J&J Amusements Bumper Boat 2014 Service Manual Download | Manualshive

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0

General Data and
Maintenance.

1

Boat Top
Assembly

2

Boat Hull -
Lower Assembly

3

Motor Assembly
(Electric-powered)

4

Basic Electrical
Troubleshooting

5

Engine assembly
(Gas-powered)

6

Decals

7

Care & Storage

0-7

Specifications

0-9

Monthly maintenance chart

0-13

Pre-opening daily checklist

0-17

Bumper boat area checklist

0-18

Printable work order tags

0-19

How a warranty is processed

0-20

Product return procedures

0-21

Limited warranty-bumper boat

0-22

Limited warranty-super tube II

0-23

Unpacking & setup

0-25 Tube

setup

0-26 Boat

assembly

0-27 Battery

installation

0-31

Boat launch procedure

0-32

Motor installation

2-1 General boat hull assembly
2-2

Main power post

2-4

Boat half protector

2-6 Bilge

pump

2-11 Battery-full kit

2-13

Super tube

2-14 Super tube inflation
2-16 Checking super tube for leaks
2-17 Patching super tube
2-19 Super tube valve replacement

3-1 General information
3-2 Motor

cover

3-4

Control rods/grips/handle bar

3-8 Flex

wire

3-11 Motor
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

Battery-fill quick-release coupler

1-31

Motor power supply cable

4-1 General information
4-2 Basic electrical troubleshooting
4-4 Voltage drop test
4-6 Testing fuse
4-7 Major electrical components
4-13 Specific gravity test

4-15 Equalizing batteries
4-16 Battery maintenance - winter
4-17 Master charger
4-18 Wiring schematic
4-19 Motor wiring schematic
4-20 Boat Captain Wiring Schematic

6-1 General

information

6-2

Motor cover decals

6-3

Boat top decals

6-5 Decal

removal/installation

7-1 General

information

7-2 Fiberglass care & maintenance

7-4 303 Aerospace protectant
7-6 Storage

5-1 General

information

5-2 Handle

bar

5-3 Pivot
5-4 Prop guard

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Summary of Contents for Bumper Boat 2014

Page 1: ...Service Manual Bumper Boat 2014 Published by J J Amusements Inc A Corporation of Oregon 2014 J J Amusements Inc All Rights Reserved G O KARTS B U M PERBOAT S ...

Page 2: ...nload a single copy of this manual onto 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 ...

Page 3: ...for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads It may also be necessary to apply heat to some parts that are held with 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 engine or when turning i...

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 change deterioration or seizure SPECIFICATIONS Specif...

Page 5: ...er 3 4 Control rods grips handle bar 3 8 Flex wire 3 11 Motor 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 Re...

Page 6: ...0 6 NOTES ...

Page 7: ... 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 3 8 264 mm LOWER UNIT Gear ratio 1 1 Propeller 3 7 ...

Page 8: ...mum 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 120 mm Rotating direction Clockwise viewed from rear ...

Page 9: ...ump 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 terminals 12 Tubes Clean Check pressure Weekly Check v...

Page 10: ... 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 every 2 months Use a UV protectant weekly to reduce color ...

Page 11: ...inkage Check adjust 7 Fuel tank tank 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 SCHEDULE Gas 1 Service more frequently when used in dusty ...

Page 12: ...cified 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 months Use a UV protectant weekly to reduce color fading J J pa...

Page 13: ...e 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 of this and other check list on our web site at www...

Page 14: ...through hull vent check battery terminals for vis ible 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 NOT OPERATE UNTIL DAMAGED CONNECTORS AND OR CABLE ARE REPLACED PI...

Page 15: ...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 16: ... 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 etc If no leakage top off fuel tank PIVOT Check for smooth operatio...

Page 17: ...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 Signage Visually inspect Fencing Visually inspect Dock area Visually inspect Download extra copies of this and other checklists on our website at www jjamusements com ...

Page 18: ...ont 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 information Printable Work Order Tags ...

Page 19: ...inspects the goods and one of two things will happen a 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 b 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 charges will be billed See limited warranty for det...

Page 20: ...age where applicable and cannot be altered with custom 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 returned to J J and is proven defective in manufacture or wo...

Page 21: ... 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 pins pivot bushings starter rope switches relays and...

