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BELOW ARE EXPLANATIONS OF THE SERVICES LISTED IN THE MAINTENANCE CHARTS FOR
ELECTRIC-POWERED GO-KARTS.
The proper fluids and lubricants to use are listed in this section. Make sure to always use the recommended fluids and lubricants. All
parts should be replaced, and all necessary repairs done before the kart is operated.
‹
CAUTION
›
J&J recommends use of safety goggles or approved glasses during all servicing of J&J go-karts.
1. SB175 CHARGER PLUG/CHARGER BRUSHES: Make sure that the plug is lubed with dielectric grease. Inspect the plug for deep
grooving or signs of arcing. Make sure charger brushes
(if equipped) are in good condition and they both slide up and down
freely
in the holder. Inspect the UHMW brush holder to be sure it is tightly fastened to kart’s chassis. Look for loose or damaged cables or
connections. Check that the brushes are making good contact with the floor plates. Repair or replace as needed.
2. 4 GAUGE POWER WIRE: Check for bare wires or heavy discoloration; Replace as needed.
3. MOTOR: Check for discoloration of the motor casing and tightness of the terminal. Use compressed air to remove dust and debris
.
4. CHARGE-STOP FUNCTION:
Ensure that with charger plugged in, the acceleration function does not work.
5. SWITCH BOX:
Check the switch box for proper operation (see service schedule). Externally inspect the switch box for bare or
damaged wires. Check and tighten the set screw for the on/off and forward/reverse knob (see service schedule).
6. BATTERIES: Check the terminal connections for tightness.
7. COMPONENT BOARD:
Remove the cover and inspect all the components. Check for bare wires, proper connection, and any signs
of excessive heat, arcing or melting.
8. FRONT HUBS AND SPINDLES:
Inspect and grease the front spindles every 2 weeks or 200 hours. The front hub nuts should be
torqued to 50 ft. lbs.
9. AXLE & AXLE BEARINGS:
Inspect the axle for bending and cracking. Clean and grease all axle bearings 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, alignment and tension. Twisted or cracked belts should be replaced.
<
WARNING
> :
Too much tension shortens belt and bearing life.
12. PULLEYS & SPROCKETS:
Inspect for proper deflection and alignment.
13. WHEEL LUG NUTS & STUDS:
Check for loose wheel lug nuts and studs daily, and torque to 35 ft. lbs.
<
WARNING
> :
Check the tightness frequently during the first week or 100 hrs, and when the wheel is changed.
14. ALL NUTS AND BOLTS: Check for loose and/or missing nuts and bolts. Replace as needed.
15. HYDRAULIC DISC BRAKES INSPECTION:
When the engine oil is changed, inspect the lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Check the fluid level in the master cylinder. A low fluid level can indicate worn disc brake pads,
which may need to be replaced. Inspect the disc for wear and alignment.
<
WARNING
> : Inspect brakes more often if driving conditions result in frequent braking.
16. SEATBELTS: Inspect all belts, buckles, latch plates and anchorages daily, replace if necessary
.
<
CAUTION
> :
Don’t let anyone operate the go-kart if they can’t wear a seatbelt properly. If the kart is in a crash and they are not
wearing a seatbelt, they could hit things inside the kart or be ejected from it; they can be seriously injured or killed. Always properly
fasten customers’ seatbelts, and then double-check to make certain the straps are not loose.
17. TIRES: For proper wear and maximum tire life, rotate the tires and check inflation (see service schedule). A properly inflated
and aligned tire should wear evenly across the tread. Replace tires when the wear indicator lines are no longer visible around the
sidewalls.
18. CHASSIS LUBRICATION:
Lubricate the steering linkage, throttle linkage, pedal, and throttle control arm at the specified intervals,
or after washing. When used in dusty or wet conditions, service more frequently.
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES
