manualshive.com logo in svg

J&J Amusements Can-Am, Service Manual, Page: 196 / 272

Share
Download
J&J Amusements Can-Am Service Manual Download Page 196

12-4

GO

-KARTS

B

U

MPERBOAT

S

Specifications subject to change without notice - Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com

503-304-8899

ENDURANCE CL

UTCH PLA

TES

TM

BODY REMOVAL

SCORPION & KING SCORPION:

Unlatch the body latches.
Remove the two 3/4” nuts that secure the body to 
the chassis. Lift the body off the chassis with the 
front of the body slightly higher than the rear to 
clear the steering wheel. 
 < CAUTION > Use two people when lifting the 
body.

Make sure the T-bushings are in place on the 
chassis.

Lower the body onto the chassis with the front 
slightly higher than the rear to allow clearance 
around the steering wheel. Be careful not to tear the 
body seals (see page 12-12).

The “T” bushings are compressed when the 3/4” 
nuts are tightened. Do not over-tighten these nuts, 
as the bushing expansion can crack the body.

Latch the body latches.

NOTE: The body latches must be latched in order to 
lock the body to the chassis.

SIDEWINDER & SIDEWINDER DOUBLE

Unlatch the four body latches. There are two 
behind the front wheels and two behind the rear 
wheels.

Remove the roll bar as shown on page 5-3. Place 
the roll bar onto the bottom seat cushion. 
Lift the body off the chassis.
 < CAUTION > Use two people when lifting the 
body.

Lower the body onto the chassis.

Install the roll bar as shown on page 5-3.

Latch all four body latches.
NOTE: The body latches must be latched in order to 
lock the body to the chassis.

Body latch

Body latch

Body latch

3/4” nut

“T” bushings

KEEP YOUR FIBERGLASS BODIES LOOKING THEIR BEST WITH 303!

303 Aerospace protectant (1 gallon)

#3-60-0035

Summary of Contents for Can-Am

Page 1: ...e Manual Single Double Go Karts 2014 Published by J J Amusements Inc An Oregon Corporation 2013 J J Amusements Inc All Rights Reserved G O KARTS B U M PERBOAT S Specifications subject to change without notice ...

Page 2: ...ard 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 Fax 5...

Page 3: ...ew 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 engine or turning it over HIGH FLASH POINT SOLVENT A high flash point solvent is recommended to reduce fire danger A commercial so...

Page 4: ...isassembled 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 Specification terms are defined as follows Standards Show dimensions or performances which brand new parts or systems have Servic...

Page 5: ...ring wheel 4 12 Steering column pad 4 13 Engine overview 8 1 Grabber plate 8 3 Engine assembly removal 8 4 Engine mounted items 8 6 Hour meter schematic without kartrol 8 7 Hour meter schematic with kartrol 8 8 Tiny tach schematic 8 9 Clutch reduction rebuild 8 14 Overview 7 1 Caliper assembly 7 3 Brake pads removal installation 7 4 Removing brake caliper assembly 7 5 Master cylinder overview 7 9 ...

Page 6: ...ons 13 2 Basic electrical troubleshooting 13 4 Voltage drop testing 13 7 Testing fuse 13 8 Wire schematic 13 9 Battery pack 13 10 Battery pack testing 13 11 Battery pack replacement 13 12 Fuse 13 13 Relay 13 17 Linear throttle potentiometer 13 20 Throttle cable 13 27 Throttle cable adjustment 13 29 Motor controller 13 32 Interconnect board 13 36 Switch box 13 44 Switch box testing 13 45 Remote shu...

Page 7: ...lve single cylinder inclined by 25 Cooling system forced air Starting system recoil optional electric start Spark plug bpr6es ngk w20epr u nd Lubrication system splash DRIVE TRAIN Clutch type centrifugal wet multi disc Clutch engagement lock engagement 1800 rpm lock 2200rpm Final drive system 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings phosphate dipped and electrostatic pow...

Page 8: ...lve single cylinder inclined by 25 Cooling system forced air Starting system recoil optional electric start Spark plug bpr6es ngk w20epr u nd Lubrication system splash DRIVE TRAIN Clutch type centrifugal wet multi disc Clutch engagement lock engagement 1800 rpm lock 2200rpm Final drive system 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings phosphate dipped and electrostatic pow...

Page 9: ... Speed controller sevcon Power 48 vdc qty 4 12 volts blue yellow optima battery 870 amps cold cranking amps per battery 120 amps reserve capacity per battery DRIVE TRAIN Clutch type direct drive Forward reverse yes High low optional yes with Kartrol Final drive system 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings Phosphate dipped and electrostatic powder coated 425 f Steering...

Page 10: ...con Speed controller sevcon Power 48 vdc qty 4 12 volts blue yellow optima battery 870 amps cold cranking amps per battery 120 amps reserve capacity per battery DRIVE TRAIN Clutch type direct drive Forward reverse yes High low optional yes with Kartrol Final drive system 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings phosphate dipped and electrostatic powder coated 425 f Steer...

Page 11: ... forced air Starting system recoil optional electric start Spark plug bpr6es ngk w20epr u nd Lubrication system splash DRIVE TRAIN Clutch type centrifugal wet multi disc Clutch engagement lock engagement 1800 rpm lock 2200rpm Final Drive System 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings phosphate dipped and electrostatic powder coated 425 f Steering angle 24 to either side...

Page 12: ...con Speed controller Sevcon Power 24 vdc qty 2 12 volts Trojan T 31 AGM 720 amps cold cranking amps per battery 100 amps reserve capacity per battery DRIVE TRAIN Clutch type direct drive Forward reverse yes High low optional yes with Kartrol Final drive system 520 X ring hd chain cog belt FRAME Type unitized monocoque Coatings phosphate dipped and electrostatic powder coated 425 f Steering angle 2...

Page 13: ...and on but the key is to maintain the equipment rather than react to failures Utilize the maintenance logs to track problems with your fleet Log kart numbers and parts replaced to track other issues that may be causing a particular kart s parts to be damaged more quickly than they should As an example you may have a kart that continually fouls a spark plug If you do not track that type of usage th...

Page 14: ...ront end alignment weekly or every 100 hrs 11 DRIVE BELTS Inspect the drive belts for proper deflection alignment and tension Twisted or cracked belts should be replaced WARNING Too much tension shortens belt and bearing life 12 PULLEYS SPROCKETS Inspect for damage and proper alignment Replace as needed 13 WHEEL LUG NUTS STUDS Check for loose wheel lug nuts and studs daily and torque to 35 ft lbs ...

Page 15: ...Adjust When necessary Replace When necessary 12 Pulleys Check Daily Adjust When necessary Replace When necessary 13 Wheel lug nuts studs Check Daily Torque wheels 35 ft lbs When replaced Replace When damaged 14 All nuts bolts Check Daily Torque Yearly Replace When damaged 15 Hydraulic brakes Check pad wear Check fluid level Fluid change Yearly 16 Seatbelts Check Daily Replace When damaged 17 Start...

Page 16: ...r wet conditions 10 STEERING Check for smooth and precise movement from full turn left to full turn right Inspect the tie rods and rod ends for loosening damage or wear To prevent uneven tire wear and a poor handling kart check the front end alignment weekly or every 100 hrs 11 DRIVE BELTS Inspect drive belts for proper deflection alignment and tension Twisted or cracked belts should be replaced W...

Page 17: ...gs Check Grease Yearly 10 Steering Check Daily 11 Drive belts Check Daily Adjust When necessary Replace When necessary 12 Pulleys Check Daily Adjust When necessary Replace When necessary 13 Wheel lug nuts studs Check Daily Torque wheels 35 ft lbs When replaced Replace When damaged 14 All nuts bolts Check Daily Torque Yearly Replace When damaged 15 Hydraulic brakes Check pad wear Check fluid level ...

Page 18: ...0 12 Go kart ID ____________________ Date _____ ______ _______ Hour meter reading Maintenance performed Parts used Serviced by Finish date Maintenance Record Make extra copies for future use ...

Page 19: ... roll bar steering wheel and steering post pads for damage replace as needed 6 ACCELERATOR check for smooth operation and full return when released 7 BRAKES check pedal travel check for proper action during test drive 8 STEERING check for smooth action visually check front wheel alignment 9 REMOTE SHUT OFF SYSTEM if equipped verify proper operation per manufacturer s recommendations 10 ENGINE REDU...

Page 20: ...mooth action visually check front wheel alignment 8 REMOTE SHUT OFF SYSTEM if equipped verify proper operation per manufacturer s recommendations 9 BATTERIES check battery voltage if low inspect load test battery 10 TEST GO KART drive kart to verify proper operation 11 ROLL BAR check for any looseness in roll bar system 12 CHARGING SYSTEM check SB175 plug for deep grooving or signs of arcing 2 che...

Page 21: ...e track surface is clean clear of any safety hazards 6 RIDE BRIEFING SYSTEM verify ride message works 7 SHUT DOWN SYSTEM if equipped check that the shut down pit loops are functioning if equipped 8 PIT AREA check that the pit area is clean clear of any safety hazards ensure all gates are latched secure 9 QUEUE LINE check that the queue line area is clean clear of any safety hazards ensure all gate...

Page 22: ...0 16 Go kart ID Date Describe problem Maintenance performed Serviced by Finish date NON SCHEDULED MAINTENANCE RECORD Make extra copies for future use ...

Page 23: ...c 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 Make extra copies for future use ...

Page 24: ...minants Clean and drain carburetor float bowl before storing to prevent deposits caused by fuel that evaporates over time CLEANING AND WAXING Storing a dirty go kart can lead to corrosion because dirt retains moisture Thoroughly wash and dry go kart Polish and wax all painted gelcoat surfaces Spray the unpainted castings such as engine reduction gear case spindles and related hardware with a corro...

Page 25: ...he brake fluid as contaminated fluid will cause corrosion and deterioration of the hydraulic brake system Fluid should be light amber in color If it is dark or cloudy the system must be flushed and fluid renewed CLEANING AND WAXING Storing a dirty go kart can lead to corrosion because dirt retains moisture Thoroughly wash and dry go kart Polish and wax all painted gelcoat surfaces Spray the unpain...

Page 26: ...pay for new replacement items The most common reason for a customer to not receive credit is failure to return the warranty item to J J If we do not receive the item we cannot get credit from our vendors and therefore cannot issue credit to the customer RETURNED GOODS POLICY No merchandise may be returned nor any account adjustments made unless authorized by J J Amusements Inc A Return Merchandise...

Page 27: ...ance with this paragraph This warranty does not extend to products accessories or parts purchased for use outside of the United States or Canada Specific Exclusions Normal wear and tear items such as tires brake pads brake rotors seat belts pads spark plugs final drive belts final drive pulleys brake fluid and fuel filters Appearance related damage including but not limited to scratches nicks dent...

Page 28: ...s per season During very cold damp weather more frequent application may be required FINISH DAMAGE Any stone chips fractures or deep scratches in the finish should be repaired right away Minor chips and scratches can be repaired with materials available from almost any auto parts store Larger areas of finish damage can be corrected by a local body and paint shop CHEMICAL SPOTTING SUN FADING Some w...

Page 29: ...ruck certified Each go kart is mounted to the shipping rack with two brackets The brackets are mounted on each side of the kart in a diagonal pattern Remove each bracket before the go karts are unloaded from the shipping rack Remove the top kart first Always remove from the rear of the kart engine side Run the forks between the cross bar and frame of the kart NOTE FOR ELECTRIC GO KARTS Take specia...

Page 30: ...e from the kart below Repeat the same steps for the remaning karts NOTE When removing the middle and bottom karts make sure to keep clearance from the steering wheel and the cross bar Go karts are shipped with the roll bars detached to allow karts to fit on the shipping racks 3 high Carefully unwrap the roll bar and install See page 5 2 NOTE Shipping racks are included with shipping and handling a...

Page 31: ...0 25 TIP A great use for the shipping racks is to turn them into storage racks for your maintenance facity ...