Page 22: ...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 NATURE INCLUDING BUT NOT LIMITED TO LOSS OF TIME OR USE OF...

Page 23: ...NG SETUP General Information 1 19 Unpacking 1 20 Tube Setup 1 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 bum...

Page 24: ...the box sides and discard Remove the tube and place it aside with the box top Remove plastic wrap from the boat hull and discard Leave the boat hull on the cardboard base for protection from scratches UNPACKING Protect your boat from harmful ULTRA VIOLET rays and keep it looking like new with 303 Aerospace Protectant J J carries many clean ing and protection products to keep your go karts in top c...

Page 25: ...60 0124 as shown in figure 5 Carefully inflate the tube to the 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 PRES SURE 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 b...

Page 26: ...ople when lifting the hull assembly Make sure to grab the lip of the boat bottom when lifting the assembly USE WORK GLOVES TO PROTECT HANDS FROM FIBER GLASS 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 bum per boat as well as reducing the risks posed by guests a...

Page 27: ...qty 3 Battery fill kit qty 1 Wiring schematic qty 1 Battery fill 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 lifti...

Page 28: ...lves into the batteries Make sure the manifold valves 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 kink...

Page 29: ...he negative post of battery 2 Install a cable from the positive 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 t...

Page 30: ...reaker to the positive post of battery 4 Install the BLACK 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 Bat...

Page 31: ...ld be two ropes and two dock rails per boat Install the boat 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 m...

Page 32: ... prop guard will clear the motor pivot Carefully lower 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 ...

Page 33: ...nts it is imperative that warning decals are legible and in 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 S Q U I R T G O W...

Page 34: ...ubject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 00156 2 40 0001 www jjamusements com 001688 001686 009800 001681 ...

Page 35: ...rced 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 prob lems and the removal and replacement of parts associated with the boat top NOTE The top and hull assembly for the gas bumpe...

Page 36: ... routed through here as well as all incoming power from the charging device and wire leads NOTICE 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 t...

Page 37: ...attery 1 Disconnect the positive cable leading to the breaker from battery 4 Disconnect the positive cable leading to the breaker from the power post Note Your J J Blaster Boat may be equipped with 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 ...

Page 38: ...99 ENDURANCE CLUTCH PLATES TM Hold the inside nylock nut during the next step Remove the bolts Carefully remove the breaker NOTICE 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECH NICAL INFORMATION RELATED TO OUR PRODUC...

Page 39: ...rviceable 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 cor responds to end point voltages of 5 25 volts for 6 volt batteries readings obtained at 80 degrees F State of Open Circuit Voltage...

Page 40: ...UTCH PLATES TM 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELATE...

Page 41: ... left of the vent plate With a flat screwdriver push and turn counterclockwise 1 4 turn Remove the 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 specifi cation could result in poo...

Page 42: ...o change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM PIVOT RECEIVER General Information 1 8 Pivot Receiver Removal Installation 1 9 ...

Page 43: ...with 8 bolts and nylock 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION REL...

Page 44: ...musements com 503 304 8899 ENDURANCE CLUTCH PLATES TM SAFETY 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 45: ...oat top Remove the nylock nuts and flat washers Replace the hardware as needed Each dock rail hook is 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 REPLACEMENT BOAT HOOKS AND ROPE AVAILABLE ROPE BY THE FOOT 00388 BOAT H...

Page 46: ...ent and water level TECH TIP After cutting the rope lightly singe and melt one end of the rope form a point using a folded piece of cardboard match book cover for example and cover the end to form the point while insulating your fingers from the heat Insert a fid through the rope about 10 inches from the end Next insert the rope through the eye of the boat hook DOCK RAIL ROPE INSTALLATION Fid STAI...

Page 47: ...orkshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 48: ... workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 approxi mately six inches Bring the fid out through the stitching Tuck any excess back inside the hollow core of the rope ...

Page 49: ... 304 8899 ENDURANCE CLUTCH PLATES TM With the other end of the rope 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 50: ...luding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 51: ...including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 52: ...able information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 53: ... tape REMOVAL To remove the old trim first drill out the rivets and pull the trim off of the fiberglass Make sure to remove any trim adhesive and thor oughly 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 pul...

Page 54: ... manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELATED TO OUR PRODUCTS ...

