and other off-road vehicles. Always exercise your cautions and use your extra care on rough, slippery and loose terrain. Failure to use your extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in accidents, including an overturn. Don t operate on excessively rough, slippery or loose terrain until you ve learned and practised the skills necessary to control your BUGGY on such terrain. Always be especially cautious on these kinds of terrain. 24

25 Don t Perform Stunts You should always operate your BUGGY in a safe and reasonable manner. When driving, always keep all of the four wheels on the ground. Attempting wheelies, jumps, and any other stunts increases the chances of accidents, including an overturn. Never attempt stunts, such as wheelies or jumps. Don't try to show off. 25

26 OPERATION A. Operation Controls Don t attempt to start or operate the engine until you ve been completely familiar with the location and use of each control that is necessary to operate your BUGGY. You must know how to stop your BUGGY before starting and driving. 1) Throttle Pedal The right foot pedal is the throttle pedal that controls your BUGGY speed. As the engine speed is 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. Throttle Pedal 26

27 Each time before starting the engine, check the throttle assembly to ensure that when you push the pedal all the way forward, the throttle assembly is working smoothly, and when you release the pedal, the throttle assembly returns to idle. Don t operate if the pedal or throttle linkage fails to return to the idle position. If you re unable to correct the problem through lubrication, adjustment or replacement of worn parts, please contact an authorized service center for assistance. 2) Brake Pedal The brake is located on the left side of the vehicle. Applying pressure to the pedal can draw the brake calipers around the brake pumps (one at the rear wheel), and slows or stops your BUGGY. 27 Brake Pedal

28 3) Control Panel Engine Stop Button Important-----the Engine Stop Button test. Before driving your BUGGY, test the Engine Stop Button to assure that it is operating properly.when the engine is running, move the Stop Button to the OFF position. Neutral Indicator Lamp Button Press the neutral indicator lamp button, then after the engine has started, the neutral indicator lamp turns on automatically when the gearshift lever is in N position; and the lamp turns off when the gearshift lever is in the forward / backward gear position. Engine Stop Button Neutral Indicator Lamp Button Key Switch 28

29 Key Switch Insert the key into the key switch, turn the key clockwise, and 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 formal RPM. Warning: Don't crank the starter more than 5 seconds at one time. B. Pre-Drive Inspection Perform this pre-drive inspection every time before driving your BUGGY. If not, serious damages to your BUGGY or personal injuries to yourself may be caused. 1) Engine Oil: Check for the engine oil level, and add oil if required; check for oil leaks; don t let any water go into the engine, otherwise the engine can t start; 2) Fuel: Check for the fuel level, and add fuel if necessary (but don t overfill); check for fuel leaks. 3) Brakes: Depress the rear brake pedal several times to see if it works properly, and check for the proper free play of brake pedal; adjust the brake pedal if necessary. 29

30 4) Tires: Check the tire conditions and pressures. Front Tire Pressure: 4 P.S.I. Rear Tire Pressure: 7 P.S.I. 5) Drive Chain: Check for the chain conditions and tension; lubricate it if necessary. 6) Throttle: Check for the smooth operation; assure that the throttle "snaps" back to the idle position. 7) Engine Stop Button: Perform the engine stop button test; repair it if necessary. 8) Nuts, Bolts & Fasteners: Check all the nuts, bolts and other fasteners to see if they have been tightened to the specified condition; adjust them if necessary. 9) Brush Guard: Ensure that all the protective roll bars are in place. 10) Wheels: Check the wheels to see if all the axle nuts have been tightened properly and been secured by cotter pins. 11) Steering: Check for the free operation of the steering and for any unusual looseness in any area. Always follow rules for safe operation. Always wear a helmet. 30

31 Locations of Parts: Double-Seat Brush Guard Seat Safety Belt Control Panel Steering Wheel Rear Rack Rear Wheel Front Wheel Throttle Pedal Brake Pedal Front Shock Absorber 31

32 Rear Rack Fuel Tank Cap Fuel Tank Air Cleaner Reverse lever Engine Muffler Drive Chain 32

33 C. Preparations before Starting the Engine 1) Check the engine fasteners before starting; 2) Fill in the fuel and lubrication oil as specified; Oil Capacity Crankcase: 0.7~0.9L; Transmission Box: 0.2 L; D. Passengers The vehicle allows for two riders only for the double-seat unit. The combined maximum weight of the driver and passenger for the double-seat unit should not exceed 120kg or 200lbs. E. Seat Adjustment The seat must always be securely fastened in the position that affords the best control of the foot pedals, steering wheel and engine stop button for the operator. 33

