J&J Amusements Bumper Boat 2014 Service Manual - page 49

Manual is about: Go-Karts Bumberboats

Summary of Bumper Boat 2014

  • Page 1

    Service manual bumper boat 2014 published by j&j amusements, inc. A corporation of oregon © 2014 j&j amusements inc. - all rights reserved go -karts b u mperboat s.

  • Page 2

    Warning - important safety notice proper service and repair procedures are vital to safe, reliable operation of j&j bumper boats, as well as to the personal safety of those performing the repairs. This manual outlines procedures for servicing and repairing j&j bumper boats using safe, effective meth...

  • Page 3

    Instructions to eliminate unnecessary work, careful reading of the applicable section is recommended before starting to service a bumper boat. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has ...

  • Page 4

    Circlip, retaining ring replace any removed circlips and retaining rings with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Cotter pin replace any cotter pins that were remove...

  • Page 5

    0 general data and maintenance. 1 boat top assembly 2 boat hull - lower assembly 3 motor assembly (electric-powered) 4 basic electrical troubleshooting 5 engine assembly (gas-powered) 6 decals 7 care & storage 0-7 specifications 0-9 monthly maintenance chart 0-13 pre-opening daily checklist 0-17 bum...

  • Page 6

    0-6 notes:.

  • Page 7

    0-7 specifications: electric-powered blaster boat. Dimensions: overall diameter .......................................................................................................................................72”(182 cm) overall height .............................................................

  • Page 8: Specifications: Gas-Powered

    0-8 specifications: gas-powered water bug. Dimensions: overall diameter .......................................................................................................................................72”(182 cm) overall height .....................................................................

  • Page 9

    0-9 item # item service type check frequency 1st 20 hrs every 50 hrs monthly or every 200 hrs log hours of operation to determine proper maintenance intervals. 1 sb-120 plug(s) check daily replace when damaged grease terminals (2) 2 motor check condition check wires 3 batteries check water level wee...

  • Page 10

    0-10 below are explanations of service listed in the monthly maintenance charts on previous page. Explanations of monthly maintenance shall include, but are not limited to the following: 1. Sb-120 plug(s): make sure that the plug is lubed with dielectric grease. Inspect the plug for deep grooving or...

  • Page 11

    0-11 item # item service type check frequency 1st 20 hrs every 50 hrs every 150 hrs monthly or every 200 hrs log hours of operation to determine proper maintenance intervals. 1 engine(*) check level daily change oil 2 gear case(*) check level change oil 3 spark plug(*) check-adjust replace 4 valve c...

  • Page 12

    0-12 below are explanations of service listed in the monthly maintenance charts on previous page. Explanations of monthly maintenance shall include, but are not limited to the following: 1. Engine: always use api service sg.Sf/cc.Cd. Designation shown on the container; see “engine oil” in the honda ...

  • Page 13

    0-13 **see explanation of check procedure** pre-opening daily checklist (electric) week of / / bumper boat id# attendant must initial each empty box every day. If any- thing is not ok, see a supervi- sor. Body color item service type mon tues wed thu fri sat sun boat tube - check pressure hull - vis...

  • Page 14

    0-14 below are explanations of service listed in the pre-opening checklist chart on previous page. Explanations of pre-opening checklist shall include, but are not limited to the following: boats: tube - check air pressure using a high-quality, low-pressure gauge. Super tube should be inflated to 2-...

  • Page 15

    0-15 pre-opening daily checklist (gas) bumper boat id# attendant must initial each empty box every day. If any- thing is not ok, see a supervi- sor. Body color item service type mon tues wed thu fri sat sun boat tube - check pressure. Hull - visually inspect. Receiver - visually inspect. Handrails &...

  • Page 16

    0-16 pre-opening checklist - explanation (gas) below are explanations of service listed in the pre-opening checklist chart on previous page. Explanations of pre-opening checklist shall include, but are not limited to the following: boats: tube - check air pressure using a high-quality, low-pressure ...

