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J&J Amusements Can-Am Service Manual

Summary of Can-Am

  • Page 1

    Service manual single & double go-karts (2014) published by j&j amusements, inc. An oregon corporation © 2013 j&j amusements inc. - all rights reserved go -karts b u mperboat s specifications subject to change without notice..

  • Page 2

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

  • Page 3

    To eliminate unnecessary work, careful reading of the applicable section is recommended before starting to service a go- kart. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations; a c...

  • Page 4

    Cotter pin replace any cotter pins that were removed with new ones, since removal deforms and breaks them. Replacement parts when there is a replacement instruction, replace these parts with new ones every time they are removed. Removed parts will be damaged and/or lose their original function. Insp...

  • Page 5

    0 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 .................................

  • Page 6

    9 fuel tank & emission system 10 throttle, cable, pedal 11 carburetor 12 body, body mounts, decals 13 electrical system overview .................................................... 9-1 remote fuel tank removal ........................... 9-2 remote fuel tank bracket removal ............... 9-3 engi...

  • Page 7

    0-1 specifications: gas-powered doubles double seat go-karts, king scorpion, sidewinder double, f-22 double, sidekick, double eagle dimensions overall length ............................................................................................................................................ 8...

  • Page 8

    0-2 specifications: gas -powered singles single seat go-karts, scorpion, sidewinder, f-22, can-am, eagle dimensions overall length ............................................................................................................................................ 82”(208 cm) overall width .....

  • Page 9

    0-3 specifications: electric -powered doubles double go-karts, sidewinder double, double eagle dimensions overall length ............................................................................................................................................ 82”(208 cm) overall width ...............

  • Page 10

    0-4 specifications: electric-powered singles single seat go-karts, sidewinder, eagle dimensions overall length ............................................................................................................................................ 82”(208 cm) overall width .........................

  • Page 11

    0-5 specifications: gas-powered rookies stinger, talon dimensions overall length ............................................................................................................................................ 73”(185 cm) overall width .......................................................

  • Page 12

    0-6 specifications: electric-powered rookies talon - electric dimensions overall length ............................................................................................................................................ 73”(185 cm) overall width ................................................

  • Page 13: Important Information

    0-7 important information throughout this manual, we will discuss the proper repair techniques for your j&j go-karts: however, the most important job of any technician is to maintain the fleet. Properly maintained equipment, in most cases, will have fewer failures, as the problems are addressed befo...

  • Page 14

    0-8 explanation of scheduled maintenance below are explanations of the services listed in the maintenance charts for gas-powered go-karts. The proper fluids and lubricants to use are listed in this section. Make sure to always use the recommended fluids and lubricants. All parts should be replaced a...

  • Page 15

    0-9 item # item service type check frequency 1st 20 hrs every 50 hrs every 100 hrs every 300hrs every 500hrs log hours of operation to determine proper maintenance intervals. 1 engine oil check level daily change 1 reduction gear oil check level daily change 2 air filter check daily clean (1) replac...

  • Page 16

    0-10 below are explanations of the services listed in the maintenance charts for electric-powered go-karts. The proper fluids and lubricants to use are listed in this section. Make sure to always use the recommended fluids and lubricants. All parts should be replaced, and all necessary repairs done ...

  • Page 17

    0-11 item # item service type check frequency 1st 20 hrs every 50 hrs every 100 hrs every 300hrs every 500hrs log hours of operation to determine proper maintenance intervals. 1 sb175 charger plug/ charger brushes (*) check daily replace when damaged grease terminals (2) 2 4ga. Power wire check repl...

  • Page 18: Maintenance Record

    0-12 go-kart id#____________________ date _____/______/_______ hour meter reading maintenance performed parts used serviced by finish date maintenance record make extra copies for future use..

  • Page 19: Gas-Powered Go-Karts

    0-13 pre- opening daily checklist for gas-powered go-karts week of / / go-kart id# servicer must initial each empty box every day. If anything is not ok, see a supervisor. Body color item # description mon tues wed thu fri sat sun 1 fuel system: check for any signs of fuel leaks from the tank, cap, ...

  • Page 20: Electric Go-Karts

    0-14 pre- opening daily checklist for electric go-karts week of / / go-kart id# servicer must initial each empty box every day. If anything is not ok, see a supervisor. Body color item # description mon tues wed thu fri sat sun 1 covers & guards: check for proper installation of the steering cover, ...

