J&J Amusements KING SCORPION, SIDEKICK, SIDEWINDER DOUBLE, F-22 DOUBLE, DOUBLE EAGLE Service Manual

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Service Manual

Single & Double Go Karts (2018)

Speciﬁ cations subject to change without notice.

Published by J&J Amusements, Inc.

An Oregon Corporation

2018

Amusements, Inc.

4897 Indian School Rd NE Suite 150 Salem Oregon 97305-1126

www.jjamusements.com Phone: 503-304-8899 Tol l Free Phone : 800 - 854 -314 0 Fax: 503-304-1899 Tol l Free Fa x: 800 -36 6 -7505

TECHNICAL CONTACT INFORMATION

We value your feedback; technical comments and suggestions are helpful to us. Please e-mail your comments to service@jjamusements.com.

From time to time, updates may be made to this manual. For the latest updates, please visit our technical website at http://jjamusements.com/technical/index.htm.

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, eﬀ ective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed (along with standard safety procedures) to reduce the possibility of personal injury or improper service, which could damage the go kart or compromise its safety.

It is important to note that repair procedures, techniques, tools and parts for servicing J&J go karts, as well as the skill and experience of the individual performing the work, vary widely. It is not possible to anticipate all conceivable ways, or conditions under which J&J go karts may be serviced, or to provide cautions to all possible hazards that may result. St andard p recautio ns sho uld be used whe n hand ling toxic or ﬂ ammable ﬂ uids, and safety goggles or other protection should be used during cutting, grinding, chiseling, prying or any other process that can cause material removal or projectiles. J&J recommends the use of safety goggles or approved glasses during all servicing of J&J go karts.

All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. All rights reserved. Except as expressly provided herein, no part of the manual may be reproduced, copied, transmitted, disseminated, downloaded or stored in any storage medium, for any purpose, without prior written consent of J&J Amusements, Inc. An Oregon Corporation. J&J Amusements, Inc. grants permission to download a single copy of this manual onto a hard drive or other electronic storage medium to be viewed for personal use, provided that such electronic or printed copy of this manual contains the complete text of this copyright notice. Any unauthorized commercial distribution of this manual is strictly prohibited.

As you read this manual, you will ﬁ nd information that is preceded by a NOTE symbol. The purpose of this message is to

prevent damage to the go kart, other property, or the environment.

SAFETY MESSAGES

Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all of the hazards associated with ser vicing a go kart. You must use your own good judgement. You will ﬁ nd important safety information in a variety of forms, including:



SAFETY MESSAGES - preceded by a safety alert symbol and one of four signal words:

DANGER, WARNING, CAUTION, or SAFETY ITEM.

THESE SIGNAL WORDS MEAN:

DANGER ..............................You WILL be KILLED or SERIOUSLY INJURED if you do not follow the subsequent instructions.

WARNING ............................You CAN be KILLED or SERIOUSLY INJURED if you do not follow the subsequent instructions.

CAUTION...................................................................You WILL be INJURED if you do not follow the subsequent instructions.

SAFETY ITEM ...This safety device was installed at the factory and may be required by state, local, or ASTM standards.

 INSTRUCTIONS - how to service these go karts correctly and safely.

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 certain amount of basic knowledge is also required for successful work.

Especially note the following:

DIRT

Before removal and disassembly, clean the go kart. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of these parts. For the same reason, before installing a new part, clean oﬀ any dust or metal ﬁ lings.

TIGHTENING SEQUENCE

Generally, when installing a part with several bolts, nuts or screws, start them all in their appropriate holes and tighten them to a snug ﬁ t, then tighten them evenly in a cross pattern. This action will avoid distortion of the part. Conversely, when loosening the bolts, nuts or screws, loosen each by a quarter turn, and then remove in a similar cross pattern. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts or screws must be tightened in the order and method indicated.

TORQUE

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

FORCE

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially diﬃ cult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. It also may be necessary to apply heat to some parts that are held with a locking compound.

