J&J Amusements Double Eagle - Electric Service Manual Download

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7-1

BRAKE SYSTEM

OVERVIEW

BRAKE CALIPER OVERVIEW

Overview ....................................................................................page 7-1

Caliper assembly .......................................................................page 7-3

Brake pads - removal & installation .......................................page 7-4

Removing brake caliper assembly ..........................................page 7-5

Master cylinder overview .........................................................page 7-9

Master cylinder removal ........................................................page 7-10

Brake pedal ..............................................................................page 7-13

Brake

uid level inspection ....................................................page 7-14

Brake

uid change ..................................................................page 7-14

Bench bleeding master cylinder ...........................................page 7-15

Bleeding the brake system ....................................................page 7-17

Brake troubleshooting ...........................................................page 7-18

Drum brake system overview ...............................................page 7-19

Drum brake parts identi

cation ............................................page 7-20

Changing brake shoes ............................................................page 7-21

Drum brake adjustments .......................................................page 7-27

The disc brake system used on J&J go-karts is a simple, one-circuit design using an oversized master cylinder (for extra

reservoir capacity). Brake lines are covered with a braided, stainless steel outer covering for additional strength and

durability; these special lines are made at J&J for this application. It is not recommended to substitute other types of brake

lines on J&J go-karts.

The caliper assemblies are a dual-piston (one piston per side, applying equal pressure to brake pads), very simple system

with only two moving parts (the pistons).

Brake Pads: two pads (one on each side) are pushed against the disc via hydraulic pressure behind the caliper pistons. The

material is organic and chosen for the speeds and rigors of concession go-kart use.

Brake Disc: a simple, 1/4” steel disc with two holes provide access to the caliper mounting bolts.

The J&J/FPX brake caliper is a dual-piston design. The pistons travel in the machined bore of each caliper half. A simple,

square-edge seal retains the

uid and suspends the machined piston in the caliper bore. As the diagram shows,

uid

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” plywood (cut to the width of the brake pads) between the two pistons.

Use a rubber-tipped air nozzle to gently blow air into the brake

uid

tting of the caliper. This will cause the pistons to

pop out against the plywood surface. Unbolt the two Allen-head cap screws and separate the two halves. Be aware that

between the two halves is an o-ring seal. This o-ring is to seal the

uid passage between the two halves. If the o-ring is

missing and/or damaged, the brake caliper will leak

uid out between the two halves. Remove the caliper pistons. The

piston bores may be pitted or rough; this is not usually a problem unless the seal groove is damaged.

When replacing the piston seal, carefully install the seal into the groove of the caliper bore. Make sure the seal is not

twisted and

ts nicely into the groove. Use a brake assembly lube (such as Wilwood 290-11087) on the piston and seal

surface to make the procedure of piston installation easy. Screw the two caliper halves (with o-ring seal) together and

torque the Allen-head cap screws to 29 ft.lbs.

NOTE:

The piston is

nely machined steel, and any rust spot or other damage to the seal surface means the part must be

replaced. The piston can be cleaned using a “Scotch Bright”-type material. Use “Brake Clean” to clean all parts; avoid using

water-based or oil-based cleaners.

Piston travel

Piston

Seal groove

Caliper half

Caliper bore

Piston seal

O-ring seal

Summary of Contents for Double Eagle - Electric

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

Page 2: ...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 503 3...

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

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

Page 5: ...rman eﬀect 4 10 Steering shaft cover 4 11 Steering 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 cali...

Page 6: ...rning decals 12 7 Body seal 12 12 FPX is The Tire Store for concession go kart tires We carry only the best and most popular sizes We stock so many tires we have another warehouse on the east coast That s right we have a warehouse in Atlanta Georgia and one at our headquarters in Salem Oregon 5 TIRE TUBE COMBINATION DEALS Part Description Price 007880COMBO Tire 12 x 4 00 5 SL72 Bigfoot COMBO W Tub...

Page 7: ...da GX160k1 GX200 GX240k1 GX270k1 Type 4 stroke overhead valve 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...

Page 8: ...del Honda GX160k1 GX200 GX240k1 GX270k1 Type 4 stroke overhead valve 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 u...

Page 9: ...d air Maximum horsepower 18 6 hp 13 9 kw Controller sevcon 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 Coatings Phosphate dippe...

Page 10: ...stem forced air Maximum horsepower 18 6 hp 13 9 kw Controller sevcon 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 Coatings phosp...

Page 11: ...erhead valve 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 Coatings phosphate dipped and electrostatic powd...

Page 12: ...em forced air Maximum horsepower 9 3 hp 6 9 kw Controller Sevcon 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 ...

Page 13: ...earings and cause premature failure The list goes on 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...

Page 14: ...revent uneven tire wear and a poor handling kart check the front 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 l...

Page 15: ...0 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 35ft 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 Se...

Page 16: ... at the specified intervals or sooner if operated in dirty or 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 alignme...

Page 17: ...rque When necessary Grease Yearly 9 Axle axle bearings 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 1...

Page 18: ...s and prices subject to change without notice Download latest update to this manual on line 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: ...ed or illegible 5 Pads check seat seat back seat belt 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 operati...

Page 20: ... drive Check brake shut oﬀ function 1 7 Steering check for smooth 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 ...

Page 21: ...t rails missing bolts etc 5 Track surface check that the 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 ar...

Page 22: ... and prices subject to change without notice Download latest update to this manual on line Go kart ID Date Describe problem Maintenance performed Ser viced by Finish date NON SCHEDULED MAINTENANCE RECORD Make extra copies for future use ...

Page 23: ...ption of Work Performed Parts Used Front Back Mechanic Date Time Manager This sample maintenance work order tag can be copied for use in your facility Copy and cut tag along dashed line and fold along the fold line indicated Simply attach a maintenance work order tag to a machine in need of repair When maintenance is complete file with other service and maintenance information PRINTABLE WORK ORDER...

Page 24: ...EL TANK Drain the fuel tank to remove any moisture or contaminants 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 gel coat surfaces Spray the unpainted castings such as engine re...

Page 25: ... been performed recently it is advisable to change the 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 a...

Page 26: ...m Problems come from short paying statements or refusing to 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 ...

Page 27: ... 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 spark plugs final drive belts final drive pulleys brake fluid and fuel filters Appearance related damage including but not limited to scratches nicks dents fading paint trim and corrosion Service Logs The customer must use m...

Page 28: ...Apply silicone grease with a clean cloth at least three times 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 l...

Page 29: ...ading of equipment the operator must be lift truck 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 WARNING Remove each bracket before attempting to unload the go karts 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 ba...

Page 30: ...en lifting the kart from the rack make sure to keep clearance from the kart below Repeat the same steps for the remaining 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 ...

Page 31: ...PECIFICATIONS phone 1 800 854 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com TIP A great use for the shipping racks is to turn them into storage racks for your maintenance facility ...