  • Page 21

    0-15 go-kart track area checklist week of / / track # servicer must initial each empty box every day. If anything is not ok, see a supervisor. Item # description mon tues wed thu fri sat sun 1 fire extinguishers: verify proper placement. 2 warning signs & restrictions: check for damage and/or legibi...

  • Page 22

    0-16 go-kart id# date describe problem maintenance performed serviced by finish date non-scheduled maintenance record make extra copies for future use..

  • Page 23: Maintenance

    0-17 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 24

    0-18 proper care in the “off season”: some go-kart tracks do not operate all year long. For this reason, j&j inc. Has prepared this information on how to properly condition your go-kart fleet for periods of storage or inactivity. We urge you to follow the simple instructions and advice contained her...

  • Page 25

    0-19 go-kart seasonal storage (electric) proper care in the “off season”: some go-kart tracks do not operate all year long. For this reason, j&j inc. Has prepared this information on how to properly condition your go-kart fleet for periods of storage or inactivity. We urge you to follow the simple i...

  • Page 26

    0-20 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 27

    0-21 j&j amusements, inc., accessories, product and replacement parts. This warranty is limited to j&j amusements, inc. Product, parts and accessories when distributed by j&j amusements, inc. 4897 indian school road ne, suite 150, salem, oregon 97305- 1126 usa (j&j). Products covered by this warrant...

  • Page 28: Cleaning Go-Karts

    0-22 cleaning go-karts cleaning kart bodies the best way to preserve your go-karts’ finish is to keep it clean by washing it often with lukewarm or cold water. Don’t wash your kart in the direct rays of the sun. Don’t use strong soaps or chemical detergents. Use liquid hand, dish or car washing (mil...

  • Page 29: Unloading Go-Karts

    0-23 all shipments come via commercial truck. Go-karts are stacked 2-3 high in shipping racks. Inspect the go-karts for damage before unloading the go-karts from the shipping racks. Take photographs to document any damage that may have occured during shipping. A forklift is required to unload the tr...

  • Page 30

    0-24 slide the forks all the way up until the kart’s bumper is touching the front of the forklift. Pivot the end of the forks up and remove the kart from the rack. Note: when lifting the kart from the rack, make sure to keep clearance from the kart below. Repeat the same steps for the remaning karts...

  • Page 31

    0-25 tip: a great use for the shipping racks is to turn them into storage racks for your maintenance facity..

  • Page 32: Initial Setup

    0-26 initial setup check and fill (if needed) engine with 4-stroke motor oil that meets or exceeds the requirements for api service classification sf or sg. Always check the api service label on the oil container to be sure it includes the letters sf or sg. Sae 10w-30 is recommended for general, all...

  • Page 33

    0-27 fuel remove the filler cap and check the fuel level. Refill the tank if the fuel level is low. Fill 1” from the lowest point of the filler neck. Do not overfill the fuel tank. Ensure that the filler cap is securely replaced. Extra capacity fuel tank: 2.2 gal (8.3 liters) 3.3gal (12.4 liters) 3....

  • Page 34: Warning    Decals

    All go-karts leave j&j amusements with warning decals in place. All warning decals must be legible. If any warning decal cannot be read you must replace it immediately. J&j carries all the decals you need. See section 12 for decals placement locations. Warning decals do n ot remove this de ca l do n...

  • Page 35: Tires, Tubes, Rims

    1-1 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 tires, tubes, rims overview tube & rim information ................

  • Page 36: Frequent   Tire Questions:

    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 when should i rotate my tires? Front and rear tires perform diff...

  • 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 tubes the j&j bigfoot tire was designed to give maximum tread li...

  • 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 proper installation of socket over both halves of disc-lock nut....

  • Page 39: Wheel  Removal

    1-5 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 use a floor jack or a lift so the wheels are off the ground. Use...

  • Page 40

    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 pull tube out of tire. Changing tires & tubes - disassembly loos...

  • 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 install the tube into the tire and inflate it slightly to help e...

  • Page 42

    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 place the second rim half onto the tool. Screw down the self-cen...

  • Page 43: Side Extensions!

    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 inflate the tire to 50 psi (max) to set the beads. The tire pres...

