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J&J Amusements 24v 1750 rpm, Service Manual, Page: 108 / 171

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J&J Amusements 24v 1750 rpm Service Manual Download Page 108

phone: 1-800-854-3140 | 1-503-304-8899   fax: 1-800-366-7505 | 1-503-304-1899   www.jjamusements.com

3-21

MOTOR RELAY (J&J# 2-70-0033)

General Relay Information ................................................ 3-21

Testing the Relay................................................................. 3-22

Relay - Removal & Replacement ....................................... 3-23

Th

  e relay (J&J# 2-70-0033) is a simple 24VDC marine-style unit. It consists of a spring-loaded plunger that is moved via an electromagnet. 

Th

  is magnet is created when the control circuit (two small contact posts) is energized via the micro/solid state switch circuit. When the control 

circuit is energized, the plunger moves up and a large contact washer makes the connection between the input and output (large) terminals, 
thus allowing high amperage current to fl ow to the motor. 

To verify that the relay is functioning properly (without replacing it with a unit that is known to be so), perform the following simple tests. 
Before beginning, fi rst verify the voltage at the main power post of motor. Th

  e voltage should match the battery voltage (same as voltmeter 

reading on back of boat).

Summary of Contents for 24v 1750 rpm

Page 1: ...Service Manual Bumper Boat 2018 Published by J J Amusements Inc An Oregon Corporation 2018 J J Amusements Inc All Rights Reserved Specifications subject to change without notice 2018 ...

Page 2: ... a hard drive or other electronic storage medium to be viewed for personal use provided that such electronic or printed copy of this manual contains the complete text of this copyright notice Any unauthorized commercial distribution of this manual is strictly prohibited 4897 Indian School Rd NE Suite 150 Salem Oregon 97305 1126 www jjamusements com Phone 503 304 8899 Toll Free Phone 800 854 3140 F...

Page 3: ...an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads It also may be necessary to apply heat to some parts that are held with a locking compound EDGES Watch for sharp edges especially during major motor engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the motor engin...

Page 4: ... time they are removed Removed parts will be damaged and or lose their original function INSPECTION When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to their condition replace them with new parts Abrasions cracks hardening warping bends dents scratches wear color changes deterioration seizure SPECIFICATIONS Specifi...

Page 5: ...otor 3 19 Magnetic trigger 3 21 Motor relay 3 25 Solid State Switch 3 27 Boat captain 3 29 Pivot 3 33 Lower unit assembly 3 37 Squirt pump Assembly 3 42 SB 120 terninal 1 2 Breaker main cutoff switch 1 5 Volt meter 1 7 Bilge pump 1 8 Pivot receiver 1 10 Safety dock rail hooks 1 12 Dock rail rope installation 1 18 Trim 1 21 Vent plate 1 23 Reinforced rubber hinge 1 27 Battery charging cable 1 30 Ba...

Page 6: ... 139lbs 63kg Minimum water depth 3ft 91m MOTOR Model 24v 1750 rpm Type Continuous duty 3 4 hp 1118w 24v permanent magnet Motor weight 78lbs 36kg Cooling system Air Maximum horsepower 3 4 hp 1750 rpm Maximum speed 3 5 mph 4 8 km h Throttle Green rod push button on off Squirt Blue rod push button on off Squirter Type 24v submersible BATTERY Type 6 volt deep cycle 225 AH Weight 62 lbs 28 kg Length 10...

Page 7: ...Tube II weight 23lbs 11kg Hull deck weight 139lbs 63kg Minimum water depth 3ft 91m ENGINE Model J J equipped Honda BF2 3D Type 4 stroke overhead valve single cylinder Engine weight 32 0 lbs 14 6kg Cooling system Forced air Starting system Recoil Lubrication system Splash Fuel capacity 1 16 US qt 1L LOWER UNIT Gear ratio 2 42 29 12 Gear case oil capacity 0 05 US qt Propeller 3 7 2 x 4 7 in 3 184 x ...

Page 8: ...and grease terminals 2 Replace When damaged 6 Sump pump 1 Clean strainer 7 Propeller guard Inspect Replace When damaged 8 Hull Inspect clean Safety decals Polish 9 General wires connections Check for damage Clean connections Replace When necessary Spay corrosion protectant 10 Anode Clean Replace When damaged 11 Squirter Replace filter When needed Check for damage Check hose fitting Clean grease te...

Page 9: ...minals Look for signs of wear Replace as needed 6 SUMP PUMP Clean strainer as needed Check pump operation If pump is not cycled periodically check all wiring connections Repair or replace pump as needed 7 PROPELLER GUARD Inspect for damage or foreign materials Replace if damaged SAFETY ITEM WARNING DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING 8 HULL Keep clean and wax every 200 hours or...

Page 10: ...heck adjust 5 Idle speed Check adjust 6 Carburetor linkage Check adjust 7 Fuel tank fuel filter Clean 8 Fuel line Check Replace When needed 9 Starter rope Check 10 Propeller guard Inspect Replace When damaged 11 Hull Inspect clean Safety decals Polish 12 Anode Clean Replace When damaged 13 Pivot 1 Check Daily Grease 3 14 Tubes Clean Check pressure Weekly Check visually Daily MONTHLY SERVICE SCHEDU...

Page 11: ... Honda Shop Manual 8 FUEL LINE Check and replace at the specified intervals see the Honda Shop Manual 9 STARTER ROPE Check and replace at the specified intervals see the Honda Shop Manual 10 PROPELLER GUARD Inspect for damage or foreign materials Replace if damaged SAFETY ITEM WARNING DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING 11 HULL Keep clean and wax every 200 hours or every 2 mont...

Page 12: ...not OK see a supervisor Body color Item Service type Mon Tues Wed Thu Fri Sat Sun BOAT Tube Check pressure Hull Visually inspect Receiver Visually inspect Handrails hardware Visually inspect Sump pump Visually inspect Batteries Visually inspect volt meter MOTOR Motor Physically inspect Motor charger cables Visually inspect Pivot Physically inspect Prop guard Visually inspect Download extra copies ...

Page 13: ... BATTERIES Check volt meter for full charge of 24 26 volts Viewing through hull vent check battery terminals for visible corrosion MOTOR MOTOR Visually and physically check motor operation go and squirt function loose hardware grips handlebar condition and abnormal noises during operation MOTOR POWER CABLE Check for bare wires proper connection and any signs of excessive heat or melting WARNING DO...

Page 14: ...x every day If anything is not OK see a supervisor Body color Item Service type Mon Tues Wed Thu Fri Sat Sun BOAT Tube Check pressure Hull Visually inspect Receiver Visually inspect Handrails hardware Visually inspect Water in hull Drain if needed ENGINE Engine gear case Check oil Level Throttle Check operation Fuel system Visually inspect Pivot Physically inspect Prop guard Visually inspect ...

Page 15: ...t HANDRAILS HARDWARE Check for loosening and missing hardware WATER IN HULL Drain if excessive water is present inside hull ENGINE ENGINE GEAR CASE Visually and physically check engine operation grips handlebar condition and abnormal noises during operation THROTTLE Check for smooth operation and full return when released FUEL SYSTEM Check for any signs of fuel leaks from the tank cap fuel filter ...

Page 16: ...ce type Mon Tues Wed Thu Fri Sat Sun POND Boat rope hooks Check for broken hooks and unsafe ropes Dock Rail Check for cracks or loose hardware Pond Water Check chemical condition and clarity FILTRATION Pump Follow manufacturer s recommendation SAFETY Equipment Visually inspect Signs Visually inspect Fencing Visually inspect Dock area Visually inspect Download extra copies of this and other checkli...

Page 17: ...m Employee Name Description of Work Performed Parts Used Front Back Mechanic Date Time Manager This sample maintenance work order tag can be copied for use in your facility Copy and cut tag along dashed line and fold along the fold line indicated Simply attach a maintenance work order tag to a machine in need of repair When maintenance is complete file with other service and maintenance informatio...