34 1) Pull the seat adjustment handle left to disengage the seat slide; 2) Move the seat to a desired position; 3) Be sure that the seat adjustment handle snaps back into place and that the seat is locked into position. 2) 1) Before attempting to adjust the seat, ensure that the engine of your BUGGY has stopped. Never operate your BUGGY when the provided seat is not securely fastened. Otherwise, it could result in a strong possibility of severe personal injuries or loss of life. Before attempting to adjust the seat, ensure that the engine of your BUGGY has stopped. 34

35 F Gearshift Lever Adjustment 1) Press down the gearshift lever to the N position, then the vehicle is in the neutral gear; 2) Push the gearshift lever to the D position so that the vehicle can move forward in the first /second gear; 3) Pull back the gearshift lever to the R position so C a b that the vehicle can move backward in the reverse gear. Gearshift Lever Notes: If the gearshift lever can not move smoothly, adjust the nut#1 and nut #2 at the front /rear end of the gearshift lever. Nut #1 Nut #2 35

36 G. Starting and Operating Instructions 1) Before starting the engine, be sure that you ve properly sat in your BUGGY and tightened the seat belt; 2) Test your BUGGY in the beginning to learn how to start, turn and stop; 3) Operate your BUGGY slowly until you ve been familiar with it; 4) The turning radius of your BUGGY is small and agile, so the centrifugal force is very high when turning at high speed. You d better slow down to a more controllable speed to prevent your BUGGY from rolling over; 5) To prevent your vehicle from rolling over when turning, be sure to only turn your vehicle at a more controllable slow speed and to keep your heel on the ramp of the main board. If you keep your legs on the foot pedals, you can feel the vehicle is stable because the gravity is adjusted. So your vehicle won t roll over. H. Starting Engine 1) Check if the fuel system is smooth; 2) Check if the ignition system is working properly; 3) Press the starting button when the throttle is closed; 4) Warm up the engine for 2-3 minutes after starting the cold engine. 36

37 Note: 1) Before starting the engine, the fuel tank cock must be in the ON position, and the carburetor oil-inlet switch must be in the ON position; Fuel Tank Cock 2) Move the manual choke handle upwards to the top position, then the enriching device starts working; push the handle downwards to the lowest position, the enriching device stops working. Carburetor Oil-inlet Switch Manual Choke Handle If the engine cannot get started easily, push the manual choke handle upwards to the highest position, then the hand enriching device starts working; after the engine has got started and warmed up, move the manual choke handle back to the lowest position, and the hand enriching device stops working. 37 Hand Enriching Device

38 3) Release the button and cut the power of the starting motor immediately after starting the engine. 4) Don t press the starting button after starting the engine. Otherwise it may cause damages to the engine. 5) Don t press the starting button for more than 3-4 seconds for one time; wait for about 10 seconds to repress, and press the button with the throttle slightly opened; 6) In cold weather, warm up the engine for several minutes at the idle speed; then speed up once the operation temperature has reached the requirements specified; In hot weather, avoid running the engine at the idle speed for a long time; otherwise, it may overheat the engine. I. Stopping the Engine 1) Run the engine for about 3-5 minutes at the idle speed to cool down; 2) Turn off the throttle; 3) Turn off the ignition switch. J. Running-in of New Engine The running-in distance is 1000km. During this period, please follow the instructions below: 1) Run the engine according to the requirements specified; 38

39 2) Rotate the throttle slowly after starting the engine; don t speed up or speed down suddenly; 3) Drive on smooth roads; don t drive uphill or on rough roads for a long time; 4) Keep the oil lines smooth; 5) Avoid speeding up suddenly or running the engine at a high speed without loading; 6) Maintain your vehicle according to the service intervals, and if necessary, repair it as soon as possible; 7) After the running-in period, clean the crankcase and replace the oil; remove the carbon on the top of the piston and in the combustion chamber; adjust the spark plug electrode gap and valve clearance; check if the oil lines are smooth; maintain your whole vehicle according to the requirements specified in this Owner s Manual. 39