  • Page 44: Tire/wheel Inspection

    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 how to check use a quality gauge to check the tire pressure. Si...

  • Page 45: Troubleshooting Tires

    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 troubleshooting tires under-inflation of tires can cause: • too...

  • Page 46: Longest

    Part # description price tires 736 1-20-0037 007880 007880combo 007890wet 1-20-0049 tire, 11 x 3.60 - 5" sl72 736hd tire, 12 x 4.00 - 5" sl72 bigfoot tire, 12 x 4.00 - 5" sl72 bigfoot (w/tube) $ 21.99 (100+ qty) tire, 12 x 4.00 - 5" sl72 duckfoot all weather tire, 13 x 4.00 - 6" sl72 736hd 21.10 21....

  • Page 47: Frame

    2-1 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 frame overview frequent questions .................................

  • Page 48: B Umpers  & D-Rubber

    2-2 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 inspection inspect the bumper rail daily for cracks, missing har...

  • Page 49: Bumper/d-Rubber Removal

    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 when removing the bumpers, start at either the front or rear of ...

  • Page 50: Timing and Traffic

    2-4 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 note: not all d-rubbers will mount to bumper rail. There are no ...

  • Page 51

    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 the nerf bar (a) is mounted to the frame through four d-rubbers;...

  • Page 52: Warning    Decals

    2-6 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 installation is performed in the reverse order of removal. Using...

  • Page 53: Front   Hubs & Spindles

    3-1 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 front hubs & spindles frequent questions ..........................

  • Page 54: Overview

    3-2 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 overview hub & spindle faq q: i removed my front hub and a space...

  • Page 55: Front  Hubs

    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 undo the 3/4-inch lock nut on the end of the spindle. Slide the ...

  • Page 56: Spindle

    3-4 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 check the spindle shaft for any pitting, galling or corrosion. I...

  • Page 57

    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 remove the wheel from the hub. Gently tap the dust cap off of th...

  • Page 58

    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 remove the rear seal and wipe off the excess grease from the whe...

  • Page 59

    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 put a light film of grease around the inner lip of the seal to k...

  • Page 60: Spindle  Dissassembly

    3-8 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 break down the yoke and cross assembly remove the spindle assemb...

  • Page 61: Spindle  Assembly

    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 remove all dirt and debris from the entire spindle assembly, ens...

  • Page 62: Wheel Assembly Tool

    7kh)xq3duwv;suhvvzkhhodvvhpeo\wrrofrphvzlwkwkh iroorzlqj x wluhfodpszlwkvrfnhwh[whqvlrqv x vrfnhwvzlwkpdjqhwviruzkhhovzlwkkdugzduh x odujhvslqrqglvfiruerowoxjsdwwhuqzkhho rev 3/27/2012 **please call for availability* all prices are subject to change without prior notice part # description price 7 7r...

  • Page 63: Steering System

    4-1 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 steering system steering system adjustments - overview ............

  • Page 64: Overview-Caster

    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 overview-caster caster: to understand caster, you need to pictur...

  • Page 65

    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 remove the steering cover and/or the body to access the spindle ...

  • Page 66

    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 to increase the amount of caster, rotate the spindle arm downwar...

  • Page 67: Toe - In

    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 toe - in: toe is the pointing in or pointing out of the front wh...

  • Page 68: Steering Adjustments - Toe

    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 steering adjustments - toe using a c-clamp, lock the steering sh...

  • Page 69

    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 if the measurement is not within specifications, loosen the two ...

  • Page 70: Tie Rods/  Tie Rod Ends

    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 tie rods/ tie rod ends removal- remove the body from the kart (i...

  • Page 71: Tie Rod Ends

    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 tie rod ends removing the tie rod ends requires two open- end wr...

  • Page 72: Overview-  Ackerman Effect

    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 ackerman effect: ackerman is the difference in turn radius betw...

  • Page 73

    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 steering column & cover q: the steering shaft is bent on the lo...

  • Page 74: Steering Wheel

    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 to remove the steering wheel, undo the three acorn nuts (round ...

  • Page 75: Steering Column Pad

    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 the steering column pad is held on by one 5/16” nylock nut and ...