  • Page 17: Bumper Boat Area Checklist

    0-17 bumper boat area checklist week of / / attendant must initial each empty box every day. If any- thing is not ok, see a supervi- sor. Item service type mon tues wed thu fri sat sun pond boat rope & hooks -check for broken hooks and unsafe ropes. Dock rail -check for cracks or loose hardware. Pon...

  • Page 18: Maintenance

    0-18 fold h ere fold here fold h ere fold here maintenance work order go-kart # bumperboat # explanation of problem: employee name: description of work performed: parts used: front back mechanic: date/time: manager: this sample maintenance work order tag can be copied for use in your facility. Copy ...

  • Page 19: How A Warranty Is Processed

    0-19 1. The customer contacts j&j with the warranty problem. The product warranty department or parts department gathers information and makes arrangements to send the needed replacement to the customer. The parts department also gives the customer an rma # (return merchandise authorization) at that...

  • Page 20: Product Return Procedures

    0-20 returned goods policy: no merchandise may be returned, nor any account adjustments made, unless authorized by j&j amusements, inc. A return merchandise authorization (rma#) is required for all returns. Only items authorized (listed) on an rma# may be returned. Obsolete and discontinued merchand...

  • Page 21

    0-21 this warranty is limited to j&j amusements, inc. Products, parts and accessories when distributed by j&j amusements, inc., 4897 indian school road ne, suite 150, salem, oregon 97305-1126 usa, hereinafter referred to as (j&j). Products covered by this warranty: length of warranty: bumper boat hu...

  • Page 22

    0-22 this warranty is limited to j&j amusements, inc. Products, parts and accessories when distributed by j&j amusements, inc., 4897 indian school road ne, suite 150, salem, oregon 97305-1126 usa, hereinafter referred to as (j&j). Products covered by this warranty: length of warranty: super tube ii ...

  • Page 23: Unpacking & Setup

    0-23 go -karts b u mperboat s 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 unpacking & setup general information ............................

  • Page 24: Unpacking

    0-24 go -karts b u mperboat s 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 cut and remove the metal packing straps. Remove the box top and...

  • Page 25: Tube Setup

    0-25 go -karts b u mperboat s 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 tube setup carefully unfold the tube and lay it flat on the boa...

  • Page 26: Boat Assembly

    0-26 go -karts b u mperboat s 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 boat assembly lift the hull assembly and carefully place it ins...

  • Page 27

    0-27 go -karts b u mperboat s 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 battery installation (electric only) open the boat top and use ...

  • Page 28

    0-28 go -karts b u mperboat s 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 battery fill kit installation (electric only) remove the caps f...

  • Page 29: Battery Fill Kit

    0-29 go -karts b u mperboat s 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 battery wiring (electric only) notice see the battery wiring di...

  • Page 30

    0-30 go -karts b u mperboat s 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 install the “red” cable from the breaker to the positive post o...

  • Page 31: Boat Launch Procedure

    0-31 go -karts b u mperboat s 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 boat launch procedure latch the dock ropes to the dock rails an...

  • Page 32: Motor Installation

    0-32 go -karts b u mperboat s 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 have a helper carefully pass the motor assembly to the person i...

  • Page 33: Warning

    0-33 go -karts b u mperboat s 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 warning decals (typical locations) go-karts are terribly unforg...

  • Page 34

    0-34 go -karts b u mperboat s 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 00156 2-40-0001 www.Jjamusements.Com 001688 001686 009800 00168...

  • Page 35: Boat Top Assembly

    1-1 boat top assembly general boat top information ......................................1-1 breaker/main cutoff switch (electric only) ...................1-2 volt meter (electric only) .............................................1-5 bilge pump fuse (electric only) ....................................

  • Page 36

    1-2 go -karts b u mperboat s 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 breaker/main cutoff switch (electric only) the safety switch/bre...