Page 18: ...ith RMA on the outside of package The warranty manager inspects the goods and one of two things will happen Credit will be authorized to the customer s account in the amount charged for the replacement Note Cash refunds are not given on warranty items If part is not warrantable because of normal wear and tear damage by accident etc the warranty will be denied and no credit will be issued shipping ...

Page 19: ...merchandise must be in good condition in the original package where applicable and cannot be altered with cus tom labels stickers numbers etc Merchandise that is returned without an RMA will be refused WARRANTY RETURN POLICY All warranty item returns must be authorized by the Warranty Department and have an assigned RMA number before any adjustment or credit will be given All merchandise that is r...

Page 20: ...tside of the United States and Canada contact us for warranty questions regarding your country Honda motor warranty is only covered by American Honda Motor Co Inc Electric battery charger is only covered by manufacturer Specific exclusions Normal wear and tear items such as throttle cables spark plugs fuel filers hand grips throttle levers over inflated tubes tube wear from rough pool walls shear ...

Page 21: ...ing any obligations under this limited warranty to inspect the damaged goods in order to determine compliance with this paragraph This warranty does not extend to products accessories or parts purchased for use outside of the United States and Canada Disclaimer of consequential damage and limitation of implied warranties J J DISCLAIMS ANY RESPONSIBILITY FOR ANY CONSEQUENTIAL DAMAGES OF ANY KIND OR...

Page 22: ...21 Boat Assembly 1 22 Battery Installation electric only 1 23 Battery Fill Kit Installation electric only 1 24 Battery Wiring electric only 1 25 Boat Launch Procedure 1 27 Motor Installation 1 28 Your new J J bumper boat is shipped in a heavy duty cardboard box This section of the Service Manual describes the process to get your new bumper boat s unpacked and ready for service ...

Page 23: ...cleaning and protection products to keep your go karts in top condition From smaller spray bottles to 5 gallon containers of product we ve got you covered Give us a call CLEANERS AND PROTECTANTS CLEANERS PROTECTANTS Part Description Price 00316 Cleaner Protect All Cleaner 19 26 00317 Cleaner Protect All Wash 14 81 00320 Cleaner Protect All 13oz Aerosol Spray 14 81 3 60 0033 Protectant 303 Aerospac...

Page 24: ...e recommended 3 PSI Always use a low pressure gauge such as J J 3 96 0024 to accurately measure tube pressure NOTICE TUBES SHOULD BE FILLED COLD AS AIR PRESSURE CHANGES WHEN HOT See Super Tube Inflation on page 2 14 After inflating make sure the valve is closed by pushing the valve in and turning it clockwise Check the valve for leaks by applying a solution of soapy water If bubbles form the valve...

Page 25: ... the lip of the boat bottom when lifting the assembly USE WORK GLOVES TO PROTECT HANDS FROM FIBERGLASS EDGES Rotate the boat hull inside of the tube so the air valve on the tube is located at the back of the hull This allows simple maintenance to be performed from one direction on the bumper boat as well as reducing the risks posed by guests accessing the valve This adapter makes it easy to fill y...

Page 26: ...ll kit instructions Batteries should be placed in such a position as to allow ease of wiring Place the batteries with terminals as shown in Figure 1 Place battery 1 in the hull first followed by battery 4 2 and finally 3 This sequence helps keep the boat balanced during battery installation Fig 1 Battery 2 Battery 4 CAUTION Proper lifting procedures must be followed Carefully place batteries in th...

Page 27: ...are flush with the batteries before tightening Push the hose T fittings into the manifolds Use equal pressure until the fittings snap into place NOTICE Be careful not to damage the T fitting o ring TECH TIP Wet the T Fitting with distilled water to help it slip into the manifold more easily NOTICE Twist the manifolds slightly to remove any kinks in the water lines All kinks must be removed for the...

Page 28: ...e post of battery 2 to the negative post of battery 3 Install a cable from the positive post of battery 3 to the negative post of battery 4 Battery 1 Battery 2 Battery 4 Battery 3 Battery 1 Battery 2 Battery 4 Battery 3 Battery 1 Battery 2 Positive Bat 1 N e g a ti v e B a t 3 P o s i t i v e B a t 4 Negative Bat 4 Negative Bat 3 Save time topping off the water in your batteries with the complete ...

Page 29: ...ACK cable from the negative main power post to the negative post of battery 1 Carefully remove the wooden prop rod place inside the hull and lower the boat top until it s fully closed Check the volt meter display If the meter is not displaying 24 volts check the breaker If the breaker is on then the battery wiring will need to be rechecked Battery 4 Battery 3 Battery 1 Battery 2 Battery 3 Battery ...

Page 30: ...dock rail hooks as described in the dock rope installation on page 1 12 Carefully move the boat to the edge of the pond NOTICE Make sure to move the boat with the box lid underneath it to prevent damage CAUTION This is a two person job Do not try to launch a bumper boat with only one person Carefully slide the boat assembly without the motor into the pond Inspect the boat and latch the boat hooks ...

Page 31: ...r the motor through the hole Align the motor to the motor pivot and slide down into place There is an index hole and pin that need to be aligned for proper positioning NOTE For electric powered boats only Treat all SB120 plug terminals with corrosion block J J part 99109 Connect the blue SB120 plug from the boat hull into the blue SB120 plug on the motor NOTICE Boats equipped with remote shut down...

Page 32: ...place The following outlines the typical locations of particular warning decals on bodied and non bodied go karts as installed at the time of manufacture Inspect and replace them as needed see the maintenance and daily checklist schedules located in section 0 of this manual 00169 00170 00170S Spanish weight limit 450 lbs 6 4 8 5 7 G O WARNING Keep Hands And Feet In Boat At All Times DO NOT REMOVE ...

Page 33: ...34 SPECIFICATIONS Specifications and prices subject to change without notice Download latest update to this manual on line 00156 2 40 0001 www jjamusements com 001688 001686 009800 001681 ...

Page 34: ...Trim 1 18 Vent plate electric only 1 21 Reinforced rubber hinge electric only 1 23 Battery charging cable electric only 1 27 Battery fill quick release coupler electric only 1 30 Motor power supply cable 1 31 This section of the Service Manual describes the various components of the boat top assembly how to diagnose problems and the removal and replacement of parts associated with the boat top NOT...

Page 35: ...harging device and wire leads NOTE If there is high resistance in the system heat and possible fire can occur without tripping the breaker this is why the switch breaker is located in an easily accessible position on the outside of the hull The charge line and charger feed current through the SB 120 connector breaker and main buss to the battery pack Keep in mind that even when disconnected the ch...

Page 36: ...h one of two types of power posts The Pre 2012 version utilizes two rounded style posts one for the positive feed and one for the negative feed Blaster Boats built during the 2012 model year changed to a single rectangular style post that contains both the negative and positive feeds BREAKER SWITCH Electric only Battery 4 Battery 3 Battery 1 Battery 2 Disconnect negative Disconnect positive Power ...

Page 37: ... manual on line 1 4 Hold the inside nylock nut during the next step Remove the bolts Carefully remove the breaker NOTE Inspect wires and connections for corrosion damage Clean off any corrosion from cable ends and apply corrosion block on the cable ends before re installing Replace as needed ...

Page 38: ...lt meter is a sealed unit and therefore not serviceable If the unit shows zero voltage the systems breaker switch may be in the OFF position the meter is inoperative or the batteries charge is very low Limit discharging the batteries beyond 1 75 volts per cell 1 125 specific gravity per cell 1 75 volts per cell corresponds to end point voltages of 5 25 volts for 6 volt batteries readings obtained ...

Page 39: ... 6 VOLT METER Electric only The volt meter is located on the back of the boat top to the left of the vent plate Removal installation Remove the two nuts that hold the bracket to the boat top Remove the volt meter from the outside of the boat top See the wiring diagram for volt meter connections on page 4 18 ...

Page 40: ...fuse and holder by pulling outward Remove the fuse from the holder Check for continuity through the fuse with a multimeter see page 4 6 for a fuse test NOTE The replaceable fuse is a 3 amp time delay slow blow cartridge style fuse Using any fuse type other than this specification could result in poor performance and or pump failure Replace as needed BILGE PUMP FUSE Electric only FUSE FUSE RELATED ...

Page 41: ...Specifications and prices subject to change without notice Download latest update to this manual on line 1 8 PIVOT RECEIVER General Information 1 8 Pivot Receiver Removal Installation 1 9 ...

Page 42: ...ock nuts and 16 flat washers Removal installation Remove the bolts nylock nuts and washers Install a new pivot by using the existing holes Replace the hardware with new hardware as needed ID Plate Remove the ID plate from the old pivot Install the ID plate to the new pivot with 4 stainless steel rivets PIVOT RECEIVER REMOVAL INSTALLATION ...

Page 43: ...RAILS DOCK RAIL HOOKS General Information 1 10 Safety Rails Dock Rail Hooks 1 11 Dock Rail Rope Installation 1 12 DOCK RAILS ARE NOW FULLY STAINLESS STEEL WITH BLUE POWDER COAT J J Dockrails are made from stainless steel and powder coated for ultra protection We have dockrails available for both concrete or wood docks ...

Page 44: ...s mounted with 1 U bolt 1 outside plate 1 inside plate 4 nylock nuts and 4 lock washers REMOVAL INSTALLATION Remove the nylock nuts and the inside plate Replace the hardware as needed SAFETY RAILS DOCK RAIL HOOKS BOAT HOOKS ROPE Each boat should have two Boat Hooks and 3 to 5 feet of bumper boat rope Note Bumper boat rope is determined by how far dockrails are spaced from edge of pool ROPE BUMPER ...

Page 45: ...e through the eye of the boat hook DOCK RAILS ARE NOW FULLY STAINLESS STEEL WITH BLUE POWDER COAT Don t sacrifice safety Only FPX bumper boat pond dock rails should be used for any bumper boat pond Swimming pool rails are not designed for this use Stainless steel construction Powder coated 2 per boat for safety DOCK RAIL ROPE INSTALLATION Fid 00711SS 00713SS DON T LET YOUR BOATS DRIFT DOCK RAILS P...

Page 46: ...w jjamusements com 1 13 Thread the fid back through each side of the loop Insert the fid at the first rope thread under the loop To make the loop insert the rope through the end of the fid and the thread the fid through the rope Pull the rope making a small loop at the hook ...

Page 47: ...date to this manual on line 1 14 Pass the fid down through the hollow core of the rope just below the loop Run the fid down the hollow center of the rope for approximately six inches Bring the fid out through the stitching Tuck any excess back inside the hollow core of the rope ...

Page 48: ...repeat the previous steps without the boat hook to permanently attach the rope to the dock rails Insert the rope through the eye of the dock rail Insert the fid through the rope about 10 inches down Insert the rope through the end of the fid and thread the fid through the rope Pull the rope making a small loop at the dock rail ...

Page 49: ...oad latest update to this manual on line 1 16 Thread the fid back through each side of the loop Pass the fid down the hollow core of the rope just below the loop Run the fid through the penetrated rope and continue down the hollow center for approximately six inches ...

Page 50: ... 1 503 304 1899 www jjamusements com 1 17 The dock rail rope should have about 2 inches of slack when attached to the boat so the hooks can be easily connected Bring the fid out through the stitching Tuck the excess back inside the hollow core of the rope ...

Page 51: ...without notice Download latest update to this manual on line 1 18 TRIM General Information 1 18 Trim Installation Removal 1 19 The boat trim serves to protect the tube and your hands from the exposed fiberglass edge on the bottom of the boat top ...

Page 52: ...nd pull the trim off of the fiberglass Make sure to remove any trim adhesive and thoroughly clean off the surface of the fiberglass before installing the new boat trim INSTALLATION Heat trim before installing Peel off 2 of tape backing Line up the trim with the center of the vent plate Carefully wrap the trim around the boat top pulling the tape backing off in 2 inch sections at a time Cut off any exc...

Page 53: ...otice Download latest update to this manual on line 1 20 Drill through the outside of the trim by matching the existing rivet holes Insert rivets through the trim Install a backing washer on the inside of each of the rivets Install the rivets to boat top ...

Page 54: ...04 1899 www jjamusements com 1 21 VENT PLATE Electric only General Information 1 21 Vent Plate Assembly 1 22 The vent plate is a multi purpose access port into the boat hull It acts as a vent for the hull and also allows easy access to the charge cable Vent Plate ...

Page 55: ...ace the vent plate assembly remove the six screws Inspect the gasket for damage and replace as needed To open turn counterclockwise Vent Plate Protect your boat from harmful ULTRA VIOLET rays and keep it looking like new with 303 Aerospace Protectant CLEANERS PROTECTANTS Part Description Price 3 60 0033 Protectant 303 Aerospace 2 oz pump sprayer 2 75 3 60 0034 NLA Protectant 303 Aerospace 32 oz tr...

Page 56: ...03 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 1 23 REINFORCED RUBBER HINGE Electric only General Information 1 23 Reinforced Rubber Hinge 1 24 The reinforced rubber hinge connects the boat top to the hull ...

Page 57: ...ce REINFORCED RUBBER HINGE Electric only EXCLUSIVE DESIGN MANUFACTURED BY AUTOMATED BATTING CAGES These batting cage balls are specifically designed for accuracy in ABC s wheel style pitching machines Along with the standard Urethane balls we also carry the Softflight this ball helps to reduce bat sting and pitches just like standard balls right on track BATTING CAGE BALLS Part Description Price 5...

Page 58: ...ng plate of the rubber hinge and the boat top J J carries all locktite brand threadlocker and other sealants THREAD LOCKERS GLUES Part Description Price 3 20 0002 Loctite Threadlocker 50ml Bottle Blue 83 73 3 20 0003 Loctite Threadlocker 250ml Bottle Blue 191 76 3 20 0005 Loctite Threadlocker 50ml Bottle Red 76 60 3 20 0006 Loctite Threadlocker 250ml Bottle Red 191 76 4 95 0044 Loctite 50ML Green ...

Page 59: ...e the boat top on the hull Open the vent plate to access the rubber hinge Pre drill through the rubber hinge Insert six rivets through the hull and rubber hinge Insert a backing washer on inside of each rivet Holding the backing plate insert the rivets Connect all wiring connections see wiring diagram on page 4 18 ...

Page 60: ...ements com 1 27 BATTERY CHARGING CABLE Electric only General Information 1 27 Battery Charging Cable 1 28 The battery charging cable is approximately 15 long and is located inside the boat It is easily accessed through the vent plate access cover located on the back of the boat top ...

Page 61: ...by the eye bolt A clamp on cable stop prevents over extension of the cable REMOVING BATTERY CHARGER CABLE Unscrew the vent plate hole cover Access the cable through the vent plate hole NOTE Cable length approximately 15 ft Disconnect the charger cable wiring from the main post see wiring diagram Page 4 18 CAUTION Remove the ground wire from the battery to avoid electrical shock BATTERY CHARGING CA...

Page 62: ...9 Pull the charging cable out through the inside of the boat top Loosen the rubber cable stop Remove the cable stop from the cable Close the boat top Pull the cable out through the vent plate hole Charging cable Pull THE RIGHT TOOL FOR THE JOB HexCrimp jr terminal crimping tool J J 2 70 0073 120 ...

Page 63: ...lastic nut Remove the coupler from the outside of the boat top J J 2 70 0108 BATTERY FILL QUICK RELEASE COUPLER STRAIN RELIEF 2 70 0211 This combination strain relief and plug end protector has an easy to grab hand hold for connecting and disconnecting SB 120 charger plugs from your bumper boats No more broken plug ends from charger leads being dropped on the ground BATTERY PLUG ENDS Part Descript...

Page 64: ...hone 1 800 854 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 1 31 MOTOR POWER SUPPLY CABLE Electric only General Information 1 31 Motor Power Supply Cable 1 32 J J 2 70 A0011 ...