  • Page 76: Shop Supplies

    Gas caddy: tired of the 5 gallon gas can hassle? Concerned about safety? Insurance inspector been bugging you? The gas caddy can be your salvation. Featuring heavy-gauge epoxy powder coated and welded steel construction, the sturdy wheels also allow easy roll- around for up to 30 gallons of fuel. Th...

  • Page 77: Overview

    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 roll bars/pads/seatbelts overview frequent questions ..............

  • Page 78: Roll  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 there are two cross bolts that secure the roll bar to the frame-...

  • Page 79: Roll Bar /

    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 roll bar / removable to allow body service (sidewinder, double a...

  • Page 80: Pads/ Back/ Roll Bar/seat

    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 roll bar pads are held on by two nuts on the back side of the ro...

  • Page 81: We Have Replacment

    5-5 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 the back pad is held on by four nuts on the back side of the bac...

  • Page 82: Fixing  Pads

    5-6 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 sometimes pads get small tears or rips in the outer skin. If the...

  • Page 83: Seat Belts

    5-7 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 seatbelts must be inspected and maintained on a regular basis. F...

  • Page 84: Lap Belts On Bodied Go-Karts

    5-8 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 bodied go-karts such as sidewinder, sidewinder double, and sting...

  • Page 85: Cleaning  Seatbelts

    5-9 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 cleaning seatbelts the seatbelt manufacturer recommends a mild s...

  • Page 86

    5-10 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 contact j&j for more info about the xpress track products..

  • Page 87: Single Drive Axle

    6-1 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 axle/axle cover/drive system components overview ..................

  • Page 88: Overview

    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 overview axle/drive system cover - to address safety concerns wi...

  • Page 89: Axle Cover Removal

    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 remove the engine (see page 8-1). Remove the axle cover shoulder...

  • Page 90: Drive Cover Removal

    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 remove the drive wheel. Remove the lower wing support bolts. Mov...

  • Page 91

    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 remove the drive cover allen bolts. Pull the drive cover rubber ...

  • Page 92: Drive Belt Replacement

    6-6 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 note: before engine can be moved or removed, the grabber plate m...

  • Page 93

    6-7 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 use a 9/16” offset-ratcheting-box wrench and loosen the engine-m...

  • Page 94: Chain Drive Removal

    6-8 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 chain drive removal keep your throttle cables operating smoothly...

  • Page 95

    6-9 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 drive chain/sprocket replacement the tension adjustment procedur...

  • Page 96

    6-10 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 if adjustment is needed, use a 1/4” allen wrench and loosen the...

  • Page 97: Drive Hub

    6-11 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 remove the drive wheel. Use a 1-1/8” socket and remove the driv...

  • Page 98: Drive Pulley Removal

    6-12 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 drive wheel/tire (see page 1-29). Remove the drive b...

  • Page 99

    6-13 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 drive hub pulley from the axle. Before installing th...

  • Page 100: Floater Hub Removal

    6-14 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 use a 1-1/4” open end wrench on the axle keyway. This will keep...

  • Page 101: Floater Hub Installation

    6-15 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 floater hub installation apply anti-seize to the axle. Install ...

  • Page 102: Axle Bearing Removal

    6-16 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 axle bearing removal the positive lock bearing grips evenly and...

  • Page 103: Bearing Removal

    6-17 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 push the lock tabs up from the sleeve jam nut index slots. Loos...

  • Page 104

    6-18 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 the bearing assembly can be removed as a whole at this time, or...

  • Page 105: Single Drive Axle Removal

    6-19 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 remove the drive cover (page 6-4), drive pulley (page 6-12), an...

  • Page 106

    6-20 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 unbolt the floater hub bearing and remove the brake caliper bra...

  • Page 107

    6-21 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 loosely assemble and install the axle into the frame. Loosely i...

  • Page 108

    6-22 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 use a spanner wrench to tighten the jam nut (j&j # 1-60-0193) o...

  • Page 109

    6-23 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 once set, torque the sleeve nut by using the spanner wrench (#1...

  • Page 110

    6-24 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 install the brake caliper assembly (see page 7-7). Note: the fl...

  • Page 111

    6-25 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 the axle has two 1-1/4” (2 piece) split collars. One on the ins...

  • Page 112: Two Wheel Drive (Live) Axle

    6-26 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 two wheel drive (live) axle overview this system uses a continu...