40 SERVICE INSTRUCTIONS Remove Air Cleaner Cover A. Air Cleaner Service the air cleaner every 20 hours of usage. Note: Service more often when running under dusty conditions. 1) Remove the air cleaner cover; 2) Remove the air cleaner element; 3) Fill the non-flammable cleaning agent into a basin and dip the element in it; 4) Dry it after cleaning, and dip it into the engine oil specified by the manufacturer, then dry it again. Air Cleaner Cover Air Cleaner Element Air Cleaner Screen 40

41 B. Engine Lubrication After the new engine has operated for the first 5 hours and for every 10 hours thereafter, change the oil in the crankcase to insure the proper lubrication of internal parts and to prevent costly repairs due to the excessive wear. 1) Remove the filler plug located on the rear side of engine; remove the drain plug; tip the vehicle backwards slightly by blocking up the front end ; drain the oil into a suitable container; 2) Place the vehicle in a level position, replace the filler plug and tighten it securely; 3) Refill the crankcase with SAE 10W/40 oil (approximately 0.7~0.9L); use the same grade of oil as used originally; 4) Check the oil level before each drive; add the oil up to the proper level. Engine Oil Filler Note: Don t mix various grades of oil together. 41

42 C. Spark Plug 1) Remove the spark plug and inspect it with a spark plug wrench each time you change the oil; Note: The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will greatly reduce the proper engine performance. If possible, check the spark plug gap (area between the electrodes) With a wire feeler gauge. This specification is mm. 2) Before installing the spark plug, coat the threads lightly with the graphite grease if possible, to ensure the easy removal next time when the spark plug needs inspection; 3) It is advisable to replace the spark plug at least once a year to insure the easy starting and good engine performance. 42

43 D. Carburetor Adjustment Never make unnecessary adjustments. The manufacturer recommended settings are correct for most applications. It's not necessary to disassemble the screw unless the carburetor needs to be replaced. Prepare a 50r/w tachometer before the adjustment. 1) Warm up the engine for about 5~10 minutes; 2) Tighten the airscrew gently and back out 2-3/8 turns anticlockwise; 3) Connect the tachometer, and adjust the throttle to limit the idle speed (the standard value is 1500 RPM); 4) Slowly turn the airscrew anticlockwise; observe the RPM of the engine, and stop the adjusting as the RPM reaches the top speed; 5) Adjust the screw, and adjust the idle speed to an ideal value; 6) Repeat the steps d and e until the rotate speed of the engine becomes stable. Carburetor Idle Speed Adjust Screw 43

44 E. Cleaning Instructions Use a clean rag to wipe off the dirt and oil from the controls, and any spilled fuel and oil from the vehicle. Keep the engine clean of foreign objects. Make sure the cylinder and cylinder head cooling fins are clean. F. Vehicle Lubrication Lubricate your vehicle every 90 days of use. Apply several drops of oil in the specific points. G.A-arm Lubrication Lubricate the left/right front A-arm periodically. H. Chain Lubrication Fill a spay atomizer with the specified chain lubrication, and lubricate the chain. Left A-arm Grease Nipple 44

45 I. Storage Instructions In the event your vehicle isn t to be operated for periods in excess of 30 days or at the end of each driving season, prepare for the storage as follows: 1) Drain (or use a fuel stabilizer) all the fuel out of the fuel tank and carburetor; 2) Remove the spark plug; pour one ounce of clean cylinder lubricating oil through the spark plug hole into the cylinder, and crank the engine slowly to spread the oil so as to lubricate the cylinder better; replace the spark plug; 3) Don t save or store gasoline over winter, because the old gasoline has deteriorated in the winter storage, and will cause hard starting and affect the engine performance. Don t drain the fuel while the engine is hot. Be sure to move your BUGGY outside before draining the fuel. J. Engine Maintenance 1) Daily Maintenance: 1.1) Remove the dust and dirt on the surface; 45

46 1.2) Check all the exterior fasteners at the joints, and fasten or replace them if necessary; 1.3) Check for the oil leakage, and check the compression at the mating surface; 1.4) Check the engine oil, and add some if necessary. Note: The oil level should be between the upper index line and the lower index line of the gauge. 2) 50 Hour Maintenance: 2.1) Finish the daily maintenance; 2.2) Remove the dust in the air cleaner element; replace the element if there is too much dust or any damp; Note: Don t dip the element in water or oil. Don t apply any lubrication oil or any other oil on the element. Don t clean the element with gasoline or solvent of low flash point. 46

