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J&J Amusements King Scorpion, Service Manual

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J&J Amusements King Scorpion Service Manual Download Page 166

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GO

-KARTS

B

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MPERBOAT

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

503-304-8899

ENDURANCE CL

UTCH PLA

TES

TM

 REMOTE FUEL  TANK REMOVAL

NOTE: Remove the fuel from the tank before 
removing the tank from the go-kart by using a Gas 
Caddy (J&J #00223). The Gas Caddy is equipped 
with a reversible pump for this purpose.

<DANGER> 
Gasoline is highly flammable. Do not drain the fuel 
tank near any open flame or heaters.
Always use approved containers for fuel storage.

Remove the four Allen-head fuel tank mounting 
bolts.

Disconnect the fuel line.

TECH TIP: The quick-connect fitting in the tank 
has an automatic shut-off, but a small amount of 
spillage will occur. Place a rag or cloth under the 
fuel tank quick connector to keep fuel off of the axle 
cover.

Lift one side of the fuel tank and remove.

GAS CADDY:
Tired of the 5 gallon gas can hassle? Concerned about safety? Insurance inspector 
been bugging you? The Gas Caddy can be your salvation. Featuring heavy-gauge 
epoxy powder coated and welded steel construction, the sturdy wheels also allow 
easy roll-around for up to 30 gallons of fuel. The clear hose enables you to observe 
flow, and the reversible rotary pump allows you to dispense or remove fuel. The sight 
gauge keeps tabs on the amount of fuel remaining in the unit. Every Gas Caddy 
includes a ground wire clip. Be Safe; Sleep Nights; Get a Gas Caddy.

 (

J&J #00223)

Summary of Contents for King Scorpion

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

Page 2: ...rd 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 unauthori...

Page 3: ...w 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 you...

Page 4: ...sassembled 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 de...

Page 5: ...ing 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 ka...

Page 6: ...ns 13 2 Basic electrical troubleshooting 13 4 Voltage drop testing 13 7 Testing fuse 13 8 Wire schematic 13 9 Battery pack 13 10 Battery pack testing 13 11 Battery pack replacement 13 12 Fuse 13 13 Re...

Page 7: ...ve 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 centrifug...

Page 8: ...ve 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 centrifug...

Page 9: ...Speed controller sevcon Power 48 vdc qty 4 12 volts blue yellow optima battery 870 amps cold cranking amps per battery 120 amps reserve capacity per battery DRIVE TRAIN Clutch type direct drive Forwar...

Page 10: ...on 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 For...

Page 11: ...forced air Starting system recoil optional electric start Spark plug bpr6es ngk w20epr u nd Lubrication system splash DRIVE TRAIN Clutch type centrifugal wet multi disc Clutch engagement lock engageme...

Page 12: ...on 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 revers...

Page 13: ...nd 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 th...

Page 14: ...ont 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 shorte...

Page 15: ...djust 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 d...

Page 16: ...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...

Page 17: ...s 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 n...

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

Page 19: ...roll bar steering wheel and steering post pads for damage replace as needed 6 ACCELERATOR check for smooth operation and full return when released 7 BRAKES check pedal travel check for proper action d...

Page 20: ...ooth 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 t...

Page 21: ...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...

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

Page 23: ...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 w...

Page 24: ...inants 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...

Page 25: ...e 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 flu...

Page 26: ...ay 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 vendo...

Page 27: ...nce 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 t...

Page 28: ...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 an...

Page 29: ...uck certified Each go kart is mounted to the shipping rack with two brackets The brackets are mounted on each side of the kart in a diagonal pattern Remove each bracket before the go karts are unloade...

Page 30: ...from the kart below Repeat the same steps for the remaning karts NOTE When removing the middle and bottom karts make sure to keep clearance from the steering wheel and the cross bar Go karts are ship...

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

Page 32: ...tick 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 reco...

Page 33: ...he 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...

Page 34: ...O SPILL FUEL WHEN REFUELING SPILLED FUEL OR FUEL VAPOR MAY IGNITE IF ANY FUEL IS SPILLED MAKE SURE THE AREA IS DRY BEFORE STARTING THE ENGINE NEVER REFUEL WHEN RIDERS ARE PRESENT J J Amusements Inc 1...

Page 35: ...on go kart tire by working with a large manufacturer and buying in bulk The J J Bigfoot tire was introduced to provide a new tire with extra thick tread while maintaining overall diameter in order to...

Page 36: ...r over or under other karts When replacing tires all four tires should be replaced at one time CAN I MIX AND MATCH TIRES Ideally tires should be of the same type and design have the same tread depth a...

Page 37: ...ehicles such as trucks trailers and buses with hub piloted wheel systems They are used only on J J serrated bead lock rims 1 50 0189 The system is essentially a double nut with ramps on two mating hal...

Page 38: ...jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Proper installation of socket over both halves of Disc Lock nut Improper fitting of socket over the nut causes the nut to come apart Two halves...

Page 39: ...go kart due to jack failure Avoid the possibility of injury NEVER get under a go kart when it is supported only by a jack Using a 15mm deep thin wall socket for 3 8 disc lock lug nuts remove the four...

Page 40: ...Remove the rim half from the valve stem side of the tire J J part 3 96 A0001 Bead Breaker recommended Remove the tube from the tire so that is does not get pinched Flip the tire over and press out the...

Page 41: ...rim half bolts in the magnetic sockets of the tire assembly tool J J Part 1 20 T0001 Install the rim half valve stem rim half into the tire assembly tool and down over the bolts Place the tire on the...

Page 42: ...im half onto the tool Screw down the self centering retaining nut as far as possible by hand Pull on the lever on the bottom of the tool to squeeze the rim halves together Install the lock washers and...

Page 43: ...or easy loading The lift is a solid steel fabrication and is powered by a pneumatic cylinder from your air source 90 100 psi It can be used with or without accessories W 24 x L 80 CE Approved MADE IN...