  • Page 113: Drive Sprocket Spreadsheet

    6-27 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 drive sprocket spreadsheet **lower “driven” sprocket for chart ...

  • Page 114: No Matter What Type

    6-28 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 drive system components - belts part # description 1-20-0020-g ...

  • Page 115: Brake  System

    7-1 brake system overview brake caliper overview overview ........................................................... Page 7-1 caliper assembly ................................................ Page 7-3 brake pads - removal & installation .................... Page 7-4 removing brake caliper assembly ...

  • Page 116: Hydraulic Brake System

    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 hydraulic brake system when working with the disc brake, observe...

  • Page 117: Brake Caliper Assembly

    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 brake caliper assembly installation overview spherical washers t...

  • Page 118: Brake  Pad Inspection

    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 check the lining thickness and condition of pads in each caliper...

  • Page 119

    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 use a 3/8” wrench to hold the brake line and keep the brake line...

  • Page 120

    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 using an air or electric impact wrench, remove the caliper mount...

  • Page 121

    7-7 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 set the brake caliper assembly on the drive and floater brake di...

  • Page 122

    7-8 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 attach the brake line to the floater caliper. Use an 3/8” fittin...

  • Page 123: Master  Cylinder

    7-9 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 master cylinder overview general information ......................

  • Page 124

    7-10 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 some j&j go-karts are equipped with a master cylinder guard. Th...

  • Page 125

    7-11 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 unbolt the two d-rubbers and remove the master cylinder angle g...

  • Page 126

    7-12 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 push rod shoulder bolts adjuster lock nut brake pedal “free-pla...

  • Page 127: Brake   Pedal Removal

    7-13 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 brake adjuster bolts. Disconnect the brake pedal spr...

  • Page 128: Brake Fluid Change

    7-14 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 in accordance with the periodic maintenance chart, change the b...

  • Page 129: Overview

    7-15 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 after repair or replacement of the master cylinder, there will ...

  • Page 130

    7-16 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 install the master cylinder into the frame, or gently hold the ...

  • Page 131

    7-17 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 attach a clear plastic hose (1/8id) to the bleed valve on the c...

  • Page 132

    7-18 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 *note: beware: loose or worn bearings can cause the brake disc ...

  • Page 133: Drum   Brakes

    7-19 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 drum brakes overview some j&j go-karts are equipped with a mech...

  • Page 134

    7-20 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 drum brake - parts identification actuating rod brake drum floa...

  • Page 135: Changing   Brake Shoes

    7-21 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 changing brake shoes to gain access to the drum brake system, i...

  • Page 136: Changing   Brake Shoes

    7-22 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 grab both brake shoes as shown and pull inwards to release the ...

  • Page 137

    7-23 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 brake shoe replacement - inboard drum remove the (4) allen-head...

  • Page 138

    7-24 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 grab both brake shoes as shown and pull inwards to release the ...

  • Page 139

    7-25 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 assemble the new shoes with the bottom spring in place and move...

  • Page 140

    7-26 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 re-assemble the brake drum/hub with the 7/16” jam nuts and 5/32...

  • Page 141: Drum  Brake Adjustments

    7-27 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 adjustment to the drum brake system is accomplished by loosenin...

  • Page 143: Engine

    8-1 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 overview engine overview....................................

  • Page 144: Governor

    8-2 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 governor q: how does the governor work? A: much maligned but sel...

  • Page 145: Grabber Plate

    8-3 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 grabber plate anti vibration “grabber plate” the motor mount pla...

  • Page 146: Engine  Assembly Removal

    8-4 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 engine assembly removal remove the engine mount lock-down bolts ...

  • Page 147

    8-5 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 the engine/motor mount assembly can now be removed by turning th...

  • Page 148: Engine-Mounted Items

    8-6 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 engine-mounted items over the years, certain problems have arise...

  • Page 149: Hour Meter Schematic

    8-7 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 hour meter schematic on off on off + - hour meter #010732 motor-...

  • Page 150: Kartrol

    8-8 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 on off + - kartrol on off hour meter schematic hour meter #01073...

  • Page 151: Tiny Tach Schematic

    8-9 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 tiny tach schematic tiny tach - installation 1. The best place t...

  • Page 152: Electric Start Engine

    8-10 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 electric start engine overview the electric start option allows...