  • Page 37

    1-3 go -karts b u mperboat s 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 notice: all power goes through breaker. When breaker is in the o...

  • Page 38

    1-4 go -karts b u mperboat s 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 hold the inside nylock nut during the next step. Remove the bolt...

  • Page 39: Volt Meter (Electric Only)

    1-5 volt meter (electric only) general information ....................................................1-5 removal/installation ....................................................1-6 the built-in volt meter constantly monitors the overall condition of the battery pack. When in “charge mode” the typ...

  • Page 40: Volt Meter (Electric Only)

    1-6 go -karts b u mperboat s 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 volt meter (electric only) the volt meter is located on the back...

  • Page 41

    1-7 go -karts b u mperboat s 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 removal/installation the bilge pump fuse is located on the back ...

  • Page 42: Pivot Receiver

    1-8 go -karts b u mperboat s 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 pivot receiver general information ................................

  • Page 43

    1-9 go -karts b u mperboat s 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 the pivot is attached with 8 bolts and nylock nuts, and 16 flat ...

  • Page 44: Steel With Blue Powder Coat.

    1-10 go -karts b u mperboat s 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 safety rails & dock rail hooks general information ...............

  • Page 45: Boat Hooks & Rope

    1-11 go -karts b u mperboat s 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 the safety rails are mounted with 6 phillips head bolts, 6 nylo...

  • Page 46: Dock Rail Rope Installation

    1-12 go -karts b u mperboat s 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 the length of rope needed varies depending on dock rail placeme...

  • Page 47

    1-13 go -karts b u mperboat s 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 thread the fid back through each side of the loop. Insert the f...

  • Page 48

    1-14 go -karts b u mperboat s 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 pass the fid down through the hollow core of the rope just belo...

  • Page 49

    1-15 go -karts b u mperboat s 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 with the other end of the rope, repeat the previous steps, with...

  • Page 50

    1-16 go -karts b u mperboat s 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 thread the fid back through each side of the loop. Pass the fid...

  • Page 51

    1-17 go -karts b u mperboat s 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 the dock rail rope should have about 2 inches of slack when att...

  • Page 52: Trim

    1-18 go -karts b u mperboat s 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 trim general information .........................................

  • Page 53: Trim Installation/removal

    1-19 go -karts b u mperboat s 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 the boat trim is mounted with 9 stainless steel rivets and doub...

  • Page 54

    1-20 go -karts b u mperboat s 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 drill through the outside of the trim by matching the existing ...

  • Page 55: Vent Plate (Electric Only)

    1-21 vent plate (electric only) general information ..................................................1-21 vent plate assembly ..................................................1-22 the vent plate is a multi-purpose access port into the boat hull. It acts as a vent for the hull and also allows easy ...

  • Page 56

    1-22 go -karts b u mperboat s 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 the vent plate is located at the rear of the boat top. Open the...

  • Page 57

    1-23 reinforced rubber hinge (electric only) general information ..................................................1-23 reinforced rubber hinge ..........................................1-24 the reinforced rubber hinge connects the boat top to the hull..

  • Page 58

    1-24 go -karts b u mperboat s 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 removal/installation disconnect wiring from the boat hull to th...

  • Page 59

    1-25 go -karts b u mperboat s 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 drill out the rivets and remove the rubber hinge. Insert five 3...

  • Page 60

    1-26 go -karts b u mperboat s 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 place the boat top on the hull. Open the vent plate to access t...

  • Page 61

    1-27 battery charging cable (electric only) general information ..................................................1-27 battery charging cable ..............................................1-28 the battery charging cable is approximately 15’ long and is located inside the boat. It is easily accessed ...

  • Page 62

    1-28 go -karts b u mperboat s 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 the battery charging cable is approximately 15’ long and is loc...

  • Page 63

    1-29 go -karts b u mperboat s 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 pull the charging cable out through the inside of the boat top....

  • Page 64: Strain Relief

    1-30 go -karts b u mperboat s 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 the battery filling system allows easy top-off of the battery w...

