DN250 Go-Kart Set Up Instructions

Removal from crate

1. Remove cardboard carton.

2. Remove parts, hardware box and owners manual.

REVB082807

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Hardware and Parts

Battery Battery strap and cover

Hardware Bag

Radiator Fluid

Radiator

Seat belts

Tools

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Front Wheel Mud Flaps

Rear Wheel Mud Flaps

Hardware and Parts

Front Mud Flap Brackets

Rear Mud Flap Brackets

Wheel covers

Rear Wheels

Front Wheels

�

Hardware and Parts

Side Brush guardsFront Brush guards

Cross Brush guard

Top Brush guard

Rear Rack

5

Hardware and Parts

Fuel Tank Fuel Tank Breather Tube

Side Mirrors

Steering Wheel and cover

Steering Wheel screws

Seats

�

�. Attach upper a-arm to lower a-arm. Place spacer (step 1) on bolt of upper a-arm before attaching to lower a-arm. Then attach washer and castle nut (step 2). Be sure to install cotter pin (step �).

Rear Shock

�. Attach left and right rear shocks to rear chassis. Torque bolts to �5 ft.lb.

Front WheelStep 1

Step 2

Step �

Spacer

Washer

Castle nutCotter pin

Front of kart

5. Attach front wheels to hub making sure tread pattern arrows face front of kart. Use (�) 10mm nuts and torque to �� ft.lb.

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7. Attach rear wheels using 10mm nut (qty �), torque to �� ft.lbs. Make sure tread pattern arrows face front of kart.

Front Mud Flap

6. Attach left and right front mud flaps to front of frame using �mm X �5mm bolt, lock washer and �mm locknut.

Rear Wheel

Front of kart

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Rear Mud Flap

Transforming Lever

9. Attach transforming lever. Unscrew 8mm X 1�mm bolts on lever and attach to frame. Torque bolts to 20 ft.lb.

8. Attach left and right rear mud flap to frame using 8mm bolt.

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Seat belts

11. Attach part A to bracket between seats using bolt, spacer, lock washer and nut. Torque to �5 ft.lb.

Seats

10. Attach driver and passenger seat to frame, use 8mm locknut.

A

B

C C

A

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Seat belts

12. Unlatch seat buckle. Seat buckle

Bolt

Spacer

Lock washer

Nut

Part C

Part C

Opening 1

Opening 2

1�. Pull part C through opening 1 around back of seat and through opening 2.

1�. Attach part C to frame using bolt, spacer, lock washer and nut. Torque to �5 ft.lb.

15. Attach part B to frame behind seat. Torque bolt to �5 ft.lb.

Repeat steps 12 through 15 for driver seat belt installation. Seat belts fully assembled

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1�. Attach steering wheel to steering rod, secure by attaching steering wheel cap and (qty �) �mm allen head screws. Torque to 10 ft.lb.

Steering Wheel

Fuel Hoses

17. Attach fuel vacuum hose to splitter. 18. Attach fuel filter hose to inlet stem located on carburetor.

Fuel vacuum hose Splitter Fuel filter hose

inlet stemCarburetor

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Fuel Tank

19. Attach fuel tank to rear of frame, use 8mm X 25mm bolt (qty �) and insert the fuel vent tube on top of fuel cap.

Radiator

20. Attach radiator to frame using �mm bolts.

1�

Radiator

21. Remove zip ties that secure hoses to frame allowing slack for attachment. Please note Hose A and Hose B in photo for installation.

22. Attach radiator hose A (hose end connected to water pump) to bottom of radiator. Secure with metal clamp.

2�. Attach radiator hose B (hose end connected to thermostat assembly) to top of radiator. Secure with metal clamp.

Hose B

Hose A

Thermostat assembly located on right side of engine next to carburetor.

Hose B

Metal clamp

Metal clamp

Hose A

Metal clamp

Metal clamp

Water pump located on right side of engine below rear shock.

1�

2�. Attach rear luggage carrier to frame on both sides.

8mm X �5mm bolt (qty 2)

8mm X 1�mm bolt (qty 2)

Rear Rack

Radiator

25. Once radiator hoses have been attached. Secure loose hoses to frame using zip ties.

2�. Connect the radiator fan plug.

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Brush guards

27. Attach left and right front brush guards to front and rear of frame.

28. Attach top brush guard to left and right front brush guards, use 8mm X 50mm (qty �) and beveled spacer (qty �)

29. Attach cross brush guard to left and right front brush guards behind seats, use 8mm X 50mm bolt (qty 2) and beveled spacer (qty 2).

�0. Attach extra support bracket to radiator and rear frame.

8mm X 50mm bolt (qty 2), beveled spacer (qty �) and 8mm nut (qty 2)

8mm X 50mm bolt (qty 2), beveled spacer (qty 2) and 8mm nut (qty 2)

1�

Brush guards

�1. Attach vinyl wraps to all brush guards.

�2. Attach passenger handle to right front brush guard.

��. Attach top and rear vinyl covers by tying to brush guards.

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Mirrors

��. Attach adjustment nut to left and right mirrors. Attach mirrors to brackets on frame and secure with 8mm nut.

Battery

Adjustment nut 8mm nut

Adjustment nut

INITIAL SERVICE AND INSTALLATION OF BATTERY:

The following procedure is very dangerous and should be performed with utmost care and attention. Wear protective eye wear, 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 BURNSContains sulfuric acid.Avoid contact with skin, eyes, or clothingTo prevent accidents, rinse empty container with water.

ANTIDOTE:External – flush with waterInternal – 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 REACH OF CHILDREN.

WARNING!

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BatteryNote: 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 A)· 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 B)

· Push the container down strongly enough to break the silver seals. (see figure B)

· 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 �0 minutes the battery is ready for its initial charge. Place cap strip loosely over the filling holes as shown in the picture. (see figure C)

Figure A

Figure B

Figure C

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Battery

How to Initially Charge the battery:1. Connect the red positive (+) cable to the red positive (+) pole

of the battery. (see figure D)

2. Connect the black negative (-) cable to the black negative (-) pole of the battery. (see figure E)

Note: The red positive (+) cable has a larger diameter than the black negative y cable.

�. 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 F)

• Install battery into battery compartment. The battery terminals should be facing the front (see figure G)

• Once battery is firmly seated in battery compartment attach the red positive wire to the red positive terminal on the battery.

• Then attach the black negative wire to the black negative terminal on the battery.

• Install the battery cover and straps. (see figure G)

NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE.

Figure D

Figure E

Figure F

Figure GWARNING!

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The following points should be checked for cotter pins. These cotter pins are attached at the factory. If your go-kart is missing any of these cotter pins please contact Baja Motorsports.

Located on upper and lower A-arm

Located on upper and lower A-arm

Located under front wheel cover on hub.

Located under front wheel cover on hub.

Located under rear wheel cover on hub.

Located under rear wheel cover on hub.

Cotter Pins

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Gas and Oil

�8. Fill engine with correct amount of oil. Refer to owners manual for oil types and quantity.

36. Fill gas tank as specified in owners manual.

!!WARNING!!

This engine may be shipped with packing oil. This oil should be drained and replaced with new oil as described in the owners manual. Never attempt to start engine without first replacing engine oil with proper amount and grade as described in the owners manual.

�9. Refer to owners manual for proper starting instructions.

37. Fill radiator with 25 ounces of radiator fluid. Fill the reserve water tank with 10 ounces.

Reserve water tank