EDGES

Watch for sharp edges, especially during major motor/engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lif ting the motor/engine or turning it over.

HIGH-FLASH-POINT SOLVENT

A high-ﬂ ash-point solvent is recommended to reduce ﬁ re danger. A commercial solvent commonly available in North America is “standard solvent” (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

GASKET, O-RING

Do not reuse a gasket or O-ring once it has been in ser vice. The mating sur faces around the gasket must be free of foreign matter and perfectly smooth.

LIQUID GASKET, NON-PERMANENT LOCKING AGENT

Follow manufacturers’ directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly, as excessive amounts may cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite® Lock’n Seal (Blue).

PRESS

A part installed using a press or driver, such as a wheel bearing, should ﬁ rst be coated with oil on its outer or inner circumference so that it will go into place smoothly.

OIL SEAL AND GREASE SEAL

Replace any oil or grease seals that were removed with new parts, since removal generally damages seals. When pressing in a seal containing manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver (which contacts evenly with the side of the seal) until the face of the seal is even with the end of the hole. Always use assembly oil or grease on the lip (sealing edge) of any seal prior to assembly.

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 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.

INSPECTION

When parts have been disassembled, visually inspect these parts for the following conditions or other damage (If there is any doubt as to their condition, replace them with new parts): Abrasions, cracks, hardening, warping, bends, dents, scratches, wear, color changes, deterioration, seizure.

SPECIFICATIONS

Speciﬁ cation terms are deﬁ ned as follows:

“Standards”: Show dimensions or performances which brand-new par ts or systems have. “Service Limits”: Indicate the usable limits. If measurement shows excessive wear or deteriorated performance, replace

the damaged parts.

GENERAL DATA AND MAINTENANCE.