  • Page 65

    1-31 motor power supply cable (electric only) general information ..................................................1-31 motor power supply cable ........................................1-32 j&j # 2-70-a0011.

  • Page 66

    1-32 go -karts b u mperboat s 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 motor power supply cable (electric only) removal/installation d...

  • Page 67

    1-33 go -karts b u mperboat s 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 carefully loosen the nut from the plastic strain relief elbow. ...

  • Page 68: Bumper Boat Motor

    1-34 rev 3/27/2012 a division of j&j amusements, inc. Bumper boat motor work bench mount 800-854-3140 / 503-304-8899 www.Funpartsxpress.Com receiver, socket type part# 50011 a receiver mounted to your work bench will make servicing your fleet of bumper boat motors safer and quicker. There’s no bette...

  • Page 69: Boat Hull - Lower Assembly

    2-1 boat hull - lower assembly general boat hull assembly .........................................2-1 main power post (electric only) ...................................2-2 boat half protector (electric only).................................2-4 bilge pump (electric only) ..............................

  • Page 70

    2-2 main power post (electric only) general information ....................................................2-2 positive & negative main power post ...........................2-3 your j&j blaster boat may be equipped with one of two types of power posts. The pre-2012 version utilizes two rounded pos...

  • Page 71

    2-3 go -karts b u mperboat s 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 (for boats manufactured between 2008- 2011) the positive and neg...

  • Page 72

    2-4 boat half protector (electric only) general information ....................................................2-4 boat half protector .......................................................2-5 the boat half protector acts as a seal for the motor cavity in the hull, preventing any water from enteri...

  • Page 73

    2-5 go -karts b u mperboat s 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 unscrew the clamps and remove the protector. Carefully remove an...

  • Page 74: Bilge Pump (Electric Only)

    2-6 bilge pump (electric only) general information ....................................................2-6 diagnosing problems...................................................2-7 bilge pump assembly removal .....................................2-8 the bilge pump and fuse circuit feeds directly fro...

  • Page 75

    2-7 go -karts b u mperboat s 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 diagnosing problems (electric only) most bilge pump problems are...

  • Page 76

    2-8 go -karts b u mperboat s 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 disconnect wiring from the main post (see the wiring diagram for...

  • Page 77

    2-9 go -karts b u mperboat s 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 remove the two 10-24 nylock nuts. Notice: replacement of the pum...

  • Page 78

    2-10 go -karts b u mperboat s 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 remove/loosen the plastic hose clamp. Pull and slightly twist t...

  • Page 79

    2-11 battery-fill kit (electric only) general information ..................................................2-11 battery-full kit installation .........................................2-12 the battery filling system allows easy top-off of the battery water level from the outside of the boat. Simply ...

  • Page 80

    2-12 go -karts b u mperboat s 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 battery-fill kit installation (electric only) remove the caps f...

  • Page 81: Super Tube

    2-13 super tube general information ..................................................2-13 super tube inflation ...................................................2-14 checking super tube for leaks ....................................2-16 patching super tube ............................................

  • Page 82: Super Tube Inflation

    2-14 go -karts b u mperboat s 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 fill adapter insert a fill adaptor and turn clockwise 1/2 turn....

  • Page 83

    2-15 go -karts b u mperboat s 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 use a tire inflator to fill the tube. Vacuum/blower inflator op...

  • Page 84

    2-16 go -karts b u mperboat s 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 fully inflate the tube. Place three to four drops of washing de...

  • Page 85: Patching Super Tube

    2-17 go -karts b u mperboat s 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 completely clean the surface of the tube to be patched before a...

  • Page 86

    2-18 go -karts b u mperboat s 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 place the patch over the damaged tube surface and use roller or...

  • Page 87: Super Tube Valve Replacement

    2-19 go -karts b u mperboat s 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 insert a valve removal tool by lining up the prongs on the tool...