Page 55: ...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 56: ...oat top Open the vent plate to access the charging cable and to perform visual inspections VENT PLATE ASSEMBLY Electric only The vent plate assembly is mounted with six 10 32 phillips head screws with six 10 32 nylock nuts To replace 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 harm...

Page 57: ...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 58: ...503 304 8899 ENDURANCE CLUTCH PLATES TM REMOVAL INSTALLATION Disconnect wiring from the boat hull to the boat top see wiring diagram on page 4 18 Close the boat top From the rear drill out the six rivets from the hull Remove the top from the hull Place the top upright on a soft surface REINFORCED RUBBER HINGE Electric only Who would have thought J J sells mini golf and batting cage supplies ...

Page 59: ...rations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Drill out the rivets and remove the rubber hinge Insert five 3 16 x 3 4 aluminum rivets J J 002473 through the bracket and rubber hinge Install the rivets through the backing plate of the rubber hinge and the boat top J J carries all locktite brand threadlocker and other sealants ...

Page 60: ...LATES TM Place 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATIO...

Page 61: ...c 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 62: ...e vent cover guided by the eye bolt A clamp on cable stop pre vents 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 shoc...

Page 63: ... manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 64: ...atteries to equal levels Hold the quick release coupler from outside so it doesn t spin while loosening the inside nut Loosen the hose clamp Remove the hose from the coupler Loosen and remove the plastic nut Remove the coupler from the outside of the boat top J J 2 70 0108 BATTERY FILL QUICK RELEASE COUPLER STRAIN RELIEF VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELA...

Page 65: ...1 31 MOTOR POWER SUPPLY CABLE Electric only General Information 1 31 Motor Power Supply Cable 1 32 J J 2 70 A0011 ...

Page 66: ...8899 ENDURANCE CLUTCH PLATES TM MOTOR POWER SUPPLY CABLE Electric only REMOVAL INSTALLATION Disconnect wiring at the main post see wiring diagram page 4 18 CAUTION Remove the ground wire from the battery to avoid electrical shock Loosen the plastic cable clamp Slide the cable through the loosened plastic Adel style clamp THE RIGHT TOOL FOR THE JOB HexCrimp jr terminal crimping tool J J 2 70 0073 1...

Page 67: ...amusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELATED TO OUR PRODUCTS Orientation Figure 1 ...

Page 68: ... 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 69: ...ry 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 prob lems 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 this section ...

Page 70: ... equipped with one of two types of power posts The pre 2012 version utilizes two rounded 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 post that contains both the negative and positive feeds Power post pre 2012 Power post post 2012 ...

Page 71: ...ive and negative main posts are located 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 be ing replaced See wiring diagram on page 4 18 Remove the mounting screws Remove the power post MAIN POWER POST Electric only VISIT WWW JJA...

Page 72: ...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 73: ...ove and clean any silicone from the boat hull Install the protector and tighten the clamps securely Apply silicone between the boat 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 tempera ture and amount of silicone used see silicone instructions for details BOAT HALF PROTECTOR Electric on...

Page 74: ... 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 removing the vent plate and using a flashlight inspecti...

Page 75: ...ack then clip the black 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...

Page 76: ... wiring from the main post see the wiring diagram for bilge pump connections on page 4 18 Squeeze the blue mounting tabs located on each side of the pump Remove the pump from its mount The screen is located between the pump and the mount NOTICE Clean the screen before installing the bilge pump BILGE PUMP ASSEMBLY REMOVAL Electric only ADD ANOTHER SOURCE OF REVENUE TO YOUR BUMPER BOAT POND THE COIN...

Page 77: ...99 ENDURANCE CLUTCH PLATES TM Remove the two 10 24 nylock nuts NOTICE 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELATED TO OUR PRODUC...

Page 78: ... www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove loosen the plastic hose clamp Pull and slightly twist the hose to remove it from the fitting To remove the hose fitting carefully hold the inside plastic nut Remove the outside plastic nut Remove the fitting from the inside of the hull KEEPING YOUR BUMPER BOAT POOL CLEAN PERFECT HAS NEVER BEEN SO EASY ...

Page 79: ... 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 80: ...o the batteries Make sure the manifold valves are flush with the battery be fore 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 more easily into the manifold NOTICE Twist the manifolds slightly to remove any kinks in the ...