Speciﬁ cations ....................................................... 0-1

Scheduled maintenance ....................................0-8

Service schedule - gas ........................................0-9

Service schedule - electric ................................0-11

Maintenance records .......................................0-12

Pre-opening checklist - gas .............................. 0-13

Pre-opening checklist - electric .......................0-14

Go-kart track area checklist .............................0-15

Non-scheduled maintenance record .............. 0-16

Work order tags ................................................0-17

How a warranty is processed .......................... 0-20

Product return procedures ..............................0-20

Limited warranty ...............................................0-21

Cleaning go-karts ..............................................0-22

Unloading go-karts ...........................................0-23

Initial setup ........................................................ 0-26

1 2 3 4

TUBES, TIRES, RIMS

FRAME, BUMPERS, NERF BARS

FRONT HUBS, SPINDLES

STEERING SYSTEM

Tube & rim information .................................... 1-1

Frequent questions ...........................................1-2

Rotating tires ...................................................... 1-2

Disc-lock lug nuts ...............................................1-3

Wheel removal ................................................... 1-5

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

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

Frequent que stions (hu bs & spindles) ......................... 3-1

Front hub removal .............................................3-3

Spind le .................................................................3- 4

Steering system.................................................. 4-1

Cast er ................................................................... 4 -3

Toe-in ...................................................................4- 6

Tie rods/ends ......................................................4-8

Changing tires & tubes ......................................1-6

Tire & wheel inspec tion ..................................1-10

Troubleshooting tires ...................................... 1-11

Bumper & D-rubber removal ........................... 2-3

Nerf bar removal ................................................2-5

Tapered spindle & roller bearings ....................3-5

Spindle dissassembly ........................................3- 8

Spindle assembly ...............................................3-9

Ackerman eﬀ ect ...............................................4-10

Steering shaft & cover ..................................... 4-11

Steering wheel .................................................. 4-12

Steering column pad ....................................... 4-13

5 6 7 8

ROLL BARS, PADS, SEATBELTS

AXLE, AXLE COVER, DRIVE SYSTEM COMPONENTS

BRAKE SYSTEM

ENGINE, CLUTCH, ENGINE MOUNTED ACCESSORIES

Frequent questions ...........................................5 -1

R ol l ba r (Eagle, Sc orpion, Ca n-Am, F -22, Sidek ick) .. . 5- 2

Roll bar (Sidewinder, Sidewinder double) .................. 5-3

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

Over view .............................................................6-2

Axle cover ............................................................6-3

Drive cover ..........................................................6-4

Drive belt .............................................................6-6

Drive hub ........................................................... 6-11

Drive pulley ....................................................... 6-12

Over view ............................................................. 7-1

Caliper assembly ................................................7-3

Brake pads - removal & installation ...............7-4

Removing brake caliper assembly .................7-5

Master cylinder over view ................................. 7-9

Master cylinder removal ................................. 7-10

Brake pedal ....................................................... 7-13

Brake ﬂ uid level inspection ............................7-14

Engine overview............................................ 8-1

Grabber plate .....................................................8-3

Engine assembly removal.................................8- 4

Engine-mounted items .....................................8-6

Fixing pads ..........................................................5-6

Seat b el t s .............................................................. 5 -7

Cleaning seatbelts .............................................5-9

Floater hub ........................................................ 6-14

Axle bearing overv iew .................................... 6-16

Bear in g s ............................................................. 6-17

Axle - single drive ............................................. 6-19

Axle - two-wheel drive ....................................6-26

Drive sprocket spreadsheet ...........................6 -27

Brake ﬂ uid change ........................................... 7-14

Bench -bleeding master cylinder ................... 7-15

Bleeding the brake system ............................. 7-17

Brake troubleshooting ....................................7-18

Drum brake sy stem over view........................ 7-19

Drum brake par ts identiﬁ c ation ...................7-20

Changing brake shoes .....................................7-21

Drum brake adjustments ...............................7-27

Hour meter schematic (without kar trol) ....... 8 -7

Hour meter schematic (with kartrol) .................8-8

Tiny tach schematic ........................................... 8-9

Clutch/reduction rebuild ................................ 8-14

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

FUEL TANK & EMISSION SYSTEM

Over view ............................................................. 9-1

Remote f uel tank removal ................................9-2

Remote f uel tank bracket removal .................9-3

Engine-mounted fuel t ank removal ................9-4

Fuel cap/vent ......................................................9-5

Evaporative system ...........................................9-6

Evaporative system maintenance................... 9-7

Evaporative system routing .............................9-9

11 12 13

THROTTLE, CABLE, PEDAL

CARBURETOR

BODY, BODY MOUNTS, DECALS

ELECTRICAL SYSTEM

Throt tle cable ...................................................10-1

Throt tle cable routing (bodied go-kart) .......10 -2

Throt tle cable routing (eagle go-kar t) ..........10-3

Throt tle cable removal ....................................10-5

Throt tle cable lubrication ...............................10-6

Over view ........................................................... 11-1

Identifying carburetor items ......................... 11-3

Over view ........................................................... 12-1

Body mounts (F-2 2) .........................................12-3

Eagle body panels ............................................12-5

Frequent questions .........................................13-2

Basic electrical troubleshooting ...................13- 4

Voltage drop testing ........................................13-7

Testing fuse .......................................................13-8

Wire schematic ................................................. 13-9

Battery pack .................................................... 13-10

Battery pack testing ......................................13-11

Battery pack replacement ............................13-12

Fuse .................................................................. 13-13

Relay ................................................................. 13-17

Throt tle cable/speed adjustment .................10-7

Throt tle pedal removal ...................................10-9

Throt tle pedal bushings................................10-10

Carburetor check sheet................................11-7

Warning decals ................................................. 12-7

Body seal ......................................................... 12-12

Linear throt tle potentiometer .....................13-20

Throt tle cable .................................................13-27

Throt tle cable adjus tment............................13-29

Motor controller .............................................13-32

Interconnect board ........................................13-36

Switch box ...................................................... 13-44

Switch box tes ting ......................................... 13-45

Remote shutdown wire harness .................13-52

Tes tin g ﬂ ash codes ........................................13-54

Controller ﬂ ash faults ...................................13-58

FPX is “The Tire Store” for concession go kart tires. We carr y only the best and most popular sizes.