Page 65: ...cable through the loosened plastic Adel style clamp THE RIGHT TOOL FOR THE JOB HexCrimp jr terminal crimping tool J J 2 70 0073 120 2 80 0003 2 7 0 0 0 7 3 1 2 0 Terminal crimper BATTERY ACCESSORIES Part Description Price 2 70 0149 Meter Volt Indicator EBB Round W J J Logo 24 47 3 60 0081 Tool Battery Load Tester 500amp 195 84 3 96 0100 Tool Battery Tester 6 or 12 volt 111 18 2 80 0003 Tool Hydrom...

Page 66: ...304 1899 www jjamusements com 1 33 Carefully loosen the nut from the plastic strain relief elbow Remove the nut by sliding it to the cable end Remove the cable through the boat top Note the location of the elbow for installation See Figure 1 Orientation Figure 1 ...

Page 67: ...oat Motor Work Bench Mount 800 854 3140 503 304 8899 www FunPartsXpress com Receiver Socket Type Part 50011 A Receiver mounted to your work bench will make servicing your fleet of bumper boat motors SAFER and QUICKER There s no better way to hold your motors steady while servicing Maximize efficiency in your shop add two or three receivers to your work bench today ...

Page 68: ...ic only 2 4 Bilge pump electric only 2 6 Battery full kit electric only 2 11 Super tube 2 13 This section of the Service Manual describes the various components of the boat hull assembly how to diagnose problems and the removal and replacement of parts associated with the boat hull NOTE The top and hull assembly for the gas bumper boat is permanently attached Super tube information only applies in...

Page 69: ...hout notice Download latest update to this manual on line 2 2 MAIN POWER POST Electric only General information 2 2 Positive negative main power post 2 3 The power post is a single rectangular post that contains both the negative and positive feeds ...

Page 70: ... at the rear of boat hull WARNING Before removing wires disconnect the main ground wire from the negative power post REMOVAL Disconnect the negative cable from the battery Remove all wiring to the main power post that is being replaced See wiring diagram on page 4 18 Remove the mounting screws Remove power post MAIN POWER POST Electric only ...

Page 71: ...notice Download latest update to this manual on line 2 4 BOAT HALF PROTECTOR Electric only General information 2 4 Boat half protector 2 5 The boat half protector acts as a seal for the motor cavity in the hull preventing any water from entering the hull ...

Page 72: ...at hull and protector For best results use J J 013331 Let the silicone cure before putting the boat back in service Note Curing time varies depending on outside temperature and amount of silicone used see silicone instructions for details BOAT HALF PROTECTOR Electric only MARINE GOOP ADHESIVE 013331 the PERFECT SOLUTION TO ATTACH BOAT HALF PROTECTOR Silicone THREAD LOCKERS GLUES Part Description P...

Page 73: ...w is above a preset threshold it indicates that water is present and the pump will continue operation until the amp draw drops indicating that no water is present Note If the inlet is sufficiently blocked no water will enter the inlet and the pump will not sense amp draw so it will shut off even though water continues to accumulate in the hull It is imperative that the daily inspection includes remov...

Page 74: ...ack wire ground to the negative post of the battery pack Tip Replace re charge batteries prior to testing If the battery pack is discharged pull up another boat with a charged system and pull the charge lead out Use this as your power source to evacuate the water from the inoperative unit Remove the bilge pump from the holder clips and clean the screen and back flush the intake with a water hose I...

Page 75: ...RACTIVE POND SQUIRTER Part Description Price 2 60 A0024 Pondside Squirter Assy Coin Operated 24v 1 125 Token 1 200 00 2 60 A0028 Pondside Squirter Assy Coin Operated 24v CAD Loonie 1 200 00 2 60 A0008 Pondside Squirter Assy Coin Operated 24v USD CAD Quarter 1 200 00 2 60 A0027 Pondside Squirter Assy Coin Operated 24v NO COIN ACCEPTOR 1 200 00 2 60 A0023 Pondside Squirter Timing Box Assy Complete W...

Page 76: ...nts com 2 9 Remove the two 10 24 nylock nuts NOTE Replacement of the pump mount and screen is needed only if damaged Remove the bilge pump mount from the hull To disconnect the output hose remove loosen the plastic hose clamp Pull and slightly twist the hose to remove it from the pump ...

Page 77: ...he inside of the hull KEEPING YOUR BUMPER BOAT POOL CLEAN PERFECT HAS NEVER BEEN SO EASY POND CLEANING AGENTS Part Description Price 3 60 0019 Pool Clean Perfect 5Gal 640oz 236 22 3 60 0018 Pool Clean Perfect 22oz Trigger Spray 7 93 3 60 0015 Pool Perfect Cleaner Concentrate 3L 101 50 oz 38 10 3 60 0017 Pool Phosfree 3L 101 50 oz 31 37 2 80 0001 Test Kit Water Complete High K 2005 Test Kit for Poo...

Page 78: ...ric only General information 2 11 Battery Full kit installation 2 12 The battery filling system allows easy top off of the battery water level from the outside of the boat Simply attach the battery fill squeeze bulb J J 2 70 A0021C to the access port on the back of the boat top to fill all the batteries to equal levels ...

Page 79: ...th the battery before tightening Push the hose T fittings into the manifolds Use equal pressure until the fittings snap into place NOTE Be careful not to damage the T fitting o ring TECH TIP Wet the T Fitting with distilled water to help it slip more easily into the manifold NOTE Twist the manifolds slightly to remove any kinks in the water lines All kinks must be removed for the watering system t...

Page 80: ...fax 1 800 366 7505 1 503 304 1899 www jjamusements com 2 13 SUPER TUBE General information 2 13 Super tube inflation 2 14 Checking super tube for leaks 2 16 Patching super tube 2 17 The Super Tube II is built with a urethane coated fabric ...

Page 81: ...sure Test adapter filler 2 60 A0006 00367 TUBE TOOLS BUMPER BOAT Part Description Price 2 60 0046 Gauge Low Pressure 0 15 Used for Super Tube 58 00 3 96 0024 Gauge Low Pressure 0 15 Super Tube Poly Tube Motion Pro 95 00 00367 Filler Super Tube Plastic Type 8 86 2 60 A0006 Filler Super Tube Use ST Cap and Valve Fill Super Tubes 16 83 2 60 0124 Tool Inflator Deflator Super Tube 4 0hp 130cfm 199 00 2...

Page 82: ...hose Turn the blower on to fill Inflate the tube to the recommended 3 PSI Check it with a low pressure gauge Before returning the boat to service check the valve for leaks by applying a solution of soapy water If bubbles form valve needs to be tightened With the tube inflated insert the valve tighter and turn the nut 1 8th turn Re check with the soapy water solution Repeat as needed until no bubbl...

Page 83: ...w a small circle around any punctures or rips in the tube for easy location of the repair then deflate tube NOTE The glue and patch will bubble up and fail to bond properly if the tube is fully inflated when the repair is made Do not attempt to patch around or near a tube seam as the patch will not bond CHECKING SUPER TUBE FOR LEAKS TUBE REPAIR BUMPER BOAT Part Description Price 003370 Patch Super...

Page 84: ...e or cut a vinyl patch from the repair kit making sure it is large enough to cover the damaged area with at least 1 to 2 inches of extra vinyl on all sides Round off any corners Patch kit J J 003371 003370 Recommended vinyl cement J J 2 60 0072 Apply an even coat of cement to both of the surfaces to be joined and let it dry only 2 5 minutes PATCHING SUPER TUBE VINYL CEMENT 2 60 0072 TUBE REPAIR BUM...

Page 85: ...r If desired leave the tube inflated overnight and recheck it before putting it back into service NOTE When patching the relative humidity must be less than 70 preferably as low as 40 Temperature should be 64 C to 77 C 147 2 F to 170 6 F Bond strength drops very rapidly with heat or high humidity Don t patch the tube near water or in direct sunlight TUBE TOOLS BUMPER BOAT Part Description Price 2 ...

Page 86: ...the corresponding slots in the valve With tube deflated grasp the female fitting through tube Once you have a solid grip unscrew the valve by turning counterclockwise Remove the male portion and install the replacement The replacement procedure is same as loosening only the valve is turned clockwise The valve needs to be hand tightened SUPER TUBE VALVE REPLACEMENT ...