Page 44: ...worn down past the last line WHEEL REPLACEMENT Replace any wheel that is bent cracked or badly rusted If the wheel nuts loosen frequently the wheel bolts and nuts should be replaced Elongated stud hol...

Page 45: ...weight distribution a go kart can appear to operate normally Watch for the bead being not quite seated on the rim or the valve stem being loose at an odd angle or missing FRONT TIRE WEAR If the steeri...

Page 46: ...SL72 739 Slick 4 Ply 3 5 W x 10 8 od 16 50 14 99 26 25 21 90 43 00 12 99 1 20 0054 TIRES 738 Tire 4 10 3 50 4 SL72 738HD 15 80 TUBES 1 20 0048 1 20 0038 1 20 0045 00780 M 1 20 0027 00782 Tube 10 x 4 5...

Page 47: ...shop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FRAME OVERVIEW Frequent questions page 2 1 Go kart frames are robotically welded then cleaned and powder coated...

Page 48: ...l replacement page 2 5 FAQ s Q CAN THE BUMPER BE REPAIRED OR WELDED A No The bumper is made of a special spring steel It can not be welded or modified J J offers a limited lifetime warranty on its ste...

Page 49: ...r it is common for the hardware to get damaged Replace any hardware as necessary Bent D rubber plates can be straightened and reused as long as the nut cannot pull through the hole in the plate Inspec...

Page 50: ...r plate Fasten the 5 16 flat washer and the 5 16 nylock nut to the bolt Install all bolt plates nuts loosely before attempting to tighten any Tighten all bolts evenly Using a rubber hammer make sure t...

Page 51: ...ubbers two corner B and two center C D rubbers The corner D rubbers are frame mounted only NERF BAR REMOVAL AND INSTALLATION Loosen the two center D rubber rail bolts Remove the two center D rubber fr...

Page 52: ...bar by pulling it out of the two center D rubbers WARNING DECALS WARNING Go karts have rotating parts Hair longer than shoulder length must be secured above shoulder Serious injury or death could occu...

Page 53: ...nformation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FRONT HUBS SPINDLES Frequent questions page 3 2 Front hub removal page 3 3 Spin...

Page 54: ...n the bearings are replaced it is a good idea to also replace the inner spacer that goes between them If this spacer becomes worn the bearings receive too much lateral preload when the hub is tightene...

Page 55: ...his indicates that it needs to be replaced Also inspect the spacer between the bearings it should be snug with little play between the two inner bearing races The bearings for the hub of the radius cu...

Page 56: ...reely and smoothly in the yoke Any free play or roughness means the spindle should be broken down further and the bearing cups inspected NOTE See the Steering Adjustment section page 4 6 for complete...

Page 57: ...ATES TM Remove the wheel from the hub Gently tap the dust cap off of the hub to expose the end of the spindle Slide the hub off of the spindle be careful not to drop the outer bearing as the hub comes...

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...

Page 59: ...d to aid retention when it sets up Insert the newly packed bearing into the appropriate race Install the front wheel bearing thrust washer and castle nut Torque the castle nut to 15 ft lbs to seat the...

Page 60: ...ocket works well Using a suitable tool press the top bearing cup until the bottom one falls out Remove the spindle from the press the u joint can be twisted and removed from the yoke The other bearing...

Page 61: ...ent caps Replace the bearing cap by inserting it partially into the yoke Begin installing the universal joint into the cap Partially insert the opposing cap Line up the universal joint and push both c...

Page 62: ...VAILABILITY ALL PRICES ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE Part Description Price 7 7RRO KHHO VVHPEO LWK 0DJQHWLF 6RFNHWV 800 854 3140 503 304 8899 www FunPartsXpress com LYLVLRQ RI PXVHPHQWV Q...

Page 63: ...videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM STEERING SYSTEM Steering system adjustments Overview page 4 1 Caster page 4 3 Toe in page 4 6 Tie r...

Page 64: ...ter Positive caster provides the directional stability in your go kart Too much positive caster will make the steering effort difficult Power steering will allow you to run more positive caster Negati...

Page 65: ...straightened The frame has four small index holes on the spindle mount Each hole represents a different setting The first hole closest to the front of the kart represents 0 degrees and the fourth hole...

Page 66: ...arts Our legendary Bigfoot tire with its extra thick tread will help keep your karts on track generating the revenue Bigfoot tires and tubes ship from either our west coast or east coast location so t...

Page 67: ...lls of the tires A tape is placed on the inside front of the tire as near to the rim as possible as close to center horizontal as possible and then measured in the same location on the front edge of t...

Page 68: ...center position before toe can be set correctly Now from the front of the spindle facing the front of the go kart measure the distance from the frame rail to the straight edge Subtract the measurement...

Page 69: ...cifications Tighten the lock nuts and then recheck measurements Make sure that when the wheels are straight the steering wheel is in the center position Cable Lubricator 00122 Cable Lube 3 60 0029 Cab...

Page 70: ...rods can be bent during heavy impacts Bent tie rods can be removed straightened and re installed The tie rod ends can be removed by holding them with an open end wrench or appropriate adjustable wrenc...

Page 71: ...toe in it is important that the rod ends be positioned properly The rod ends should be perpendicular to their mounting surface at rest When the kart is steered the tie rods twist If the tie rod ends a...

Page 72: ...ntly have by using a set of turn plates Typically Ackerman is measured by turning the right front tire 10 degrees to the left If you have Ackerman the left front will travel further than the right fro...

Page 73: ...g shaft for straightness Clean and inspect the steering bushings for damage and wear bushings should fit snugly to the shaft while still al lowing the shaft to pivot with only slight resistance Check...

Page 74: ...steering wheel and pad for damage Replace as needed SAFETY ITEM All J J karts use a pad on the steering wheel column to help reduce the possibility of injury to the rider s in the event of a collision...

Page 75: ...pad Installation is performed in the reverse order of removal NOTE When installing the steering pad be careful not to over tighten the nut CAUTION If any part of the pad is torn or damaged enough to...