We stock so many tires we have another warehouse on the east coast! That’s right, we have a warehouse in Atlanta, Georgia and one at our headquar ters in Salem, Oregon!

5” TIRE/TUBE COMBINATION DEALS

Part# Description Price

007880COMBO Tire, 12 x 4.00 - 5” SL72 Bigfoot COMBO (W/Tube) $22.99

007880 Tire, 12 x 4.00 - 5” SL72 Bigfoot (TIRE ONLY NO TUBE!) $21.99

1-20-0037 Tire, 11 x 3.60 - 5” SL72 736HD $22.99

Quantity discounts available on 007880COMBO. QTY 100+ $21.99, 500+ $20.99

4” TIRES

Part# Description Price

1-20-0054 Tire, 4.10/3.50 - 4” SL72 738HD $15.80

TIRES - FALCON

Part# Description Price

1-60-0185 Tire, 4.10/3.50-5 4-ply Falcon Electric King Nob Style $18.99

1-20-0037 Tire, 11 x 3.60 - 5” SL72 736HD $22.99

TIRES - OTHER

Part# Description Price

1-60-0009 Tire, 10 x 4.50 - 5” SL72 739 Race Style Slick $16.50

1-20-0064 Tire, 11 x 4.50 - 5” SL72 739 Race Style Slick $18.99

1-60-0008 Tire, 11 x 7.10 - 5” SL72 739 Race Style Slick $39.99

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

KING SCORPION SIDEWINDER DOUBLE F-22 DOUBLE

SIDEKICK DOUBLE EAGLE

0-1

SPECIFICATIONS

SPECIFICATIONS: GAS-POWERED DOUBLES

DOUBLE SEAT GO KARTS, KING SCORPION, SIDEWINDER DOUBLE, F-22 DOUBLE, SIDEKICK, DOUBLE EAGLE

DIMENSIONS

Overall length ...................................................................................................................................................................... 82”(208 cm)

Overall width ......................................................................................................................................................................... 55” (139cm)

Overall height .......................................................................................................................................................................40” (101 cm)

Wheel base ..................................................................................................................................................................... 44.125” (112cm)

Ground clearance ....................................................................................................................................................................2.5” (6cm)

Fuel capacity .............................extra-capacity fuel tanks available, model dependent, 2.2, 3.3, 3.5 or 4.75 gallon capacities

ENGINE

Model .........................................................................................................................Honda™ GX160k1, GX200, GX240k1, GX270k1

Type ......................................................................................................... 4-stroke, overhead valve, single cylinder, inclined by 25°

Cooling system ........................................................................................................................................................................ forced air

Starting system ....................................................................................................................................... recoil, optional electric start

Spark plug ..................................................................................................................................................bpr6es (ngk), w20epr-u (nd)

Lubrication system .......................................................................................................................................................................splash

DRIVE TRAIN

Clutch type ..................................................................................................................................................centrifugal, wet multi-disc

Clutch engagement /lock .......................................................................................................engagement 1800 rpm/lock 2200rpm

Final drive system ...................................................................................................................................520 X ring hd chain, cog belt

FRAME

Type .............................................................................................................................................................................................. unitized

Coatings ............................................................................................... phosphate dipped and electrostatic powder-coated 425°f

Steering angle .............................................................................................................................................................24° to either side

Caste r ..................................................................................................................................................................... adjustable, 0° to 14°

Tires .........................................................................................................................................................5” extended-wear pneumatic

Brake type .............................................................................................(self-adjusting) hydraulic disc, optional mechanical drum

