J&J Amusements Falcon Go-kart 2018 Service Manual Download Page 8

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Falcon maintenance chart

ITEM

SERVICE TYPE

FREQUENCY

Body & fenders

Check

Daily

Replace

When damaged

Warning decals

Check

Daily

Replace

When damaged or illegible

Seat belt

Check

Daily

Replace

When damaged

Bumpers

Check Daily

Replace

When damaged

Pads

Check

Daily

Replace

When damaged

Brake system

Check operation

Daily

Check brake shoe wear

Every year

Adjust

When necessary

Replace

When necessary

Remote shut down system
(if equipped)

Check operation

Daily

Replace

When necessary

On/off switch

Check operation

Daily

Inspection

Monthly

Replace

When necessary

Clean terminals

When necessary

Throttle lever

Check operation

Daily

Check return o-ring

Daily

Replace

When necessary

Wheels

Check Daily

Torque wheels

When replaced

Replace

When necessary

Tires (45 psi)

Check

Daily

Replace

When damaged

Batteries

Check volts

Daily

Load test

Monthly

Replace

When necessary

Clean terminals

When necessary

Steering

Check

Daily

Battery charger

Check

Daily

Replace

When necessary

Clean terminals

When necessary

Axle & drive chain

Check

Monthly

Lube drive chain

Daily

All nuts, bolts & fasteners

Check

Daily

Torque

Yearly

Replace

When damaged

General wires & connections

Check for damage

Monthly

Clean connections

Monthly

Replace

When necessary

Clean terminals

When necessary

Summary of Contents for Falcon Go-kart 2018

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

Page 2: ... 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 503 304 18...

Page 3: ... 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 turning it over High F...

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 bends dents scratches wear color changes deterioration hardening warping seizure Specifications Specifi...

Page 5: ... guard removal page 2 2 Wheel guard installation page 2 2 Batteries page 3 1 Battery removal page 3 2 Battery installation page 3 3 Battery testing page 3 4 Battery charger page 3 4 Body page 4 1 Body removal page 4 2 Fender removal page 4 4 Power drive train page 5 1 Accellerator operation page 5 2 Replacing accellerator switch page 5 2 Circuit breaker page 5 3 Motor removal page 5 3 Relay page 5...

Page 6: ...Rear tire 11 x 3 60 5 Wheel base 32 8 840 in mm Dry weight 131 25lbs 59kg Length 55 1397 in mm Width 42 1066 in mm Height 24 4 620 in mm Ground clearance 1 8 45 in mm Seat height 8 1 205 in mm Specifications Set up anywhere p y Set up anywhere Portable inflatable Falcon track that sets up in minutes anywhere Dimensions 48 x31 5 x8 Track comes with heavy duty blower Falcon go karts not included ...

Page 7: ...at pads Strong steel rollover protection Butterfly steering wheel optional Specifications Length Width 73 185cm 45 114cm Optional Nerf Bar Rookie Go karts J J s Stinger Talon go karts fit into the middle of the pack Designed for those kids that are a little too small to drive the adult sized go karts but too large for the smallest go kart the Falcon ...

Page 8: ... Monthly Replace When necessary Clean terminals When necessary Throttle lever Check operation Daily Check return o ring Daily Replace When necessary Wheels Check Daily Torque wheels When replaced Replace When necessary Tires 45 psi Check Daily Replace When damaged Batteries Check volts Daily Load test Monthly Replace When necessary Clean terminals When necessary Steering Check Daily Battery charge...

Page 9: ...ion replace as needed Throttle lever Inspect for smooth lever operation full opening and automatic closing of lever Inspect for deterioration damage cuts and nicks of switch wiring and throttle return o ring replace as needed Tires wheels Inspect the wheels for damage Check the tires for cuts nails or other sharp objects Check the tire pressure at cold tire conditions 45 psi replace as needed Batt...