Page 32: ...stick clean Insert the dipstick into the filler neck but do not screw in Remove the cap dipstick and read the indicated oil level If the level is low fill to the upper level mark with the same oil recommended for the engine Do not overfill see diagram WARNING Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not sm...

Page 33: ...the tank to prevent spillage due to the sloshing of fuel Use unleaded gasoline with a pump octane rating of 86 or higher The Honda engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or a premixed oil gasoline mixture Avoid getting dirt or water in the fuel tank ...

Page 34: ...TO SPILL FUEL WHEN REFUELING SPILLED FUEL OR FUEL VAPOR MAY IGNITE IF ANY FUEL IS SPILLED MAKE SURE THE AREA IS DRY BEFORE STARTING THE ENGINE NEVER REFUEL WHEN RIDERS ARE PRESENT J J Amusements Inc 1 800 854 3140 DANGER Hair longer than shoulder length must be secured above shoulder Keep arms and legs in kart at all times BRAKE GAS DO NOT REMOVE THIS DECAL WARNING The Engine Exhaust from this pro...

Page 35: ...ion go kart tire by working with a large manufacturer and buying in bulk The J J Bigfoot tire was introduced to provide a new tire with extra thick tread while maintaining overall diameter in order to accomodate gearing and clearances for existing go karts TUBES J J was the first to offer tire and tube combo packs with a tube specific to the Bigfoot tire it made sense to do so J J moved the angle ...

Page 36: ...or over or under other karts When replacing tires all four tires should be replaced at one time CAN I MIX AND MATCH TIRES Ideally tires should be of the same type and design have the same tread depth and be inflated to the correct pressure Frequent tire questions WHAT IS THE PROPER INFLATION FOR MY BIGFOOT TIRES J J recommends 40 50psi 276 345kPa WHAT DOES THE DIRECTIONAL ARROW ON THE SIDE OF THE ...

Page 37: ...vehicles such as trucks trailers and buses with hub piloted wheel systems They are used only on J J serrated bead lock rims 1 50 0189 The system is essentially a double nut with ramps on two mating halves When the inner hex of the nut tries to loosen it works against the incline of the outer hex This is a simple and very posi tive way to help insure that lug nuts will not work loose To install the...

Page 38: ... jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Proper installation of socket over both halves of Disc Lock nut Improper fitting of socket over the nut causes the nut to come apart Two halves can come apart but often can be reassembled Disc Lock nut showing that both halves can move independently of each other Lug Nut 3 8 24 Z Lug Nut Post 09 DISC LOCK 1 50 0189 ...

Page 39: ...e go kart due to jack failure Avoid the possibility of injury NEVER get under a go kart when it is supported only by a jack Using a 15mm deep thin wall socket for 3 8 disc lock lug nuts remove the four lug nuts USE J J SPECIAL TOOL 1 60 A0311 Some older model go karts may not have the updated hub installed and will need to use a special 15mm socket designed to fit within the tight confines of the ...

Page 40: ... Remove the rim half from the valve stem side of the tire J J part 3 96 A0001 Bead Breaker recommended Remove the tube from the tire so that is does not get pinched Flip the tire over and press out the other rim half Make sure to deflate the tire completely either by removing the valve core or depressing the valve core until all the air is released DANGER Attempting to disassemble an inflated tire...

Page 41: ... rim half bolts in the magnetic sockets of the tire assembly tool J J Part 1 20 T0001 Install the rim half valve stem rim half into the tire assembly tool and down over the bolts Place the tire on the rim half insert the tube into the tire with the valve stem facing down through the valve stem hole of the rim half This is the J J tire assembly tool 1 20 T0001 Using this device to change tires is a...

Page 42: ...rim half onto the tool Screw down the self centering retaining nut as far as possible by hand Pull on the lever on the bottom of the tool to squeeze the rim halves together Install the lock washers and nuts and tighten Remove the complete wheel from the tool you may need to tap it out with a rubber mallet DANGER Never inflate the tire while it is on the assembly tool Retaining nut Rim Assy 5 4 Lug...

Page 43: ...for easy loading The lift is a solid steel fabrication and is powered by a pneumatic cylinder from your air source 90 100 psi It can be used with or without accessories W 24 x L 80 CE Approved MADE IN USA Easy all around access for vehicle repair Finish your work quickly and comfortably Change tires Work on brakes Tune engines Change oil Clean TIRE TUBE COMBO PACKAGES AND WHEELS AVAILABLE If you v...

Page 44: ... worn down past the last line WHEEL REPLACEMENT Replace any wheel that is bent cracked or badly rusted If the wheel nuts loosen frequently the wheel bolts and nuts should be replaced Elongated stud holes can cause damage to hubs Each new wheel should have the same diameter width offset and mount position as the one it replaces If you need to replace any of your wheels wheel bolts or wheel nuts rep...

Page 45: ... weight distribution a go kart can appear to operate normally Watch for the bead being not quite seated on the rim or the valve stem being loose at an odd angle or missing FRONT TIRE WEAR If the steering wheel is centered both tires should be pointing straight ahead If one or both tires are pointed at odd angles the tie rods are bent The tires will show scrubbing as well Due to the nature of your ...

Page 46: ... SL72 739 Slick 4 Ply 3 5 W x 10 8 od 16 50 14 99 26 25 21 90 43 00 12 99 1 20 0054 TIRES 738 Tire 4 10 3 50 4 SL72 738HD 15 80 TUBES 1 20 0048 1 20 0038 1 20 0045 00780 M 1 20 0027 00782 Tube 10 x 4 50 5 JS87 Tube 11 x 6 00 5 JS87 Tube 11 x 7 10 5 JS87 Tube 3 40 3 00 5 Bent Stem 45 Degree Middle Tube 15 x 6 00 6 Used for 15 x 6 00 6 Tire JS87 Tube 4 10 3 50 6 Bent Stem JS87 4 99 4 99 4 99 3 80 4 ...

Page 47: ...kshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FRAME OVERVIEW Frequent questions page 2 1 Go kart frames are robotically welded then cleaned and powder coated FREQUENT FRAME QUESTIONS Q CAN I WELD THE FRAME A Due to safety concerns it is advisable to contact J J prior to doing any work of this type ...

Page 48: ...al replacement page 2 5 FAQ s Q CAN THE BUMPER BE REPAIRED OR WELDED A No The bumper is made of a special spring steel It can not be welded or modified J J offers a limited lifetime warranty on its steel bumpers attempting to modify the bumpers will void the warranty Note Abrasive wear can result in thinning the bumper Breakage after such wear is not covered under warranty RUBBER LOGS Special form...

Page 49: ...er it is common for the hardware to get damaged Replace any hardware as necessary Bent D rubber plates can be straightened and reused as long as the nut cannot pull through the hole in the plate Inspect D rubber for cracks and damage replace as necessary To install the bumper hold up the front section of the side bumper curve goes towards front of kart and match the first one in the middle with th...

Page 50: ...er plate Fasten the 5 16 flat washer and the 5 16 nylock nut to the bolt Install all bolt plates nuts loosely before attempting to tighten any Tighten all bolts evenly Using a rubber hammer make sure the D rubber is level with the frame and rail Ride timers traffic lights and Kartrol remote go kart shutdown systems are available to help keep your track operation running smoothly No mount holes Out...

Page 51: ...rubbers two corner B and two center C D rubbers The corner D rubbers are frame mounted only NERF BAR REMOVAL AND INSTALLATION Loosen the two center D rubber rail bolts Remove the two center D rubber frame bolts Remove the two corner D rubbers NOTE The two corner D rubbers are frame mounted only they do not mount to the bumper and there is no hole in the bumper at that location A A C B B PROTECT YO...

Page 52: ... bar by pulling it out of the two center D rubbers WARNING DECALS WARNING Go karts have rotating parts Hair longer than shoulder length must be secured above shoulder Serious injury or death could occur DO NOT REMOVE THIS DECAL 1 60 0288 1 60 0020 EAGLE DANGER Hair longer than shoulder length must be secured above shoulder Keep arms and legs in kart at all times BRAKE GAS DO NOT REMOVE THIS DECAL ...

Page 53: ...information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FRONT HUBS SPINDLES Frequent questions page 3 2 Front hub removal page 3 3 Spindle page 3 4 Tapered spindle roller bearings page 3 5 Spindle dissassembly page 3 8 Spindle assembly page 3 9 ...

Page 54: ...en the bearings are replaced it is a good idea to also replace the inner spacer that goes between them If this spacer becomes worn the bearings receive too much lateral preload when the hub is tightened to the spindle The excess preload creates drag and causes premature bearing failure Front hubs and spindles J J pioneered the billet machined hubs for concession go karts Easily replaced lug studs ...

Page 55: ...this indicates that it needs to be replaced Also inspect the spacer between the bearings it should be snug with little play between the two inner bearing races The bearings for the hub of the radius cut spindle are sealed If the seal is damaged the bearing should be replaced FRONT HUBS The front hubs are billet machined from solid stock The lug studs are 3 8 fine thread allen head cap screws that ...

Page 56: ...freely and smoothly in the yoke Any free play or roughness means the spindle should be broken down further and the bearing cups inspected NOTE See the Steering Adjustment section page 4 6 for complete adjustment and installation SPINDLE Tapered spindle shown Before installing the hub put a small amount of anti seize compound on the spindle Slide the hub back onto the spindle install a 3 4 inch nut...

Page 57: ...LATES TM Remove the wheel from the hub Gently tap the dust cap off of the hub to expose the end of the spindle Slide the hub off of the spindle be careful not to drop the outer bearing as the hub comes off Remove the cotter pin from the spindle The castle nut and thrust washers can now come off TAPERED SPINDLE ROLLER BEARINGS CORROSION BLOCK HIGH PERFORMANCE GREASE 16 oz Tub 99109 14oz Cartridge 9...

Page 58: ...rease from the wheel bearings as well as the hub assembly NOTE Do not use solvent to clean the bearings Inspect the wheel bearings and the bearing races for pitting or excess wear and replace as needed Put a film of grease on both wheel bearing races and on the spindle shaft Pack the wheel bearings with wheel bearing grease either by hand or with a wheel bearing packing tool BEAD BREAKER HD A QUIC...

Page 59: ...nd to aid retention when it sets up Insert the newly packed bearing into the appropriate race Install the front wheel bearing thrust washer and castle nut Torque the castle nut to 15 ft lbs to seat the wheel bearings Then loosen the castle nut to the first available cross hole that the cotter pin will push through The hub should rotate freely If the hub does not turn smoothly and freely at this po...

Page 60: ...socket works well Using a suitable tool press the top bearing cup until the bottom one falls out Remove the spindle from the press the u joint can be twisted and removed from the yoke The other bearing cup can now be removed Remove the spindle from the press the u joint can be twisted and removed from the yoke The other bearing cup can now be removed NOTE Make sure all needle bearings are in the b...

Page 61: ...ment caps Replace the bearing cap by inserting it partially into the yoke Begin installing the universal joint into the cap Partially insert the opposing cap Line up the universal joint and push both caps into place using a press vice or special U joint tool Press each cap into the universal joint just enough so that the clips can be installed After installing make sure spindle moves freely Add 2 ...

Page 62: ...AVAILABILITY ALL PRICES ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE Part Description Price 7 7RRO KHHO VVHPEO LWK 0DJQHWLF 6RFNHWV 800 854 3140 503 304 8899 www FunPartsXpress com LYLVLRQ RI PXVHPHQWV QF Wheel Assembly Tool This Wheel Assembly Tool is designed for assembly and disassembly of your tire rim assemblies It was designed just like the one J J Amusements uses to put together thousands of ...

Page 63: ...g videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM STEERING SYSTEM Steering system adjustments Overview page 4 1 Caster page 4 3 Toe in page 4 6 Tie rods ends page 4 8 Ackerman effect page 4 10 Steering shaft cover page 4 11 Steering wheel page 4 12 Steering column pad page 4 13 ...