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

SPECIFICATIONS

0-2

CAN-AM

SIDEWINDER F-22

SCORPION EAGLE

SPECIFICATIONS: GAS -POWERED SINGLES

SINGLE SEAT GO KARTS, SCORPION, SIDEWINDER, F-22, CAN-AM, EAGLE

DIMENSIONS

Overall length ......................................................................................................................................................................82”(208 cm)

Overall width .........................................................................................................................................................................45” (114cm)

Overall height ...................................................................................................................................................................... 40” (101 cm)

Wheel base .....................................................................................................................................................................44.125” (112cm)

Ground clearance ....................................................................................................................................................................2.5” (6cm)

Fuel capacity ............................ extra-capacity fuel tanks available, model dependent, 2.2, 3.3, 3.5 or 4.75 gallon capacities

ENGINE

Model ........................................................................................................................ Honda™ GX160k1, GX200, GX240k1, GX270k1

Type .........................................................................................................4 -stroke, overhead valve, single cylinder, inclined by 25°

Cooling system ........................................................................................................................................................................forced air

Starting system .......................................................................................................................................recoil, optional electric start

Spark plug ................................................................................................................................................. bpr6es (ngk), w20epr-u (nd)

Lubrication system .......................................................................................................................................................................splash

DRIVE TRAIN

Clutch type .................................................................................................................................................. centrifugal, wet multi disc

Clutch engagement /lock ...................................................................................................... engagement 1800 rpm/lock 2200rpm

Final drive system ..................................................................................................................................520 X ring hd chain, cog belt

FRAME

Coatings .............................................................................................. phosphate-dipped and electrostatic powder-coated 425°f

Steering angle .............................................................................................................................................................24° to either side

Caste r .....................................................................................................................................................................adjustable, 0° to 14°

Tires ........................................................................................................................................................ 5” extended-wear pneumatic

Brake type .............................................................................................(self-adjusting) hydraulic disc, optional mechanical drum

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

SIDEWINDER DOUBLE - ELECTRICDOUBLE EAGLE - ELECTRIC

SPECIFICATIONS: ELECTRIC -POWERED DOUBLES

DOUBLE GO KARTS, SIDEWINDER DOUBLE, DOUBLE EAGLE

0-3

SPECIFICATIONS

DIMENSIONS

Overall length .......................................................................................................................................................................82”(208 cm)

Overall width ......................................................................................................................................................................... 55” (139cm)

Overall height ....................................................................................................................................................................... 40” (101 cm)

Wheel base ..................................................................................................................................................................... 44.125” (112cm)

Ground clearance .................................................................................................................................................................... 2.5” (6cm)

MOTOR

Model ................................................................................................................................................................................................. D&D

Type ................................................................................................................48vdc, separately excited, 48vdc permanent magnet

Cooling system .........................................................................................................................................................................forced air

Maximum horsepower ............................................................................................................................................... 18.6 hp (13.9 kw)

Controll e r .................................................................................................................... ................................................................... sevcon

Speed controller ........................................................................................................................................................................... sevcon

Power .................................................................................................................. 48 vdc qty 4 (12 volts blue/yellow optima battery)

............................................................................................................................................870 amps cold cranking amps per battery

................................................................................................................................................. 120 amps reserve capacity per battery

DRIVE TRAIN

Clutch type ............................................................................................................................................................................ direct drive

For w ard /re verse .................................................................................................................................................................................. yes

High/low (optional) .......................................................................................................................................................yes, with Kartrol

Final drive system ...................................................................................................................................520 X ring hd chain, cog belt

FRAME

Coatings ............................................................................................... Phosphate-dipped and electrostatic powder-coated 425°f

Steering angle ............................................................................................................................................................. 24° to either side

Caste r ......................................................................................................................................................................adjustable, 0° to 14°

Tires ......................................................................................................................................................... 5” extended-wear pneumatic

Brake type .............................................................................................................................................. (self-adjusting) hydraulic disc