47 2.3) Remove the carbon on the spark plug; 2.4) Clean the crankcase and replace the oil; 2.5) Clean the transmission box and replace the engine oil; Remove the oil-drain bolt; Drain out all the engine oil. Note: When draining the oil, the engine should be at some temperature, which can ensure the quick and complete draining. 2.6) Clean up all the dirt on the cylinder body and cylinder cover fins. Engine Oil-drain Bolt 3) 100-Hour Maintenance: 3.1) Finish the 50-hour maintenance; 3.2) Remove the cylinder cover and cylinder body, and clean out the carbon on the cylinder cover, cylinder body, piston top and in/ex valve, etc.; 47

48 3.3) Clean the inner part of the crankcase, and rotate the crankshaft during the cleaning to clean the main bearing and connecting rod big end needle bearing; 3.4) Check if the fixed screw of the generator stator is loose; 3.5) Keep the connectors and electric parts dry and clean. 4) 150-Hour Maintenance: 4.1) Finish 100-hour maintenance; 4.2) Clean the crankcase and replace oil; 4.3) Check if there is any leakage on the oil seals; replace the oil seals if necessary. 5) 300-Hour Maintenance: 5.1) Finish 150-hour maintenance; 5.2) Check if the parts of the clutch and the transmission are normal; adjust or replace the parts if necessary. 48

49 6) 500-Hour Maintenance: 6.1) Finish 300-hour maintenance; 6.2) Disassemble the engine (except the crankshaft connecting rod); check the parts for wear, and repair or replace the parts if necessary; K. Battery Maintenance 1) Initial Service 49

50 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 50

51 2) Battery Installation 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. 2.1) Place battery on level surface; Remove sealing tape from top; 2.2) Take the electrolyte container out of the plastic bag; 2.1) 2.3) Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery; 2.3) 51

52 2.4) Push the container down strongly enough to break the silver seals; 2.5) As electrolyte starts flowing into battery, air bubbles will come up from the mouths of the plastic electrolyte bottles; 2.6) Leave bottles upside down in battery holes until electrolyte is completely drained; Note: Never leave children unattended around battery. 2.4) 2.7) If air bubbles cease to float to the top of the electrolyte bottles, tap lightly on top; Note: DO NOT remove container from battery while it is draining.. Never cut or pierce electrolyte container. 2.8) After all the electrolyte has drained from the bottles into the battery, pull plastic electrolyte bottles gently out of the battery; 52

53 2.9) Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals; 2.10) 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); 2.11) After 30 minutes the battery is ready for its initial charge, place cap strip loosely over the filling holes as shown in the picture. 2.11) 3) Initial Charge 3.1) Connect the red positive (+) cable to the red positive (+) pole of the battery; 3.1) 53

54 3.2) Connect the black negative (-) cable to the black negative (-) pole of the battery; Note: The red positive (+) cable has a larger diameter than the black negative y cable. 3.3) Charging rate: Charge 0.7 Amps for 5 ~ 10 hours; 3.4) After charging is complete, press down firmly with both hands to seat the caps, and the battery is now sealed; Note: Do not pound or hammer. 3.2) 3.4) 54

55 . NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE. 3.5) Install battery into battery tray making sure that the rubber mat is in place; Note: The warning label on the battery should be facing the warning label on the gray tray. 3.5) 3.6) 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 )

56 3.7) Then attach the black negative wire to the black negative terminal on the battery;. 3.8) Place grey plastic battery cover on top of the battery and threadwires through the cover cuts outs. Finally, secure the battery with the wide black rubber strap using the hooks on both ends. 3.7) 3.8) 56

57 . 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. 4. Battery Replacement: 4.1) Remove old battery; Mark which cable is connected to the positive terminal (+) and which cable is connected to the negative (-) terminal; 4.2) Clean cable connectors with wire brush or sandpaper to remove oxidation; 57

58 4.3) After charging, install new battery; Put dielectric grease on the battery terminals to avoid corrosion; 4.4) Connect cables to the proper terminals: positive cable to positive terminal, and negative cable to negative terminal; Note: Positive (+) cable is red and larger in diameter; Negative y cable is black and smaller of the two in diameter. CONNECT NEGATIVE CABLE LAST. 4.5) Torque terminal bolts to 40 in. / lbs; 4.6) 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. 58