Page 81: ...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 82: ...d operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FILL ADAPTER Insert a fill adaptor and turn clockwise 1 2 turn Use a rubber tip blow gun to fill the tube VALVE FILL ADAPTER Insert a valve fill adaptor and turn clockwise 1 2 turn SUPER TUBE INFLATION Supertube fill adapter pressure Test adapter filler 2 60 A0006 00367 ...

Page 83: ...M BLOWER INFLATOR Open the tube valve and cover it with an inflator 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...

Page 84: ...ent in a spray bottle with water Check small areas of the tube at a time spraying the surface of the tube and looking for any bubbles Draw a small circle around any punctures or rips in the tube for easy location of the repair then deflate tube NOTICE 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 ...

Page 85: ...e Remove any 303 or other silicone petroleum based product from the tube surface Follow the gluing instructions closely Use 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 b...

Page 86: ...ching 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 J J Supertube II on electric powered Blaster boat J J s Supertube is a great eye pleaser for your boat pond The Supertube is constructed of a UV resistant Uret...

Page 87: ...lining up the prongs on the tool with 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 REPLACE...

Page 88: ...fill adapter and an air filler nozzle Inflate the tube to the recommended PSI of 3 lbs Before returning the boat to service check the valve for leaks by applying a solution of soapy 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 iNFLATE AND ...

Page 89: ... 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 stand is to mount a pivot receiver J J 50011 ...

Page 90: ...3 2 MOTOR COVER General Information 3 2 Motor Cover And Neoprene Protector 3 3 ...

Page 91: ...d washers to remove the mo tor 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 handle bars It will be a little snug as it passes the hand grips Lift VISIT WWW JJAMUSEMENTS COM TECHNICA...

Page 92: ...tion 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 93: ...ring will need to be 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 N...

Page 94: ...and grips and hand grip cement available at J J HAND GRIPS REMOVAL Use a razor blade and cut down the grip Peel the grip away from the handlebar INSTALLATION Set a new grip over the 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...

Page 95: ... two parts and is mounted on 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 vis...

Page 96: ...uge 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 insulation then transitions to an extreme wear gorilla ...

Page 97: ... including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FLEX WIRE Remove the SB 120 connector from the 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 ...

Page 98: ...nd rotate the UHMW disk up over 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 insu lator for the flex wires If they look compressed heat dam aged or show signs of material loss replace them VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHN...

Page 99: ...oing out of the motor black wire If voltage is present at the white wire 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 ...

Page 100: ...ments com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 Add another fun feature to your bumper boat pond and generate more revenue Pondside squirter 2 60 a0008 ...

Page 101: ...rmation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the squirter assembly see page 3 37 Remove the solid state switches see page 3 25 Remove the flex wire assembly see page 3 8 Specialty tools available at j j Call us to find that elusive tool ...

Page 102: ...uding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the gearbox assembly and drive shaft see page 3 34 Remove the pivot assembly see page 3 29 Remove the UHMW lower disk VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX HTM FOR TECHNICAL INFORMATION RELATED TO OUR PRODUCTS ...

Page 103: ...s workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the power post see motor wiring schematic on page 4 19 Remove the four 3 8 hex head motor mount bolts Remove the handle bar assembly see page 3 7 Remove the drive shaft housing Dielectric grease and other grease Products available at j j ...

Page 104: ...NDURANCE CLUTCH PLATES TM Before motor disassembly make sure to mark the location of the cap in relation to the motor casing NOTICE If the motor cap is assembled 180 degrees off this will reverse polarity and cause the motor to turn counter clockwise Remove the fan cover Remove the fan bolt and slide the fan off of the shaft INFLATE AND DEFLATE BOAT TUBES QUICKLY WITH THIS 4HP VACUUM BLOWER J J 2 ...

Page 105: ...bsite for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the brush caps Remove the brushes Remove the four cap bolts BASIC RIDE TIMER SIMPLE AND EFFECTIVE WITH LIGHT AND BUZZER TO ALERT ATTENDANT 01328 ...

Page 106: ...OTICE Clean the commutator with an emory cloth and electric mo tor 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...

Page 107: ...r that is designed to be loose when properly mounted but not able to 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...

Page 108: ... by removing 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 MAGNE...

Page 109: ... 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 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 pro...

Page 110: ...ry volt age same as the voltmeter reading on the back of the 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 volt...

Page 111: ...kshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 112: ...relay to the 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 VISIT WWW JJAMUSEMENTS CO...