  • Page 88

    2-20 go -karts b u mperboat s 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 fill the tube using the super tube fill adapter and an air-fill...

  • Page 89

    3-1 motor assembly (electric only) general information ....................................................3-1 motor cover.................................................................3-2 control rods/grips/handlebars ......................................3-4 flex wire ..............................

  • Page 90: Motor Cover

    3-2 motor cover general information ....................................................3-2 motor cover and neoprene protector .........................3-3.

  • Page 91

    3-3 go -karts b u mperboat s 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 remove the four 1/4” screws and washers to remove the mo- tor co...

  • Page 92

    3-4 control rods/grips/handlebars general information ....................................................3-4 control rods ...............................................................3-5 hand grips..................................................................3-6 handlebar assembly ..............

  • Page 93: Control Rods

    3-5 go -karts b u mperboat s 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 each control rod has a spring located between the rod and the bo...

  • Page 94: Hand Grips

    3-6 go -karts b u mperboat s 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 replacement hand grips and hand grip cement available at j&j han...

  • Page 95: Handlebar Assembly

    3-7 go -karts b u mperboat s 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 handlebar assembly the handlebar assembly has two parts and is m...

  • Page 96: Flex Wire

    3-8 flex wire sb-120 sb-120 flex wire flex wire general information ....................................................3-8 flex wire removal/installation ...................................3-9 the flex wire consists of a 10/2 gauge wire that feeds power from the main distribution post through the h...

  • Page 97: Flex Wire

    3-9 go -karts b u mperboat s 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 flex wire remove the sb-120 connector from the bracket. Remove t...

  • Page 98

    3-10 go -karts b u mperboat s 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 1 2 3 4 5 6 7 8 9 10 11 12 13 5 5 5 lift and rotate the uhmw di...

  • Page 99: Motor

    3-11 go -karts b u mperboat s 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 motor the high-efficiency, brush-type, permanent magnet motor s...

  • Page 100: Motor Disassembly

    3-12 go -karts b u mperboat s 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 remove the motor cover and neoprene protector (see page 3-3). R...

  • Page 101

    3-13 go -karts b u mperboat s 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 remove the squirter assembly (see page 3-37). Remove the solid ...

  • Page 102

    3-14 go -karts b u mperboat s 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 remove the gearbox assembly and drive shaft (see page 3-34). Re...

  • Page 103

    3-15 go -karts b u mperboat s 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 remove the power post (see motor wiring schematic on page 4-19)...

  • Page 104

    3-16 go -karts b u mperboat s 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 before motor disassembly, make sure to mark the location of the...

  • Page 105

    3-17 go -karts b u mperboat s 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 remove the brush caps. Remove the brushes. Remove the four cap ...

  • Page 106

    3-18 go -karts b u mperboat s 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 to remove the motor cap, tap off by using a rubber mallet or so...

  • Page 107

    3-19 go -karts b u mperboat s 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 bottom the magnetic trigger is a high-quality, neodymium magnet...

  • Page 108: Magnetic Trigger

    3-20 go -karts b u mperboat s 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 remove the motor cover and neoprene protector (see page 3-3). R...

  • Page 109: Motor Relay (J&j# 2-70-0033)

    3-21 go -karts b u mperboat s 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 motor relay (j&j# 2-70-0033) general relay information............

  • Page 110: Testing The Relay

    3-22 go -karts b u mperboat s 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 note: the relay controls the ground side of the motor circuit. ...

  • Page 111

    3-23 go -karts b u mperboat s 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 relay - removal & replacement remove the motor cover and neopre...

  • Page 112

    3-24 go -karts b u mperboat s 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 remove the 5/16” bolt that secures the relay to the motor housi...

  • Page 113: Solid State Switch

    3-25 go -karts b u mperboat s 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 solid state switch the solid state switches are completely seal...

  • Page 114: Solid State Switch

    3-26 go -karts b u mperboat s 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 remove the magnetic trigger (see page 3-19). Remove the wire le...