  • Page 153

    8-11 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 battery the exact location of the battery can vary depending on...

  • Page 154: Kartrol

    8-12 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 engine sw circuit protector off on start engine switch box cdi ...

  • Page 155: Kartrol Component Layout

    8-13 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 pit sensor sensor wire receiver (bodied go-kart) receiver (eagl...

  • Page 156: Clutch/  Reduction Rebuild

    8-14 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 clutch/ reduction rebuild grabber plate and engine not shown fo...

  • Page 157

    8-15 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 6mm bolts holding the reduction cover and inspect th...

  • Page 158

    8-16 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 remove the inner reduction case; inspect the bolts as you remov...

  • Page 159

    8-17 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 install a new clutch pressure plate on the weight assembly. Wit...

  • Page 160

    8-18 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 the great enemy of any clutch material is heat, with sludge and...

  • Page 161: Keeper  Removal Tips

    8-19 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 technique combined with proper tools makes this pesky job easy....

  • Page 162: Keeper  Installation Tips

    8-20 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 to install the keepers, use a good pair of small, snub-nosed pl...

  • Page 163

    8-21 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 the reduction case oil filler cap/dipstick is made up of two pa...

  • Page 164: Oil Change Kits

    Rev 1/9/2014 oil prod- **please call for availability* all prices are subject to change without prior notice 3duw 'hvfulswlrq 3ulfh 2lo([wudfwru(ohfwulf)3; 2lo'lvshqvhu*do$lu:0hwhu $5 2lo'udlq.Lw(qjlqh&oxwfk shu.Duw $5 2lo'udlq.Lw(qjlqh&oxwfk shu.Duw &rpprq)lwwlqjv )lwwlqj%xvklqjqswqswihpdoh )lwwlqj...

  • Page 165: Fuel Tank & Emissions System

    9-1 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 fuel tank & emissions system overview overview ....................

  • Page 166: Remote Fuel  Tank Removal

    9-2 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 remote fuel tank removal note: remove the fuel from the tank bef...

  • Page 167

    9-3 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 first, remove the remote fuel tank as shown on page 9-2. Remove ...

  • Page 168

    9-4 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 engine-mounted fuel tank removal j&j extra-capacity fuel tanks a...

  • Page 169: Fuel  Cap Vent

    9-5 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 fuel cap vent fuel cap & fuel tank field test procedure: the ven...

  • Page 170: Evaporative System

    9-6 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 evaporative system evaporated gasoline is one of the leading cau...

  • Page 171

    9-7 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 evaporative system maintenance check that all of the fittings an...

  • Page 172

    9-8 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 evaporative system maintenance to check that the carbon canister...

  • Page 173: Evaporative System Routing

    9-9 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 evaporative system routing.

  • Page 175: Throttle Cable

    10-1 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 throttle cable throttle cable.....................................

  • Page 176: Throttle Cable Routing

    10-2 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 throttle cable routing bodied go-karts clip clip large curves; ...

  • Page 177: Throttle Cable Routing

    10-3 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 throttle cable routing eagle go-karts large curves; do not kink...

  • Page 178

    10-4 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 note: always maintain large-radius curves on the throttle cable...

  • Page 179: Throttle  Cable Removal

    10-5 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 disconnect the throttle cable from the engine. Remove the cable...

  • Page 180

    10-6 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 remove the throttle cable by pulling it out of the side panel f...

  • Page 181

    10-7 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 throttle cable/speed adjustment remove the air cleaner from the...

  • Page 182

    10-8 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 remove the throttle stop screw from the throttle control on top...

  • Page 183: Throttle Pedal Removal

    10-9 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 cable from the throttle cable override springs. On s...

  • Page 184: Throttle  Pedal Bushings

    10-10 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 the bolt and pedal spacer/sleeve. Press-fit replaceable...

  • Page 185: Carburetor

    11-1 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 carburetor overview overview .....................................

  • Page 186

    11-2 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 idle (pilot) circuit to provide fuel for idling (when throttle ...

  • Page 187

    11-3 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 fuel feed holes provide fuel to all carb circuits. Here is the ...

  • Page 188

    11-4 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 tech tip: to remove the idle mixture screw, use a sharp pair of...

  • Page 189

    11-5 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 always use a proper width flat-blade screwdriver when removing ...