Page 32: ...CENTRIFUGAL CLUTCH Remove the oil filler cap and wipe the dipstick 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 Refue...

Page 33: ...FILLER NECK Allow approximately 1 of airspace inside 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 ...

Page 34: ...NIGINE 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 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 ...

Page 35: ...rder to accommodate 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 and location of the valve stem to better fit the needs of concession go karts RIMS The current rim design features a special and unique to J J locking style lug nut and serrated rim for better ...

Page 36: ... 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 TIRE MEAN Nothing the arrow was used in the early days on treaded tires Bigfoot tir...

Page 37: ...eel 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 positive way to help insure that lug nuts will not work loose To install the Disc Lock locking nut follow the same procedure for convention...

Page 38: ...embled Disc Lock nut showing that both halves can move independently of each other The Disc lock safety wheel nut is a free spinning vibration proof wheel nut specifically designed to prevent wheel loss from commercial vehicles such as trucks trailers and buses with hub piloted wheel systems LUG STUDS NUTS RELATED HARDWARE Part Description Price 00970 Nut 5 16 24 Lug Nut Pre 98 0 40 1 50 0189 Nut ...

Page 39: ... 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 wheel assembly Pull the wheel assem...

Page 40: ...ve 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 can result in injury Tubes J J 00780 M Tube 3 40 3 00 5 Bent stem 45 degree middle See the bead breaker to...

Page 41: ...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 major time saver it simply bolts to the work bench CHANGING TIRES TUBES ASSEMBLY TIRE TOOLS Part Description Price 3 20 A0008 Tool Wheel Assembly 4 Lug J J Formula K Johnso...

Page 42: ...e 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 1 20 A0020 New style rims with bead lock and flat lug holes Use Disc lock style lug nuts Fits most J J Formula K Johnson Amusement Products Pacer go karts RIMS Par...

Page 43: ...e tires work on brakes tune engines change oil clean tear down and assembly If you need more than the standard 24 width take a look at our optional side extensions Utilizing the quick detachable side extensions you can turn your air lift into a versatile all purpose lifting tool for a multitude of diﬀerent items Electric Lift 3 60 0043 These small electric or manual lifts are perfect for maintaini...

Page 44: ...ace 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 replace them only with new J J original equipment parts ...

Page 45: ...y 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 track and a preponderance of right turns or left turns the t...

Page 46: ...e tube combination deals to almost every U S city within 3 days We also ship worldwide 5 TIRE TUBE COMBINATION DEALS Part Description Price 007880COMBO Tire 12 x 4 00 5 SL72 Bigfoot COMBO W Tube 22 99 007880 Tire 12 x 4 00 5 SL72 Bigfoot TIRE ONLY NO TUBE 21 99 1 20 0037 Tire 11 x 3 60 5 SL72 736HD 22 99 Quantity discounts available on 007880COMBO QTY 100 21 99 500 20 99 4 TIRES Part Description P...

Page 47: ...4 1899 www jjamusements com FRAME OVERVIEW Frequent questions page 2 1 Go kart frames are robot 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: ...DURABLE LONGEST LASTING BUMPER SUPPORT AVAILABLE THAT FIT MOST TYPES OF GO KARTS Special formulation gives these rubber bumper strips extra long life and resistance to cracking Can easily be cut to any length to suit your needs Thousands of uses Rubber sections can be cut to any size Pre cut and drilled more natural rubber compound to resist breaking The unique A design with rounded edges helps pr...

Page 49: ...are 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 the first D rubber on the side of the kart Put the bolt through the...

Page 50: ...lock 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 m ount holes Outer plate 8 Traﬃc Light Assy A01342 1 60 5003 Basic Ti...

Page 51: ...ers 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 your investment add Nerf bars to your go karts today SGL 010126 DBL...

Page 52: ... your safety longer hair must be secured above the shoulder and any personal items clothing jewelry etc must be secured and contained within the seating area 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 All go ka...

Page 53: ... 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 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 disassembly page 3 8 Spindle assembly page 3 9 ...

Page 54: ...o 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 are simply threaded through the hub flange Sealed bea...

Page 55: ...etween 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 are tightened through the threaded hub flange and held with thread locking compound Damaged studs can easily be replaced Remo...

Page 56: ...ed 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 and torque to spec 50 ft lbs Check to see that the hub spins freely TIRE TOOLS Part Description Price 3 20 A0008 Tool Wheel Assembly 4 Lug J J Formula K Johnson AP 99 95 3 20 A0009 Tool Wheel Assembly 3 Lug Shaller Type 99 95 3 96 A0001 Tool...

Page 57: ...e that protecting your equipment now is ten times cheaper than repairing it later As a bonus electrical and mechanical parts will run smoother and more eﬃciently SO WHAT IS IT Corrosion Block is a revolutionary product that Kills corrosion on contact Stops corrosion from ever coming back Lubricates the area Is safe to nearly all electronics CORROSION PROTECTION Part Description Price 3 60 0002 Cor...

Page 58: ...ease 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 ...

Page 59: ... 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 lb 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 point then back oﬀ the castle nut to the next...

Page 60: ...he 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 bearing cup Check the bearings for wear or damage If the grease in the bearing cup is old and or dirty clean it out Put the bearing cup on the end of the u joint and check that it spins freely SPINDLE DISASSEMBLY Special tools made for universal joint...

Page 61: ...th 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 to 3 pumps of grease SPINDLE ASSEMBLY Grease Bearing cap U joint Bearing GMax GM2X open face helmet DOT approved lightweight injection molded poly carbonate shell Clear coated painted shell Deluxe ...

Page 62: ...ol Tire Iron Set 8 11 15 36 95 01345 Tool Valve Core Remover 7 52 01344 Gauge Tire Pressure 0 50 psi Karts Only 12 66 1 60 A0311 Tool Socket 15mm 6pt Machined 14 99 LUG STUDS NUTS RELATED HARDWARE Part Description Price 0095120 Bolt 5 16 18 x 3 4 Grade 5 Zinc plated 0 59 1 50 0046 Stud Front Hub Tapered Style 5 16 18 X 1 1 4 SSS Grade 0 64 00998 Stud Lug Press In Type 5 16 Fine 1 1 8 L 1 50 00970 ...

Page 63: ...6 7505 1 503 304 1899 www jjamusements com 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: ... 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 hole which is approximately 4 7 degrees two wheel drive karts are set stock at the third hole which is approximatel...

Page 65: ... 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 ADJUSTMENTS CASTER Loosen all four 3 8 bolts holding the spindle to the frame NOTE Do not remove the bolts only loosen them enough to allow the spindle to rotate Heavy duty tube style tie rods rod ends GO KART TIE RODS Part Descrip...

Page 66: ... 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 visible or the spindle is being replaced the spindle wi...