Page 64: ...ster Positive caster provides the directional stability in your go kart Too much positive caster will make the steering effort difficult Power steering will allow you to run more positive caster Negative caster requires less steering effort but can cause the car to wander down the straightaway J J go karts only provide for positive caster Karts with single wheel drive are set stock at the second h...

Page 65: ... straightened The frame has four small index holes on the spindle mount Each hole represents a different setting The first hole closest to the front of the kart represents 0 degrees and the fourth hole farthest from the front of the kart represents approximately 14 degrees Factory caster settings Single wheel drive karts 4 7 degrees second hole Two wheel drive karts 9 2 degrees third hole STEERING...

Page 66: ...karts Our legendary Bigfoot tire with its extra thick tread will help keep your karts on track generating the revenue Bigfoot tires and tubes ship from either our west coast or east coast location so they get to you fast 007880combo Tire 12 x 4 00 5 SL72 Bigfoot COMBO W Tube M ark here Spindles installed from the factory have been marked to make the correct caster adjustments If the mark is not vi...

Page 67: ...alls of the tires A tape is placed on the inside front of the tire as near to the rim as possible as close to center horizontal as possible and then measured in the same location on the front edge of the other front tire Remember to measure from the same locations each time you check the toe Now check the rear side of the front tires as close to the center rear of the tires as possible If this num...

Page 68: ... center position before toe can be set correctly Now from the front of the spindle facing the front of the go kart measure the distance from the frame rail to the straight edge Subtract the measurement reading from the rear of the spindle to the measurement reading received from the front of the spindle this measurement equals the toe in Standard tow in is 0 1 8 with a service limit of 1 4 of tota...

Page 69: ...ecifications Tighten the lock nuts and then recheck measurements Make sure that when the wheels are straight the steering wheel is in the center position Cable Lubricator 00122 Cable Lube 3 60 0029 Cable lube provides the smoothest operation and longest cable life Our special blend of Red Line synthetic lubricant and rust inhibitors keep your cables working smoothly in any weather conditions from ...

Page 70: ... rods can be bent during heavy impacts Bent tie rods can be removed straightened and re installed The tie rod ends can be removed by holding them with an open end wrench or appropriate adjustable wrench on the machined flat then loosening the locknut holding it in place one rod end is right hand threaded the other is left hand threaded Reinstallation Install the tie rod assembly by reversing the p...

Page 71: ... toe in it is important that the rod ends be positioned properly The rod ends should be perpendicular to their mounting surface at rest When the kart is steered the tie rods twist If the tie rod ends are installed and are tilted they may reach their working limit as they pivot when the kart is steered This can create binding in the steering system Note Any excess clearance slop in a rod end will a...

Page 72: ...ently have by using a set of turn plates Typically Ackerman is measured by turning the right front tire 10 degrees to the left If you have Ackerman the left front will travel further than the right front A typical amount would be three degrees in 10 degrees of steering To simplify moving the right front from zero through 10 degrees of steering will cause the left front to move 13 degrees in this s...

Page 73: ...ng shaft for straightness Clean and inspect the steering bushings for damage and wear bushings should fit snugly to the shaft while still al lowing the shaft to pivot with only slight resistance Check that the bushing sleeves are no shorter than the two bushing halves If the bushing sleeves are shorter than the steering bushings it will cause the steering shaft to bind Before installing the steeri...

Page 74: ... steering wheel and pad for damage Replace as needed SAFETY ITEM All J J karts use a pad on the steering wheel column to help reduce the possibility of injury to the rider s in the event of a collision These pads should be in place and in good condition at all times Installation is the reverse of removal NOTE Your go kart may be equipped with a butterfly steering wheel Removal installation procedu...

Page 75: ...n pad Installation is performed in the reverse order of removal NOTE When installing the steering pad be careful not to over tighten the nut CAUTION If any part of the pad is torn or damaged enough to expose the steering column the pad should be replaced STEERING COLUMN PAD SAFETY ITEM All J J karts use a pad on the steering wheel column to help reduce possibility of injury to the rider s in the e...

Page 76: ...e unit Every Gas Caddy includes a ground wire clip Be Safe Sleep Nights Get a Gas Caddy J J 00223 Change oil in the pits Change oil in your whole fleet in 30 minutes Protect your engines Save time and eliminate the hassles of changing oil in your go kart engines These oil drain kits replace the drain plugs on the motor case and clutch Just use the quick connector to attach an oil extractor and or ...

Page 77: ...5 6 Seatbelts page 5 7 Cleaning seatbelts page 5 9 FAQs Q CAN I WELD THE ROLL BAR SOLIDLY TO THE FRAME A Yes using proper safety and welding techniques in addition to mounting bolts the roll bar of the type shown above can be welded to frame The roll bar assembly fits tube inside tube receptacles on the go kart frame The roll bar is then bolted and cross bolted to firmly attach it to the frame Add...

Page 78: ...s NOTE The holes on the back side of the receiver are larger to allow nuts to draw directly against the roll bar thus cinching it tight to the receiver 1 4 bolts attach the roll bar to the seat back NOTE A center bolt is not used in this application NOTE Keep the seam side of the pad away from the rider and towards the outside of the go kart Seatbelt pads are captured underneath the seatbelt brack...

Page 79: ...allow for body removal A clipped hitch pin secures the roll bar A locking set screw holds the roll bar in place and prevents it from rattling Acorn nuts are used to help reduce the possibility of injury from exposed threads NOTE Make sure acorn nuts are installed and the seatbelt pads are secured in their proper position with the seam away from the rider Seatbelt pads are captured underneath the s...

Page 80: ...ough the plywood Any pad with damage that exposes the underlying part should be replaced Torn pads that do not completely cover parts such as the roll bar back panel or steering column can cause injury All pads should be inspected daily for damage Karts should always be operated with all pads and safety covers in place CAUTION The seat pad takes high abuse from loading and un loading riders Holes ...

Page 81: ...maged pads that expose any part of the back panel assembly The Sidewinder and Sidewinder Double seat back pads are glued onto the body there are no bolts holding them to the frame or body When replacing make sure all of the pad is removed the body must be free of old adhesive and debris Lightly sand the body surface to remove old glue Wipe and clean the surface Apply contact adhesive to the body a...

Page 82: ... com 503 304 8899 ENDURANCE CLUTCH PLATES TM Sometimes pads get small tears or rips in the outer skin If the pad has one of these you can easily repair it with Rapid Patch J J 1 60 0071 Clean the area to be patched with mild soap and water rinse and dry thoroughly Apply Rapid Patch to the tear and allow it to dry for 15 minutes Simply sand the patch down flush with the pad FIXING PADS ...

Page 83: ...atpan of the chassis Be sure to orient the belt brackets as shown The photo below shows the reinforcment plate used on the bottom side of the chassis seatbelt mounting point Inspect all seatbelt pads frequently frayed worn or split pads must be replaced The pads are held in place with the smooth side toward the rider s neck by capturing the pad end under the seatbelt bracket when it is bolted to t...

Page 84: ...stead of the chassis NOTE Orient the seatbelt mounting tabs as shown The backside of the lap belt attachment utilizes a fender style washer large flat to keep the bolt from pulling through the body When installing new seatbelt pads it s easiest to use a stiff wire or coat hanger to pull the belt through the pad Just bend a small hook in the stiff wire to grab the hole in the seltbelt mounting brac...

Page 85: ...olution when cleaning the seatbelts CAUTION No chemicals should be used to clean the seatbelts or their mechanism We carry many of the tools you ll need to keep your facility looking great THE FPX J J FORCE BLOWER IS A GREAT TOOL TO HAVE AROUND YOUR FACILITY EASILLY BLOWS WATER DEBRIS OFF YOUR TRACK PARKING LOT COURTYARD OR OTHER AREAS A CLEAN FACILITY KEEPS THOSE CUSTOMERS COMING BACK FPX force b...

Page 86: ...s 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 CONTACT J J FOR MORE INFO ABOUT THE XPRESS TRACK PRODUCTS ...

Page 87: ...99 ENDURANCE CLUTCH PLATES TM AXLE AXLE COVER DRIVE SYSTEM COMPONENTS Overview page 6 2 Axle cover page 6 3 Drive cover page 6 4 Drive belt page 6 6 Drive hub page 6 11 Drive pulley page 6 12 Floater hub page 6 14 Axle bearing overview page 6 16 Bearings page 6 17 Axle single drive page 6 19 Axle two wheel drive page 6 26 Drive sprocket spreadsheet page 6 27 SINGLE DRIVE AXLE LIVE AXLE 2 wheel dri...

Page 88: ...ng access for maintenance The vacuum formed system is made from high impact TPO plastic for long life It is purposely rubber mounted to the frame to avoid cracking from vibration FREQUENT QUESTIONS Q CAN I REMOVE THE COVER AND OPERATE THE GO KARTS A Go karts should not be operated without the factory installed guards covers in place Q CAN I DRILL HOLES OR MAKE CUT OUTS IN THE COVER A No holes and ...

Page 89: ... 8899 ENDURANCE CLUTCH PLATES TM Remove the engine see page 8 1 Remove the axle cover shoulder bolts Remove the wheel and fender Lift the rear of the axle cover and pull the cover away from both the center and wheel clips Remover the axle cover AXLE COVER REMOVAL Lift Pull ALWAYS MAKE SURE ALL SAFETY RELATED DECALS ARE LEGIBLE REPLACE IF NECESSARY WARNING DECAL TO PREVENT INJURY OR DEATH 1 60 0388...

Page 90: ... 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive wheel Remove the lower wing support bolts Move the wing support up and tighten the upper wing support bolt to hold it out of the way DRIVE COVER REMOVAL Wing support SIMPLE EASY OIL EXTRACTION JUST INSERT THE SUCTION TUBE INTO THE CRANKCASE FILLER NECK AND GIVE IT A FEW PUMPS TO START THE SUCTION Hand operated oil extractor 5958434 ...

Page 91: ...usements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive cover Allen bolts Pull the drive cover rubber flap away from engine Pull the drive cover from the front support clip D r i v e c o v e r Pull BLEED YOUR BRAKES WITH EASE EASY TO USE POWER BLEEDER SIMPLY WORKS GREAT REDUCES PEDAL MUSH BY FORCING ALL THE AIR OUT OF THE SYSTEM Power brake bleeder tool 3 96 0032 ...

Page 92: ...ES TM NOTE Before engine can be moved or removed the grabber plate must be loosened see page 8 3 Using a 9 16 offset ratcheting box wrench loosen the engine mount lock down bolts DRIVE BELT REPLACEMENT Remove the drive cover Twist the drive cover down and away from the engine GO KART ENGINE LONG BLOCKS Save time and money with these easy to change long blocks for GX160 GX200 and GX270 engines GX16...

Page 93: ...djust the drive belt tension by turning the motor adjusting bolt clockwise to loosen belt tension and counterclockwise to tighten belt tension by using a 3 4 socket with an extension NOTE Make sure the drive belt is tensioned to prevent jumping of the teeth under the most severe load conditions that the drive belt will encounter during operation Tighten the engine mount lock down bolts and make su...

Page 94: ...r website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM CHAIN DRIVE REMOVAL KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY WITH CABLE LIFE LUBRICANT 00122 Cable lube tool 3 60 0029 Cable Life lubricant ...

Page 95: ... SPROCKET REPLACEMENT The tension adjustment procedure is the same as for the cog belt 1 2 of deflection up or down is the correct tension Install the drive chain on the top and bottom pulley Turn the axle to guide the drive chain onto the sprocket Loosen the engine mount and slide the engine all the way forward procedure is the same as the drive belt see page 6 7 Remove the drive chain REPLACEMEN...