Page 113: ...e function of the solid state switch is dependent upon the proximity 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 com...

Page 114: ...netic trigger see page 3 19 Remove the wire leads from the power 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 c...

Page 115: ...RANCE CLUTCH PLATES TM BOAT CAPTAIN Standard equipment on U S models 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 ...

Page 116: ...ost The motor should work normally If testing indicates a problem 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 pre vent inadvertent motor actuation by the rider when entering or exiting the boat The boat captain is installed to allow the ride operator ...

Page 117: ...fications subject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM PIVOT General Information 3 29 Pivot 3 30 ...

Page 118: ...ent and use of the flat washers and spacer sleeves Make sure that all threads are treated with anti galling and corrosion resistant thread compound such as Loctite Marine Grade Anti Seize Remove the pivot shield 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 ...

Page 119: ...ve 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 SUR FACES DURING REASSEMBLY NOTICE Index tabs of the insert bushing face each other inside the pivot shield These tabs align with the pivot stop on the drive housing NOTICE When installing Nylock nu...

Page 120: ...ings Install the pivot shield Install and tighten the pivot bracket nuts to 20 ft lbs WARNING If the pivot bracket nuts are over tightened binding of the pivot assembly may occur Finish by installing the allen cap headed screws Make sure to have the flex wire cable clamps in the correct position see flex wire removal on page 3 8 Protect yourself with the right protective wear Mechanix wear it s wh...

Page 121: ... without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM LOWER UNIT ASSEMBLY General Information 3 33 Gearbox Drive Shaft 3 34 Prop Guard 3 35 Anode 3 36 ...

Page 122: ... shaft must be replaced 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...

Page 123: ... prop Pull the prop 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 Instal...

Page 124: ...ic anode corrodes so that the anode material is consumed in preference 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 ...

Page 125: ...see page 3 2 to the squirt nozzle The electrical supply feeds from the 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 s...

Page 126: ... 8899 ENDURANCE CLUTCH PLATES TM Remove the motor cover and neoprene protector see page 3 3 Cut and remove the zip 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 IN LINE SQUIRT PUMP FILTERS AVAILABLE 00177...

Page 127: ...ect the wire from the squirt 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 Visit www Jjamusements Com and download a copy of our ...

Page 128: ...TCH PLATES TM Cut the zip tie to remove the hose from the handle bar base Carefully remove the wiring and hose from the handlebar plate Remove the two bolts from the drive shaft housing Note A metal anode is mounted between the squirt pump and drive shaft housing When installing the anode apply a small amount of silicone on each bolt CORROSION SOLUTION CORROSION BLOCK PRODUCTS AVAILABLE AT J J 12 ...

Page 129: ...s attached to the motor 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 VISIT WWW JJAMUSEMENTS COM TECHNICAL INDEX H...

Page 130: ...eral Information 3 42 SB 120 Terminal Replacement 3 43 NOTICE 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 cha...

Page 131: ...the cable shielding back 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 Hydrau lics 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 nega tive battery pack cable f...

Page 132: ...94 over the cable and install strain relief on both sides of the cable utilizing the two pan head screws and nylocks 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 u...

Page 133: ...teries 4 15 Battery Maintenance Winter Storage 4 16 Master Charger 4 17 Wiring Schematic 4 18 Motor Wiring Schematic 4 19 Boat Captain Wiring Schematic 4 20 This section of the Service Manual describes basic electrical troubleshooting and testing procedures to help you correctly diagnose electrical problems that may arise This section also contains the complete wiring schematics of the J J Blaster...

Page 134: ...it It can also trick you into 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 ...

Page 135: ...d with a voltmeter or scope A test 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 ti...

Page 136: ...ower flows in from the charge circut and out to all load devices 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 ca...

Page 137: ...ted wires and or connections stop current flow After you fix an open 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 ...

Page 138: ...in them so small that it cannot be seen by the naked eye Therefore 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 ...

Page 139: ... sealing items Due to the size and difficulty of effectively crimping the SB 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 ...

Page 140: ...M Testing Use the DVOM and perform voltage drop tests to troubleshoot the wire 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 F l e x w i r ...

Page 141: ...nostic tool to aid in troubleshooting these devices White lead from 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 s...

Page 142: ...e to the unit The bottom side must face toward the solid state 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...