Page 76: ...e unit Every Gas Caddy includes a ground wire clip Be Safe Sleep Nights Get a Gas Caddy J J 00223 Change oil in the pits Change oil in your whole fleet in 30 minutes Protect your engines Save time and...

Page 77: ...6 Seatbelts page 5 7 Cleaning seatbelts page 5 9 FAQs Q CAN I WELD THE ROLL BAR SOLIDLY TO THE FRAME A Yes using proper safety and welding techniques in addition to mounting bolts the roll bar of the...

Page 78: ...NOTE The holes on the back side of the receiver are larger to allow nuts to draw directly against the roll bar thus cinching it tight to the receiver 1 4 bolts attach the roll bar to the seat back NO...

Page 79: ...llow for body removal A clipped hitch pin secures the roll bar A locking set screw holds the roll bar in place and prevents it from rattling Acorn nuts are used to help reduce the possibility of injur...

Page 80: ...ugh the plywood Any pad with damage that exposes the underlying part should be replaced Torn pads that do not completely cover parts such as the roll bar back panel or steering column can cause injury...

Page 81: ...aged pads that expose any part of the back panel assembly The Sidewinder and Sidewinder Double seat back pads are glued onto the body there are no bolts holding them to the frame or body When replacin...

Page 82: ...com 503 304 8899 ENDURANCE CLUTCH PLATES TM Sometimes pads get small tears or rips in the outer skin If the pad has one of these you can easily repair it with Rapid Patch J J 1 60 0071 Clean the area...

Page 83: ...tpan of the chassis Be sure to orient the belt brackets as shown The photo below shows the reinforcment plate used on the bottom side of the chassis seatbelt mounting point Inspect all seatbelt pads f...

Page 84: ...tead of the chassis NOTE Orient the seatbelt mounting tabs as shown The backside of the lap belt attachment utilizes a fender style washer large flat to keep the bolt from pulling through the body Whe...

Page 85: ...lution when cleaning the seatbelts CAUTION No chemicals should be used to clean the seatbelts or their mechanism We carry many of the tools you ll need to keep your facility looking great THE FPX J J...

Page 86: ...subject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM CONTACT J J F...

Page 87: ...9 ENDURANCE CLUTCH PLATES TM AXLE AXLE COVER DRIVE SYSTEM COMPONENTS Overview page 6 2 Axle cover page 6 3 Drive cover page 6 4 Drive belt page 6 6 Drive hub page 6 11 Drive pulley page 6 12 Floater h...

Page 88: ...g access for maintenance The vacuum formed system is made from high impact TPO plastic for long life It is purposely rubber mounted to the frame to avoid cracking from vibration FREQUENT QUESTIONS Q C...

Page 89: ...8899 ENDURANCE CLUTCH PLATES TM Remove the engine see page 8 1 Remove the axle cover shoulder bolts Remove the wheel and fender Lift the rear of the axle cover and pull the cover away from both the ce...

Page 90: ...503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive wheel Remove the lower wing support bolts Move the wing support up and tighten the upper wing support bolt to hold it out of the way DRIVE COVE...

Page 91: ...sements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive cover Allen bolts Pull the drive cover rubber flap away from engine Pull the drive cover from the front support clip D r i v e c o...

Page 92: ...S TM NOTE Before engine can be moved or removed the grabber plate must be loosened see page 8 3 Using a 9 16 offset ratcheting box wrench loosen the engine mount lock down bolts DRIVE BELT REPLACEMENT...

Page 93: ...just the drive belt tension by turning the motor adjusting bolt clockwise to loosen belt tension and counterclockwise to tighten belt tension by using a 3 4 socket with an extension NOTE Make sure the...

Page 94: ...website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM CHAIN DRIVE REMOVAL KEEP YOUR THROTTLE CABLES OPERATING...

Page 95: ...SPROCKET REPLACEMENT The tension adjustment procedure is the same as for the cog belt 1 2 of deflection up or down is the correct tension Install the drive chain on the top and bottom pulley Turn the...

Page 96: ...M If adjustment is needed use a 1 4 Allen wrench and loosen the two 5 16 x 1 1 2 Allen bolts on the drive hub Remove the six nuts with a 1 4 rachet 7 16 short socket on the back side of lower sprocket...

Page 97: ...two set screws Remove the drive hub from the axle If you need a puller use J J 1 60 A1000 The axle should be straight and free of burrs Apply a dab of anti seize to the axle coat the area where the hu...

Page 98: ...htly tap it in This will loosen the drive hub and allow for easy removal In some cases it may be necessary to carefully use a propane torch to heat the hub to aid removal WARNING Always use proper saf...

Page 99: ...hub and or the key stock must be replaced Install the drive hub in the reverse order of removal Before tightening the two Allen bolts the drive hub will need to be aligned with the engine driven pulle...

Page 100: ...oater hub nut and recessed washer NOTE The special recessed washer is cut out on one side this recess always goes toward and contacts the bearing inner race This allows the entire floater hub to be ti...

Page 101: ...3 304 8899 ENDURANCE CLUTCH PLATES TM FLOATER HUB INSTALLATION Apply anti seize to the axle Install the floater hub Install the recessed washer with the recess toward the bearing Torque the floater hu...

Page 102: ...ng the jam nut and indexed by the inner tab to the tapered sleeve The jam nut is beveled on the side facing the lock ring Using the spanner wrench J J part 1 60 0193 tighten the jam nut which draws th...

Page 103: ...with a spanner wrench J J 1 60 0193 To remove the bearing you must first break loose the bearing sleeve assembly Use a brass hammer and J J bearing removal tool 3 96 0104 Place the tool over the axle...

Page 104: ...www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM The bearing assembly can be removed as a whole at this time or you can remove the jam nut and lock ring and remove all pieces separately R...

Page 105: ...tions manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the drive cover page 6 4 drive pulley page 6 12 and engine page 8 1 Remove the axle cover page 6 3 and brake caliper a...

