Instruction/ maintenance manual of the product 150 Five Star
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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 norma.
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.
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 oub.
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.
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.
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 .
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.
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.
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.
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.
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.
SPECIFICA SPECIFICA TIONS TIONS DIMENSIONS Overall Length ------------------------------------------------------------------------------86 in. (2184mm) Overall Width -------------------------------------------------------------------------------54 in.
SPECIFICA SPECIFICA TIONS TIONS CHASSIS Front Brakes --------------------------------------------------- Dual Hydraulic Disc, Left Foot Control Front 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.
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.
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.
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.
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 .
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.
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 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.
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.
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.
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.
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 .
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 .
• 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.
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.
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.
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.
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.
PERIODIC MAINTENANCE PERIODIC MAINTENANCE Maintenance Char t The maintenance intervals in the following table are based upon average riding conditions.
TROUBLESHOOTING TROUBLESHOOTING The following information is provided to help you identify probable question you may have out the operation of your go kart.
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.
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 .
An important point after buying a device Five Star 150 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Five Star 150 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Five Star 150 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Five Star 150 you will learn all the available features of the product, as well as information on its operation. The information that you get Five Star 150 will certainly help you make a decision on the purchase.
If you already are a holder of Five Star 150, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Five Star 150.
However, one of the most important roles played by the user manual is to help in solving problems with Five Star 150. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Five Star 150 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