Page 87: ...oapy water If bubbles form the valve needs to be tightened With the tube inflated insert the valve tightener and turn the nut 1 8th turn Re check with soapy water solution Repeat as needed until no bubbles form 2 60 0124 TUBE TOOLS BUMPER BOAT Part Description Price 2 60 0124 Tool Inflator Deflator Super Tube 4 0hp 130cfm 199 00 THE SUPER TUBE INFLATOR DEFLATOR IS SIMPLY A GREAT TOOL ITS 4HP MOTOR...

Page 88: ...d state switch 3 25 Boat captain 3 27 Pivot 3 29 Lower unit assembly 3 33 Squirt pump assembly 3 37 SB 120 Terminal replacement 3 42 This section of the Service Manual describes the various components of the electric motor assembly how to diagnose problems and the removal and replacement of parts associated with the motor TECH TIP While working on the boat motor an easy way to make your own motor ...

Page 89: ...Specifications and prices subject to change without notice Download latest update to this manual on line 3 2 MOTOR COVER General Information 3 2 Motor Cover And Neoprene Protector 3 3 ...

Page 90: ...e the motor cover Carefully remove the motor cover Lift the motor cover to gain access to the squirter hose Disconnect the squirter hose by pushing the gray tab on the quick release coupler MOTOR COVER AND NEOPRENE PROTECTOR Remove the neoprene protector by sliding it up the handlebars It will be a little snug as it passes the hand grips Lift ...

Page 91: ...ine 3 4 CONTROL RODS GRIPS HANDLEBARS General Information 3 4 Control Rods 3 5 Hand Grips 3 6 Handlebar Assembly 3 7 The control rods are color coded anodized aluminum rods that activate the motor and squirt pump functions The green rod controls the motor power and the blue rod controls the squirt pump ...

Page 92: ... replaced Unbolt the magnetic trigger to remove the control rod Use a magnet to remove the spring The countersink hole in the control rod faces the slot on the handlebar Line up the countersink hole on the control rod with the slot in the handlebar Install the magnetic trigger and make sure to orient the trigger with the magnet facing down so the trigger can function properly NOTICE Apply anti sei...

Page 93: ...he handlebar Press the grip to move it down the handlebar Tech Tip To get the grip completely onto the handlebar it may be helpful to use a blow gun to create a cushion of air between the two as you push the grip down the handlebar Hand Grip Cement 2963874 00239 00238 HAND GRIPS BUMPER BOAT Part Description Price 00238 Grip Bumper Boat Motors Red 5 99 00239 Grip Electric Bumper Boat Black 9 50 296...

Page 94: ...n the motor with four 3 8 hex head mount bolts Part 2 10 0003 handlebar mount plate Part 2 10 0002 handlebar Remove the gear box see page 3 33 Remove the hex head motor mount bolts After the bolts are removed slide the plate up the drive shaft housing Note The drive shaft housing will be loose from the motor The handlebar is now free from the motor and can be removed ...

Page 95: ...DED THAT THE ENTIRE HARNESS BE REPLACED The 10 2 gauge wire harness for the flex wire is unique in that it must provide power to the motor and yet allow the motor 320 degrees of rotation This movement can eventually cause flex wire failure and must be monitored for high resistance and or breaks in the circuit From the motor pivot SB 120 connector the 10 2 gauge wire uses its OEM shielding and insu...

Page 96: ...he bracket Remove the cable clamps from the pivot cover Remove the pivot assembly see page 3 29 LOOKING FOR THAT ELUSIVE TOOL OR SHOP ACCESSORY CALL J J WE VE GOT THEM SHOP LIFTS Part Description Price 1031 Lift Assy Air Operated 24 x 80 1 590 00 1032 Lift Assy Electric Operated 24 x 80 1 725 00 3 60 0043 Lift Multi Lift Electric 1 222 98 ...

Page 97: ...er the steering stop This will help with further disassembly Remove the flex cable from the UHMW disk Remove the wire from the handlebar assembly Inspect all fiber washers and bushings as they act as an insulator for the flex wires If they look compressed heat damaged or show signs of material loss replace them Fiber washer Bushing B u s h i n g ...

Page 98: ...re but not at the black wire then the circuit inside the motor is open Worn brushes are a common cause of this symptom Solutions Remove and inspect the brushes replacing with new brushes and springs as needed Symptom The motor turns very slowly and the connections get hot Most common cause The motor is drawing too many amps and may cause the 50 amp safety breaker to trip Normally this is caused by...

Page 99: ...atest update to this manual on line 3 12 Remove the motor cover and neoprene protector see page 3 3 Remove the magnetic triggers see page 3 25 Disconnect wiring connections at the power post see wiring diagram on page 4 18 Remove the relay see page 3 21 MOTOR DISASSEMBLY ...

Page 100: ... 966 rated watts 3 700 surge watt 865 00 3 96 0011 Tool Magnetic Parts Dish 14 03 3 96 0001 Tool Rotor Sprocket Holder 38 04 3 96 0012 Tool T Handle 10 slot Rack 27 94 3 96 0026 Tool Ball End Allen Set 9pc Metric 19 37 3 60 0011 Tool Heli Coil Kit M6 x 1 0 78 52 3 60 0030 Tool Heli Coil Kit M14 x 1 25 Go Kart Spark Plugs 89 99 3 60 0032 Tool Heli Coil 3 8 24 Refill 2 05 1 60 1000 Tool Hub Puller 5...

Page 101: ...hout notice Download latest update to this manual on line 3 14 Remove the power post see motor wiring schematic on page 4 19 Remove the gearbox assembly and drive shaft see page 3 34 Remove the pivot assembly see page 3 29 Remove the UHMW lower disk ...

Page 102: ... a revolutionary product that Kills corrosion on contact Stops corrosion from ever coming back Lubricates the area Is safe to nearly all electronics CORROSION PROTECTION Part Description Price 3 60 0002 Corrosion Block Grease 2 oz Tube 6 25 99101 Corrosion Block Aerosol 12 oz Protector Penetrant 20 35 99101S Corrosion Block Pump Spray 4 oz Protector Penetrant 8 15 99108 Corrosion Block Grease 14oz...

Page 103: ... fan off of the shaft Supertube fill adapter pressure Test adapter filler 2 60 A0006 00367 TUBE TOOLS BUMPER BOAT Part Description Price 2 60 0046 Gauge Low Pressure 0 15 Used for Super Tube 58 00 3 96 0024 NLA Gauge Low Pressure 0 15 Super Tube Poly Tube Motion 95 00 00367 Filler Super Tube Plastic Type 8 86 2 60 A0006 Filler Super Tube Use ST Cap and Valve Fill Super Tubes 16 83 2 60 0124 Tool In...

Page 104: ...s Remove the brushes Remove the four cap bolts BASIC RIDE TIMER CLOCK F Simple and effective F Light and buzzer combination to alert attendant when ride time is over F Requires 110v AC outlet RIDE TIMER ANALOG Part Description Price 01328 Clock Timer White 60 minute 303 61 3 60 0088 Clock Timer White 15 minute 303 61 ...

Page 105: ...the commutator with an emory cloth and electric motor cleaner if needed Clean off only the carbon build up Try not to remove any brass material CAUTION Be careful when assembling the motor as the magnetism will pull the pieces together Keep fingers clear NOTICE The brush holders are plastic and held in place with a set screw Be careful to not over tighten the set screws just snug them up Set screw ...

Page 106: ... rotate because of the ears on the injection molded part The down side must face toward the solid state switch Use Anti Seize when installing the shoulder bolt to the actuator rod s NOTICE Early versions of this trigger did not have the ears molded into the trigger allowing it to rotate upside down Mounting the magnet up side down will result in a poor or non functioning sold state switch MAGNETIC...