  • Page 190

    11-6 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 to remove the pilot jet, first remove the idle stop screw. (it’...

  • Page 191

    11-7 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 1j mp ut d sfxc sb l f tb uo b ss p xq p jo u 1* - 0 54 $ 3 & 8...

  • Page 192

    303 for fiberglass. . . 1hyhuexiiruzd[djdlq /lnhylq\ojhofrdwilehujodvvsro\hvwhuuhvlqlvd89vhqvlwlyhsodvwlf7krxjkpdqxidfwxuhuvdgg89vwdel ol]huvwrylq\odqgjhofrdwilehujodvvlqwkhpdqxidfwxulqjsurfhvvwkhvhsurwhfwlyhdjhqwvzhdnhqryhuwlph dqgpxvwehuhsohqlvkhglifrqwlqxlqj89surwhfwlrqlvghvluhg&roruhgjhofrdwileh...

  • Page 193: Body  Mounts

    12-1 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 body mounts overview overview ....................................

  • Page 194

    12-2 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 rubber “t” bushings are made to collapse slightly under pressur...

  • Page 195

    12-3 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 the reinforced fiberglass body rests on rubber bumpers that sup...

  • Page 196: Body Removal

    12-4 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 body removal scorpion & king scorpion: unlatch the body latches...

  • Page 197: Overview

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  • Page 198

    12-6 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 eagle /talon side panels/fenders the front fender: the front fe...

  • Page 199

    12-7 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 warning decals (typical locations) go-karts are terribly unforg...

  • Page 200: Warning!

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  • Page 201: Brake

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  • Page 202: Warning

    12-10 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 warning the engine exhaust from this product contains chemical...

  • Page 203

    12-11 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 decal removal and installation hold a squeegee in such a way t...

  • Page 204: Body   Seal

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  • Page 205: Electric Go-Karts

    13-1 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 electric go-karts overview frequent questions ....................

  • Page 206: About Electric Go-Karts

    13-2 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 frequently asked questions about electric go-karts how long can...

  • Page 207

    13-3 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 how do i test the battery pack? The best way to test a battery ...

  • Page 208

    13-4 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 if the switch box has a problem, do i need to replace it? In ma...

  • Page 209

    13-5 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 basic electrical troubleshooting whenever testing for power (vo...

  • Page 210

    13-6 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 2) everything has resistance. The wires, connectors, and switch...

  • Page 211: Voltage  Drop Testing

    13-7 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 open-circuit problems such as broken, disconnected wires and/or...

  • Page 212: Testing  A Fuse

    13-8 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 it is extremely important to understand that if a fuse looks go...

  • Page 213: 4 Gauge   Cable Schematic

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  • Page 214: Battery  Pack

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  • Page 215: Battery  Pack - Testing

    13-11 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 battery pack - testing open circuit voltage test - no load sta...

  • Page 216

    13-12 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 turn the kart off and remove the battery covers or kart body t...

  • Page 217: Fuse

    13-13 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 fuse overview the 300-amp main fuse keeps power surges or shor...

  • Page 218

    13-14 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 fuse - removal/replacement be sure the kart is in the “off” po...

  • Page 219

    13-15 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 using a voltage/ohm tester, check the continuity of the fuse. ...

  • Page 220

    13-16 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 install the new fuse in the reverse manner that the old fuse w...

  • Page 221: Relay

    13-17 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 relay overview the j&j electric go-kart uses this device as a ...

  • Page 222

    13-18 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 remove the two large cables from the posts on the top of the r...

  • Page 223

    13-19 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 remove the two smaller wires from the lower posts on the relay...

  • Page 224

    13-20 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 linear throttle potentiometer simply put, the linear throttle ...

  • Page 225: Removal/replacement

    13-21 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 remove the negative cable from the left rear battery. Note:alw...

  • Page 226

    13-22 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 locate the linear throttle potentiometer. Remove the 4 socket ...

  • Page 227

    13-23 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 remove the throttle cable from the throttle arm. Remove the th...

  • Page 228

    13-24 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 count the number of threads showing where the clevis pin was; ...

  • Page 229

    13-25 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 be sure the jam nut has the same number of threads showing tha...

  • Page 230

    13-26 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 adjusted properly, the hole in the throttle cable end should l...