Page 106: ...his can be done without disassembling the caliper assembly Unbolt the drive axle bearing and remove the cog pulley skid guard Unbolt the center axle bearing and lift the axle out of frame MAKE QUICK W...

Page 107: ...ely install the axle bearing bolts NOTE Always set and tighten the center axle bearing last Make sure the floater hub is slid all the way onto the axle Make sure the recessed washer is installed with...

Page 108: ...a C clamp lightly snug the floater hub disc brake rotor with the block sandwiched to frame This will maintain this critical 2 distance while the drive side axle bearing is set NOTE If the axle has shi...

Page 109: ...bearing nut After the bearing is tight to the axle tighten the bearing flange to the frame mounting bolts Next set and torque the floater hub axle bearing NOTE ALWAYS SET AND TORQUE THE CENTER AXLE B...

Page 110: ...03 304 8899 ENDURANCE CLUTCH PLATES TM Install the brake caliper assembly see page 7 7 NOTE The floater hub brake disc needs to be in the center of the brake caliper Align the axle mounted drive brake...

Page 111: ...e from shifting during side impacts Apply blue Loctite on each of the split collar Allen bolts Loosely install the split collar on the axle and slide it up against the inside of the drive bearing Even...

Page 112: ...design forces the go kart in a straight line so steering effort is increased Note that castor settings for the front spindles are different from and specific to the axle configuration FAQ S Q THE GO K...

Page 113: ...4 00 5 Bigfoot tire 36 12 inches in diameter Drive sprocket engine mounted Driven sprocket axle mounted Find a handy speed calculator at www jjamusements com technical speedcheck htm Drive sprocket t...

Page 114: ...Belt Drive 8M 640 36 FL Rubber 1 20 0070 Belt Drive BX32 Tri Power Used on Pacer Karts PM 2 1 20 0072 Belt Drive 8M 720 36 SYNCHROCHAIN 1 20 0073 Belt Drive 8M 800 36 SYNCHROCHAIN 1 20 0074 Belt Drive...

Page 115: ...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...

Page 116: ...brake fluid or oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with Brake Kleen or other suitable cleaner Do not use cleaners that will leave an oily residue R...

Page 117: ...iper to its mounting bracket NOTE One washer is concave and the other is convex they mate together as shown in the drawing There is always a little bit of misalignment in any mounting system of this t...

Page 118: ...o avoid leaking brake fluid out of the cap Before pushing the caliper pistons back clean the exposed portions of the piston this will avoid damage to the piston seals Before removing the old pad gentl...

Page 119: ...ch to hold the brake line and keep the brake line from twisting Loosen and remove the brake line by using a 9 16 wrench Remove the brake pad retainer clip Remove each brake pad by pulling it straight...

Page 120: ...PLATES TM Using an air or electric impact wrench remove the caliper mounting nuts NOTE If needed use a breaker bar to help loosen the caliper mounting nuts You will need to hold the mounting bolt arro...

Page 121: ...the calipers line up we have used concave convex spherical washer pairs Snugly attach both of the brake caliper assembly mounting bolts NOTE It is always a good idea to loosen the axle mounted disc b...

Page 122: ...to remove the wheel to pull the pin when changing brake pads Bleed the brakes using a power bleeder 3 96 0032 or the Pump Bleed procedure on page 7 17 With the washers installed as shown simply snug...

Page 123: ...ylinder chamber The at rest position of the master cylinder piston and seal is critical You can see that it sits just past the fluid intake and return port small hole When the brake pedal is ap plied...

Page 124: ...uipped with a master cylinder guard The fluid level can be checked with the guard attached Recommended brake fluid Automotive D O T 3 or D O T 4 NOTE The go kart is equipped with D O T 3 brake fluid a...

Page 125: ...bers and remove the master cylinder angle guard Disconnect the brake line from the master cylinder Remove the brake pedal page 7 13 and unbolt the two 5 16 mount bolts remove the master cylinder Brake...

Page 126: ...this condition simply grasp the adjuster and check for free play between the pedal holes and the shoulder bolts The adjuster should have a slight movement wiggle without binding To adjust simply loos...

Page 127: ...he brake pedal spring Use pliers to pull and guide the spring from the hole on the frame Unbolt the 3 8 nut and remove the 3 8 x 4 bolt Remove the brake pedal The brake pedal bronze bushings 1 60 0291...

Page 128: ...de a handy brake fluid change pump the power bleeder 3 96 0032 This pump allows one person to bleed the brake system Simply remove old brake fluid from the master cylinder with turkey baster and refil...

Page 129: ...mplified Moisture is the greatest enemy of hydraulic brake systems All DOT 3 and DOT 4 systems use Poly Glycol based fluid that has a relatively high boiling point DOT 3 401 F DOT 4 446 F NOTE This is...

Page 130: ...er push rod or brake pedal all the way down and place a finger over the master cylinder outlet fitting to seal it Let the brake pedal or the master cylinder rod return fully before removing the finger...

Page 131: ...and hold Open the bleeder valve the pedal will move to the end of the stroke as the cylinder pushes the air fluid through the system DO NOT RELEASE THE PEDAL Hold the pedal all the way down until the...

Page 132: ...back Bad bearings Improper installation of rebuild parts Pedal goes to the floor after one or two laps Floater hub bearing failure Bent brake disc Axle bearing and or floater hub bearing loose or bad...

Page 133: ...ng shoe drum brake system This simple and direct configuration provides positive braking and easy maintenance When the brake pedal is applied a rod and lever linkage transfers pressure to an eccentric...

Page 134: ...ns manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM DRUM BRAKE PARTS IDENTIFICATION A ct ua tin g ro d B r a k e d r u m F lo a te r h u b B a c k i n g p l a t e C a r r i e r C a...

Page 135: ...rom the go kart page 1 5 Remove the axle nut 1 1 16 and axle collar from the axle and place to the side NOTE The axle collar is recessed on the side fac ing the brake drum Slide the hub drum assembly...