Page 67: ...e 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 number is a smaller tape reading on the back edge this indicate...

Page 68: ...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 total toe in Place a straight edge across hub flange From the rear of the spindle facing the rear of go kart measure the distance from the frame rail to the straight edge Angle iron Cable lube provides the smoothest operation an...

Page 69: ...l Bottle Blue 83 73 3 20 0003 Loctite Threadlocker 250ml Bottle Blue 191 76 3 20 0004 Loctite Threadlocker 10ml Bottle Red 28 05 3 20 0005 Loctite Threadlocker 50ml Bottle Red 76 60 3 20 0006 Loctite Threadlocker 250ml Bottle Red 191 76 4 95 0011 Loctite High Strength Red 10ml Bottle 29 17 4 95 0044 Loctite 50ML Green 94 07 81790 Loctite Blue 250 ml 217 14 81793 Loctite Red 250 ml 232 74 013330 Gl...

Page 70: ...alled 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 procedure used to remove them NOTE A spray lubricant can be used to silence squeaky tie rod e...

Page 71: ...erly 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 adversely aﬀect steering Excess clearance can only worsen kee...

Page 72: ...kerman 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 scenario Ackerman is created by your front end geometr...

Page 73: ...hings for damage and wear bushings should fit snugly to the shaft while still allowing 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 steering shaft lightly grease the inside of the steering bushings P...

Page 74: ...lace 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 procedures are virtually the same as the round wheel described above STEERING WHEEL S t e e r i n g w h e e l m o u n t i n g b o l t s Steering pad mounting screws PADS STEERING Part Description Price 008642 Pad Steering Column Forme...

Page 75: ...ged 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 event of a collision These pad should be in place and in good condition at all times REPLACEMENT STEERING WHEELS A00863 Butterfly style A01098 Round style STEERING WHEELS Part Description ...

Page 76: ...gallons capacity Durable powder coat finish Note Nozzle is not included with Gas Caddy GAS CADDY Part Description Price 00223 Gas Caddy Complete 30 Gal 565 00 3 60 0066 Pump Gas Caddy Blackmer Optional for Gas Caddy One Way Fl 209 59 C200 Pump Gas Caddy 202 00 C203 Gas Caddy Vent Dome Assy 28 65 C204 Hose Assembly Gas Caddy 58 14 C205 Gas Caddy Gauge Assembly 63 21 C206 Gas Caddy Ground Wire Assem...

Page 77: ...AN 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 Additionally bolts attach the roll bar to the backrest panel a...

Page 78: ...arger 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 Seat belt pads are captured underneath the seat belt bracket to prevent twisting of the pads on the belt ROLL B...

Page 79: ... rattling Acorn nuts are used to help reduce the possibility of injury from exposed threads NOTE Make sure acorn nuts are installed and the seat belt pads are secured in their proper position with the seam away from the rider Seat belt pads are captured underneath the seat belt bracket to prevent twisting of the pads on the belt Bracket Pad Acorn nut 010771 12 seat belt extension Flip style SEAT B...

Page 80: ...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 rips and tears can catch shoes and cause trips and fal...

Page 81: ... new seat pad and let it sit until tacky see adhesive label instructions Carefully apply the new seat pad to the body taking care to make sure it is aligned properly before it touches the body as the glue will adhere instantly Glued to body We have replacement pads Call our parts department today 800 854 3140 OR 503 304 8899 Roll bar pad Seat back pad Seat pad PADS HEAVY DUTY STANDARD SEAT PADS Pa...

Page 82: ...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 URETHANE REPAIR KIT FOR GO KART SEAT PADS Prolong the life of your go kart pads Do you have rips and tears in your seat pads Would you like to fix them in 15 easy minutes Now you can with Rapid Patch It s the easy inexpensive way to fix rips and tears before...

Page 83: ...eld in place with the smooth side toward the rider s neck by capturing the pad end under the seat belt bracket when it is bolted to the go kart SAFETY ITEM Neck injuries can occur from frayed or missing seat belt pads Replace worn out seat belts with original J J equipment only Seat beltS Smooth side Seamed side B r a c k e t B r a c k e t 110779R Rubber shoulder pad SEAT BELT PADS Part Descriptio...

Page 84: ...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 seat belt 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 seat belt mounting bracket NOTE Tape the hook end so it does not tear the inside of...

Page 85: ...ges The Track Blaster is great for all your cleaning and drying needs Use it on your track parking lots or your landscape With a throttle control arm you can adjust the wind speed to fit any of these cleaning tasks Order yours today and don t let the rain shut you down When comparing the blowing force of FPX Track Blaster blowers to other blowers on the market that claim more CFM Track Blaster blo...

Page 86: ...6 60 1 60 3003 Display Surge Protector RS 232 RJ 11 89 76 1 60 3004 Display Main Board DSUB M0076 AMB V0 2 478 26 1 00 0101 OP Converter RS 232 485 W Built In data surge protector 245 00 GO KART TIMING HARDWARE Part Description Price 1 60 0093TX140 Timing Transponder AMB140 TX One Per Kart 437 99 1 60 0093BRACKT Bracket Timing Transponder J J Karts Axle Guard 16 07 1 60 0093CLAMP Timing Clamps Hos...

Page 87: ...ENTS 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 drive ...

Page 88: ... c o v e r Shown without engine for clarity QUEUE LINE WARNING TO BE PROMINENTLY DISPLAYED SO GUESTS ARE AWARE OF POTENTIAL HAZARDS It is strongly urged that go kart operators adopt the graphic warning advising guests of the potential hazards and dangers of long hair loose clothing and the proximity to rotating machin ery Guest with hair longer than shoulder length MUST be secured above shoulder R...

Page 89: ...emove 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: ... support GREAT PRODUCT FOR SMALLER FLEETS Requires just 4 to 15 strokes to create a powerful vacuum The integrated container 6 5 liters then neatly captures the oil preventing messy spills The calibrated walls allow easy measurement of the oil extracted A built in float switch automatically stops extrac tion as soon as capacity is reached A pour spout facilitates emptying The Big PELA is a durable...

Page 91: ... 1 5 8 adaptor cap included fits FPX master cylinder Optional catch bottle is available Part 3 96 0033 Optional Wilwood rectangle adaptor Part 3 96 0035 D r i v e c o v e r Pull 3 96 0032 BRAKE TOOLS POWER BLEEDER Part Description Price 3 96 0032 Tool Brake Bleeder Power Includes 1 5 8 Male Cap 84 99 3 96 0034 Tool Brake Bleeder Power Cap Assy Only 1 5 8 Male 43 99 3 96 0036 Tool Brake Bleeder Pow...