59 L. Chain Adjustment 1) Loosen the 4 bolts M8*16 on the rear wheel axle holder, and lift up the engine support so as to raise the rear wheel above the ground; 2) If the chain is too loose, adjust the left and right rear wheel bearing holders counterclockwise at the same time; If the chain is too tight, adjust the left and right rear wheel bearing holders clockwise at the same time; Bolt M8*16 Rear Wheel Axle Holder 3) Fasten the 4 bolts M8*16 on the rear wheel axle holder. 59 Bearing Holder

60 M. Brake Cable Adjustment 1) If the brake cable is too loose, adjust the adjust nut of the brake cable clockwise; If the brake cable is too tight, adjust the adjust nut of the brake cable counterclockwise; If the adjustment doesn t work, go on with the next step; 2) Loosen the nut M6 at the adjust bolt of the brake caliper; If the brake cable is too loose, adjust the adjust bolt clockwise; If the brake cable is too tight, adjust the adjust bolt counterclockwise; Fasten the nut M6. Adjust Nut 60 Adjust Bolt Nut M6

61 N. Brake Shoe Replacement 1) Loosen the connecting clip on the chain; Remove the chain; 2) Loosen the adjust nut on the brake cable; Take out the brake cable; Chain Brake Cable Adjust Nut 61

62 3) Remove the cotter pin on the bracket of the brake caliper; Cotter Pin Castle Nut Bracket 4) Remove the cotter pin, castle nut, left rear tire, right rear tire and rear wheel hub in order; 62 Rear Wheel Hub Cotter Pin

63 5) Loosen the 4 bolts on the left/right holder of the rear wheel axle; Remove the left/right holder of the rear wheel axle; Remove the rear wheel axle together with the brake caliper assy.; Bolt Rear Wheel Axle Holder 6) Remove the lower right connecting bush, bearing seat of the right rear wheel axle and bearing; Remove the brake caliper bracket ; Replace the brake shoe; 7) Assemble in the reversed order of removal. 63 Connecting Bush Bearing Seat of Rear Wheel Axle

64 O. Idle Speed Adjustment If the rotate speed of the engine is not stable (either too low or too high) after the engine has started, adjust the idle speed adjust screw on the carburetor. If the engine rotate speed is too high, turn the adjust screw counterclockwise; If the engine rotate speed is too low, turn the adjust screw clockwise; Note: Idle Speed: 1500±100r/M Idle Speed Adjust Screw 64

65 REPAIRS A. Front Wheels Replacement 1) Remove the 3 lock bolts and lock nuts on the front wheel; 2) Remove the front wheel; 3) Assemble the new front wheel Front Wheel 4) Fasten the 3 lock bolts and lock nuts. Lock Bolt B. Rear Wheel Replacement 1) Remove the 4 lock bolts and lock nuts on the rear wheel; 2) Remove the rear wheel; 3) Assemble the new rear wheel 4) Fasten the 4 lock bolts and lock nuts. Rear Wheel Lock Bolt 65

66 PERIODICAL CHECK AND SERVICE The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent services. Interval 1 st Service in 1 st Week Daily Monthly Quarterly Yearly Items Air cleaner X X C R R Spark plug X C,A R R Carburetor A A A C Gearbox oil X X R R Engine oil X X R R R Tire pressure/wear X X X X R Brake pad X X X R R Drive chain CAL CAL CAL CAL CAL Brake cable A A A A Chassis X X X X Fuel switch/fuel tank X X X Battery X X X R 66

67 Interval 1 st Service in 1 st Week Daily Monthly Quarterly Yearly Items Valve clearance of engine A A A Throttle cable A A A A Absorber X X X R Note: X:inspect,clean or replace if necessary A: adjust; C: clean; L: lubricate; R: replace. 67

68 SPECIFICATIONS DIMENSIONS DOUBLE-SEAT Overall Length 1500mm Overall Width 1100mm Overall Height 1230mm Wheelbase 1100mm Ground Clearance 120mm VIN Accord With GMVR A01-01 Statutory Plate& Safety Labels Accord With GB ENGINE Model Type Displacement Bore Stroke Max. Power DZIP47FMF Air-Cooled, Single Cylinder, 4-Stroke 85ml 47mm 49.5mm 3.5kw /8000rpm 68