Page 96: ...TM If adjustment is needed use a 1 4 Allen wrench and loosen the two 5 16 x 1 1 2 Allen bolts on the drive hub Remove the six nuts with a 1 4 rachet 7 16 short socket on the back side of lower sprocket assy Remove the drive chain sprocket Air lift 24 x 80 1031 GO KART AIR OPERATED LIFT 1000lb capacity with a 24 x80 deck that raises to a working height of 30 makes this an ideal and valuable additio...

Page 97: ... two set screws Remove the drive hub from the axle If you need a puller use J J 1 60 A1000 The axle should be straight and free of burrs Apply a dab of anti seize to the axle coat the area where the hub will cover then slide the drive hub onto the axle Install axle lock washer nut and torque to 50 ft lbs Apply one drop of Loctite Blue to each set screw and install them into the drive hub torque to...

Page 98: ...ghtly tap it in This will loosen the drive hub and allow for easy removal In some cases it may be necessary to carefully use a propane torch to heat the hub to aid removal WARNING Always use proper safety clothing and techniques when using open flame torches Follow the manufacturer s guidelines for safe operation Keep flames away from fuel sources and combustible materials Use a dead blow or rubbe...

Page 99: ... hub and or the key stock must be replaced Install the drive hub in the reverse order of removal Before tightening the two Allen bolts the drive hub will need to be aligned with the engine driven pulley Loosen the 8 bolts holding the sprocket to ensure proper clamping to the axle A straight edge can be used to aid in belt alignment during reassembly Place a straight edge along the bottom pulley an...

Page 100: ...loater hub nut and recessed washer NOTE The special recessed washer is cut out on one side this recess always goes toward and contacts the bearing inner race This allows the entire floater hub to be tightened through the bearing races and inner spacer and against the axle shoulder to allow the hub to spin freely thus the name tight race design Remove the floater hub assembly FLOATER HUB REMOVAL Us...

Page 101: ...03 304 8899 ENDURANCE CLUTCH PLATES TM FLOATER HUB INSTALLATION Apply anti seize to the axle Install the floater hub Install the recessed washer with the recess toward the bearing Torque the floater hub to 45 ft lbs USE THE RIGHT TOOL FOR THE JOB Tightening axle bearings to the correct tension is essential and can only be accomplished with the right tool Axle bearing spanner wrench 1 60 0193 ...

Page 102: ...ing the jam nut and indexed by the inner tab to the tapered sleeve The jam nut is beveled on the side facing the lock ring Using the spanner wrench J J part 1 60 0193 tighten the jam nut which draws the tapered sleeve against the tapered inner race and collapses the sleeve tightly to the axle s shaft over its full contact area It is a good idea to tighten the lock nut snugly then tap the sleeve on...

Page 103: ... with a spanner wrench J J 1 60 0193 To remove the bearing you must first break loose the bearing sleeve assembly Use a brass hammer and J J bearing removal tool 3 96 0104 Place the tool over the axle and against the bearing sleeve Tap the tool with the brass hammer to separate tap lightly as it s easy to damage threads NOTE Be careful not to hit the axle with the hammer A brass hammer is best for...

Page 104: ...s www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM The bearing assembly can be removed as a whole at this time or you can remove the jam nut and lock ring and remove all pieces separately Remove the bearing from the tapered sleeve remove the sleeve from the axle Jam nut Lock ring SLEEVE LOCK AXLE BEARINGS Axle bearing 1 1 4 sleeve lock ring style 1 20 0080 ...

Page 105: ...ations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive cover page 6 4 drive pulley page 6 12 and engine page 8 1 Remove the axle cover page 6 3 and brake caliper assembly page 7 5 Remove the drive hub pulley hub and floater hub SINGLE DRIVE AXLE REMOVAL Million mile filter SP2748 for GX240 270 SP2747 for GX140 160 200 ...

Page 106: ...this can be done without disassembling the caliper assembly Unbolt the drive axle bearing and remove the cog pulley skid guard Unbolt the center axle bearing and lift the axle out of frame MAKE QUICK WORK OF OIL CHANGES Using our oil extractor and dispenser complete oil change takes less than a minute with no need to remove the kart body or dipsticks change oil in 30 karts in 1 hour Both are desig...

Page 107: ...sely install the axle bearing bolts NOTE Always set and tighten the center axle bearing last Make sure the floater hub is slid all the way onto the axle Make sure the recessed washer is installed with the recesses facing the hub Install a self locking axle nut and tighten Torque the floater hub to 45 ft lbs SINGLE DRIVE AXLE INSTALLATION KARTROL EXE Remote engine motor control We are the largest d...

Page 108: ... a C clamp lightly snug the floater hub disc brake rotor with the block sandwiched to frame This will maintain this critical 2 distance while the drive side axle bearing is set NOTE If the axle has shifted the calipers will be out of alignment This will cause the brake pads to drag and the axle will not turn freely Lock the axle in place using a 1 1 4 open ended wrench Place the wrench on a portio...

Page 109: ...e bearing nut After the bearing is tight to the axle tighten the bearing flange to the frame mounting bolts Next set and torque the floater hub axle bearing NOTE ALWAYS SET AND TORQUE THE CENTER AXLE BEARING LAST Set the drive side axle bearing to the axle The sleeve on the tapered end of the bearing needs to be set before torquing the sleeve nut To set the axle sleeve use a J J bearing set tool 3...

Page 110: ...503 304 8899 ENDURANCE CLUTCH PLATES TM Install the brake caliper assembly see page 7 7 NOTE The floater hub brake disc needs to be in the center of the brake caliper Align the axle mounted drive brake disc with the center of the drive side brake caliper Leave the hub bolt loose for now see install Brake Caliper Assembly page 7 7 REPLACEMENT BRAKE PADS Brake pads 010820A Retainer clip 010942 ...

Page 111: ...le from shifting during side impacts Apply blue Loctite on each of the split collar Allen bolts Loosely install the split collar on the axle and slide it up against the inside of the drive bearing Evenly tighten the Allen bolts by using a 3 16 T handle Allen wrench Install the split collar on the floater side axle bearing in the same order as performed on the drive side axle bearing Rotate the axl...

Page 112: ... design forces the go kart in a straight line so steering effort is increased Note that castor settings for the front spindles are different from and specific to the axle configuration FAQ S Q THE GO KARTS ARE VERY HARD TO STEER CAN THE CASTOR BE CHANGED TO REDUCE THE STEERING EF FORT A Yes the go kart should be tuned to each specific track Move the spindles toward flat neutral steer one notch and...

Page 113: ...x 4 00 5 Bigfoot tire 36 12 inches in diameter Drive sprocket engine mounted Driven sprocket axle mounted Find a handy speed calculator at www jjamusements com technical speedcheck htm Drive sprocket tooth RPM Speed mph Gear ratio 18 3800 14 6 4 44 18 3900 15 4 44 18 4000 15 39 4 44 19 3800 15 43 4 21 19 3900 15 84 4 21 19 4000 16 24 4 21 20 3800 16 24 4 20 3900 16 67 4 20 4000 17 1 4 21 3800 17 0...

Page 114: ... Belt Drive 8M 640 36 FL Rubber 1 20 0070 Belt Drive BX32 Tri Power Used on Pacer Karts PM 2 1 20 0072 Belt Drive 8M 720 36 SYNCHROCHAIN 1 20 0073 Belt Drive 8M 800 36 SYNCHROCHAIN 1 20 0074 Belt Drive 8M 896 36 SYNCHROCHAIN 1 20 0075 Belt Drive 8M 1000 36 SYNCHROCHAIN 1 20 0076 Belt Drive 8M 720 36 GTC 1 20 0077 Belt Drive 8M 800 36 GTC 1 20 0078 Belt Drive 8M 896 36 GTC 1 20 0079 Belt Drive 8M 1...

Page 115: ...e machined piston in the caliper bore As the diagram shows fluid pressure on the piston forces the brake pads against the disc during braking operation The seal provides a small amount of rebound when the pressure is released thus the brake pads are allowed clearance to prevent dragging on the brake disc when the brakes are released CALIPER REBUILD With the brake pads removed slide a piece of 1 4 ...

Page 116: ...o brake fluid or oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with Brake Kleen or other suitable cleaner Do not use cleaners that will leave an oily residue Replace pads with new ones if they cannot be cleaned satisfactorily 9 Brake fluid quickly ruins painted surfaces any spilled fluid should be wiped up immediately 10 If any brake line fittings or bleed...

Page 117: ...liper to its mounting bracket NOTE One washer is concave and the other is convex they mate together as shown in the drawing There is always a little bit of misalignment in any mounting system of this type the washers are used to correct this With the washers installed as shown simply snug the mounting bolts do not fully tighten Make sure the axle mounted brake disc hub is loose on the axle to allo...

Page 118: ...to avoid leaking brake fluid out of the cap Before pushing the caliper pistons back clean the exposed portions of the piston this will avoid damage to the piston seals Before removing the old pad gently pry between the disc and the old pad moving the caliper piston back into the caliper This is necessary as the piston must be forced back into the brake cylinder bore to provide sufficient clearance...

Page 119: ...nch to hold the brake line and keep the brake line from twisting Loosen and remove the brake line by using a 9 16 wrench Remove the brake pad retainer clip Remove each brake pad by pulling it straight up Each brake disc has two holes to access the axle bearing mounts and the brake caliper assembly mounts line up the hole in the brake disc with the brake caliper mounting bolts REMOVING BRAKE CALIPE...

Page 120: ... PLATES TM Using an air or electric impact wrench remove the caliper mounting nuts NOTE If needed use a breaker bar to help loosen the caliper mounting nuts You will need to hold the mounting bolt arrow with a wrench while loosening the nut Remove the brake caliper assembly 011130 Caliper piston seal 010945 Caliper halves O ring 01112 Caliper Piston 01114 Bleeder valve COMPLETE BRAKE CALIPER REBUI...

Page 121: ...p the calipers line up we have used concave convex spherical washer pairs Snugly attach both of the brake caliper assembly mounting bolts NOTE It is always a good idea to loosen the axle mounted disc brake hub so that it can move on the axle during the alignment procedure tightening sequence INSTALLING BRAKE CALIPER ASSEMBLY STEEL BRAIDED BRAKE LINE AND FITTINGS AVAILABLE J J Custom Length and Pre...

Page 122: ...e to remove the wheel to pull the pin when changing brake pads Bleed the brakes using a power bleeder 3 96 0032 or the Pump Bleed procedure on page 7 17 With the washers installed as shown simply snug the mounting bolts do not fully tighten Make sure the axle mounted brake disc hub is loose on the axle to allow movement Now press and hold down the brake pedal this will bring the calipers and the a...

Page 123: ...cylinder chamber The at rest position of the master cylinder piston and seal is critical You can see that it sits just past the fluid intake and return port small hole When the brake pedal is ap plied the piston moves a small amount and leaks back some fluid gives a bit of cushion to the force applied to the brakes and keeps fluid constantly supplied to the main chamber The back seal retains the f...

Page 124: ...quipped with a master cylinder guard The fluid level can be checked with the guard attached Recommended brake fluid Automotive D O T 3 or D O T 4 NOTE The go kart is equipped with D O T 3 brake fluid at the factory Remove master cylinder guard if applicable Use a 3 16 Allen socket and remove the two brake adjuster bolts MASTER CYLINDER REMOVAL Guard 6 BUTTON REMOTE SWITCH FOR KARTOL EXE MOUNT ANYW...

Page 125: ...bbers and remove the master cylinder angle guard Disconnect the brake line from the master cylinder Remove the brake pedal page 7 13 and unbolt the two 5 16 mount bolts remove the master cylinder Brake pedal removed for clarity THE FPX J J FORCE BLOWER IS A GREAT TOOL TO HAVE AROUND YOUR FACILITY EASILY BLOWS WATER DEBRIS OFF YOUR TRACK PARKING LOT COURTYARD OR OTHER AREAS A CLEAN FACILITY KEEPS T...

Page 126: ...k this condition simply grasp the adjuster and check for free play between the pedal holes and the shoulder bolts The adjuster should have a slight movement wiggle without binding To adjust simply loosen the adjuster lock nut Now rotate the push rod in or out by turning the rod with your fingers or long nosed pliers Adjust the rod until the shoulder bolts float freely in the pedal holes Remember t...