Page 10: ...5 PADS check seat seat back rollbar steer ing wheel for damage replace as needed 6 BRAKE LEVER BRAKES check lever travel check for proper action 7 REMOTE SHUT DOWN SYSTEM IF EQUIPPED verify proper operation per manufacturer s recommendations 8 ON OFF SWITCH Verify proper operation 9 THROTTLE LEVER Inspect return o ring for damage smooth operation full opening automatic closing of lever 10 TIRES WH...

Page 11: ...Go kart ID ____________________ Date _____ ______ _______ Date Maintenance performed Parts used Serviced by Finish date Maintenance Record Make extra copies for future use ...

Page 12: ...Non scheduled maintenance record Make extra copies for future use Go kart ID ____________________ Date _____ ______ _______ Date Maintenance performed Parts used Serviced by Finish date ...

Page 13: ... and cut tag along dashed line and fold along the fold line indicated Simply attach a maintenance work order tag to a machine in need of repair When maintenance is complete file with other service and maintenance information Printable work order tags Make extra copies for future use ...

Page 14: ...ach recharge until batteries go back into use CLEANING AND WAXING Storing a dirty go kart can lead to corrosion because dirt retains moisture Thoroughly wash and dry each go kart Polish and wax all painted gelcoat surfaces Spray the unpainted castings such as the engine reduction gear case spindles and related hardware with a corrosion protectant to retard corrosion and rust TIRES Inflate tires to...

Page 15: ...o pay for new replacement items The most common reason for a customer to not receive credit is failure to return the warranty item to J J If we do not receive the item we cannot get credit from our vendors and therefore cannot issue credit to the customer RETURNED GOODS POLICY No merchandise may be returned nor any account adjustments made unless authorized by J J Amusements Inc A Return Merchandi...

Page 16: ...ine compliance with this paragraph This warranty does not extend to products accessories or parts purchased for use outside of the United States or Canada Specific Exclusions Normal wear and tear items such as tires brake pads brake rotors seat belts pads spark plugs final drive belts final drive pulleys brake fluid and fuel filters Appearance related damage including but not limited to scratches ...

Page 17: ...eason 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 cor rected by a local body and paint shop CHEMICAL SPOTTING SUN FADING Some weather...

Page 18: ...warning decal cannot be read it must be replaced immediately J J carries all the decals you need See section 12 for decals and placement locations Warning decals DO NOT REMOVE THIS DECAL DO NOT REMOVE THIS DECAL 1 40 0122 1 40 0123 009815 FGD04 EST1 000 Falcon decal kit complete Includes all Falcon decals ...

Page 19: ...een the two bearings contacts the inner race of each bearing and causes a tight race system when the axle or spindle nut is tightened The bearing races and spacer are captured between the spindle or axle shoulder and securing washer and nut so that the radial ball bearings can turn freely Any roughness or binding will adversely affect battery life The bearing can be removed by using a long drift a...

Page 20: ...kshop and operations manuals www jjamusements com Wheel removal Remove rubber cap When changing rear tires you must remove the rear wheel guard to access the rear wheel See Wheel guard removal on page 2 2 Remove cotter pin castle nut and washer Wheel can now be removed from the spindle or axle NOTE Rear axle has spacer on the floater hub side ...

Page 21: ...e the rear wheel guard to access the rear wheel See Wheel guard removal on page 2 2 Remove wheel Wheel removal on page 1 2 Remove valve stem to release all air pressure from the tire Break the bead from the wheel with a bench vice or large vise grips Remove tire from wheel using tire spoons Note A jig bolted to your workbench helps keep the wheel secure while removing the tire Need the tools We ve...

Page 22: ...nspect the wheel for any damage specifically around the bead area Spray a mild soap water mix on the tire seating surface and push the new tire down onto the wheel Vise grips can be used to keep the tire from popping off the wheel as you work the bead into place around the wheel NOTE Be careful to avoid damaging the wheel Remove vise grips Replace valve stem and refill tire with air to 50psi ...