Page 136: ...03 304 8899 ENDURANCE CLUTCH PLATES TM Grab both brake shoes as shown and pull inwards to release the tension on the retaining springs Remove the springs and shoes Discard worn shoes and springs NOTE...

Page 137: ...inside brake drum hub There are 7 16 jam nuts on the inside of the drum hub assembly Slide the hub away from the backing plate to allow access to the drum hub jam nuts Slide the drum over the hub tow...

Page 138: ...d operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Grab both brake shoes as shown and pull inwards to release the tension on the retaining springs Remove the springs and...

Page 139: ...tom spring in place and move them into position around the axle Work the shoes over the bottom and top pins With the bottom spring in place it allows the shoes to hold their position while you install...

Page 140: ...hub assembly over the newly installed brake shoes until the drum stops at the backing plate Pull the drum assembly out 1 16 from the backing plate so the drum does not drag on the backing plate Re ins...

Page 141: ...free play between the lever barrel and adjuster nut when the lever is pushed foward Re tighten the retaining nut onto the adjuster nut Re install the engine and the axle cover Perform a test of the b...

Page 142: ......

Page 143: ...onda manual Please refer the Honda service manual for exact specifications and torque values for any repairs Q HONDA SAYS TO DECARBONIZE THE COMBUSTION CHAMBER WHY A Small engines are very sensitive t...

Page 144: ...rnor spring would pull the throttle shaft all the way open and keep it there A 5 HP small engine with the throttle all the way open without a governor is capable of turning around 6 000 RPM The object...

Page 145: ...rate and rattle in the holes To address this issue J J has fitted a special plate with rod holes which can be adjusted in a shear action that captures the rods and holds them tight and vibration free...

Page 146: ...unt lock down bolts and the plate Loosen the anti vibration grabber plate as described on page 8 3 Disconnect the fuel line if applicable The female fitting has a automatic shut off feature so fuel in...

Page 147: ...engine motor mount assembly can now be removed by turning the belt adjusting bolt counter clockwise until the engine stops moving back Disconnect the throttle cable from the engine Disconnect the remo...

Page 148: ...designed a special support bracket to help bear the weight of the muffler virtually eliminating breakage Honda s original on off switch location ends up on the back side of the engine in go kart appli...

Page 149: ...including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM HOUR METER SCHEMATIC ON OFF ON OFF Hour meter 010732 Motor grounded switch Self grounding...

Page 150: ...able information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM ON OFF Kartrol ON OFF HOUR METER SCHEMATIC Hour meter 010732 Coil 1 60 A0...

Page 151: ...e other is red The end with the solder lug should be fastened to the engine or metal frame by loosening a suitable bolt or screw and putting the solder lug between the bolt or screw and the frame 4 Th...

Page 152: ...roblem There are two versions of the electric start system the most common includes an on board battery to start the engine a lighting coil to recharge the battery and a voltage regulator with a built...

Page 153: ...d to be inspected The battery is charged by the lighting coil on the engine Follow the Honda manual to test and repair the lighting coil and charge system On the electric start option that does not ut...

Page 154: ...p a r k p l u g w i r e Blac G l S p a r k p l u g w i r e A B C Battery g g White d SB 120 Red B Black Red Starter solenoid t t l nd d Spade Electric start switch box Red Red Red Red Black ENGINE SW...

Page 155: ...e for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Pit sensor Sensor wire Receiver bodied go kart Receiver Eagle F...

Page 156: ...the threads bolt stretch or signs of damage Replace the bolt if it is in question you do not want to have the bolt snap inside the PTO shaft during reassembly While inspecting the bolt take a close lo...

Page 157: ...touching the clutch case the chain and the sprockets should be replaced as a set Remove the 8mm bolt holding the weight holder and outer pressure plate to the clutch assembly Be sure to closely inspec...

Page 158: ...he threads for the inner cover should be cleaned with an 8M 1 25 tap Closely inspect both radial ball bearings ensure smooth operation Inspect the thrust washer for any signs of wear replace as needed...

Page 159: ...19 Install the thrust washer Install the PTO shaft chain and basket Install the clutch center and keyway Install the friction and clutch plates NOTE At this point consider installing J J Cool Tek ext...

Page 160: ...with the clutch functioning normally Under long term testing the clutch oil remained clean showing only slight discoloration even after extended periods of use Sludge build up was minimal which should...

Page 161: ...short end of the bar and file or carefully grind the beveled ends to a flat blunt surface Using the edge of a suitable flat file open the nail pulling slot to 0 156 This will allow the post to pass in...

Page 162: ...ith the open end of the keeper then simply roll it toward the post while maintaining downward pressure NOTE It is always a good idea to use new springs and keepers on any clutch overhaul 45 angle KEEP...

Page 163: ...cleaned and free from any obstructions NOTE If the filler cap hole becomes plugged this will cause the reduction case to overheat The result of overheating will damage the friction disc metal plates a...

Page 164: ...QSW 0DOH IRU HQJLQH GUDLQ LWWLQJ 2LO GUDXOLF 0DOH 6WHHO QSW LWWLQJ 2LO QSW QLSSOH EUDVV 7LUHV HQJLQHV DQG FOXWFKHV DUH D JR NDUW V ODUJHVW PDLQWHQDQFH H SHQVH 7KH ODFN RI UHJXODU RLO FKDQJHV LV WKH QX...

Page 165: ...nk removal page 9 2 Remote fuel tank bracket removal page 9 3 Engine mounted fuel tank removal page 9 4 Fuel cap vent page 9 5 Evaporative system page 9 6 Evaporative system maintenance page 9 7 Evapo...

Page 166: ...ect the fuel line TECH TIP The quick connect fitting in the tank has an automatic shut off but a small amount of spillage will occur Place a rag or cloth under the fuel tank quick connector to keep fu...