  • Page 115: Boat Captain

    3-27 go -karts b u mperboat s 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 boat captain (standard equipment on u.S. Models only) general i...

  • Page 116: Testing The Boat Captain

    3-28 go -karts b u mperboat s 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 testing the boat captain to bypass the remote control for the s...

  • Page 117: Pivot

    3-29 go -karts b u mperboat s 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 pivot general information ........................................

  • Page 118: Pivot

    3-30 go -karts b u mperboat s 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 place the motor upside down with the motor cover removed. Remov...

  • Page 119

    3-31 go -karts b u mperboat s 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 remove the pivot bushing. Inspect the pivot bushing and drive s...

  • Page 120

    3-32 go -karts b u mperboat s 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 knee pads install the drive shaft housing bushings. Install the...

  • Page 121: Lower Unit Assembly

    3-33 go -karts b u mperboat s 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 lower unit assembly general information ..........................

  • Page 122: Gearbox and Drive Shaft

    3-34 go -karts b u mperboat s 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 remove the gearbox assembly. Next, remove the gasket and discar...

  • Page 123: Prop and Guard

    3-35 go -karts b u mperboat s 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 remove the prop guard cover. With a punch, carefully remove the...

  • Page 124: Anode

    3-36 go -karts b u mperboat s 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 anode a galvanic anode is the main component of a galvanic cath...

  • Page 125

    3-37 go -karts b u mperboat s 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 squirt pump assembly (j&j# 2-60-a0014) general information .......

  • Page 126: Squirt Pump Assembly

    3-38 go -karts b u mperboat s 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 remove the motor cover and neoprene protector (see page 3-3). C...

  • Page 127

    3-39 go -karts b u mperboat s 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 disconnect the wire from the squirt switch (see wiring diagram ...

  • Page 128

    3-40 go -karts b u mperboat s 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 cut the zip tie to remove the hose from the handle bar base. Ca...

  • Page 129: Squirt Nozzle

    3-41 go -karts b u mperboat s 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 the squirt nozzle is attached to the motor cover. Use an adjust...

  • Page 130: Sb-120 Terminal

    3-42 go -karts b u mperboat s 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 sb-120 terminal general information ..............................

  • Page 131: Sb-120 Terminal Replacement

    3-43 go -karts b u mperboat s 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 part # 2-70-a0022 includes: strain relief (2) terminal contacts...

  • Page 132: Sb-120 Terminal Replacement

    3-44 go -karts b u mperboat s 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 sb-120 terminal replacement install a clear tube (j&j #2-60-009...

  • Page 133

    4-1 basic electrical troubleshooting general information ....................................................4-1 basic electrical troubleshooting .................................4-2 voltage drop test...................................................... 4-4 testing fuse ...............................

  • Page 134

    4-2 go -karts b u mperboat s 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 basic electrical troubleshooting whenever testing for power (vol...

  • Page 135

    4-3 go -karts b u mperboat s 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 2) everything has resistance. The wires, connectors, and switch ...

  • Page 136: Voltage Drop Testing

    4-4 go -karts b u mperboat s 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 voltage drop testing the battery pack contains four 6-volt, deep...

  • Page 137

    4-5 go -karts b u mperboat s 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 open-circuit problems such as broken, disconnected wires and/or ...

  • Page 138: Testing Fuse

    4-6 go -karts b u mperboat s 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 testing procedure for fuse it is extremely important to understa...

  • Page 139

    4-7 go -karts b u mperboat s 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 major electrical components j&j battery-powered bumper boats uti...

  • Page 140

    4-8 go -karts b u mperboat s 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 testing: use the dvom and perform voltage drop tests to troubles...

  • Page 141

    4-9 go -karts b u mperboat s 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 the motor portion of the wire harness connects the solid state, ...

  • Page 142

    4-10 go -karts b u mperboat s 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 the magnetic trigger is a high-quality, neodymium magnet housed...