Page 23: ...Wheel gaurds Wheel guards page 2 1 Wheel guard removal page 2 2 Wheel guard installation page 2 2 The wheel guards are 1 2 inch by 4 inch virgin not recycled ultra high molecular UHMW plastic The guards are held in place by 1 4 20 elevator bolts These special bolts have a large round flat head and a square shank The holes in the wheel guard bands are precut square to match the special bolts ...

Page 24: ...r to save on shipping costs It is a good idea to remove the tape and place the guards in a sunny area to al low them to warm up and soften so they can be installed easilly The center wheel guard structure is held in place with 4 bolts To install a new replacement wheel gaurd it is a good idea to lay the new band in a sunny area to lightly heat and soften the band Replacement wheel guards are shipp...

Page 25: ...om The system Two 12VDC 50AH vent regulated lead acid batteries are wired in parallel to produce a 12 VDC system with superior capacity for long running time between charges The batteries are vent controlled and can be tipped on the side without fluid loss Batteries Batteries page 3 1 Battery removal page 3 2 Battery installation page 3 3 Battery testing page 3 5 Battery charger page 3 5 ...

Page 26: ...from the area while removing the red positive cables NOTE Both the red and the black interconnect cables are still LIVE because they are attached to the front terminals of the batteries temporarily Taping over the exposed cable ends is advised Carefully remove front battery cables the two black cables that provide ground circuit for the motor and solenoid The third black cable lead is the intercon...

Page 27: ...ery cables Lay the interconnect cables in the space between the batteries Install a hold down strap and make sure the interconnect cables are not pinched by the hold down strap See Wire diagram on page 5 6 Battery installation The batteries are wired in parallel as shown in picture By wiring the batteries this way the voltage remains 12 volts but the amperage doubles increasing the run time of the...

Page 28: ...or both of the batteries are incapable of accepting a charge and must be replaced Testing the batteries outside the kart individually using a carbon pile style tester is the best way to determine if battery is not rechargeable To check the charger fuse Unscrew fuse holder The fuse holder screws into the charger end opposite the power switch Fuse can now be removed Use a digital volt ohm meter to t...

Page 29: ...ual Specifications subject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com Body Body page 4 1 Body removal page 4 2 Fender removal page 4 4 ...

Page 30: ...ation including videos workshop and operations manuals www jjamusements com Body removal Remove the front and rear faux bumper bolts 4 Remove rear hatch cover Remove push bar seat belt harness anchor Remove brake lever and accelerator lever from steering wheel Remove steering wheel two bolts attaching to shaft flange ...

Page 31: ...information including videos workshop and operations manuals www jjamusements com Remove steering shaft cover 3 screws Remove steering shaft down cover 3 screws Remove nuts from underside of kart frame Body can now be lifted off frame Side cover accents are held on by three screws and are replaceable Side cover ...

Page 32: ...ecifications subject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com Fender removal Remove the 2 bolts holding the fender in place remove fender ...

Page 33: ... as a ground Main power feeds via 10ga wire from the two parallel wired battery pack to the 25 amp circuit breaker switch then to one side of the continuous duty relay Power also feeds 18 ga wire to the accelerator go switch at the steer ing wheel through the switch and back to the energizer circuit of the relay A separate ground wire from the other side of the relay energizer circuit goes back to...

Page 34: ...serves effectively as the return spring for the lever If free play of the lever exceeds 5 10 mm at the ball end replace the O ring to ensure switch opens upon lever release Remove lever from steering wheel Disconnect wires from harness at bullet connectors and feed wires up through steering cover top of steering cover may need to be removed Move lever to maximum open position and hold Push switch ...

Page 35: ...f switch is located at the rear of the kart under the push bar and is held in place with 2 screws Circuit breaker Motor removal Disconnect electrical connections The motor is held in place with 2 bolts and 2 allen screws The motor mount bolts are located in slotted holes for alignment of the motor sprockets chain NOTE It is important for the chain and sprockets to be in alignment Bolts Slots Slots...

Page 36: ... axle should turn at this point Relay will make audible click and power should flow to the kart motor If nothing happens no audible click no current flow to the motor Then relay has internal problem A digital volt ohm meter DVOM can be used across the two small energizer pull in windings of the relay Turn off main power system switch and using Ohm meter measure resistance between the two small ter...