Page 167: ...luding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM First remove the remote fuel tank as shown on page 9 2 Remove the four fuel tank bracket moun...

Page 168: ...er engine vibration and heat will eventually cause the inserts to loosen and possible cracks to occur There is no repair for this condition and the fuel tank must be replaced NOTE Always use the prope...

Page 169: ...rt of Stoddard Solvent into the test tank and install the cap to be tested Invert the tank and check for leakage NOTE Make sure sealing gasket is in good condition prior to test The cap should not lea...

Page 170: ...rements for this type of emissions control Starting with the fuel tank it should be noted that materials normally used for plastic fuel tanks do not meet the required permeability standards A special...

Page 171: ...ll of the fittings and clamps are connected properly When performing the scheduled maintenance it is always recommended that all the major components of the go kart be inspected The emissions control...

Page 172: ...he carbon canister is not plugged remove the fuel tank vent line from the filler neck Using compressed air gently blow air through the vent system Check that air is coming out of the end of the vent l...

Page 173: ...Specifications subject to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES T...

Page 174: ......

Page 175: ...w jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE Throttle cable page 10 1 Throttle cable routing bodied go kart page 10 2 Throttle cable routing eagle go kart page 10 3 Thrott...

Page 176: ...hop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE ROUTING BODIED GO KARTS Clip Clip Large curves do not kink cable Loosely zip tied do not kink cab...

Page 177: ...ations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE ROUTING EAGLE GO KARTS Large curves do not kink cable Cable runs through side panel tube Loosely zip tied do...

Page 178: ...nuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM NOTE Always maintain large radius curves on the throttle cable to prevent binding NOTE The throttle return springs on some go karts a...

Page 179: ...ents com 503 304 8899 ENDURANCE CLUTCH PLATES TM Disconnect the throttle cable from the engine Remove the cable from the throttle cable override springs on the gas pedal Loosen the adjuster nut and sl...

Page 180: ...of the side panel from the rear of the kart Eagle Talon models only Use J J 3 60 0029 cable lube to service the throttle cable on a regular basis Keeping the throttle cable lubricated ensures long cab...

Page 181: ...le cable adjustment should remain loose The cable adjust ment at the engine should be backed almost all the way out NOTE A pedal stop plate is installed to limit pedal travel overall travel should not...

Page 182: ...ttle cable so that there is a small amount of free play where the cable connects to the pedal Tighten the throttle cable lock nuts Recheck that the desired RPM speed has not changed Reinstall the air...

Page 183: ...verride springs On single seat go karts remove the double nuts from the throttle extension rod NOTE The plate under the throttle stop is fitted on some go karts to prevent excess throttle pedal travel...

Page 184: ...or valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the bolt and pedal spacer sleeve Press fit replaceable Bron...

Page 185: ...his occurs when the throttle blade is closed and the engine is in the idle position The pressure differential begins to decrease when the throttle begins to open and is lowest when the throttle bore i...

Page 186: ...smooth acceleration you could have fuel restriction in this area MAIN CIRCUIT From approximately 1 8 of throttle to fully open the main circuit flows fuel out of the float bowl through the main fuel...

Page 187: ...tions manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Fuel feed holes provide fuel to all carb circuits Here is the idle circuit fuel passage Inspect the float valve needle tip fo...

Page 188: ...stop this will allow easy removal Replace with a new idle mixture screw and install a new stopper as outlined in the Honda manual ALTERNATE METHOD Use a soldering iron to heat the stopper This will l...

Page 189: ...Over an extended period of use this post can become worn to the point that choke will flop and not stay indexed If the carb is worn to this point it s time for a replacement TECH TIP If the idle spee...

Page 190: ...tion Pull up on the pilot jet setting device to remove Gently pry up on the pilot jet it is held in place by an O ring The jet can now be cleaned To check it use a pen light to shine light though jet...

Page 191: ...5BLF DBSF OPU UP EBNBHF UIF TFBU TVSGBDF MPBU WBMWF XPSO PS DPBUFE XJUI GPSFJHO NBUFSJBM EJSU 3FNPWF GPSFJHO NBUFSJBM EJSU 1JMPU KFU BJS QBUI DMPHHFE 3FNPWF GPSFJHO NBUFSJBM EJSU BJO KFU DMPHHFE 3FNP...

Page 192: ...5HDSSO E VSUD LQJ RQ WKH VXUIDFH DQG ZLSLQJ GU ZLWK D VRIW DEVRUEHQW FORWK YHU PXFK OLNH GXVWLQJ IXUQLWXUH DQG MXVW DV HDV 0LVW LW OLJKWO ILUVW ZLWK WKHQ WRZHO GU WDNHV DQ H WUD VHFRQGV 7KLV LV DQ H...

Page 193: ...for damage and the rubber should be replaced to prevent damage to the body Latches should be checked for any wear or damage whenever the body is removed J J fiberglass bodies use some basic systems to...

Page 194: ...f the frame NOTE Do not overtighten snug the mounting nuts to capture the body only Rubber latches or bungees are often used to hold bodies while providing for isolation movement NOTE Failure to use b...

Page 195: ...frame Eye bolts are used to secure the hold down straps Bumpers are bolted to the mounting brackets and are easily replaced if damaged The side of the F 22 body is rubber mounted to the frame just in...

Page 196: ...dy seals see page 12 12 The T bushings are compressed when the 3 4 nuts are tightened Do not over tighten these nuts as the bushing expansion can crack the body Latch the body latches NOTE The body la...

Page 197: ...panels span between the frame spindle mounts and the roll bar body mount The formed plastic wing is rubber mounted via special grommets in the mounting holes to float which helps to eliminate stress c...

Page 198: ...on the bottom lip of the side panel THE REAR FENDER The rear fender is mounted to the side panel with one 5 16 bolt on the bottom of the wing support and two 1 4 bolts on the bottom lip of the side pa...

Page 199: ...ollowing outlines the typical locations of particular warning decals on bodied and non bodied go karts as installed at the time of manufacture Inspect and replace them as needed see the maintenance an...