Page 107: ...the 1 4 shoulder bolt with an allen wrench Inspect the nylon bushing and shoulder bolt Replace as needed Align the rode with the slot in the handlebars Make sure the magnet in the trigger is pointed down facing the solid state switch Tighten the shoulder bolt NOTICE Mounting the magnet upside down will result in a poor or nonfunctional sold state switch Tighten the shoulder bolt MAGNETIC TRIGGER B...

Page 108: ...t two small contact posts is energized via the micro solid state switch circuit When the control circuit is energized the plunger moves up and a large contact washer makes the connection between the input and output large terminals thus allowing high amperage current to flow to the motor To verify that the relay is functioning properly without replacing it with a unit that is known to be so perfor...

Page 109: ...boat A quick ohm meter check across the two small posts should verify the activation windings values should be 67 71 ohms Symptom The relay does not click and the motor does not run Most common causes A faulty relay or solid state switch Check the power to the relay input post black 10 gauge wire The voltage should match the battery voltage same as the voltmeter reading on the back of the boat Che...

Page 110: ...jjamusements com 3 23 RELAY REMOVAL REPLACEMENT Remove the motor cover and neoprene protector see page 3 3 Remove the black and white wire lead from the power post Disconnect the yellow wire lead from the relay Cut the black wire lead above the yellow 10 gauge butt connector ...

Page 111: ... motor housing and remove the relay Install the new relay CAUTION Use only a 5 16 x 1 2 bolt with lock and a flat washer This is necessary in order to keep the bolt from causing internal damage to the motor Crimp the 10 gauge butt connector to the black wire lead Install the leads to the corresponding negative and positive posts see wiring diagram on page 4 19 ...

Page 112: ... of the magnet to the switch NOTICE When replacing the magnetic trigger or anything else in this area be sure to orient the magnet trigger magnet side down so it can function properly During normal operation the LED will light when the switch is ON Symptom The light is on all the time even when the switch is not activated Most common cause The solid state switch is wired incorrectly or the magneti...

Page 113: ...ower post see wiring diagram on page 4 19 On the under side of the motor remove the solid state switch mounting nuts SOLID STATE SWITCH Remove the solid state switch Note There is NO left or right solid state switch it can be installed on the squirt blue rod or motor green rod side The LED light on the switch must face the inside of the control rods solid state switch part 2 30 A0002 ...

Page 114: ... only General Information 3 27 Testing the Boat Captain 3 28 This device individually controls the motor via the motor solid state switch and or the squirt pump via its solid state switch Like the switch it controls the ground side of the circuit ATTACH THE J J PIVOT RECEIVER TO A STURDY WORKBENCH TO SECURE A BOAT MOTOR TO A WORK BENCH 50011 ...

Page 115: ...blem with the boat captain module always make sure the transmitter is functioning properly NOTICE The J J bumper boat conforms to ASTM standards These standards require that a device be in place to prevent inadvertent motor actuation by the rider when entering or exiting the boat The boat captain is installed to allow the ride operator to disable the motor during loading and unloading of the boat ...

Page 116: ...phone 1 800 854 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 3 29 PIVOT General Information 3 29 Pivot 3 30 ...

Page 117: ...d Remove the pivot bracket NOTICE The UHMW plastic split insert has index tabs this is done so it remains static and the pivot turns plastic on plastic during operation Remove the pivot and insert bushings PIVOT Index tabs Insert bushing Index tabs Index tabs Insert bushing CORROSION PROTECTION Part Description Price 3 60 0002 Corrosion Block Grease 2 oz Tube 6 25 99101 Corrosion Block Aerosol 12 ...

Page 118: ...have a top and bottom Position the bushings thicker web to the top of the motor and the thin web toward propeller USE A LIBERAL COATING OF MARINE TYPE GREASE SUCH AS J J CORROSION BLOCK 99109 ON THE WEAR SURFACES DURING REASSEMBLY NOTICE Index tabs of the insert bushing face each other inside the pivot shield These tabs align NOTICE When installing Nylock nuts on the pivot MARINERS CHOICE NEVER SE...

Page 119: ...rect position see flex wire removal on page 3 8 Mechanix Wear kevlar knee pads Mechanix Wear original glove Mechanix Wear mechanics apron Mechanix Wear radio belt PROTECTIVE CLOTHING GEAR Part Description Price 3 00 5000 Glove Original 8 Small Mechanix Black 37 01 3 00 5001 Glove Original 9 Medium Mechanix Black 37 01 3 00 5002 Glove Original 10 Large Mechanix Black 37 01 3 00 5003 Glove Original ...

Page 120: ...phone 1 800 854 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 3 33 LOWER UNIT ASSEMBLY General Information 3 33 Gearbox Drive Shaft 3 34 Prop Guard 3 35 Anode 3 36 ...

Page 121: ...ed The drive shaft can be installed in either direction Before installing the shaft coat both ends with MARINERS CHOICE NEVER SEEZ GEARBOX AND DRIVE SHAFT Lower the shaft into the housing When the shaft contacts the motor output shaft rotate the shaft in order to align the motor shaft slot and the drive shaft keyway you will feel the drive shaft move toward the motor when this occurs Coat both sid...

Page 122: ... off of the shaft Remove the prop guard backing plate PROP AND GUARD Reinstall the prop guard backing plate Slide the prop onto the shaft taking care to line up the prop holes with the corresponding holes on the shaft Use an awl or suitable drift pin to help align the holes Using a new stainless steel roll pin tap in with a hammer and punch until it is flush with the prop Install the prop guard ...

Page 123: ...eference to the structure The loss or sacrifice of the anode material gives rise to the alternative name of sacrificial anode As this device is made to deteriorate it begins to die the minute it is placed in the water To be effective it must have good contact with the material you are protecting and have good exposure to the water With this in mind remove and clean the contact surfaces A wire brush...

Page 124: ...he main motor power posts through the fuse holder the slow blow fuse is the same that is used by the bilge pump is located in the front of the motor just under the motor cover and can be removed and checked without removing the motor cover The squirt pump is controlled by interrupting the ground side of the circuit via the solid state switch or the boat captain remote control unit standard equipme...

Page 125: ... tie from the hose Remove the hose from the filter by squeezing the spring clamp and sliding the clamp away from the filter Slightly pull and twist to remove the hose from the filter Cut and remove the zip tie from wiring SQUIRT PUMP ASSEMBLY 60 Micron In Line Fuel Filter 001772 G Ethanol compliant PUMP FILTER Part Description Price 001772 G Filter Fuel 60 Micron Stainless Steel PET Ho 3 50 ...

Page 126: ...t switch see wiring diagram on page 4 19 Disconnect the wire from the fuse holder NOTICE Carefully pry the connector from the fuse holder by using a flat blade screwdriver The squirt pump fuse is located on the side opposite the handle bars Refer to page 4 6 for fuse testing procedures Place the wiring and hose aside Fuse location ...

Page 127: ...unted between the squirt pump and drive shaft housing When installing the anode apply a small amount of silicone on each bolt CORROSION PROTECTION Part Description Price 3 60 0002 Corrosion Block Grease 2 oz Tube 6 25 99101 Corrosion Block Aerosol 12 oz Protector Penetrant 20 35 99101S Corrosion Block Pump Spray 4 oz Protector Penetrant 8 15 99108 Corrosion Block Grease 14oz Cartridge 18 99 99109 ...

Page 128: ...otor cover Use an adjustable wrench and squeeze the spring clamp Slide the clamp down the hose Pull and slightly twist the hose to remove Use a flat blade screwdriver and turn clockwise to remove the nozzle from the motor cover NOTICE The nozzle is threaded opposite of standard screws tighten and loosen with this in mind SQUIRT NOZZLE ...

Page 129: ... It is very important that the SB 120 plug connections be solid and secure This section of the manual describes the correct installation procedures however if you have any doubt about the connection and your abilities to perform the task correctly J J does sell complete cable assemblies with all connectors in place Battery to battery charger part 2 70 A0017 Battery to motor part 2 70 A0011 ...

Page 130: ...1 1 2 Strip the wire shielding back 3 4 Insert the terminal contacts and crimp the terminal to the wire using a hydraulic crimp tool such as Central Hydraulics from Harbor Freight Note Attempting to to crimp new terminals with a vise hammer etc will result in a poor connection SB 120 TERMINAL REPLACEMENT WARNING You must first disconnect the negative battery pack cable from the power post DO NOT W...

Page 131: ...Insert the terminal contacts into the SB 120 housing and push until the terminal snaps into the housing NOTICE THE WHITE WIRE IS TO POSITIVE THE BLACK WIRE IS NEGATIVE REVERSING THESE LEADS WILL RESULT IN A BLOWN CHARGER OUTPUT FUSE Install and tighten strain relief to the housing using the machine screw and nylock THE RIGHT TOOL FOR THE JOB CRIMP WITH EASE J J 2 70 0073 120 BATTERY ACCESSORIES Pa...

Page 132: ...intenance Winter Storage 4 16 Master Charger 4 17 Wiring Schematic 4 18 Motor Wiring Schematic With Boat Captain 4 19 Motor Wiring Schematic Without Boat Captain 4 20 Boat Captain Wiring Schematic 4 21 LED Lights Schematic Boat Top 4 22 LED Lights Schematic Motor 4 23 This section of the Service Manual describes basic electrical troubleshooting and testing procedures to help you correctly diagnose...

Page 133: ...nto replacing parts that are not in need of replacement The more connections and wiring a unit has the more vulnerable the electrical system is to voltage drop VOLTAGE DROPS GOOD OR BAD Voltage drop tests are usually performed to test loads and locate circuit problems As a result we may have a tendency to think of voltage drops as bad things But voltage drops can be good or bad it all depends on w...

Page 134: ...st light indicates whether voltage is present but it doesn t measure the amount of voltage Voltmeters measure and display the difference in voltage levels between the voltmeter test leads The black test lead connected to the meter COM port should be considered the reference This is the baseline it is the starting point for the measurement Voltage at the red probe tip connected to the meter VOLT por...

Page 135: ...ces as well as the volt meter system monitor located on the back of the boat top near the vent access cover Note All power in or out flows through the breaker If the volt meter reading is indicating zero make sure the switch is ON The charge system lead is a 15 long 10 gauge cable connected to the post buss The SB 120 connector on the cable end mates with the SB 120 connector on the charger lead T...

Page 136: ... circuit switch the circuit on again and check for lingering voltage drop Until you get current flowing and check the circuit again you can t know if the entire circuit is healthy Although resistance free connections wires and cables would be ideal most of them will contain at least some voltage drop MAXIMUM LIMITS 0 00V across a connection 0 20V across a wire or cable 0 30V across a switch 0 10V ...

Page 137: ...efore it is important to check a fuse with an ohmmeter or a continuity tester instead of assuming that it is good Use a multi meter and set the range switch to the lowest resistance range to check the fuse A good fuse will read 0 ohms depending on what the meter reads when the leads are held together and a bad fuse will read the same as holding the leads in the air The illustration below shows how...

Page 138: ... terminal lugs J J recommends replacement of the entire harness end that is affected by the problem 50 amp breaker switch P B E J O F 2 60 0102 Battery Battery Power post negative junction Battery Battery Battery Battery Battery Battery VOLT Power post Fuse 50 amp breaker switch 10 2 Cable to charger Volt meter fuse cable 10 2 Cable to motor METER Bilge pump 24V P B E J O F ower post P E VOLTS Fema...

Page 139: ... harness and connectors The unique portion of the wire harness system the flex wires allow the motor to rotate 320 degrees while maintaining current flow to the motor system The system is designed to eliminate as many connectors as possible and avoid problem areas while providing a simple trouble free unit e u que po t o o t e e a ess syste F le x w ir e S B 1 2 0 S B 1 2 0 Flex wire ...

Page 140: ...Kartrol unit White lead from Kartrol unit Black lead to negative post Black lead to negative post Yellow lead to negative post Yellow lead to negative post Red lead to positive post Red lead to positive post White lead to positive post Black lead Blue lead from squirt pump to positive post Yellow lead from fuse to yellow lead on squirt pump switch Orange lead from Kartrol Micro to black lead on sq...

Page 141: ...e switch NOTICE Mounting the magnet up side down will result in a poor or non functioning solid state switch The J J relay J J 2 70 0037 is a simple 24VDC marine style unit It consists of a spring loaded plunger that is moved via an electromagnet This magnet is created when the control circuit two small contact posts is energized via the micro solid state switch circuit When the pull in circuit is...

Page 142: ...ction includes removing the vent plate and with a flashlight inspecting to see if water is building up in the hull A bilge pump fuse which is accessible for service from the outside of the hull near the vent plate is located in the power feed line from the main buss See Bilge Pump page 2 40 The volt meter is the overall monitor of the electrical condition of the system It is tied in at the major d...

Page 143: ...ip At this point back probe the charger lead with your DVOM and read the DC volts Compare with chart page 5 149 to give you a quick check of the overall charge condition of the battery pack If charged voltage is not good you can proceed with the specific gravity testing to determine which battery ies are causing the poor performance A battery cell s specific gravity is a great way of measuring a b...

Page 144: ...EST For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hrs preferably 24 hrs 1 Disconnect all loads from the batteries 2 Measure the voltage using a DC voltmeter 3 Check the state of charge with table bellow LIMIT DISCHARGING THE BATTERIES BEYOND 1 75 VOLTS PER CELL OR 1 125 SPECIFIC GRAVITY PER CELL 1 75 VOLTS PER CELL CORRESPONDS TO END POINT VOLTA...

Page 145: ...erfill the cells WHAT IS THE PROPER ELECTROLYTE LEVEL IF YOU ARE USING J J FILL KIT THE FLOAT VALVES WILL SHUT OFF AUTOMATICALLY AT THE PROPER LEVEL Liquid levels should be 1 8 inch below the bottom of the vent well the plastic tube that extends into the battery The electrolyte level should not drop below the top of the plates Do you ever add acid to a battery Under normal operating conditions you...

Page 146: ...e J J Master Charger has this function The batteries will gas bubble during the equalization process WARNING MAKE SURE BATTERY COMPARTMENT IS WELL VENTILATED AND REMEMBER THE GASSES GIVEN OFF ARE HIGHLY EXPLOSIVE Measure the specific gravity See page 5 149 CLEANING Warm water and soap works well to neutralize acidic or corrosive conditions Rinse with clean water after washing In some cases almost ...

Page 147: ...teries going If you own a BLS reconnect it while recharging This will dissolve the lead sulfate crystals that are reducing your battery life and thus extend the life of your batteries If you own several 12 volt pieces of equipment you can use the BLS 12 24 B and rotate it on the different systems while charging Battery Maintenance Winter Storage Fuse VOLT Fuse 70 Amp Breaker Switch 10 2 Cable to ch...

Page 148: ...wer indicator continuously on means the unit is connected and ready for use 2 AC power indicator flickering means the positive and negative cables are reversed reverse polarity the lead is not connected the DC output fuse is burned out or the battery voltage is under 2 volts 3 EQUAL light flickering means the unit is in the process of equal charging 4 DAILY light flickering means the unit is in th...

Page 149: ...ge pump 24V P B E J O F ower post P E VOLTS Female connector Black Black Black Black A109 2 70 A0045 A108 A108 A108 Brown Green Green Red Red R e d White White male connector g g White to positive 2 70 0103 Fuse holder 2 70 0149 2 70 0104 Fuse 2 60 0102 2 70 A0044 2 70 0153 2 70 A0017 2 70 A0011 2 7 0 A 0 0 4 6 2 70 A0046 Black to negative A108 Electric Bumper Boat 24 Volt Wiring Schematic 2012 Bl...

Page 150: ...ost Black lead Blue lead from squirt pump to positive post Yellow lead from fuse to yellow lead on squirt pump switch Orange lead from Kartrol Micro to black lead on squirt pump switch Yellow lead Yellow lead Black White White Black Brown Wire black 2 70 A0031 White lead Kartrol Micro 1 60 8000 Motor 2 70 0051 Positive connection Negative connection Squirt switch 2 30 A0002 Relay 2 70 0033 W i r e...