Page 127: ...the brake pedal spring Use pliers to pull and guide the spring from the hole on the frame Unbolt the 3 8 nut and remove the 3 8 x 4 bolt Remove the brake pedal The brake pedal bronze bushings 1 60 0291 are replaceable see page 10 12 See page 7 12 for brake pedal adjustment BRAKE PEDAL REMOVAL 303 Aerospace 32 oz Protectant 3 60 0034 KEEP YOUR BODIES LOOKING NEW WITH 303 PROTECTANT Available in 32 ...

Page 128: ...ide a handy brake fluid change pump the power bleeder 3 96 0032 This pump allows one person to bleed the brake system Simply remove old brake fluid from the master cylinder with turkey baster and refill the reservoir with new fluid Do not pump excessively dirty fluid through the brake system Firmly attach the power bleeder cap to the master cylinder ensuring that the gasket seats properly Tighten ...

Page 129: ...implified Moisture is the greatest enemy of hydraulic brake systems All DOT 3 and DOT 4 systems use Poly Glycol based fluid that has a relatively high boiling point DOT 3 401 F DOT 4 446 F NOTE This is a dry boiling point meaning NO water in the system Being Poly Glycol based they do not freeze under most conditions The fluid is hydroscopic meaning it will mix with water and still perform The J J ...

Page 130: ...der push rod or brake pedal all the way down and place a finger over the master cylinder outlet fitting to seal it Let the brake pedal or the master cylinder rod return fully before removing the finger from the outlet hole Repeat the process until all the fluid coming from the outlet is bubble free Be sure to watch the fluid level in the master cylinder If the master cylinder is less than 1 3 full...

Page 131: ...p and hold Open the bleeder valve the pedal will move to the end of the stroke as the cylinder pushes the air fluid through the system DO NOT RELEASE THE PEDAL Hold the pedal all the way down until the bleeder valve is closed then release Slowly repeat the pump and bleed process until clear fluid flows out of the bleeder valve without air bubbles Monitor the fluid level in the master cylinder maki...

Page 132: ...k back Bad bearings Improper installation of rebuild parts Pedal goes to the floor after one or two laps Floater hub bearing failure Bent brake disc Axle bearing and or floater hub bearing loose or bad Loose axle Caliper piston seal leaking Pedal goes to the floor Insufficient fluid Air in the system Leak in system Axle bearing and or floater hub bearing loose or bad Loose floater hub bearing Cali...

Page 133: ...ing shoe drum brake system This simple and direct configuration provides positive braking and easy maintenance When the brake pedal is applied a rod and lever linkage transfers pressure to an eccentric cam in the backing plate that then causes the internal spring loaded shoes to expand against the cast iron lined aluminum drum This action provides the friction braking needed to stop the go kart TH...

Page 134: ...ons manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM DRUM BRAKE PARTS IDENTIFICATION A ct ua tin g ro d B r a k e d r u m F lo a te r h u b B a c k i n g p l a t e C a r r i e r C a r r i e r B r a k e h u b P i v o t A d j u s t e r Le ve r ar m USE THIS TOOL WHEN SETTING AND LOCKING DOWN THE AXLE BEARINGS Bearing Sleeve Setter 3 96 0104 ...

Page 135: ...from the go kart page 1 5 Remove the axle nut 1 1 16 and axle collar from the axle and place to the side NOTE The axle collar is recessed on the side fac ing the brake drum Slide the hub drum assembly off of the axle to ac cess the brake shoes A x l e c o l l a r A x l e n u t 1 1 1 6 KARTROL COMPONENTS Kartrol is a soild state electronic engine speed limiter used on go kart engines to reduce the ...

Page 136: ...503 304 8899 ENDURANCE CLUTCH PLATES TM Grab both brake shoes as shown and pull inwards to release the tension on the retaining springs Remove the springs and shoes Discard worn shoes and springs NOTE J J recommends always installing new springs whenever shoes are removed REPLACEMENT BRAKE SHOES WITH SPRINGS Rear brake shoe complete inc 2 springs 2 shoes F030F01 43120 0 CHANGING BRAKE SHOES ...

Page 137: ...e inside brake drum hub There are 7 16 jam nuts on the inside of the drum hub assembly Slide the hub away from the backing plate to allow access to the drum hub jam nuts Slide the drum over the hub toward the outside of the go kart to gain maximum access to the brake shoes TECH TIP Use a bungee cord to hold the brake drum in place while performing the brake shoe swap This helps to keep the drum ou...

Page 138: ...nd operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Grab both brake shoes as shown and pull inwards to release the tension on the retaining springs Remove the springs and shoes discard worn shoes SET ALL YOUR GO KARTS AT THE SAME SPEED EASILY AND QUICKLY WITH THE VORTEX SPEED GAUGE Go kart MPH gauge V3 Vortex 1 60 0206 ...

Page 139: ...ttom spring in place and move them into position around the axle Work the shoes over the bottom and top pins With the bottom spring in place it allows the shoes to hold their position while you install the top spring Attach the spring to the front shoe and pull into position on the rear shoe using a brake spring tool Once the spring has caught the hole use a large flat head screw driver to push th...

Page 140: ... hub assembly over the newly installed brake shoes until the drum stops at the backing plate Pull the drum assembly out 1 16 from the backing plate so the drum does not drag on the backing plate Re install the 5 16 Allen bolt into the hub and torque to 50 ft lbs Re install the floater hub drum assembly over the axle Secure the floater hub drum assembly with the axle collar and axle nut and torque ...

Page 141: ...4 free play between the lever barrel and adjuster nut when the lever is pushed foward Re tighten the retaining nut onto the adjuster nut Re install the engine and the axle cover Perform a test of the brake system before returning the go kart to service Re adjust the brakes as necessary to maintain optimum stopping power SAFETY The procedures performed in this manual require the removal of essentia...

Page 142: ......

Page 143: ...Honda manual Please refer the Honda service manual for exact specifications and torque values for any repairs Q HONDA SAYS TO DECARBONIZE THE COMBUSTION CHAMBER WHY A Small engines are very sensitive to carbon buildup Excess carbon will cause seemingly unrelated starting and running problems The Honda GX motors come equipped with a spring loaded trigger on the cam gear designed to crack the exhaus...

Page 144: ...ernor spring would pull the throttle shaft all the way open and keep it there A 5 HP small engine with the throttle all the way open without a governor is capable of turning around 6 000 RPM The object of the governor is to oppose the work of the governor spring and give you the safe governed speed Rarely does the governor need adjustment Most issues are the result of worn linkage rods or springs ...

Page 145: ...brate and rattle in the holes To address this issue J J has fitted a special plate with rod holes which can be adjusted in a shear action that captures the rods and holds them tight and vibration free Before installing the engine loosen the 3 8 center bolt on the grabber plate Now install the engine and align the belt tighten the engine mount bolts After the belt is aligned and the engine mount pl...

Page 146: ...ount lock down bolts and the plate Loosen the anti vibration grabber plate as described on page 8 3 Disconnect the fuel line if applicable The female fitting has a automatic shut off feature so fuel in the fuel tank will not be released Only the small amount of fuel remaining in the fuel line will be present Female end Male end Quick disconnect Replaceable Viton O ring seal 3 60 0003 Remove the st...

Page 147: ... engine motor mount assembly can now be removed by turning the belt adjusting bolt counter clockwise until the engine stops moving back Disconnect the throttle cable from the engine Disconnect the remote shut down if applicable Lift the engine motor mount assembly out of the frame CAUTION Proper lifting procedures must be followed GX ENGINE LONG BLOCKS AVAILABLE MAKES ENGINE REPLACEMENT QUICK AND ...

Page 148: ... designed a special support bracket to help bear the weight of the muffler virtually eliminating breakage Honda s original on off switch location ends up on the back side of the engine in go kart applications J J builds a laser cut and formed switch bracket to move the switch to a handy location If your go kart is equipped with an hour meter the bracket accommodates those as well The Tiny Tach 010...

Page 149: ...n including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM HOUR METER SCHEMATIC ON OFF ON OFF Hour meter 010732 Motor grounded switch Self grounding switch Coil 53020 1 60 A0203 1 60 A0094 1 60 A0202 Ground to hour meter mounting bracket Spark plug cap without Kartrol ...

Page 150: ...uable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM ON OFF Kartrol ON OFF HOUR METER SCHEMATIC Hour meter 010732 Coil 1 60 A0202 53020 1 60 A0203 1 60 A0094 Spark plug cap with Kartrol Motor grounded switch Self grounding switch ...

Page 151: ...he other is red The end with the solder lug should be fastened to the engine or metal frame by loosening a suitable bolt or screw and putting the solder lug between the bolt or screw and the frame 4 The red wire should be wrapped around the spark plug wire using about 5 to 8 turns WARNING DO NOT WRAP THE RED WIRE SO THAT IT COMES INTO DIRECT CONTACT WITH THE METAL PORTION OF THE SPARK PLUG 5 Coil ...

Page 152: ...problem There are two versions of the electric start system the most common includes an on board battery to start the engine a lighting coil to recharge the battery and a voltage regulator with a built in circuit protector The other system requires the use of a battery jump box that is plugged into the kart to power the starter The battery jump box is plugged into the karts using an Anderson style...

Page 153: ...ed to be inspected The battery is charged by the lighting coil on the engine Follow the Honda manual to test and repair the lighting coil and charge system On the electric start option that does not utilize an on board battery the starter is energized by a battery jump box not mounted to the kart The battery jump box is plugged into the Anderson style plug blue SB120 mounted to the chas sis Once t...

Page 154: ... p a r k p l u g w i r e Blac G l S p a r k p l u g w i r e A B C Battery g g White d SB 120 Red B Black Red Starter solenoid t t l nd d Spade Electric start switch box Red Red Red Red Black ENGINE SW CIRCUIT PROTECTOR OFF ON START Engine switch box C Red Black k Fuse Electric start switch Electric start switch Red B B C connector connector connector c o n n e c t o r Kartrol Antenna Fuse Ground B...

Page 155: ...te for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Pit sensor Sensor wire Receiver bodied go kart Receiver Eagle F 22 go kart mounted under wing Wire runs down wing support Motor wire KARTROL COMPONENT LAYOUT ...

Page 156: ... the threads bolt stretch or signs of damage Replace the bolt if it is in question you do not want to have the bolt snap inside the PTO shaft during reassembly While inspecting the bolt take a close look at the lock washer If it has become flat replace it as well Remove both the motor lock down bolts loosen the grabber plate bolts page 8 3 and turn the motor adjustment bolt clockwise to release th...

Page 157: ... touching the clutch case the chain and the sprockets should be replaced as a set Remove the 8mm bolt holding the weight holder and outer pressure plate to the clutch assembly Be sure to closely inspect the 8mm bolt and washer as mentioned above Replace as needed With the clutch assembly completely removed check the clutch center and sprocket basket The clutch center should slide into the basket e...

Page 158: ...The threads for the inner cover should be cleaned with an 8M 1 25 tap Closely inspect both radial ball bearings ensure smooth operation Inspect the thrust washer for any signs of wear replace as needed Install a new inner oil seal and re install the inner reduction case Remove the weight assembly from the clutch pressure plate by removing the clutch spring holder keep the holder as they are reused...

Page 159: ...8 19 Install the thrust washer Install the PTO shaft chain and basket Install the clutch center and keyway Install the friction and clutch plates NOTE At this point consider installing J J Cool Tek extended wear clutch plates Prior to installing the clutch pressure plate be sure that the inner friction disc did not slip between the clutch center and basket Install the pressure plate and torque as ...

Page 160: ... with the clutch functioning normally Under long term testing the clutch oil remained clean showing only slight discoloration even after extended periods of use Sludge build up was minimal which should result in more run time between changes You have seen nothing like it because nothing else works like it To be sure the clutch will operate properly grab the PTO shaft and rotate it to ensure that t...