Page 200: ...e rotating parts Hair longer than shoulder length must be secured above shoulder Serious injury or death could occur DO NOT REMOVE THIS DECAL NOTE This decal is located on both sides of the go kart so...

Page 201: ...SOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS REFUEL IN A WELL VENTILATED AREA WITH ENGINE STOPPED DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA WHERE THE ENIGINE IS REF...

Page 202: ...hands on steering wheel and both feet in kart at all times unless otherwise instructed by attendant One person per restraint Restraint must be worn at all times when in kart Do not bump skid or slide...

Page 203: ...or melting away the decal but for heating the adhesive enough to removal the decal Repeat until the decal is completely removed Apply a small amount of WD 40 to a clean cloth the cloth should be damp...

Page 204: ...ts 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 hai...

Page 205: ...ttery pack page 13 10 Battery pack testing page 13 11 Battery pack replacement page 13 12 Fuse page 13 13 Relay page 13 17 Linear throttle potentiometer page 13 20 Throttle cable page 13 27 Throttle c...

Page 206: ...arge time is very similar to the steps above and can be done after the tests to determine run time by following these steps Once the session time is set run the kart for the determined time Using the...

Page 207: ...placement batteries as back up for this very purpose HOW DO YOU TEST THE FUSE TO KNOW IF IT IS GOOD In many cases when the fuse fails it is possible to visually see the failure However sometimes a fus...

Page 208: ...ing to the linear throttle controller the linear throttle controller failing or the path of the signal going from the linear throttle controller to the main controller The easiest way to rule out the...

Page 209: ...trick you into replacing parts that are not in need of replacement The more connections and wiring a unit has the more vulnerable the electrical system is to voltage drop VOLTAGE DROPS GOOD OR BAD Vo...

Page 210: ...tested with a voltmeter or scope a test light indicates whether voltage is present but it doesn t measure the amount of voltage Voltmeters measure and display the difference in voltage levels between...

Page 211: ...ur 12 volt deep cycle batteries connected in series to produce a 48vdc pack 4 gauge copper cables are used to connect the pack and furnish power through the relay solenoid to the powered fuse and comp...

Page 212: ...l that it cannot be seen by the naked eye Therefore it is important to check a fuse with an ohmmeter or a continuity tester instead of assuming that it is good Use a multi meter and set the range swit...

Page 213: ...Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Battery Battery Battery Battery Sevcon Controll...

Page 214: ...ries in the electric karts must have specific characteristics to be used in this application They must first be safe when impacts to the kart occur and the batteries are jarred around They must be abl...

Page 215: ...o fully load the system with a brief maximum acceleration and or by sliding the go kart along the track s safety rail at full acceleration to load the battery pack If the pack is good typical minimum...

Page 216: ...attery covers or kart body to access the batteries WARNING Carefully remove the negative cable Be sure to not allow the wrench to touch the positive and negative lugs of the battery at the same time N...

Page 217: ...ation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FUSE OVERVIEW The 300 amp main fuse keeps power surges or short circuits from destro...

Page 218: ...nts com 503 304 8899 ENDURANCE CLUTCH PLATES TM FUSE REMOVAL REPLACEMENT Be sure the kart is in the off position by pushing the red stop button down NOTE Always disconnect the battery pack s negative...

Page 219: ...luding videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Using a voltage ohm tester check the continuity of the fuse To remove the fuse loosen the nut...

Page 220: ...t to change without notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Install the new fuse...

Page 221: ...will not handle the amperage of extended operation This test verifies that controller and cables are functioning Next remove the 10ga jumper Using a digital volt ohm meter test for system voltage at...

Page 222: ...amusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the two large cables from the posts on the top of the relay NOTE Always disconnect the battery pack negative terminal before removing the...

Page 223: ...and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the two smaller wires from the lower posts on the relay Loosen one of the button head screws holding the rel...

Page 224: ...ntiometer changes the movement of the go pedal into an electronic signal and sends that information to the controller The farther the pedal is depressed the faster the kart will travel The linear thro...

Page 225: ...m 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the negative cable from the left rear battery NOTE Always remove the negative cable first and attach it last when removing or replacing any battery or...

Page 226: ...ion including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Locate the linear throttle potentiometer Remove the 4 socket head retaining bolts The...

Page 227: ...ation including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the throttle cable from the throttle arm Remove the throttle arm from the lin...

Page 228: ...ments com 503 304 8899 ENDURANCE CLUTCH PLATES TM Count the number of threads showing where the clevis pin was you will need to know this when installing the clevis pin onto a new linear throttle pote...

Page 229: ...p and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Be sure the jam nut has the same number of threads showing that you counted before removing Install throttle clevi...

Page 230: ...nts com 503 304 8899 ENDURANCE CLUTCH PLATES TM Adjusted properly the hole in the throttle cable end should line up with the hole in the throttle cable arm With the cable connected check the movement...

Page 231: ...tion including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM THROTTLE CABLE REMOVAL REPLACEMENT Loosen the jam nut closest to the throttle arm Loo...

Page 232: ...deos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Slide the cable adjuster housing back through the cable mount Slide the wire through the slit in the c...

Page 233: ...LE CABLE ADJUSTMENT Throttle arm Cable clevis end Throttle inner cable Cable housing end Cable housing The throttle cable may need to be adjusted to either speed up or slow down the top speed of the k...

Page 234: ...g away from the throttle arm Then tighten the nut on the back side of the throttle bracket Doing this will increase the amount of the inner throttle cable showing between the throttle bracket and the...

Page 235: ...kshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM On electric karts when the cable is installed at the factory both jam nuts are on the outside of the throttle...

Page 236: ...ot operate The controller s personality is set with what is called a profile The profile of the kart determines how quickly the kart accelerates the different speeds the kart can achieve the amount of...

Page 237: ...om 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...