Page 37: ...m the circuit breaker Actuating the normally open switch should energize the circuit to the relay and full power will show on both sides of the switch Electrical testing Resistor The resistor wire is located on the underside of the kart The resistor and motor are low impedance and high amperage units Resistance across these units will be low but there must be continuity Use voltage drop tests visu...

Page 38: ...y Green F1 15 0001 Falcon Throttle O ring Return 10 Gauge 10 Gauge F030F09 HR50 12 Battery 12v Falcon 12v50AH HR50 12 F1 15 0004 2 70 0145 Fuse Holder Mega F1 15 0003 F1 15 0120 Falcon Battery Charger 12amp 12volt 18 Gauge 10 Gauge 18 Gauge 10 Gauge 10 Gauge F030E03 31300 0 Falcon Electric Motor Assy 24v 500w 10 Gauge Green wire F030F03 34913 0 RESISTOR WIRE F1 15 0002 34 Black wire Circuit breake...

Page 39: ...ice when fitted pulls power just after the circuit breaker on off switch and using a wireless controller it interrupts the relay ground circuit to make the kart power system operative or inoperative thus control the karts It s a very desirable device to have for complete control of the ride The Kartrol unit is located inside the steering down cover See Kartrol manual for kartrol spefic information...

Page 40: ...tery Battery Charger Motor Circuit breaker On Off Switch 18 Gauge 10 Gauge 10 Gauge 18 Gauge Green wire Butt connector White wire Black wire 10 Gauge 10 Gauge 10 Gauge 10 Gauge 10 Gauge Note Wires reversed at this connector due to motor polarity F1 15 0120 Falcon Battery Charger 12amp 12volt F030F09 HR50 12 Battery 12v Falcon 12v50AH HR50 12 F1 15 0004 2 70 0145 Fuse Holder Mega F1 15 0003 F030E03...

Page 41: ...mbly fix seat with two attaching points that allows it to swing from the frame A third attaching point is a slotted stay arm fix plate that serves to adjust the drive chain tension and stabilize the assembly when tightened To remove the axle assembly first disconnect the brake cable from the brake arm Loosen the two swing bolts and adjuster bolts from the yoke assembly Move the axle assembly to lo...

Page 42: ... stay adjuster bolt Double check chain deflection The drive chain is a rivet link chain there is no master link To replace a worn chain first loosen the two upper yoke bolts that attach the axle to the frame then loosen the adjuster stay bolt on the yoke Push the axle forward to loosen the chain You can then remove the chain from the sprockets and move it toward the drive wheel tire Remove that wh...

Page 43: ...www jjamusements com Floater wheel The Falcon go kart is equipped with single wheel drive to allow for easy steering This is accomplished with a floating wheel hub on the right rear of the go kart The floater wheel simply spins freely on two bearings Note the position of collars and or spacers during disassembly assembly B e a r i n g C o l l a r S p a c e r W a s h e r ...

Page 44: ...1 2 anchor bolts on 10 1 2 centers and 1 1 2 NPT nipple to interface with park fresh water supply system Uses 24VAC current provided by transformer included Always check local codes Metal parts are protected by special double coating process for corrosion protection Each unit can be adjusted height water flow and pivot arc to meet your needs Fitted with a quick change coin token mechanism The pond...

Page 45: ...ns manuals www jjamusements com Brakes Brakes page 8 1 Cable adjustment page 8 2 Changing brake shoes page 8 3 The right side collar sleeve can be removed and the brake drum removed from its spline Note the rubber dust cover protector that helps keep dirt out of inner brake drum surface When installing axle nuts torque to specification and replace cottar pins ...

Page 46: ...hoes engaging the drum Adjust so the brake lever moves 10 20 mm at the ball end of the lever Adjust brakes at brake drum Make fine adjustments at steering wheel lever only The parking brake is set with a lock out lever on the brake lever To engage the parking brake pull the brake lever RED in and push the black lever into the gap made between brake lever and lever body To release the parking brake...