Page 92: ...drive cover Twist the drive cover down and away from the engine LONG BLOCK COMPLETE ASSEMBLED Includes Barrel piston rings crank rod cover comp governor kit seals crankcase Cover camshaft valves valve cover valve cover gasket exhaust studs rods Breather tube carburetor studs spark plug hardware GX270 Long Block ENGINE LONG BLOCKS Part Description Price 1 61 0001LONG Longblock GX160 Complete See No...

Page 93: ...ns that the drive belt will encounter during operation Tighten the engine mount lock down bolts and make sure the drive belt is properly aligned A d j u s t i n g b o l t STANDARD BELT ALIGNMENT PROCEDURE A straight edge can be used to aid in belt alignment during reassembly Place a straight edge along the axle pulley and hold the straight edge firmly against both sides of the pulley The straight ...

Page 94: ... notice Download latest update to this manual on line CHAIN DRIVE REMOVAL KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY WITH CABLE LIFE LUBRICANT 00122 00121 CABLE CARE Part Description Price 00122 Cable Lubricator Luber 20 74 3 60 0029 Cable Life Lube Only 11 99 ...

Page 95: ...and slide the engine all the way forward procedure is the same as the drive belt see page 6 7 Remove the drive chain HD 520 X RING CHAIN FPX 520 drive system chain is the new choice for concession go karts where a combination of long life high strength and excel lent impact load resistance are very important Close up view of 520 X ring chain CHAIN DRIVE COMPONENTS Part Description Price 1 20 0093 ...

Page 96: ...4 ratchet 7 16 short socket on the back side of lower sprocket assy Remove the drive chain sprocket 1032 Electric lift 1031 Air operated lift Electric Lift 3 60 0043 These small electric or manual lifts are perfect for maintaining small equipment Lawn mowers Track blasters And more SHOP LIFTS Part Description Price 1031 Lift Assy Air Operated 24 x 80 1 590 00 1032 Lift Assy Electric Operated 24 x ...

Page 97: ...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 12 ft lbs DRIVE HUB Use 1 1 4 open end wrench to prevent axle fr...

Page 98: ...lly 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 rubber mallet to remove the drive hub pulley NOTE Rotate the drive hub pulley a 1 4 turn between taps of the mallet DRIVE ...

Page 99: ...during reassembly Place a straight edge along the bottom pulley and hold it firmly against two sides of the pulley The top pulley should line up just inside the flange edge RPM SPEED GAUGES Part Description Price 1 60 0206 Gauge MPH Go Kart Vortex 0 60 mph 179 00 SOME OF THE FEATURES OF THE VORTEX PRO Simple The display will automatically wake up and show the current speed once the wheel is turnin...

Page 100: ...ed 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 Use 1 1 4 open end wrench to prevent the axle from turning R...

Page 101: ...E RIGHT TOOL FOR THE JOB Tightening axle bearings to the correct tension is essen tial and can only be accomplished with the right tools 3 96 0104 Bearing sleeve setter 1 60 0193 spanner wrench HUB PULLER Works on both 5 16 and 3 8 studs on both front and rear hubs with 4 and 3 lug holes HUB BEARING TOOLS Part Description Price 1 60 A1000 Tool Hub Puller 5 16 or 3 8 Studs Rear or Front 99 86 3 96 ...

Page 102: ...d 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 the opposite side of the jam nut to help seat the taper t...

Page 103: ...te 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 this procedure BEARING REMOVAL Tool 3 96 0104 USE THE RIGHT TOOL FOR THE JOB Tightening axle bearings to the correct tension is essen tial and can only be accomplished with the right tools 3 96 0104 Bearing sleeve setter 1 60 0193 spanner wrench HUB PULLER Works on both 5 16...

Page 104: ...t 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 BEARINGS Part Description Price 1 20 0080 Bearing Axle 1 1 4 Sleeve Lock Ring Style Ductile Housing 39 00 ...

Page 105: ... 5 Remove the drive hub pulley hub and floater hub SINGLE DRIVE AXLE REMOVAL K N s filter recharger kit is a six step maintenance system designed to recharge your K N Filtercharger air filter Completely restores air flow ef ficiency so your Filtercharger performs like new Never needs replacement 1 million mile warranty K N LIFETIME FILTERS Part Description Price SP 2748 Filter Air GX240 270 K N 39...

Page 106: ...date to this manual on line Unbolt the floater hub bearing and remove the brake caliper bracket NOTE 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 ...

Page 107: ...he 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 distributor of Kartrol in the wolrd We also repair Kartrol EXE tab...

Page 108: ...pers 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 portion of the axle that has a enough 1 4 key stock showing to allow the wrench to bite 2 Use 1 1 4 open end wrench to prevent the axle from turning USE THE RIGHT TOOL FOR THE JOB Tightening axle bearings to the correct ...

Page 109: ...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 96 0104 and a light hammer to lock the sleeve onto the axle If t...

Page 110: ...ose for now See install Brake Caliper Assembly page 7 7 010820A J J and Shaller go karts BRAKE PADS HYDRAULIC Part Description Price 010820A Brake Pad Black Square FPX Wil Sold Each Pad 7 80 1 80 MC001 Brake Pad MCP Fits 1375 1 3 8 Bore Black Sold by Each 17 99 01112 01114 010945 010942 011130 BRAKE CALIPER PARTS Part Description Price 011130 O Ring Wilwood FPX Caliper Piston 2 85 010945 O Ring Se...

Page 111: ...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 axle so the Allen bolts are facing down Use the 3 16 T handle Allen wrench between the frame and axle beari...

Page 112: ...g 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 EFFORT A Yes the go kart should be tuned to each specific track Move the spindles toward flat neutral steer one notch and drive the go kart If the go kart performs well does not pu...

Page 113: ... engine mounted Driven sprocket axle mounted Find a handy speed calculator at http www jjamusements com speed check 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 05 3 8 21 3900 17 5 3 8 21 4000 17 95 3 8 22 3650 17 17 3 63 22 3800 1...

Page 114: ...ive 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 1000 36 GTC 1 20 0100 Belt Drive 8M 1120 36 GTC 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: ... 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 valves are opened at any time THE AIR MUST BE BLED FROM THE...

Page 117: ...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 allow movement Now press and hold down the brake pedal This will brin...

Page 118: ...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 to install new brake pads Remove the brake pad retainer clip and remove each brake pad by pulling straight up Place new pads in the caliper and install the retainer clip If the retainer clip shows signs of wear replace it Refill ...

Page 119: ...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 CALIPER ASSEMBLY Access hole Access hole Access hole ...

Page 120: ...arrow with a wrench while loosening the nut Remove the brake caliper assembly BRAKE PADS CALIPER PARTS Part Description Price 010820A Brake Pad Black Square FPX Wil Sold Each Pad 7 80 1 80 MC001 Brake Pad MCP Fits 1375 1 3 8 Bore Black Sold by Each 17 99 011130 O Ring Wilwood FPX Caliper Piston 2 85 010945 O Ring Seal Wilwood FPX Caliper Halves 2 36 010942 Clip Brake Pad Retainer 2 86 01112 Piston...

Page 121: ...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 Cut brake lines for any application J J has a complete line of Steel Braided brake lines Call t...

Page 122: ...ly 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 axle mounted brake disc into correct alignment with the discs With the brakes still applied fully tighten the mounting bolts and brake hub Check and make sure the brake disc turns freely and the discs are centered inside calipers a...

Page 123: ...ston 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 applied 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 fluid in the cylinder bore Any damaged or worn seal will result i...

Page 124: ...or more control over the track operation enabling him to reduce the speed of an individual kart a group of karts or all the karts at will As an optional part of the system a device can be mounted near the pit entrance that when activated will reduce RPM of every kart that passes by it without aﬀecting karts elsewhere on the track This greatly improves safety in the pit area 1 60 9006 1 60 9803 1 6...

Page 125: ... unbolt the two 5 16 mount bolts remove the master cylinder Brake pedal removed for clarity Imagine cleaning and drying your Go kart track in the time it takes to walk it Well now you can with the Track Blaster from FPX 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 those cust...

Page 126: ... the rod until the shoulder bolts float freely in the pedal holes Remember to tighten the push rod lock nut after adjusting OIL DRAIN KITS Part Description Price 1 60 A0082 R Oil Drain Kit Engine Clutch 160 200 10 12mm fittings 52 50 1 60 A0083 R Oil Drain Kit Engine Clutch 240 270 12 12mm fittings 53 00 001010X Drain Engine Oil Drain 10mm 6 with 1 8 NPT 18 99 001012X Drain Engine Oil Drain 12mm 6...

Page 127: ...291 are replaceable see page 10 12 See page 7 12 for brake pedal adjustment BRAKE PEDAL REMOVAL 303 PROTECTANT Part Description Price 3 60 0033 Protectant 303 Aerospace 2 oz pump sprayer 2 75 3 60 0034 Protectant 303 Aerospace 32 oz trigger sprayer 24 43 3 60 0035 Protectant 303 Aerospace 128 oz gallon refill 64 21 3 60 0037 Protectant 303 Aerospace 5 gallon Bucket 279 99 It is important to mainta...

Page 128: ...6 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 the pump cap onto the empty power bleeder pressurize to 1...

Page 129: ...ems 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 hygroscopic meaning it will mix with water and still perform The J J filler cap diaphragm is designed to seal the system from outside...

Page 130: ...inger 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 add brake fluid before further bleeding Temporarily plug ...

Page 131: ...se 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 making sure the level never drops below 1 3 full NOTE Never put drained used brake fluid back into the master cylinder NOTE Always proceed in a slow and deliberate manner WARNING Bleed air whenever the brake pedal action feels soft or spong...

Page 132: ...o rotor Excessive rotor run out Master cylinder wear Have to push too hard on the brake pedal to get kart to stop properly Oil or grease on brake linings Frozen pistons in calipers Old or contaminated brake fluid Pedal free play out of adjustment Brake pad worn past service limit Kartrol is a solid state electronic engine speed limiter used on go kart motors to reduce the engine RPM by remote cont...

Page 133: ...cking 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 1 20 0080 1 1 4 sleeve lock bearing 3 96 0104 Bearing sleeve setter 1 60 0193 spanner wrench BEARINGS Part Description Price 1 20 0080 Bearing Axle 1 1 4 Sleeve Lock Ring Style Ductile Housing 39 00 00883P Bearing Axl...

Page 134: ... 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 3 96 0104 Bearing sleeve setter 1 60 0193 spanner wrench HUB PULLER Works on both 5 16 and 3 8 studs on both front and rear hubs with 4 and 3 lug holes HUB BEARING TOOLS Part Description Price 1 60 A1000 Tool Hub Puller 5 16 or 3 8 Studs Rear or Front 99 86 3 96 0104 Tool Bearing Sleeve Setter 36 99 1 60 0193 Tool Bearing Spanne...

Page 135: ...mote control This gives the track operator more control over the track operation enabling him to reduce the speed of an individual kart a group of karts or all the karts at will As an optional part of the system a device can be mounted near the pit entrance that when activated will reduce RPM of every kart that passes by it without aﬀecting karts elsewhere on the track This greatly improves safety...

Page 136: ...ings whenever shoes are removed CHANGING BRAKE SHOES F030F01 43120 0 Brake shoe kit for Falcon mechanical brake equipped go karts BRAKES MECHANICAL Part Description Price F030F01 43520 0 Falcon Brake Drum Rear 37 00 F030F01 43120 0 Falcon Rear Brake Shoe Complete inc 2 springs 2 shoes 18 95 1 80 A0018 Drum Brake 4 Hole Fits Floater Brake Hub 59 95 02550 Brake Assy 6 Internal Shoe Backing plate sho...

Page 137: ... 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 out of your way and allows for maximum hand room TECH TIP Remove t...

Page 138: ...THE FEATURES OF THE VORTEX PRO Simple The display will automatically wake up and show the current speed once the wheel is turning no on oﬀ buttons to worry about Checking the max speed average speed and other stored items is simple and easy there is almost nothing to learn Rugged The Vortex is drop proof and intended for use in a demanding environment Accurate The Vortex is accurate to within 0 5 ...

Page 139: ...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 the end of the spring into the hole The spring will snap into the h...

Page 140: ...te 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 the axle nut to 50 ft lbs Re install any split collars that may have been removed Re install the rear wheel BRAKES MECHANICAL Part Description Price 1 80 A0018 Drum Brake 4 Hole Fits Floater B...

Page 141: ...r is pushed forward 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 ITEM The procedures performed in this manual require the removal of essential safety equipment from the go kart specifically the axle cov...

Page 142: ...n Price 1 60 0060 Parts Guide GX140 GX160 and GX200 Free Download 0 00 1 60 0361 Parts Guide GX270 UT2 Free Download 0 00 Complete engine parts guides are available for download at www funpartsxpress com The Honda GX Series OHV commercial grade engine is designed for the most demanding commercial applications It has set an industry standard for reliability and durability Overhead valve design oﬀer...

Page 143: ...s 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 exhaust valve and release the built up compression during starting When excessiv...

Page 144: ...tle 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 Q I HAVE ERRATIC IDLE SPEED BUT T...

Page 145: ...d 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 plate bolts are tightened simply snug up the two 5 16 grabber plate...

Page 146: ...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 starter rope guide body support GO KART FUEL TANKS Part Description Price 001772 G Filter Fuel 60 Micron Stainless Steel PET Ho 3 5...

Page 147: ...quipped with engine mounted fuel tanks before the engine can be removed the wing will need to be raised up to clear the top of the fuel neck CAUTION Proper lifting procedures must be followed LONG BLOCK COMPLETE ASSEMBLED Includes Barrel piston rings crank rod cover comp governor kit seals crankcase Cover camshaft valves valve cover valve cover gasket exhaust studs rods Breather tube carburetor st...