Page 238: ...d operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove all of the remaining cables to the controller Remove the 2 bottom Allen head bolts holding the controller to th...

Page 239: ...On a separately excited motor D D or other the cable is directional The end with the red tag must be plugged into the controller while the end with no tag plugs into the interconnect board On a perman...

Page 240: ...to controller Throttle input connection On off switch box connection Peripheral input connection i e remote shut down Relay cable connection The interconnect board s function is actually quite simple...

Page 241: ...ged into the charger NOTE When the remote shut down system is used the wires attach to the TS1 in the following order 1 Yellow Wire 2 Open 3 White Wire 4 Open 5 Blue Wire 6 Orange Wire NOTE When no sh...

Page 242: ...perations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Remove the negative cable from the left rear battery NOTE Always remove the negative cable first and attach it last when...

Page 243: ...for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Carefully remove the throttle input plug from the interconnect bo...

Page 244: ...notice Check our website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Unplug the on off switch box cable Unpl...

Page 245: ...8899 ENDURANCE CLUTCH PLATES TM Remove any wires connected to the peripheral TS1 input connection points NOTE Mark the color and connection location for reassembly Loosen the 4 pan head screws that h...

Page 246: ...p and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Place the board on a flat surface it is a good idea to use a towel or cloth underneath while you are working on it...

Page 247: ...operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM NOTE Be careful when plugging the throttle input plug into the interconnect board C2 Since the connection is on the cor...

Page 248: ...n and the forward reverse switch This button and switch go through the interconnect board to control power to the kart and put it in a forward or reverse direction WHEN THE REMOTE SPEED CONTROL SYSTEM...

Page 249: ...ements com 503 304 8899 ENDURANCE CLUTCH PLATES TM If you suspect a problem in the switch box it can be easily tested by using a unit that is known to function SWITCH BOX TESTING Remove the negative c...

Page 250: ...including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Using the alternate switch box turn the kart on If the problem was inside the switch box...

Page 251: ...SWITCH BOX REMOVAL REPLACEMENT To correct the problem created by a faulty switch box the box can be replaced however it is a good idea to check the connections inside the box as a loose wire can easi...

Page 252: ...and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM BRAKE PRESSURE SWITCH OVERVIEW The brake pressure switch is designed to drop the power out from the motor when the...

Page 253: ...L Remove the axle guard or inspection cover to gain access to the pressure switch The brake pressure switch is set to normally closed when the brake pedal is not being depressed To test use a multi me...

Page 254: ...sements com 503 304 8899 ENDURANCE CLUTCH PLATES TM If the kart does not operate and you suspect a faulty switch you can bypass the switch by using a jumper from one tab to the other If the kart now f...

Page 255: ...K The POWER BLEEDER works just like professional pressure bleeders A tank containing hydraulic fluid is attached to the hydraulic system via a special adapter the tank is then pressurized with a few p...

Page 256: ...he wires then connected to the terminal strip on the interconnect board The remote shut down receiver is not standard equipment and does not come on all karts We do suggest using the system as it can...

Page 257: ...S TM INTERCONNECT BOARD 1 2 3 4 5 6 BATT BATT 1 15 0105 REV 3 SB 175 END VIEW SB 175 TOP VIEW Schematic Charger Safety Switch without Kartrol Components not to scale ATT BATT Butt connector Black Whit...

Page 258: ...with software for a PC system The plug uses a serial port which most new PC s no longer use A USB to serial port adaptor is required and we suggest you get one that includes software for the drivers a...

Page 259: ...amusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Open your control panel and find the icon for Device Manager open the Device Manager Find the icon labeled Ports COM LPT click the icon to see th...

Page 260: ...ools tab on the top bar it will open up a box in the middle of the screen The first tab of the box is marked Connection click that tab The connection box will have a drop down for the different COM po...

Page 261: ...le tab on the top bar then choose Save from the drop down menu This will open another box asking which Node version you want to save Be sure the box is checked click the ok button A new box will now o...

Page 262: ...on both ends going from the interconnect board to the controller is called the interconnect board cable Unplug the interconnect board cable and visually inspect the terminals to be sure they are all...

Page 263: ...opy of a working profile Be sure to copy the profile from a kart that is known to work Connect the PC Pak cable to the non working controller With the kart now turned on open the Sevcon PC Pak softwar...

Page 264: ...or valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM Find the saved profile and choose Open Click the Next button on th...

Page 265: ...box will be the Rapid Download Wizard Click the large Download button in the middle of the box When the download is complete a dialog box will open stating this Click the Ok button The Rapid Download...

Page 266: ...and rotor windings allowing more control over the motor performance If either of those circuits are damaged or broken this code will come up It can refer to a major problem inside the motor or just a...

Page 267: ...This condition has come up once at a park where the regenerative braking system was adjusted too high After the kart was fully charged and was driving out on the track the guest suddenly let off the...

Page 268: ...f heat replace any problem cables If the controller is ever replaced it is important to apply thermal grease otherwise known as heat paste or thermal paste to the back of the controller J J 2 70 0112...

Page 269: ...e electric kart charging system Because of the importance of making sure the kart is being recharged properly it should be inspected for proper operation see pg 0 11 Be sure both brushes are in good c...

Page 270: ...website for valuable information including videos workshop and operations manuals www jjamusements com 503 304 8899 ENDURANCE CLUTCH PLATES TM FLOOR PLATE CONTACTS Inspect the floor plate contacts to...

Page 271: ...sc brake specification 7 2 Drum brakes Adjustment 7 27 Brake shoes 7 21 7 22 Overview 7 19 Parts identification 7 20 E Electrical schematic 13 9 Electric go kart Frequent questions 13 2 ELECTRIC START...

Page 272: ...ered single seat go karts 0 4 Gas powered rookie go karts 0 5 Gas powered single seat go karts 0 2 Spherical washers 7 3 Spindle 3 1 Assembly 3 9 Disassembly 3 8 Frequent questions 3 2 Installation In...

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