Page 143: ...ntinues to accumulate in the hull It is imperative that the daily inspection 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...

Page 144: ...the plunger down for 15 minutes while in the water Shortcut Tip 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 ba...

Page 145: ... 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 VOLTAGES OF 5 25 VOLTS FOR 6 VOLT BATTERIES State of Open Circuit Voltage 6 Volt Battery Charge Level Four Battery Pack 6 30 or Greater 100 25 2 6 16 6 30 75 100 24 64 25 20 6 00 6 16 50 75 24 00 24 64 5 90 6 00 25...

Page 146: ... 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 never need to add acid Only distilled deionized or approved water should be added to achieve the recommended levels mentioned above When a battery is shipped in a dry state or accidental spillage occurs electrolyte...

Page 147: ... on the battery before charging Set the charger to equalizing mode The 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 ...

Page 148: ...cted and with a timer program your charger to go on and off on a weekly basis NOTICE Do not leave the BLS connected if you are not programming the system to be recharged 6 When you are back reconnect the batteries and recharge them as usual If your charger does not recognize them and will not charge you can use a simple manual charger and recharge them Again recharging in a low amperage mode is th...

Page 149: ...ations See battery fill kit page 2 67 FRONT PANEL INDICATORS 1 AC power 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 proces...

Page 150: ...o 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 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 negati...

Page 151: ...ive 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 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 ...

Page 152: ...TCH PLATES TM BOAT CAPTAIN WIRING SCHEMATIC Remove black switch wires 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 wir...

Page 153: ...uard 5 4 The Honda BF2 3D engine was chosen for its reputation for dependable service and its reduced emissions less smoke and less oil in the water this motor quietly performs Initially designed for use in the corrosive marine environment this dependable unit has been modified to be controlled from behind and transformed to operate in the bumper boat This section will go over the components that ...

Page 154: ...ter it contacts leaving you with dry fuel By removing water directly from fuel it helps to prevent many service problems related to water contamination including Plugged fuel filters fuel line freeze up carburetor icing damaged fuel pumps and injectors growth of algae corrosion loss of power and down time Requires a 1 15 fuel filler opening The Honda steering handle throttle assembly and hardware ...

Page 155: ...eck our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM PIVOT The removal installion and maintenance for the pivot is performed with the same steps as for the electric motor see page 3 29 ...

Page 156: ...ding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM 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 157: ...ation 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 6 1 ...

Page 158: ...tes the squirt function The green rod activates the motor Go function MOTOR COVER DECALS elecric only WARNING Must meet posted height requirement Shoes and shirt must be worn All loose clothing must be secured Hair longer than shoulder length must be secured above shoulder length Keep both hands on steering wheel and both feet in kart at all times unless otherwise instructed by attendant One perso...

Page 159: ...p under the vent plate J J 009800 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...

Page 160: ...06 SAFETY ITEM This decal must be readable at all times to operate the boat Replace as needed Warning Never Stand Up While Boat Is Operat ing 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 Keep your boats looking new with Replacement decals available at j j WARNING Keep Hands And Feet In...

Page 161: ...ot for melting away the decal but to heat the adhesive enough to removal 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 lin...

Page 162: ...ectrical codes Metal parts protected by special double coating process for corrosion protection Each unit can be adjusted both height and water flow to meet your needs Fitted with a quick change coin token mechanism Master Blaster Base 12 x12 x3 8 Steel Mounting Holes 4 1 2 Diameter 10 5 Center to center Center Column 3 5 Steel Pipe Adjustable Height 40 to 48 Adjustable Rotation Arc 0 to 120 in 15...

Page 163: ...l 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 the value of your investment 7 1 ...

Page 164: ...les and crevices under the wax the gelcoat can oxidize underneath 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 env...

Page 165: ... to reveal the clean but not necessarily shiny surface If your boat isn t shiny at this point it s because the clean gelcoat surface is pitted and is dissipating the light instead of reflecting it By filling in the microscopic pits you can restore the shine To prove this just apply some water to the surface and see if it becomes shiny If so you then need to apply something which will fill in the p...

Page 166: ...leaning methods must be followed by a thorough rinse with water 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 manufactur...

Page 167: ...nd that does not leave a coating or sealant Use pure rubbing compound 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 sl...

Page 168: ...ry the motor cover Polish and wax the surface of the gelcoat 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...

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