Page 148: ...ght 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 01073 or J J hour meter 010732 can be used in this laser cut a...

Page 149: ...5 1 503 304 1899 www jjamusements com SCHEMATIC GX 160 GX 200 WITH HOUR METER 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: ...ge without notice Download latest update to this manual on line ON OFF Kartrol ON OFF SCHEMATIC KARTROL GX 160 GX 200 WITH HOUR METER Hour meter 010732 Coil 1 60 A0202 53020 1 60 A0203 1 60 A0094 Spark plug cap Motor grounded switch Self grounding switch ...

Page 151: ...9 fax 1 800 366 7505 1 503 304 1899 www jjamusements com Front of go kart Front o kart UNDER GLOW LIGHT UNDER GLOW LIGHT HEAD LIGHT HEAD LIGHT BRAKE LIGHT HOUR METER CHASSIS GROUND RECTIFIER OPTIONAL LIGHT OUTPUTS SCHEMATIC LED LIGHTING HOUR METER ...

Page 152: ...tions and prices subject to change without notice Download latest update to this manual on line Antenna ON OFF 3 Amp ATO ATC Fuse Grounded on engine Engine on off switch CDI Kartrol SCHEMATIC KARTROL GX 270 CDI coil ENGINE ...

Page 153: ... 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 up any extra length of wire tape or zip tie under the air cleaner...

Page 154: ...tem 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 connector blue SB120 to provide power to the starter mo...

Page 155: ...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 chassis Once the kart has been started the battery jump box is unplugged and t...

Page 156: ... 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 Black Red G A B C Electric Start Wire Schematic With Kartr...

Page 157: ...140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 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 158: ...mbly 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 the tension on the belt Once the belt is loose slip it oﬀ of the drive sprocket then rotate the bolt counter clockwise to back the motor out of the chassis R...

Page 159: ...ching 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 easil...

Page 160: ...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 The spring should not be reused the springs will lose their tension as the clutch plates wear With the clutch pressure plate removed from the weight assembly check the weights The weights should move freely from each other If they do not...

Page 161: ...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 per Honda specifications ENGINE AND CLUTCH OIL SHOULD BE CHANGED EVERY 100 HOURS ON COMMERCIAL GO KARTS THAT S ABOUT ONCE A WEEK ON MOST TRACKS MAKE THE CHANGES QUICK AND EAS...

Page 162: ... 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 163: ...ds 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 down and move the tool toward the post Use your thumb on the back ...

Page 164: ... 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 and money on these oil changes with the addition of an oil d...

Page 165: ...le 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 sure to install a round cut piece of foam like from the stock air f...

Page 166: ...g Oil 3 8 Barb 1 4 npt Female 2 47 1 50 0145 Fitting Oil 3 8 Barb to 1 8 npt male 2 24 3 50 0007 Fitting Oil Hydraulic Female Steel 29 42 3 50 0004 Fitting Oil 1 4 npt to 1 8 npt Steel Adaptor 4 00 10060 Fitting 1 8 NPT Brass 1 4 Barb Straight 1 15 3 50 0005 Fitting Oil Hydraulic Male Steel 1 8 npt 10 94 3 50 0013 Fitting Oil 1 8 npt nipple brass 1 50 001010X 001012X OIL DRAIN CHANGES MADE EASY Dr...

Page 167: ... 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 development of a simple clamping style hold down and automatic shut oﬀ...

Page 168: ... 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 ELIMINATE WATER FUEL PROBLEMS Whether you are storing fuel or operating a boat motorcycle lawn mower ATV personal watercraft snow blower generator or other machinery you need the Water Eliminator the most cost eﬀective way to re...

Page 169: ...ACKET REMOVAL PMCD17 03 COUPLERS FUEL LINES Part Description Price PMCD17 03 Coupler Female 3 16 Fuel Shutoﬀ Used with PMC22 03 Ma 12 02 PMC22 03 Coupler Male 3 16 Fuel hose Use With PMCD17 03 Female 4 44 PMCD17 04 Coupler Female 1 4 Fuel Shut Oﬀ 8 16 PMC2304V Coupler Quick Release 1 4 Barb Male Viton 90 degree Elbow 5 28 001841 Coupler Quick Release 1 4 Barb Male Polypropylene W Viton 5 28 001840...

Page 170: ... 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 place with two bolts and one screw as shown in the photo...

Page 171: ...ap 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 3 Use the special cap provided and install it on the fuel tank to be tested 4 Close oﬀ the fuel shut oﬀ at the ca...

Page 172: ...h 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 atmo sphere by permeation of the material The fuel lines are also unique and must meet special standards for non permeable fuel hose Containers of fuel will give off vapors int...

Page 173: ...orming 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 canister for any damage or leaks H o s e Fitting C l a m p C a...

Page 174: ... 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 canister may be saturated with fuel and should be replaced V e n t h o s e B l o w a i r ...

Page 175: ...9 9 FUEL TANKS phone 1 800 854 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com EVAPORATIVE SYSTEM ROUTING ...

Page 176: ...city Durable powder coat finish Note Nozzle is not included with Gas Caddy GAS CADDY Part Description Price 00223 Gas Caddy Complete 30 Gal 565 00 3 60 0066 Pump Gas Caddy Blackmer Optional for Gas Caddy One Way Fl 209 59 C200 Pump Gas Caddy 202 00 C203 Gas Caddy Vent Dome Assy 28 65 C204 Hose Assembly Gas Caddy 58 14 C205 Gas Caddy Gauge Assembly 63 21 C206 Gas Caddy Ground Wire Assembly 21 45 C2...

Page 177: ...TTLE 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 178: ...t update to this manual on line 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 179: ...usements com 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 180: ...E 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 Protects sleeved cables and prolongs cable life CABLE CARE Part Description Price 00122 Cable Lubricator Luber 20 74 3 60 0029 Cable Life Lube Only 11 99 ...

Page 181: ... Kart Vortex 0 60 mph 179 00 SOME OF THE FEATURES OF THE VORTEX PRO Simple The display will automatically wake up and show the current speed once the wheel is turning no on oﬀ buttons to worry about Checking the max speed average speed and other stored items is simple and easy there is almost nothing to learn Rugged The Vortex is drop proof and intended for use in a demanding environment Accurate ...

Page 182: ... 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 Protects sleeved cables and prolongs cable life CABLE CARE Part Description Price 00122 Cable Lubricator Luber 20 74 3...

Page 183: ...ver extension can break the springs and cause premature failure Start the engine and allow it to warm up Adjust engine idle per the Honda service manual 1400rpm 150rpm A J J Tiny Tach PN 01073 makes RPM adjustment easy just wrap the tiny tach wire around the spark plug wire The wire picks up the signal through the spark wire to activate the Tiny Tach when the en gine is started and displays the en...