69 Max. Torque 5.0N.m /5000 rpm Idle Speed 1500±100r/M Idle Speed CO Pollutant 3.8% Idle Speed HC Pollutant 800 Ppm Fuel Type SAE 90# or Above (Unleaded) Min. Fuel Consumption 367g/KW.H Lubricate Oil Type SAE 10W / 40SF Lubrication Pressure & Splash Cooling Air-Cooled Ignition C.D.I. Starting Electric Spark Plug ATRTC Spark Plug Gap 0.6~0.7mm Transmission Chain Drive Forward Gear Transmission Ratio 1st: 1.764, 2nd: Backward Gear Transmission Ratio Compression Ratio 8.8:1 69

70 Primary Reduction Ratio Clutch Wet, Multi-plate (Automatic, Single) Carburetor PZ19 Air Cleaner Filter Sponge Element Gear-Shifting Hand Control Valve Gap 0.05±0.02mm Engine Size (Length Width Height) 430mm 320mm 270mm Engine Net Weight 20kg CAPACITIES Fuel Tank 4.5L Engine Oil 0.7~0.9L Starting Time 15s Climbing 20 0 Top Speed 25km/h Turning Radius 4.5m Noise Level 80dB 70

71 Battery 12V 3Ah CHASSIS Brake System Rear Disk *1 Front Suspension Single A-arm 30 Travel Rear Suspension Swing Arm 30 Travel Front Tire 145/70 6 Rear Tire 16X8.0 7 TIRE PRESSURE Front Rear 4 P.S.I. 7 P.S.I. WEIGHT Net Weight 130kg 71

72 BAJA INC. EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer, or the date it is first used as a demonstrator, lease, or company vehicle, whichever comes first and continues for 60 months after that date, or 5,000km, whichever comes first, provided there has been no abuse, neglect or improper maintenance of your vehicle. Where a warrantable condition exists, the Distributor will repair your vehicle at no cost to you, including diagnosis, parts and labor. If an emission-related part on your vehicle is defective, the part will be repaired or replaced by the Distributor. This is your emission control defects warranty. OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance. You should maintain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle. You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts. You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the vehicle owner, you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. WARRANTY COVERAGE The Distributor warrants that each new 2009 and later vehicle: is designed, built, and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above.

73 Your emission control system warranty covers components whose failure would increase an engine s emission, including electronic controls, fuel injection system, carburetor, the ignition system, catalytic converter, or any other system utilized in this vehicle to control emission if it is originally equipped. Also included may be hoses, connectors and other emission-related assemblies. Replacing or repairing other components (including parts, labor, and other costs) not covered by this emission control system warranty or the standard warranty is the responsibility of the owner. Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility. The Distributor will not cover repairs performed outside of an authorized dealer or repair facility. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system. If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part, your claim for repair to bring your vehicle into compliance with applicable standards may be denied. This Emission Control System Warranty is in addition to the standard Limited Warranty. EXCLUSIONS AND LIMITATIONS This warranty does not cover the following: 1. Failures or malfunctions of the emission control systems caused by abuse, alteration, accident, misuse, the use of leaded gasoline. 2. Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use, and the first required replacement interval for the item has not been reached. Expendable maintenance items include but not limited to spark plugs, filters, coolant, lubricants, gaskets, hoses, and belts. 3. Replacements of parts and other services and adjustments for required maintenance. 4. Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined. 5. Repairs or replacements as a result of: o Accident o Misuse o Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance

74 6. Physical damage, corrosion, or defects caused by fire, explosions or similar causes beyond the control of the Distributor. 7. Failures not caused by a defect in material or workmanship. Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties. LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to/from the authorized dealer. The Distributor is not liable to any person for incidental, consequential or special damages of any description, whether arising out of express or implied warranty or any other contract, negligence or other tort or otherwise. No express emission control system warranty is given by the Distributor except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty. The foregoing statements of warranty are exclusive and in lieu of all other remedies. All express warranties not stated in this warranty are disclaimed. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply if it is inconsistent with the controlling state law. No dealer is authorized to modify this Emission Control System Warranty. If you have any questions regarding your warranty rights and responsibilities, you should contact BAJA INC. (888)