Page 161: ... short end of the bar and file or carefully grind the beveled ends to a flat blunt surface Using the edge of a suitable flat file open the nail pulling slot to 0 156 This will allow the post to pass into this slot To use the keeper removal tool it is best to have the closed side of the spring to the open end of the keeper Approach the open end of keeper with the tool at 45 angle Push the spring do...

Page 162: ...with the open end of the keeper then simply roll it toward the post while maintaining downward pressure NOTE It is always a good idea to use new springs and keepers on any clutch overhaul 45 angle KEEPER INSTALLATION TIPS 45 angle OIL CHANGE KITS Oil should be changed in the engine and the clutch every 100 hours of operation for commercial go kart use that s once a week at many tracks Save time an...

Page 163: ... cleaned and free from any obstructions NOTE If the filler cap hole becomes plugged this will cause the reduction case to overheat The result of overheating will damage the friction disc metal plates and seals TECH TIP To improve venting of the reduction case the filler cap vent hole can be enlarged This may need to be done in the case of extremely hot weather conditions or in hot climates Make su...

Page 164: ... QSW 0DOH IRU HQJLQH GUDLQ LWWLQJ 2LO GUDXOLF 0DOH 6WHHO QSW LWWLQJ 2LO QSW QLSSOH EUDVV 7LUHV HQJLQHV DQG FOXWFKHV DUH D JR NDUW V ODUJHVW PDLQWHQDQFH H SHQVH 7KH ODFN RI UHJXODU RLO FKDQJHV LV WKH QXPEHU RQH UHDVRQ FOXWFKHV IDLO 2LO VKRXOG EH FKDQJHG every 100 hours IRU FRPPHUFLDO JR NDUW XVH WKDW V RQFH D ZHHN IRU PDQ WUDFNV 8VLQJ RXU RLO H WUDFWRU DQG GLVSHQVHU D FRPSOHWH RLO FKDQJH WDNHV OHVV...

Page 165: ...ank removal page 9 2 Remote fuel tank bracket removal page 9 3 Engine mounted fuel tank removal page 9 4 Fuel cap vent page 9 5 Evaporative system page 9 6 Evaporative system maintenance page 9 7 Evaporative system routing page 9 9 As more fuel is needed for longer operation between fill ups larger fuel tanks are required Mounting these larger tanks away from the engine is accomplished by developm...

Page 166: ...nect the fuel line TECH TIP The quick connect fitting in the tank has an automatic shut off but a small amount of spillage will occur Place a rag or cloth under the fuel tank quick connector to keep fuel off of the axle cover Lift one side of the fuel tank and remove GAS CADDY Tired of the 5 gallon gas can hassle Concerned about safety Insurance inspector been bugging you The Gas Caddy can be your...

Page 167: ...cluding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM First remove the remote fuel tank as shown on page 9 2 Remove the four fuel tank bracket mounting bolts Remove the fuel tank bracket REMOTE FUEL TANK BRACKET REMOVAL Quick release shutoff 1 4 npt female coupler 001840 ...

Page 168: ...ver engine vibration and heat will eventually cause the inserts to loosen and possible cracks to occur There is no repair for this condition and the fuel tank must be replaced NOTE Always use the proper length bolts when attaching the fuel tank to the engine Improper bolt length can cause irreparable damage to the fuel tank The heat shield on models equipped with 2 2 gallon fuel tanks is held in p...

Page 169: ...art of Stoddard Solvent into the test tank and install the cap to be tested Invert the tank and check for leakage NOTE Make sure sealing gasket is in good condition prior to test The cap should not leak more than one ounce of fuel over five minutes while inverted The basic integrity TEST of the fuel tank shall consist of the following procedure 1 Use the special cap provided and install it on the ...

Page 170: ...irements for this type of emissions control Starting with the fuel tank it should be noted that materials normally used for plastic fuel tanks do not meet the required permeability standards A special nylon is used on J J tanks to eliminate any fuel vapors from escaping into the atmosphere by permeation of the material The fuel lines are also unique and must meet special standards for non permeabl...

Page 171: ...all of the fittings and clamps are connected properly When performing the scheduled maintenance it is always recommended that all the major components of the go kart be inspected The emissions control system is low maintenance but should be periodically inspected for any damage or defects that could affect its performance Check the fuel and vent hoses for any cracks or abrasions Inspect the carbon...

Page 172: ...the carbon canister is not plugged remove the fuel tank vent line from the filler neck Using compressed air gently blow air through the vent system Check that air is coming out of the end of the vent located in front of the rear tires Also check that air is coming out of the vent hose connected to the engine s air cleaner NOTE If fuel comes out the vent hoses the canis ter may be saturated with fu...

Page 173: ...S Specifications 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 EVAPORATIVE SYSTEM ROUTING ...

Page 174: ......

Page 175: ...ww jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE Throttle cable page 10 1 Throttle cable routing bodied go kart page 10 2 Throttle cable routing eagle go kart page 10 3 Throttle cable removal page 10 5 Throttle cable lubrication page 10 6 Throttle cable speed adjustment page 10 7 Throttle pedal removal page 10 9 Throttle pedal bushings page 10 10 ...

Page 176: ...shop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE ROUTING BODIED GO KARTS Clip Clip Large curves do not kink cable Loosely zip tied do not kink cable Zip tie on the left side driver s side of the clip as shown If you zip tie to the right side the throttle cable may bind Le ft sid e of cli p ...

Page 177: ...rations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE ROUTING EAGLE GO KARTS Large curves do not kink cable Cable runs through side panel tube Loosely zip tied do not kink cable Le ft sid e of cli p Zip tie on the left side driver s side of the clip as shown If you zip tie to the right side the throttle cable may bind ...

Page 178: ...anuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM NOTE Always maintain large radius curves on the throttle cable to prevent binding NOTE The throttle return springs on some go karts are hooked to a hole in the muffler shield KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY WITH CABLE LIFE LUBRICANT 00122 Cable lube tool 3 60 0029 Cable Life lubricant ...

Page 179: ...ments com 503 304 8899 ENDURANCE CLUTCH PLATES TM Disconnect the throttle cable from the engine Remove the cable from the throttle cable override springs on the gas pedal Loosen the adjuster nut and slide the cable end out of the throttle bracket THROTTLE CABLE REMOVAL Push cable SET EQUAL SPEEDS ON ALL YOUR GO KARTS WITH THE VORTEX SPEED GAUGE Go Kart MPH gauge V3 Vortex 1 60 0206 ...

Page 180: ... of the side panel from the rear of the kart Eagle Talon models only Use J J 3 60 0029 cable lube to service the throttle cable on a regular basis Keeping the throttle cable lubricated ensures long cable life and proper operation Use J J 00122 cable lubrication tool to help feed the lubricating oil down into the cable jacket THROTTLE CABLE LUBRICATION KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY W...

Page 181: ...tle cable adjustment should remain loose The cable adjust ment at the engine should be backed almost all the way out NOTE A pedal stop plate is installed to limit pedal travel overall travel should not stretch the springs more than 1 4 Over extension can break the springs and cause premature failure Start the engine and allow it to warm up Ad just engine idle per the Honda service manual 1400rpm 1...

Page 182: ...ottle cable so that there is a small amount of free play where the cable connects to the pedal Tighten the throttle cable lock nuts Recheck that the desired RPM speed has not changed Reinstall the air cleaner on the engine L o c k n u ts L o c k n u t s You can find a handy go kart ratio analysis calculator on our wbsite at http www jjamusements com technical speedcheck htm or scan the code With a...

Page 183: ...override springs On single seat go karts remove the double nuts from the throttle extension rod NOTE The plate under the throttle stop is fitted on some go karts to prevent excess throttle pedal travel Excess pedal travel will hyperextend the throttle cable override spring and cause spring failure Springs should not extend more than 1 4 6 35mm beyond their relaxed state THROTTLE PEDAL REMOVAL MILL...

Page 184: ...for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the bolt and pedal spacer sleeve Press fit replaceable Bronze Oilite bushings into frame J J 1 60 0291 THROTTLE PEDAL BUSHINGS Automatic air lift 24 x 80 1031 ...

Page 185: ...This occurs when the throttle blade is closed and the engine is in the idle position The pressure differential begins to decrease when the throttle begins to open and is lowest when the throttle bore is wide open For this reason intake air leaks have minimal effect on high speed operation NEEDLE AND SEAT FLOAT VALVE This device has one job to control the amount of fuel in the float bowl reservoir ...

Page 186: ...n smooth acceleration you could have fuel restriction in this area MAIN CIRCUIT From approximately 1 8 of throttle to fully open the main circuit flows fuel out of the float bowl through the main fuel jet up the main air fuel nozzle to the venturi The fuel delivery carburetor circuits used in this application have two requirements fuel and air in calibrated amounts This provides the air fuel ratio...

Page 187: ...ations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Fuel feed holes provide fuel to all carb circuits Here is the idle circuit fuel passage Inspect the float valve needle tip for worn steps or grooves This is a replacement item however the float seat hinge assembly is not IDENTIFYING CARBURETOR ITEMS K N air filter GX160 200 SP 2747 ...

Page 188: ...e stop this will allow easy removal Replace with a new idle mixture screw and install a new stopper as outlined in the Honda manual ALTERNATE METHOD Use a soldering iron to heat the stopper This will loosen the epoxy glue holding the stopper to the screw and it can then be pushed off while it is still hot The initial adjustment is 1 1 2 to 2 turns out from the lightly seated position IDLE MIXTURE ...

Page 189: ...e Over an extended period of use this post can become worn to the point that choke will flop and not stay indexed If the carb is worn to this point it s time for a replacement TECH TIP If the idle speed checks out fine check the slack in the linkage Always keep any slack in this linkage to a minimum Replace it with a new rod and spring to keep the linkage tight Extended use can cause the governor ...

Page 190: ...ation Pull up on the pilot jet setting device to remove Gently pry up on the pilot jet it is held in place by an O ring The jet can now be cleaned To check it use a pen light to shine light though jet air path and visually inspect the fuel passage for obstructions A nice round pin hole should be visible use Honda jet cleaner tool 07JPZ 001010B NOTE Any carb jet can build up with varnish or other m...

Page 191: ...SF OPU UP EBNBHF UIF TFBU TVSGBDF MPBU WBMWF XPSO PS DPBUFE XJUI GPSFJHO NBUFSJBM EJSU 3FNPWF GPSFJHO NBUFSJBM EJSU 1JMPU KFU BJS QBUI DMPHHFE 3FNPWF GPSFJHO NBUFSJBM EJSU BJO KFU DMPHHFE 3FNPWF GPSFJHO NBUFSJBM EJSU BJO OP MF DMPHHFE 3FNPWF GPSFJHO NBUFSJBM EJSU BJO OP MF BJS QBUI DMPHHFE 3FNPWF GPSFJHO NBUFSJBM EJSU PS FYUFOEFE TUPSBHF PG UIF FOHJOF PSF UIBO NPOUIT SBJO HBTPMJOF GSPN á PBU DIBNC...

Page 192: ...g 5HDSSO E VSUD LQJ RQ WKH VXUIDFH DQG ZLSLQJ GU ZLWK D VRIW DEVRUEHQW FORWK YHU PXFK OLNH GXVWLQJ IXUQLWXUH DQG MXVW DV HDV 0LVW LW OLJKWO ILUVW ZLWK WKHQ WRZHO GU WDNHV DQ H WUD VHFRQGV 7KLV LV DQ H FHOOHQW ZD WR NHHS XS WKH 89 VFUHHQ DQG WRWDOO SUHYHQW 89 FDXVHG VORZ IDGH When To Reapply LV ZDWHU UHSHOOHQW EHDGV ZDWHU KHQ WKH ZDWHU UHSHOOHQF EHJLQV WR GLPLQLVK LW V WLPH WR UHDSSO I RX WKLQN LW ...