Page 184: ...here the cable connects to the pedal Tighten the throttle cable lock nuts Re check 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 website at http www jjamusements com technical speedcheck htm or scan the code With a J J Vortex gauge or a tachometer where you can see it r...

Page 185: ...le override spring and cause spring failure Springs should not extend more than 1 4 6 35mm beyond their relaxed state THROTTLE PEDAL REMOVAL K N s filter recharger kit is a six step maintenance system designed to recharge your K N Filtercharger air filter Completely restores air flow eﬃciency so your Filtercharger performs like new Never needs replacement 1 million mile warranty K N LIFETIME FILTE...

Page 186: ...e bushings into frame J J 1 60 0291 THROTTLE PEDAL BUSHINGS 1031 Air operated lift Electric Lift 3 60 0043 These small electric or manual lifts are perfect for maintaining small equipment Lawn mowers Track blasters And more SHOP LIFTS Part Description Price 1031 Lift Assy Air Operated 24 x 80 1 590 00 1032 Lift Assy Electric Operated 24 x 80 1 725 00 3 60 0043 Lift Multi Lift Electric 1 222 98 ...

Page 187: ...dle 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 If the float bowl is overflowing there is a problem with the float valve f...

Page 188: ...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 the engine requires When cleaning passageways and or troubleshooting it is always necessary to clear the air passa...

Page 189: ...304 1899 www jjamusements com 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 ...

Page 190: ...he 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 SCREW Choke stop bracket prevents choke lever from inadvertently moving to ON position and fouling the spark plug CHO...

Page 191: ...he 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 rod and spring to wear resulting in slight excess movement of t...

Page 192: ... should be visible use Honda jet cleaner tool 07JPZ 001010B NOTE Any carb jet can build up with varnish or other material that will not be dislodged with carburetor cleaner or air blast always hold up to the light and verify a nice clean round hole COOL TEK ENDURANCE CLUTCH PLATES LAST LONGER AND COST LESS THAN OEM The greatest enemy of any clutch material is heat with sludge and foreign material ...

Page 193: ...I 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 DIBNCFS CZ SVOOJOH UIF FOHJOF VOUJM JU TUPQT PS CZ MPPTFOJOH UIF ESB...

Page 194: ... them more attractive for your customers prolong their life and keep them safe PROTECT YOUR INVESTMENT AND KEEP YOUR GO KARTS LOOKING NEW Faded go kart bodies Cracked seat pads 303 aerospace protectant is the answer We ve all witnessed what the sun s damaging UV light can do to fiberglass paint vinyl etc Go karts bumper boats and probably most of the products used at your facility use some or all ...

Page 195: ...ge 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 unsatisfactory vibration would soon cause damage to the mounting h...

Page 196: ...viding 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 under the rubber bumpers or brackets to keep the bodies mounted firmly Set screw Latch T bushing Ad jus tm en t BRAKE TOOLS Part Description Price 3 96 0...

Page 197: ...ace to isolate the body from the frame BODY MOUNTS F 22 GO KART E y e b o l t s Bumper Bump er GREAT PRODUCT FOR SMALLER FLEETS Requires just 4 to 15 strokes to create a powerful vacuum The integrated container 6 5 liters then neatly captures the oil preventing messy spills The calibrated walls allow easy measurement of the oil extracted A built in float switch automatically stops extraction as so...

Page 198: ...n 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...

Page 199: ... 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 operate by helping to keep dirt and or other track debris from ...

Page 200: ...e 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 the bottom of the side panel between the fenders To remov...

Page 201: ...n 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 00979 00979 00979 OIL CHANGE KITS SAVE TIME MONEY Do a complete oil cha...

Page 202: ...any personal items clothing jewelry etc must be secured and contained within the seating area 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...

Page 203: ...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 FUEL WHEN REFUELING SPILLED FUEL OR FUEL VAPOR MAY IGNITE IF ANY...

Page 204: ... Keep Hands And Arms In Car At All Times DO NOT REMOVE THIS DECAL 00980 00980 00180 001712R Kartrol is a solid state electronic engine speed limiter used on go kart motors to reduce the engine RPM by remote control This gives the track operator more control over the track operation enabling him to reduce the speed of an individual kart a group of karts or all the karts at will As an optional part ...

Page 205: ... 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 a lint free cloth Peel the backing paper from the new decal st...

Page 206: ...ncidents 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 1032 Electric lift 1031 Air operated lift Electric Lift 3 60 0043 These smal...

Page 207: ...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 Schematic 4 gauge cable with voltage battery tester page 13 52 Schematic LED lighting page 13 53 Schematic Interconnect board with Kartrol page 13 54 Schematic Interc...

Page 208: ... 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 the session disconnect the charger and check the batte...

Page 209: ...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 exceeds a predetermined amount It prevents catastrophic da...

Page 210: ...rottle 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 controller was the problem the flash code should stop and the...

Page 211: ...placement The more connections and wiring a unit has the more vulnerable the electrical system is to voltage drop VOLTAGE DROPS GOOD OR BAD Voltage drop tests are usually performed to test loads and locate circuit problems As a result we may have a tendency to think of voltage drops as bad things But voltage drops can be good or bad it all depends on where they occur in the circuit and whether the...

Page 212: ...cates 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 tip connected to the meter VOLT port is compared to th...

Page 213: ...o 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 pack to breaker switch for excessive resistance The vo...

Page 214: ... it is important to check a fuse with an ohmmeter or a continuity tester instead of assuming that it is good Use a multi meter and set the range switch to the lowest resistance range to check the fuse A good fuse will read 0 ohms depending on what the meter reads when the leads are held together and a bad fuse will read the same as holding the leads in the air The illustration below shows how to t...

Page 215: ...304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com Battery Battery Battery Battery Sevcon Controller F2 F1 B1 M1 B M2 Motor F2 A2 F1 A1 Relay Fuse SB 175 Charger Pickups Fuse Ground Positive Positive Positive Ground 4 Gauge Cable Schematic ...

Page 216: ...cteristics 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 and maintained properly The J J go kart uses a total c...

Page 217: ...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 a DVOM with a min max feature This will memorize the maximu...

Page 218: ...ARNING 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 hold down brackets to access the batteries Battery P...

Page 219: ...99 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 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 220: ...se 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 221: ...800 366 7505 1 503 304 1899 www jjamusements com 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 222: ...13 16 ELECTRIC GO KARTS Specifications and prices subject to change without notice Download latest update to this manual on line Install the new fuse in the reverse manner that the old fuse was removed ...

Page 223: ...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 the ground circuit to switch the relay on or oﬀ If system ...

Page 224: ...ine 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 225: ... 1899 www jjamusements com 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 226: ... 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 position of the actuator rod and send this information to t...

