BAJA MOTORSPORTS
Contents
1. BAJA MOTORSPORTS Assembly instruction manual for MINI BAJA DUNE65 Please carefully before assembling your MINI BAJA DUNE65 Go kart General Instructions e Please follow the assembly steps given in this manual for assembly Please check first all the hardwares are fixed at the proper locations Always first tighten manually and then by wrench for proper assembly Please ensure full tightening of bolts nuts to get the proper torque on the hardware for safety If nuts bolts are not tightened properly it can result into loosening and accidents while driving the DUNE65 e It may be required to have 2 people for assembly of DUNE65 Assembly procedure e Step 1 e Please open the box carefully and you will find the loose parts as shown in picture below Parts Loose 1 Swing Arm with engine mounted 2 Frame with aluminum footboard and steering pad 3 Steering Pad in sliding down condition 4 Rear brush guard 5 Front brush guard bottom 6 Front brush guard top 7 Seat with cover 8 Seat belt e Step 2 Please separate out all parts shown in picture with tool kit provided e Step 3 o First assemble the swing arm 1 and frame 2 with 2 joints as per pictures shown Remove the bolts and washer and keep safely and remember the sequence Then assemble both as per pictures below on both sides same procedure e Step 4 Assemble swing arm 1 and frame 2 along with rear brush guard 4 as follows First remove the bolt and2. all assembly points throughly for tightening Ensure no loose parts left behind and all cables are tied properly And now you are ready to take ride of your DUNE65 Just start it and have fun with it
3. front brush guard as show below o Insert the end of front brush guard into the front frame assembly holes and then tighten the screw by wrench e Step 11 Assemble the middle brush guard Remove the bolt and washer from the middle brush guard and keep safe Remember the assembly sequence Assemble with sequence shown in picture insert the middle brush guard into the assembly hole add the bolt and washer and then tighten hv wrench oo oO 0 eStep 12 o Assembly the rear brush guard o Insert the end of the rear brush guard to the carrier add the bolt a Pa lt S e Step 13 o Assembly seat belt processed as the picture e Step 14 Now assemble cable ties as follows Please see that the cables does not obstruct for movement and working smooth Excessive tightening of throttle or brake cable will result insudden accelearation and brake jamming resulting into accident Please check the smooth functioning of both before starting N e Step 15 Now adjust the throttle and brake lever with allen key provided in tool kit as per your required position and tighten it fully e Step 16 o Please check the oil inside the engine by opening the dipstick as shown below The engine may or may not have oil inside it P1 refer the user s manual instructions If not then fill up the proper oil in required qty before starting the engine P1 refer the user s manual instructions O After this check
4. nut from shock and keep safe Remember the assembly sequence First assemble swing arm and frame and match the boles Then assemble rear brush guard and match the holes of 3 parts Then assemble bolt and nuts as shown in picture Oo 0000 0 e Step 5 Now assemble all three joints by wrench and allen key provided in tool kit fully as shown in pictures below e Step 6 o Assemble the steering pad as follows o First lift upwards by sliding the U shape bars o Then fix the stoper by allen screw o Then tighten all the related 3 positions nuts fully by wrench e Step 7 Assemble the headrest as follows Insert the two poles of the headrest to the hole of Luggage Carrier Adjust the position of the headrest Tighten the nut with washer from bottom with wrench fully oo0 0 e Step 8 o Assembly the Luggage Carrier as follows o Insert the Lugge Carrier end to the hole of the rear frame add the screw o Remove the bolt from the Luggage carrier and keep them safe o Insert the Luggage Carrier to the install braket add the bolt and tighten by wrench e Step 9 Now assemble the seat 7 as follows First remove the cover and all 4 screws and nuts Then position the seat on the frame mounting place Then assemble the screws from top and nuts with washer from bottom Tighten fully with screw driver and wrench all 4 screws Then assemble cover for seat and tighten the less provided on front o0o0000 e Step 10 o Assembly the
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