Page 47: ...xle sleeve Slide brake drum away to access the brake shoes The brake lining thickness service limit is 2 0mm 008 If either lining is worn beyond the service limit replace both brake shoes To remove the shoes grab both brake shoes as shown and pull inwards to release the tension from the retaining springs Remove the springs and shoes Discard worn shoes and springs NOTE J J recommends always install...

Page 48: ...including videos workshop and operations manuals www jjamusements com This welded steel tube frame is very strong It is replaceable however if you are experiencing frame damage you should curtail bumping These karts are not intended as bumper cars Speeds can also be adjusted Call J J service for how to Frame Frame page 8 4 ...

Page 49: ...achined on one end to fit the lower ball bearing and is threaded to provide for attachment of tie rod ends The lower shaft bearing is a light press fit into the frame mount providing a strong and easily turned steering shaft A plummer block housing is mounted to support the shaft and uses replaceable plastic bushing as a wear surface Steering page 9 1 Steering column page 9 2 Toe in adjustment pag...

Page 50: ...ation including videos workshop and operations manuals www jjamusements com Steering column To remove unbolt the steering wheel and set aside leaving cables and wiring attached Remove the two nuts holding the plummer block together and remove the upper half of the block Remove tie rod ends using 17mm wrench or socket ...

Page 51: ... sure the shaft turns smoothly with no excess lateral movement Clearance on the soft plastic bushing should be no more than 0 0012 inch The studded rod ends are threaded right turning or left turning to match the tie rod which is threaded right turning on one end and left turning on the op posite The 8mm jam nuts are also right and left turning thread The right turning threads on the tie rod are o...

Page 52: ...nt and back Compare the two measurements the front measurement toe in should be 5mm less than the rear measurement To adjust loosen the four jam nuts on the tie rods remember the right and left thread Turn each tie rod an equal amount to achieve the desired toe in More toe in causes more self centering when steering wheel is released however it takes more effort to turn the wheel When adjustment i...

Page 53: ...er removal on page 4 4 Remove tie rod from spindle Toe in adjustment on page 9 4 Remove rubber dust cap Remove cotter pin and castle nut Spindle will slide out the bottom Inspect the king pin for damage or cracks Measure king pin outer diameter Upper limit 15 40mm Lower limit 16 90mm Inspect bushings There are two bushings in the A arm Check bush ings for wear or damage Measure the inside diameter...

Page 54: ...s building bumper boats The original owners of J J Amusements operated several busy family entertainment centers and used that experience to develop the world famous Waterbug and Blaster bumper boats The rugged fiberglass hull boasts the largest load capacity 450lbs in the industry State of the art corrosion resistant materials add safety a long service life and simplicity of operation and mainten...

Page 55: ...using the push bar studs The harness goes over the driver s shoulders and uses a single crotch mount for the release mechanism The crotch strap feeds through the body and mounts directly to the kart frame NOTE To obtain the proper relationship of the shoulder harness to the driver the belts feed through the push bar and come over the top Seat belt pads Seat belt removal page 9 8 Seat pad removal p...

Page 56: ...ations manuals www jjamusements com Seat belt removal To access the seat belt bolts remove the rear battery cover NOTE Never operate a kart without seat belts Remove the nuts holding the push bar seat belt bracket in place Remove the push bar to access the seat belt brackets Remove the nut bolt on the under side of the kart that holds the seat belt bracket ...

Page 57: ...ss to the seat bottom nuts is under the kart Remove 2 nuts and seat pad will pull off top of body NOTE When replacing pads make sure self locking style nuts are used The seat pad is held in place with 2 studs as shown The seat back pad is access through the battery compartment Remove batteries See Battery removal on page 3 2 to access the 2 nuts Seat back pad can then be removed Seat pad removal ...

Page 58: ...hout notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com Steering wheel pad is attached with 4 phillips head screws Remove screws replace pad NOTE Never operate a kart without pads Steering pad removal ...

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