Page 227: ...ive 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 228: ...e without notice Download latest update to this manual on line 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 229: ...99 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 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 230: ...ount 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 231: ...4 1899 www jjamusements com 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 232: ...usted 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 233: ...9 fax 1 800 366 7505 1 503 304 1899 www jjamusements com 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 234: ...t update to this manual on line Slide the cable adjuster housing back through the cable mount Slide the wire through the slit in the cable mount Protects sleeved cables and prolongs cable life CABLE CARE Part Description Price 00122 Cable Lubricator Luber 20 74 3 60 0029 Cable Life Lube Only 11 99 ...

Page 235: ... 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 performance throughout the range of the kart ...

Page 236: ...n 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 note that this adjustment should be done by qualified...

Page 237: ...3 304 1899 www jjamusements com 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 238: ... 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 to go back to in case of problems Essentially this is ...

Page 239: ...ble 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 intermittent connection problems Motor Controller Removal Replace...

Page 240: ... update to this manual on line 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 241: ...ck On occasion they can be installed and not fully snapped into place causing them to vibrate out when the kart is driven If you have any type of intermittent problem that comes and goes check to see if any of the small terminals have slid out and therefore may not be making good contact with the pins The cable would not need to be replaced if the terminal has pushed out just carefully push the te...

Page 242: ...tch 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 There is no logic switches or relays on the board itself...

Page 243: ...tem 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 prevent the kart from moving while being charged C1 Out...

Page 244: ...date to this manual on line 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 245: ...4 3140 1 503 304 8899 fax 1 800 366 7505 1 503 304 1899 www jjamusements com Carefully remove the throttle input plug from the interconnect board Unplug the communication cable interconnect board cable Unplug the brake pressure switch cable ...

Page 246: ...ARTS Specifications and prices subject to change without notice Download latest update to this manual on line Unplug the on oﬀ switch box cable Unplug the relay cable Remove any wires connected to an external power point ...

Page 247: ...ed to the peripheral TS1 input connection points PE 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 board ...

Page 248: ...test update to this manual on line 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 249: ...9 www jjamusements com 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 250: ...h 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 with a snap style Deutsch conne...

Page 251: ...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 252: ...ithout notice Download latest update to this manual on line 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 253: ...ated 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 this step only if the switch box is being removed from the ...

Page 254: ...est update to this manual on line 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 255: ... 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 someone depress the brake pedal the meter will show the circ...

Page 256: ... 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 257: ...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 bleeding It s the same way we do it here at the factory Male 1 ...

Page 258: ...le With Votage Battery Tester LEFT REAR NEGATIVE POSITIVE POSITIVE NEGATIVE NEGATIVE POSITIVE POSITIVE NEGATIVE LEFT FRONT RIGHT REAR RIGHT FRONT Fuse Fuse Motor F2 A2 F1 A1 Relay Sevcon Controller F2 F1 B1 M1 B M2 Front of go kart ELECTRIC PANEL FLOOR CHARGE PICKUPS SWITCH BOX SB 175 RIGHT LEFT VOLT METER LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR ...

Page 259: ...ts com NEGATIVE POSITIVE POSITIVE NEGATIVE POSITIVE NEGATIVE LEFT REAR LEFT FRONT RIGHT REAR RIGHT FRONT Front of go kart POS POS NEG Front o kart VE TIVE UNDER GLOW LIGHT UNDER GLOW LIGHT HEAD LIGHT HEAD LIGHT BRAKE LIGHT OPTIONAL LIGHT OUTPUTS BRAKE SWITCH ON CALIPER SWITCH 1 60 0347 Schematic Led Lighting ...

Page 260: ...terconnect 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 loop detector Schematic Interconnect Board With Kartrol ...

Page 261: ... INTERCONNECT BOARD 1 2 3 4 5 6 BATT BATT 1 15 0105R3 REV 1 SB 175 END VIEW SB 175 TOP VIEW Butt connector Black Red White White Black Black wire to this plug Red wire to this plug Black BRAKE SWITCH 1 Sevcon Controller F2 F1 B1 M1 B M2 LINEAR THROTTLE POTENTIOMETER ON OFF SWITCH MOTOR CONTROLLER CHARGE INDICATOR LIGHT RELAY Fuse 2 SB 175 Fuse Charger Pickups ...

Page 262: ...l 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 controller via the Molex style plug in the A slot Wit...

Page 263: ...n 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 264: ...e 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 computer will now open the controller screen showing...

Page 265: ...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 Choose a location for the file Again it is best to save it ...

Page 266: ...he 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 is a red tag on the side that attaches to the contro...

Page 267: ...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 in the center of the screen Click the button Show to open a...

Page 268: ...ces subject to change without notice Download latest update to this manual on line 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 269: ...nload 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 department at J J for further instructions ...

Page 270: ...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 throttle...

Page 271: ...ondition 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 open the ...

Page 272: ...inum plate which is designed to distribute the heat away from the controller One other problem to look for is excessive drag on the motor causing the amperage to remain very high when the kart is in operation This can be a problem with the motor or axle or can even occur if the guest drives against the rail for an entire race Be sure to inspect the kart closely for a problem Once the controller co...

Page 273: ...cted for proper operation Be sure both contacts are in good condition and they slide both up and down freely in the holder Inspect the UHMW contact holder to be sure it is tightly fastened to kart s chassis Look for loose or damaged cables or connections Floor Plate Contacts Inspect the alignment with the karts floor charging contacts to ensure that they are making good contact with the floor plat...

Page 274: ...VE SYSTEM ROUTING 9 9 F Fender 12 5 12 6 Flash codes Testing 13 54 Flash faults 13 58 FLOOR CHARGING BRUSH SYSTEM 13 65 FLOOR PLATE CONTACTS 13 66 Frame 2 1 Frequent questions 2 1 Front hub 3 1 Frequent questions 3 2 Removal Inspection 3 3 Seal 3 6 Fuel Type 0 25 Fuel cap 9 5 Fuel Cap Fuel Tank Field Test Procedure 9 5 Fuel line fittings 8 4 Fuel tank Bracket 9 3 Engine mounted tanks 9 4 Heat shie...

Page 275: ...rt 13 44 Removal replacement 13 47 Testing 13 45 T Tapered Spindle Removal 3 5 T bushings 12 2 BRAKE PRESSURE SWITCH TESTING RE MOVAL 13 49 Throttle cable 10 1 Adjustment 10 7 Electric go kart 13 29 Electric go kart 13 27 Lubrication 10 6 Removal 10 5 THROTTLE CABLE ROUTING 10 2 THROTTLE PEDAL BUSHINGS 10 10 THROTTLE PEDAL REMOVAL 10 9 Tie rod 4 7 4 8 Tiny Tach 10 7 TINY TACH INSTALLATION 8 9 Tire...

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