  • Page 143

    4-11 go -karts b u mperboat s 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 j&j’s exclusive high-efficiency, brush-type, permanent magnet m...

  • Page 144: Hydrometer Battery Tester

    4-12 go -karts b u mperboat s 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 a simple, effective and proven system the j&j electric bumper b...

  • Page 145: Specific Gravity Test

    4-13 go -karts b u mperboat s 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 specific gravity test make sure you wear gloves and eye protect...

  • Page 146: Call Fpx Today

    4-14 go -karts b u mperboat s 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 call fpx today call fpx today to fi nd a local to fi nd a local...

  • Page 147: Equalizing Batteries

    4-15 go -karts b u mperboat s 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 lead plates become sulfated as a natural result of their functi...

  • Page 148

    4-16 go -karts b u mperboat s 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 1. On the days before leaving, do a thorough cleanup of connect...

  • Page 149: Master Charger

    4-17 go -karts b u mperboat s 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 24-volt/30-amp output battery charger with switchable 120/240 v...

  • Page 150

    4-18 go -karts b u mperboat s 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 + battery - + battery - + battery - + battery - volt power post...

  • Page 151: Motor Wiring Schematic

    4-19 go -karts b u mperboat s 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 motor wiring schematic white lead from kartrol unit white lead ...

  • Page 152

    4-20 go -karts b u mperboat s 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 boat captain wiring schematic remo v e black swit ch wir es fr ...

  • Page 153: Engine Assembly

    5-1 go -karts b u mperboat s 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 engine assembly general information ...............................

  • Page 154: Handle Bar

    5-2 go -karts b u mperboat s 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 handle bar eliminate water/fuel problems whether you are storing...

  • Page 155: Pivot

    5-3 go -karts b u mperboat s 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 pivot the removal, installion and maintenance for the pivot is p...

  • Page 156: Prop Guard

    5-4 go -karts b u mperboat s 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 prop guard the prop guard used on the gas engine is also used fo...

  • Page 157: Decals

    Decals general information ....................................................6-1 motor cover decals ....................................................6-2 boat top decals ......................................................6-161 decal removal and installation...............................6-163...

  • Page 158

    6-2 go -karts b u mperboat s 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 “arrow” and “blaster boat” motor decal are located on the top of...

  • Page 159: Boat Top Decals

    6-3 go -karts b u mperboat s 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 boat top decals j&j amusements website decal is located at the r...

  • Page 160: Boat Top Decals

    6-4 go -karts b u mperboat s 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 boat top decals “weight limit 450 lbs” decal is located on the r...

  • Page 161

    6-5 go -karts b u mperboat s 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 decal removal and installation hold a squeegee in such a way tha...

  • Page 162

    Go -karts b u mperboat s decades of evolution have created the highest quality, best performing go-karts & bumperboats in the industry. Coin operated “pond side” water squirter 4897 indian school road ne salem, or. U.S.A. 97305 1-800-854-3140 or 1-50-304-8899 www.Jjamusements.Com are you looking for...

  • Page 163: Care & Storage

    Care & storage general information ..................................................... 7-1 fiberglass care & maintenance ..................................... 7-2 303 aerospace protectant ............................................7-4 storage .........................................................

  • Page 164

    7-2 go -karts b u mperboat s 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 what is fiberglass? Fiberglass is a common term for fiber-reinfo...

  • Page 165

    7-3 go -karts b u mperboat s 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 cleaning faded or oxidized fiberglass there really isn’t any sec...

  • Page 166: 303 Aerospace Protectant

    7-4 go -karts b u mperboat s 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 303 aerospace protectant bumper boats - make them look better an...

  • Page 167

    7-5 go -karts b u mperboat s 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 303 for fiberglass: never buff or wax again! Like vinyl, gelcoat...

  • Page 168: Storage

    7-6 go -karts b u mperboat s 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 storage batteries when your boats are not in use and your park i...