  • Page 231

    13-27 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 throttle cable removal/replacement loosen the jam nut closest ...

  • Page 232

    13-28 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 slide the cable adjuster housing back through the cable mount....

  • Page 233: Throttle  Cable Adjustment

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  • Page 234

    13-30 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 throttle cable adjustment is setting the amount of “throw” or ...

  • Page 235

    13-31 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 on electric karts, when the cable is installed at the factory,...

  • Page 236: Motor  Controller

    13-32 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 controller this is the controller: the most technical pa...

  • Page 237

    13-33 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 remove the negative cable from the left rear battery. Note: al...

  • Page 238

    13-34 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 all of the remaining cables to the controller. Remove t...

  • Page 239

    13-35 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 before installing the new controller, be sure to put a film of...

  • Page 240: Interconnect  Board

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  • Page 241

    13-37 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 many of the components previously listed connect to the interc...

  • Page 242

    13-38 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 negative cable from the left rear battery. Note:alw...

  • Page 243

    13-39 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 carefully remove the throttle input plug from the interconnect...

  • Page 244

    13-40 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 unplug the on/off switch box cable. Unplug the relay cable. Re...

  • Page 245

    13-41 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 remove any wires connected to the peripheral (ts1) input conne...

  • Page 246

    13-42 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 place the board on a flat surface (it is a good idea to use a ...

  • Page 247

    13-43 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 note: be careful when plugging the throttle input plug into th...

  • Page 248: Switch   Box

    13-44 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 switch box overview this is the on/off button and the forward/...

  • Page 249: Switch  Box Testing

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  • Page 250

    13-46 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 using the alternate switch box, turn the kart on. If the probl...

  • Page 251

    13-47 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 loosen the 4 pan-head screws holding the cover on the switch b...

  • Page 252: Brake Pressure Switch

    13-48 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 brake pressure switch overview the brake pressure switch is de...

  • Page 253

    13-49 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 brake pressure switch testing/removal remove the axle guard or...

  • Page 254

    13-50 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 if the kart does not operate and you suspect a faulty switch, ...

  • Page 255

    13-51 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 and replace the existing pressure switch and re-connect...

  • Page 256

    13-52 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 this is the remote shut-down receiver and wire harness. The re...

  • Page 257

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  • Page 258

    13-54 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 flash codes (pc-pak) this is the sevcon pc pak. This i...

  • Page 259: Testing Flash Codes

    13-55 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 your control panel and find the icon for device manager; ...

  • Page 260

    13-56 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 program open, click on the “tools” tab on the top bar...

  • Page 261

    13-57 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 save a copy of the workin g profile, follow these steps: wi...

  • Page 262: Controller  Flash Faults

    13-58 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 controller flash faults symptom: no light = no power to contro...

  • Page 263

    13-59 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 you will need a working profile to install into the non-functi...

  • Page 264

    13-60 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 find the saved profile and choose “open.” click the “next” but...

  • Page 265

    13-61 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 next box will be the rapid download wizard. Click the larg...

  • Page 266

    13-62 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 symptom: 2 flashes = illegal start condition. This code relate...

  • Page 267

    13-63 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 charging system utilizes a smart charger; it reads the bat...

  • Page 268: Kartrol Locations

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  • Page 269

    13-65 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 floor-charging brush system the floor-charging brush system is...

  • Page 270: Floor Plate Contacts

    13-66 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 floor plate contacts inspect the floor plate contacts to make ...

  • Page 271: Index

    Index a ackerman effect 4-10 anti vibration grabber plate 8-3 b battery replacement 13-12 battery pack 13-10 testing 13-11 bearing caps 3-9 bleeding brakes 7-17 body latch 12-2 body mounts 12-1 f-22 go-kart 12-3 body panels eagle go-kart 12-5 , 12-6 body seal 12-12 brake fluid change/inspection 7-14...

  • Page 272

    Guard 7-10 overview 7-9 removal 7-10 motor controller electric go-kart 13-32 n nerf bar removal installation 2-5 non scheduled maintenance 0-16 o oil type 0-24 on/off switch 13-44 p pad 4-13 repair 5-6 seat belt 5-8 pads 5-1 pc pak 13-54 pedal adjustment 7-12 brake removal 7-13 bushings 10-10 pedal ...