Page 193: ... for damage and the rubber should be replaced to prevent damage to the body Latches should be checked for any wear or damage whenever the body is removed J J fiberglass bodies use some basic systems to attach the body to the kart frame Most bodies use the center section of the kart floor pan as an index for the body location Early on the bodies were mounted directly to the frame which proved unsat...

Page 194: ...of the frame NOTE Do not overtighten snug the mounting nuts to capture the body only Rubber latches or bungees are often used to hold bodies while providing for isolation movement NOTE Failure to use body latches will result in excess body damage Bodies settle over time so rubber mounting bushings bumpers plates etc must be adjusted to best support the body Use adjustable stand offs and washers un...

Page 195: ... frame Eye bolts are used to secure the hold down straps Bumpers are bolted to the mounting brackets and are easily replaced if damaged The side of the F 22 body is rubber mounted to the frame just in front of the rear wheels NOTE Make sure the rubber well nut is in place to isolate the body from the frame BODY MOUNTS F 22 GO KART E y e b o l t s Bumper Bump er SIMPLE EASY OIL EXTRACTION JUST INSE...

Page 196: ...ody seals see page 12 12 The T bushings are compressed when the 3 4 nuts are tightened Do not over tighten these nuts as the bushing expansion can crack the body Latch the body latches NOTE The body latches must be latched in order to lock the body to the chassis SIDEWINDER SIDEWINDER DOUBLE Unlatch the four body latches There are two behind the front wheels and two behind the rear wheels Remove t...

Page 197: ... panels span between the frame spindle mounts and the roll bar body mount The formed plastic wing is rubber mounted via special grommets in the mounting holes to float which helps to eliminate stress cracks in the plastic The wing also protrudes toward the rear of the go kart to keep patrons and attendants away from the hot exhaust on gas powered go karts The fenders are safety related item that o...

Page 198: ... on the bottom lip of the side panel THE REAR FENDER The rear fender is mounted to the side panel with one 5 16 bolt on the bottom of the wing support and two 1 4 bolts on the bottom lip of the side panel Front fender Rear fender THE SIDE PANEL The side panel is mounted to the frame with one 5 16 bolt at the rear the roll bar body mount two 3 8 bolts on the spindle mount and seven 5 16 bolts on th...

Page 199: ...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 DO NOT REMOVE THIS DECAL DO NOT REMOVE THIS DECAL Eagle Talon go karts Decal 00979 00978 Bodied go karts F 22 go karts 00978 0 0 9 7 8 ...

Page 200: ...ve rotating parts Hair longer than shoulder length must be secured above shoulder Serious injury or death could occur DO NOT REMOVE THIS DECAL NOTE This decal is located on both sides of the go kart so that it can be read when entering the go kart from either side Can Am Sidekick Eagle Talon Sidewinder s F 22 s 1 6 0 0 2 8 8 1 6 0 0 2 8 8 1 6 0 0 2 8 8 1 6 0 0 2 8 8 1 6 0 0 2 8 8 1 6 0 0 2 8 8 Oil...

Page 201: ...ASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS REFUEL IN A WELL VENTILATED AREA WITH ENGINE STOPPED DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA WHERE THE ENIGINE IS REFUELD OR WHERE GASOLINE IS STORED DO NOT OVERFILL THE TANK THERE SHOULD BE NO FUEL IN THE FILLER NECK AFTER REFUELING MAKE SURE THE FUEL CAP IS CLOSED SECURSLY AND VENT OPEN BE CAREFUL NOT TO SPILL FU...

Page 202: ...h hands on steering wheel and both feet in kart at all times unless otherwise instructed by attendant One person per restraint Restraint must be worn at all times when in kart Do not bump skid or slide karts Riders must remain seated at all times unless instructed by attendant No one under the influence of drugs or alcohol is allowed to ride This ride is not recommended for individuals who have he...

Page 203: ...for melting away the decal but for heating 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 and 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 ...

Page 204: ...nts involving long hair or loose clothing is to never allow a guest to operate or ride in the go kart with hair unsecured below the shoulder Guests with hair longer than shoulder length MUST secure hair above the shoulder If the guests refuse to comply they should not be allowed to operate or ride in the go kart Seal 14476 CV 17 Cycle Vise 10730 8 Side Extensions 10728 12 Side Extensions 16011 13 ...

Page 205: ...attery pack page 13 10 Battery pack testing page 13 11 Battery pack replacement page 13 12 Fuse page 13 13 Relay page 13 17 Linear throttle potentiometer page 13 20 Throttle cable page 13 27 Throttle cable adjustment page 13 29 Motor controller page 13 32 Interconnect board page 13 36 Switch box page 13 44 Switch box testing page 13 45 Remote shutdown wire harness page 13 52 Testing flash codes pa...

Page 206: ...harge time is very similar to the steps above and can be done after the tests to determine run time by following these steps Once the session time is set run the kart for the determined time Using the stop watch begin timing once the charger begins the recharge cycle and allow the kart to charge for the same period of time as the session Once the recharge time has reached the same time period of t...

Page 207: ...eplacement batteries as back up for this very purpose HOW DO YOU TEST THE FUSE TO KNOW IF IT IS GOOD In many cases when the fuse fails it is possible to visually see the failure However sometimes a fuse will look good and still be bad You should use a voltage meter in the Ohm setting to check the continuity of the fuse WHAT CAUSES A FUSE TO FAIL A fuse is a device designed to fail if the amp draw ...

Page 208: ...oing to the linear throttle controller the linear throttle controller failing or the path of the signal going from the linear throttle controller to the main controller The easiest way to rule out the linear throttle controller as the problem is to unplug the existing unit from the interconnect board and plug into a working linear throttle controller see page 13 20 If the linear throttle controlle...

Page 209: ...o 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 or bad it all...

Page 210: ...e tested 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 the starting point for the measurement Voltage at the red probe t...

Page 211: ...our 12 volt deep cycle batteries connected in series to produce a 48vdc pack 4 gauge copper cables are used to connect the pack and furnish power through the relay solenoid to the powered fuse and components From the main fuse power flows in from the charge circuit and or the battery pack then out to all load devices Use the voltage drop test to check the battery terminal to cable end and battery ...

Page 212: ...ll 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 holding the le...

Page 213: ... Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Battery Battery Battery Battery Sevcon Controller F2 F1 B1 M1 B M2 Motor F2 A2 F1 A1 Relay Fuse SB 175 4 GAUGE CABLE SCHEMATIC ...

Page 214: ...eries in the electric karts must have specific characteristics to be used in this application They must first be safe when impacts to the kart occur and the batteries are jarred around They must be able to withstand rapid discharge and recharge with minimal to no venting By far the batteries are the most heavily stressed electrical component of an electric kart and should be inspected regularly an...

Page 215: ...to fully load the system with a brief maximum acceleration and or by sliding the go kart along the track s safety rail at full acceleration to load the battery pack If the pack is good typical minimum voltage readings will be in the 47 48 volt range Anything less requires immediate further testing see testing individual batteries LOAD TESTING INDIVIDUAL BATTERIES WITH DVOM This procedure requires ...

Page 216: ...battery covers or kart body to access the batteries WARNING Carefully remove the negative cable Be sure to not allow the wrench to touch the positive and negative lugs of the battery at the same time NOTE Always remove the negative cable first and attach it last when removing or replacing any battery or performing any electric service With the cables removed the batteries can be removed remove the...

Page 217: ...mation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FUSE OVERVIEW The 300 amp main fuse keeps power surges or short circuits from destroying the electronic components All power from the battery pack or to the pack from the charger goes through this fuse ...

Page 218: ...ents com 503 304 8899 ENDURANCE CLUTCH PLATES TM FUSE REMOVAL REPLACEMENT Be sure the kart is in the off position by pushing the red stop button down NOTE Always disconnect the battery pack s negative terminal before removing the electronics cover see page 13 12 for negative terminal removal Remove the electronic cover by removing the 4 bolts holding the cover Locate the fuse holder ...

Page 219: ...cluding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Using a voltage ohm tester check the continuity of the fuse To remove the fuse loosen the nuts on each end With the nuts loosened the fuse can be removed by lifting the right side then sliding the fuse out of the holder ...

Page 220: ...ct 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 Install the new fuse in the reverse manner that the old fuse was removed ...

Page 221: ...d will not handle the amperage of extended operation This test verifies that controller and cables are functioning Next remove the 10ga jumper Using a digital volt ohm meter test for system voltage at the white wire terminal of the relay the relay has system power to the activation windings at all times via this wire The ground side black wire goes to the controller which uses the interruption of ...

Page 222: ...jamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the two large cables from the posts on the top of the relay NOTE Always disconnect the battery pack negative terminal before removing the electronics cover see page 13 12 for negative terminal removal Remove the electronic cover Locate the relay on the heat sink board RELAY REMOVAL REPLACEMENT Relay Heat sink board ...

Page 223: ...p and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the two smaller wires from the lower posts on the relay Loosen one of the button head screws holding the relay to the heat sink panel Remove the opposite button head screw completely Slide the relay off of the remaining screw to completely remove the relay ...

Page 224: ...entiometer changes the movement of the go pedal into an electronic signal and sends that information to the controller The farther the pedal is depressed the faster the kart will travel The linear throttle potentiometer plugs into the interconnect board with a Molex style plug The linear throttle potentiometer is not a traditional variable resistor in that solid state electronics sense the positio...

Page 225: ...om 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the negative cable from the left rear battery NOTE Always remove the negative cable first and attach it last when removing or replacing any battery or performing any electric service Remove the electronic cover Remove the axle guard to allow better access to the linear throttle potentiometer LINEAR THROTTLE POTENTIOMETER REMOVAL REPLACEMENT ...

Page 226: ...tion including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Locate the linear throttle potentiometer Remove the 4 socket head retaining bolts The throttle plate can now be removed to allow better access do not pull excessively on the throttle inner cable or housing ...

Page 227: ...mation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the throttle cable from the throttle arm Remove the throttle arm from the linear throttle potentiometer Using two wrenches loosen the throttle clevis pin while being sure not to move the jam nut ...

Page 228: ...ements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Count the number of threads showing where the clevis pin was you will need to know this when installing the clevis pin onto a new linear throttle potentiometer Remove the two hex head pan screws be sure to hold the lock nut on the back side Install the new linear throttle controller screw on the jam nut for the throttle clevis pin ...

Page 229: ...op and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Be sure the jam nut has the same number of threads showing that you counted before removing Install throttle clevis pin hand tight Move the throttle arm into position in the clevis pin then tighten the jam nut tightly be sure the arm moves freely back and forth ...

Page 230: ...ents com 503 304 8899 ENDURANCE CLUTCH PLATES TM Adjusted properly the hole in the throttle cable end should line up with the hole in the throttle cable arm With the cable connected check the movement Be sure the cable and arm move smoothly and go to a complete rest with no tension Re install the throttle mount and plug the linear throttle controller back into the interconnect board ...

Page 231: ...ation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE REMOVAL REPLACEMENT Loosen the jam nut closest to the throttle arm Loosen the nut holding the cable in place on the bracket Remove the nut holding the cable clevis pin to the throttle arm ...

Page 232: ...ideos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Slide the cable adjuster housing back through the cable mount Slide the wire through the slit in the cable mount KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY WITH CABLE LIFE LUBRICANT 00122 Cable lube tool 3 60 0029 Cable Life lubricant ...

Page 233: ...TLE CABLE ADJUSTMENT Throttle arm Cable clevis end Throttle inner cable Cable housing end Cable housing The throttle cable may need to be adjusted to either speed up or slow down the top speed of the kart The picture above identifies the names of the parts involved in adjusting the throttle cable NOTE This is a critical adjustment as the overall travel of the linear actuator rod dictates the perfo...

Page 234: ...ng away from the throttle arm Then tighten the nut on the back side of the throttle bracket Doing this will increase the amount of the inner throttle cable showing between the throttle bracket and the throttle arm This process will allow more travel on the throttle thus making the kart s top speed faster To slow down the top speed of the kart the process would be reversed NOTE It is important to n...