Page 151: ...on squirt pump switch Yellow lead Yellow lead Black Black Black White White Black Brown Wire black 2 70 A0031 White lead Motor 2 70 0051 Positive connection Negative connection Squirt switch 2 30 A0002 Relay 2 70 0033 W i r e w h i t e 2 7 0 A 0 0 2 5 W i r e w h i t e 2 7 0 A 0 0 3 0 W ire black 2 70 A0029 Fuse 2 70 0104 Fuse holder 2 70 0103 Go switch 2 30 A0002 Squirt pump 2 60 0086 MOTOR WIRIN...

Page 152: ...s from ground terminal Cut off ring terminals and replace with female end spade terminals Ground terminal negative On Off switch Squirter switch Positive terminal Connect orange wire to black wire from squirter switch Connect white wire to black wire from On Off switch Connect red wire to positive terminal Connect black yellow wires to gound terminal ...

Page 153: ...E LE LE LE E D D D D D D D LI LI LI LI LI LI LIGH GH GH GH GH GH GH G T T T T T T T LE LED D LI LIGH GHT T 1 1 1 1 1 1 60 60 60 60 60 60 60 0 0 0 0 0 0 039 39 39 39 39 39 39 3 3 3 3 3 3 3 3 LE LE LE LE LE LED D D D D D LI LI LI LI LI LIGH GH GH GH GH GHT T T T T LE LE LE LE LE LE LE L D D D D D D D D D LI LI LI LI LI LI LI LI LIGH GH GH GH GH GH GH GH GHT T T T T T T T T LED LIGHTS SCHEMATIC BOAT ...

Page 154: ... 1899 www jjamusements com 4 23 LED LIGHTS SCHEMATIC MOTOR RESISTOR 2 70 0154 SQUIRT PUMP 2 60 0086 SOLID STATE SWITCH 2 30 0004 FUSE HOLDER 2 70 0103 BROWN BLACK RED YELLOW BLUE LED LIGHT POSITIVE POST LE LE LE LE LED D D D D LI LI LI LI LIGH GH GH GH GHT T T T T E ...

Page 155: ...Specifications and prices subject to change without notice Download latest update to this manual on line 4 24 ...

Page 156: ...3D MOTOR BREAK IN PROCEDURE Like all motors the BF2 3 needs to be broken in well to ensure a long trouble free life Please follow these starting instructions to help the process 1 Lift the motor cover and turn the chrome limiter cap on the side of the carburetor back and forth 6 to 8 times to break lose any dry gas that may have formed during storage Turn the limiter cap all the way to the left 2 ...

Page 157: ...fer to the Honda shop manual for repairing troubleshooting and maintaining the throttle system ELIMINATE WATER FUEL PROBLEMS Whether you are storing fuel or operating a boat motorcycle lawn mower ATV personal watercraft snow blower generator or other machinery you need the Water Eliminator the most cost effective way to remove water from gasoline diesel fuel oil kerosene or hydraulic fluid Easy to ...

Page 158: ...54 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 5 3 PIVOT The removal installation and maintenance for the pivot is performed with the same steps as for the electric motor see page 3 29 ...

Page 159: ...ad latest update to this manual on line 5 4 PROP GUARD The prop guard used on the gas engine is also used for the electric motor see page 3 25 for removal and installation Refer to the Honda shop manual for repairing troubleshooting and maintaining the extension case ...

Page 160: ...99 www jjamusements com 6 1 DECALS General Information 6 1 Motor Cover Decals 6 2 Boat Top Decals 6 161 Decal Removal and Installation 6 163 This section of the Service Manual depicts the location of various decals on the bumper boat and how to remove and replace them ...

Page 161: ...l J J 001686 Squirt and Go decals are located on the motor cover next to the control rods Squirt decal J J 0097102 Go decal J J 0097101 NOTE These decals indicate the function of the control rods The blue rod activates the squirt function The green rod activates the motor Go function MOTOR COVER DECALS elecric only KEEP YOUR BOATS LOOKING NEW WITH REPLACEMENT DECALS AVAILABLE AT J J DECALS BUMPER ...

Page 162: ... Blaster Boat decal is located on the boat top above the vent plate on the electric bumper boat J J 001688 Water Bug decal is located on the boat top above the water drain plug on the gas bumper boat J J 00168 Warning Keep Hands And Feet In Boat At All Times decal is located on the right inboard side of the boat top J J 00169 SAFETY ITEM This decal must be readable at all times to operate the boat...

Page 163: ...perating decal is located on the left inboard side of the boat top J J 00170 SAFETY ITEM This decal must be readable at all times to operate the boat Replace as needed Star Stripes decal is located at the rear of the gas bumper boat top J J 00156 KEEP YOUR BOATS LOOKING NEW WITH REPLACEMENT DECALS AVAILABLE AT J J DECALS BUMPER BOAT GENERAL Part Description Price 0097101 Decal GO Button EBB 2 13 0...

Page 164: ...oval the decal Repeat until the decal is completely removed Apply a small amount of WD 40 to a clean cloth the cloth should be damp but not soaked Wipe away the glue on the fiberglass using the moistened cloth INSTALLATION Clean the surface with a grease cutting liquid detergent and water Rinse with fresh water then dry with a lint free cloth Peel the backing paper from the new decal starting at t...

Page 165: ...nt a few of the Master Blaster water squirters around your bumper boat pond and voila A simple rugged money maker Easy installation with four 1 2 anchor bolts on 10 1 2 centers and one half inch NPT nipple to interface with the park s fresh water supply system Uses 24VAC current provided by transformer included Always check local codes Metal parts protected by special double coating process for co...

Page 166: ...FF SEASON Some bumper boat ponds do not operate all year long For this reason J J Inc has prepared this information on how to properly condition your bumper boat fleet for periods of storage or inactivity We urge you to follow the simple instructions and advice contained here referencing specific information from your Owner s Service Manual to maintain the highest level of safety and to preserve t...

Page 167: ...neath the wax Fiberglass sealers like Vertglas avoid this problem by filling in all the holes pits and crevices in the gelcoat surface FIBERGLASS SEALERS Unlike wax a fiberglass sealer penetrates into the gelcoat surface filling in the microscopic holes and crevices to prevent future oxidation The sealer provides a barrier between the environment and the gelcoat cutting off the chemical reaction wh...

Page 168: ...tion Price 00316 Cleaner Protect All Cleaner 19 26 00317 Cleaner Protect All Wash 14 81 00320 Cleaner Protect All 13oz Aerosol Spray 14 81 SFG Q Cleaner Fiberglass 32 fl oz 8 93 SZP Q Cleaner Boat Zoap 1 Quart 10 57 3 60 0033 Protectant 303 Aerospace 2 oz pump sprayer 2 75 3 60 0034 Protectant 303 Aerospace 32 oz trigger sprayer 24 43 3 60 0035 Protectant 303 Aerospace 128 oz gallon refill 64 21 3...

Page 169: ...er Obviously abrasives should never be used on vinyl Petroleum distillates are a universal no no for both vinyl and rubber Waxes should never be used on vinyl because a Most waxes contain petroleum distillates b Wax is a build up product holding in the heat absorbed from the sun and accelerating heat damage Virtually all vinyl manufacturers agree that no type of oil should be used on vinyl Silicon...

Page 170: ...d with only the finest abrasive REAPPLYING Reapply by spraying 303 on the surface and wiping dry with a soft absorbent cloth very much like dusting furniture and just as easy Mist it lightly first with 303 then towel dry takes an extra 30 40 seconds This is an excellent way to keep up the UV screen and totally prevent UV caused slow fade WHEN TO REAPPLY 303 is water repellent beads water When the ...

Page 171: ...You can store motors upright or flat but make sure motors are stored free from moisture and high humidity TUBE Thoroughly wash and dry the tube Deflate tubes and store them flat In time folds will damage the tube surface and cause leaks so if there is a lack of storage space try to minimize the number of folds CLEANING AND WAXING Storing a dirty bumper boat can lead to corrosion since dirt retains...

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