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J&J Amusements King Scorpion, Руководство по обслуживанию

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General data and 
maintenance.

1

Tubes, tires, rims

2

Frame, bumpers,
nerf bars

3

Front hubs, 
spindles

4

Steering system

5

Roll bars, pads, 
seatbelts

6

Axle, axle cover, 
drive system 
components

7

Brake system 

8

Engine, clutch,
engine mounted 
accessories

Specifications .............................................. 0-1
Scheduled maintenance .............................. 0-8
Service schedule - gas ................................. 0-9
Service schedule - electric .........................0-11
Maintenance records ..................................0-12
Pre-opening checklist - gas ........................0-13
Pre-opening checklist - electric ..................0-14
Go-kart track area checklist .......................0-15

Non-scheduled maintenance record ..........0-16
Work order tags .........................................0-17
How a warranty is processed .................... 0-20
Product return procedures ........................ 0-20
Limited warranty ....................................... 0-21
Cleaning go-karts ...................................... 0-22
Unloading go-karts.................................... 0-23
Initial setup ............................................... 0-26

Tube & rim information ................................1-1
Frequent questions .......................................1-2
Rotating tires ................................................1-2
Disc-lock lug nuts ........................................1-3

Wheel removal ............................................1-5
Changing tires & tubes ................................ 1-6
Tire & wheel inspection .............................1-10
Troubleshooting tires .................................. 1-11

Frequent questions (frame) ...........................2-1
Frequent questions (bumper) ........................2-2

Bumper & D-rubber removal .......................2-3
Nerf bar removal ..........................................2-5

Steering system ........................................... 4-1
Caster .......................................................... 4-3
Toe-in .......................................................... 4-6
Tie rods/ends ............................................... 4-8

Ackerman 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 caliper assembly  ...............7-5
Master cylinder overview .............................7-9
Master cylinder removal .............................7-10
Brake pedal ................................................7-13
Brake fluid level inspection ........................7-14

Brake fluid change ......................................7-14
Bench-bleeding master cylinder .................7-15
Bleeding the brake system .......................... 7-17
Brake troubleshooting ................................7-18
Drum brake system overview .....................7-19
Drum brake parts identification..................7-20
Changing brake shoes ................................7-21
Drum brake adjustments ............................7-27

Frequent questions ...................................... 5-1
Roll bar 

(Eagle, Scorpion, Can-Am, F-22, Sidekick)

 ........ 5-2

Roll bar 

(Sidewinder, Sidewinder double)

 ......................5-3

Seat back pads ............................................ 5-4

Fixing pads .................................................. 5-6
Seatbelts ...................................................... 5-7
Cleaning seatbelts ....................................... 5-9

Overview .................................................... 6-2
Axle cover ................................................... 6-3
Drive cover ................................................. 6-4
Drive belt .................................................... 6-6
Drive hub ...................................................6-11
Drive pulley ...............................................6-12

Floater hub .................................................6-14
Axle bearing overview ...............................6-16
Bearings .....................................................6-17
Axle - single drive ......................................6-19
Axle - two-wheel drive .............................. 6-26
Drive sprocket spreadsheet ....................... 6-27

Frequent questions (hubs & spindles) .......... 3-1
Front hub removal ....................................... 3-3
Spindle ........................................................ 3-4

Tapered spindle & roller bearings ................ 3-5
Spindle dissassembly ................................... 3-8
Spindle assembly......................................... 3-9

Содержание King Scorpion

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 142: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 174: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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