Page 235: ...rkshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM On electric karts when the cable is installed at the factory both jam nuts are on the outside of the throttle cable bracket Both nuts will need to be removed then one threaded on the cable housing end prior to being re installed to change the adjustment ...

Page 236: ...not operate The controller s personality is set with what is called a profile The profile of the kart determines how quickly the kart accelerates the different speeds the kart can achieve the amount of regenerative braking present as well as the maximum amp draw of the motor The profile s parameters should only be adjusted by qualified personnel and the original profile should be saved as a base t...

Page 237: ...rom the left rear battery NOTE Always remove the negative cable first and attach it last when removing or replacing any battery or performing any electric service Remove the electronic cover Locate the controller and unplug the interconnect board cable NOTE Always inspect the wire end of the connector Terminals are small and can sometimes be pushed back into the connector plug This can cause inter...

Page 238: ...nd operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove all of the remaining cables to the controller Remove the 2 bottom Allen head bolts holding the controller to the heat sink board and one of the top Allen head bolts Remove the remaining top bolt be sure to support the controller as you are removing the last bolt ...

Page 239: ... On a separately excited motor D D or other the cable is directional The end with the red tag must be plugged into the controller while the end with no tag plugs into the interconnect board On a permanent magnet motor ASMO or other the cable is not directional NOTE This Molex type plug utilizes very small contacts that click into place when installed from the back On occasion they can be installed...

Page 240: ...n to controller Throttle input connection On off switch box connection Peripheral input connection i e remote shut down Relay cable connection The interconnect board s function is actually quite simple it takes the place of wires and terminal blocks to send the inputs to the controller By using the interconnect board it simplifies the connections making troubleshooting much easier and quicker Ther...

Page 241: ...gged into the charger NOTE When the remote shut down system is used the wires attach to the TS1 in the following order 1 Yellow Wire 2 Open 3 White Wire 4 Open 5 Blue Wire 6 Orange Wire NOTE When no shut down system is used there must be a jumper on the TS1 going from 1 to 2 and a jumper from 5 to 6 Also with the overhead charging system there is an additional wire on terminal 1 and a wire on 4 to...

Page 242: ...operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the negative cable from the left rear battery NOTE Always remove the negative cable first and attach it last when removing or replacing any battery or performing any electric service Remove the electronic cover Locate the interconnect board INTERCONNECT BOARD REMOVAL ...

Page 243: ... for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Carefully remove the throttle input plug from the interconnect board Unplug the communication cable interconnect board cable Unplug the brake pressure switch cable ...

Page 244: ...t notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Unplug the on off switch box cable Unplug the relay cable Remove any wires connected to an external power point ...

Page 245: ...4 8899 ENDURANCE CLUTCH PLATES TM Remove any wires connected to the peripheral TS1 input connection points NOTE Mark the color and connection location for reassembly Loosen the 4 pan head screws that hold the interconnect board to the heat sink panel Carefully remove the interconnect board Be sure to leave the pan head screws in place they are holding the spacers in place while you remove the boar...

Page 246: ...op and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Place the board on a flat surface it is a good idea to use a towel or cloth underneath while you are working on it Carefully remove the pan head screws holding the interconnect board guard to the board To install a new interconnect board reverse the steps above ...

Page 247: ...d operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM NOTE Be careful when plugging the throttle input plug into the interconnect board C2 Since the connection is on the corner of the board it can flex the board into the heat sink plate causing a short in the board or causing traces to crack due to the flexing of the board ...

Page 248: ...on and the forward reverse switch This button and switch go through the interconnect board to control power to the kart and put it in a forward or reverse direction WHEN THE REMOTE SPEED CONTROL SYSTEM IS USED THE KART WILL NOT GO INTO A REVERSE SPEED UNTIL THE KART IS PUT INTO THE SLOW OR STOP MODE The wires travel to the interconnect board through a multi conductor cable and connect to the board...

Page 249: ...sements com 503 304 8899 ENDURANCE CLUTCH PLATES TM If you suspect a problem in the switch box it can be easily tested by using a unit that is known to function SWITCH BOX TESTING Remove the negative cable from the battery pack see page 13 12 Remove electric component cover Locate the switch box plug on the interconnect board and unplug Plug in switch box that is known to function ...

Page 250: ...n including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Using the alternate switch box turn the kart on If the problem was inside the switch box the kart should turn on and the light on the controller should be solid green Reconnect the battery ground removed earlier ...

Page 251: ...t SWITCH BOX REMOVAL REPLACEMENT To correct the problem created by a faulty switch box the box can be replaced however it is a good idea to check the connections inside the box as a loose wire can easily be repaired FOLLOW THE STEPS BELOW Remove the negative cable from the battery pack see page 13 12 Remove the electric component cover and unplug the switch box from the interconnect board perform ...

Page 252: ...p and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM BRAKE PRESSURE SWITCH OVERVIEW The brake pressure switch is designed to drop the power out from the motor when the brake pedal is depressed If this circuit were not in place the kart s motor would fight against the brake system causing extreme amp draw situations ...

Page 253: ...AL Remove the axle guard or inspection cover to gain access to the pressure switch The brake pressure switch is set to normally closed when the brake pedal is not being depressed To test use a multi meter set to test continuity place one lead on each tab on the back of the pressure switch If the switch is working properly the meter will show a closed circuit when the leads make contact Next have s...

Page 254: ...usements com 503 304 8899 ENDURANCE CLUTCH PLATES TM If the kart does not operate and you suspect a faulty switch you can bypass the switch by using a jumper from one tab to the other If the kart now functions properly then the switch must be replaced Coat the threads on the new switch lightly with pipe thread sealer Remove the two wires from the tabs on the brake pressure switch ...

Page 255: ...RK The POWER BLEEDER works just like professional pressure bleeders A tank containing hydraulic fluid is attached to the hydraulic system via a special adapter the tank is then pressurized with a few pumps When one of the bleed valves is opened old or contaminated fluid is expelled as new fluid from the pressure tank is added POWER BLEEDER FEATURES One person operation Quick and Clean forward blee...

Page 256: ...the wires then connected to the terminal strip on the interconnect board The remote shut down receiver is not standard equipment and does not come on all karts We do suggest using the system as it can greatly enhance the safety of the track operation For installation maintenance and troubleshooting see the Kartrol service manual J J 1 99 0006 1 60 9027 WITHOUT PIT LOOP DETECTOR 1 60 9029 WITH PIT ...

Page 257: ...ES TM INTERCONNECT BOARD 1 2 3 4 5 6 BATT BATT 1 15 0105 REV 3 SB 175 END VIEW SB 175 TOP VIEW Schematic Charger Safety Switch without Kartrol Components not to scale ATT BATT Butt connector Black White White White Black Black wire to this plug White wire to this plug Blue Jumper Blue Red Butt con n Black White BA ATT RELAY 1 15 A0116 nnector Butt con n Black SB 175 Black White CONN 1 15 INTERC Wh...

Page 258: ... with software for a PC system The plug uses a serial port which most new PC s no longer use A USB to serial port adaptor is required and we suggest you get one that includes software for the drivers as newer operating systems do not recognize serial port devices Follow the installation instructions for the USB to serial port adaptor to ensure it is installed correctly The adaptor plugs into the c...

Page 259: ...jamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Open your control panel and find the icon for Device Manager open the Device Manager Find the icon labeled Ports COM LPT click the icon to see the drop down menu With the drop down open you will see the COM port location In this case it is com port 3 Close the Device Manager and open the PC Pak program TESTING FLASH CODES ...

Page 260: ...Tools tab on the top bar it will open up a box in the middle of the screen The first tab of the box is marked Connection click that tab The connection box will have a drop down for the different COM ports Choose the correct COM port shown in the previous steps and close the box With the correct COM port now set and the kart turned on click the green Connect button in the top left of the screen The...

Page 261: ...ile tab on the top bar then choose Save from the drop down menu This will open another box asking which Node version you want to save Be sure the box is checked click the ok button A new box will now open asking the file name and where to save the file Give the file a basic name such as base profile 7 16 2012 It works well to name the profile with the date of when it was saved in part of the name ...

Page 262: ...s on both ends going from the interconnect board to the controller is called the interconnect board cable Unplug the interconnect board cable and visually inspect the terminals to be sure they are all in place Re connect the interconnect board cable Be sure it is attached correctly as there is a specific side that plugs into the interconnect and a specific side that plugs into the controller there...

Page 263: ...copy of a working profile Be sure to copy the profile from a kart that is known to work Connect the PC Pak cable to the non working controller With the kart now turned on open the Sevcon PC Pak software but DO NOT CLICK THE CONNECT BUTTON With the software open click the Load Settings button on the top of the page it looks like a paper with a green arrow pointing downward This will open a new box ...

Page 264: ...for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Find the saved profile and choose Open Click the Next button on the bottom of the box The box will change to Check the node compatibility click the Next button again ...

Page 265: ...t box will be the Rapid Download Wizard Click the large Download button in the middle of the box When the download is complete a dialog box will open stating this Click the Ok button The Rapid Download box will reappear click the Finish button on the bottom right Now turn the kart off then back on the flashing light should clear If you experience any issues with loading a profile call the service ...

Page 266: ... and rotor windings allowing more control over the motor performance If either of those circuits are damaged or broken this code will come up It can refer to a major problem inside the motor or just a damaged or broken cable going to the motor from the controller SYMPTOM 5 FLASHES NOT USED SYMPTOM 6 FLASHES ACCELERATOR WIRE FAULT This code is generated when there is a problem in the linear throttl...

Page 267: ...e This condition has come up once at a park where the regenerative braking system was adjusted too high After the kart was fully charged and was driving out on the track the guest suddenly let off the go pedal and the power going back to batteries from the motor would spike up past the predetermined parameter To adjust the amount of regenerative braking follow these steps Connect PC Pak cable and ...

Page 268: ...of heat replace any problem cables If the controller is ever replaced it is important to apply thermal grease otherwise known as heat paste or thermal paste to the back of the controller J J 2 70 0112 This product will help the controller transfer the heat from the controller to the large aluminum plate which is designed to distribute the heat away from the controller One other problem to look for...

Page 269: ...he electric kart charging system Because of the importance of making sure the kart is being recharged properly it should be inspected for proper operation see pg 0 11 Be sure both brushes are in good condition and they slide both up and down freely in the holder Inspect the UHMW brush holder to be sure it is tightly fastened to kart s chassis Look for loose or damaged cables or connections Inspect...

Page 270: ... website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FLOOR PLATE CONTACTS Inspect the floor plate contacts to make sure they are clean and clear from debris and show no signs of excess heat or arcing ...

Page 271: ...isc brake specification 7 2 Drum brakes Adjustment 7 27 Brake shoes 7 21 7 22 Overview 7 19 Parts identification 7 20 E Electrical schematic 13 9 Electric go kart Frequent questions 13 2 ELECTRIC START BATTERY SWITCH BOX 8 11 ELECTRIC START ENGINE 8 10 Electric Start Wire Schematic 8 12 Engine Removal 8 4 ENGINE 8 1 ENGINE ASSEMBLY REMOVAL 8 4 Enigine RPM Adjustment 10 7 EVAPORATIVE SYSTEM 9 6 EVA...

Page 272: ...wered single seat go karts 0 4 Gas powered rookie go karts 0 5 Gas powered single seat go karts 0 2 Spherical washers 7 3 Spindle 3 1 Assembly 3 9 Disassembly 3 8 Frequent questions 3 2 Installation Inspection 3 4 Steering Ackerman effect 4 10 Caster 4 2 Tie rods 4 7 4 8 Toe adjustments 4 5 Toe In 4 5 Steering column 4 11 Pad 5 4 Steering column pad 4 13 Steering cover 4 11 Steering system 4 1 Ste...

Reviews:

No comments