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-4

SPECIFICATIONS

SPECIFICATIONS: ELECTRIC-POWERED SINGLES

SINGLE SEAT GO KARTS, SIDEWINDER, EAGLE

SIDEWINDER - ELECTRICEAGLE ELECTRIC

DIMENSIONS

Overall length .......................................................................................................................................................................82”(208 cm)

Overall width ..........................................................................................................................................................................45” (114cm)

Overall height ....................................................................................................................................................................... 40” (101 cm)

Wheel base ..................................................................................................................................................................... 44.125” (112cm)

Ground clearance .................................................................................................................................................................... 2.5” (6cm)

MOTOR

Type .................................................................................................................48vdc separately excited, 48vdc permanent magnet

Cooling system .........................................................................................................................................................................forced air

Maximum horsepower ............................................................................................................................................... 18.6 hp (13.9 kw)

Speed controller ........................................................................................................................................................................... sevcon

Power .................................................................................................................. 48 vdc qty 4 (12 volts blue/yellow optima battery)

............................................................................................................................................870 amps cold cranking amps per battery

................................................................................................................................................. 120 amps reserve capacity per battery

DRIVE TRAIN

Clutch type ............................................................................................................................................................................ direct drive

High/low (optional) .......................................................................................................................................................yes, with Kartrol

Final drive system ...................................................................................................................................520 X ring hd chain, cog belt

FRAME

Coatings ............................................................................................... phosphate-dipped and electrostatic powder-coated 425°f

Steering angle ............................................................................................................................................................. 24° to either side

Caste r ......................................................................................................................................................................adjustable, 0° to 14°

Tires ......................................................................................................................................................... 5” extended-wear pneumatic

Brake type .............................................................................................................................................. (self-adjusting) hydraulic disc

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

STINGER TALON

0-5

SPECIFICATIONS

SPECIFICATIONS: GAS-POWERED ROOKIES

STINGER, TALON

DIMENSIONS

Overall length ....................................................................................................................................................................... 73”(185 cm)

Overall width ..........................................................................................................................................................................45” (114cm)

Overall height ......................................................................................................................................................................... 33” (84 cm)

Wheel base ........................................................................................................................................................................... 36” (91.4cm)

Ground clearance .................................................................................................................................................................... 2.5” (6cm)

Fuel capacity ....................................................................................................................................(extra-capacity)2.2 gal (8.3 liters)

ENGINE

Model ............................................................................................................................................................ Honda™ GX160k1, GX200,

Type ..........................................................................................................4- stroke, overhead valve, single cylinder, inclined by 25°

Cooling system .........................................................................................................................................................................forced air

Starting system ........................................................................................................................................recoil, optional electric start

Spark plug .................................................................................................................................................. bpr6es (ngk), w20epr-u (nd)

Lubrication system ....................................................................................................................................................................... splash

DRIVE TRAIN

Clutch type ...................................................................................................................................................centrifugal, wet multi-disc

Clutch engagement /lock ....................................................................................................... engagement 1800 rpm/lock 2200rpm

Final Drive System ...................................................................................................................................520 X ring hd chain, cog belt

FRAME

Coatings ............................................................................................... phosphate-dipped and electrostatic powder-coated 425°f

Steering angle ............................................................................................................................................................. 24° to either side

Caste r ......................................................................................................................................................................adjustable, 0° to 14°

Tires ......................................................................................................................................................... 5” extended-wear pneumatic

Brake type ............................................................................................. (self-adjusting) hydraulic disc, optional mechanical drum

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-6

SPECIFICATIONS

TALON - ELECTRIC

SPECIFICATIONS: ELECTRIC-POWERED ROOKIES

TALON - Electric

DIMENSIONS

Overall length ....................................................................................................................................................................... 73”(185 cm)

Overall width ..........................................................................................................................................................................45” (114cm)

Overall height ......................................................................................................................................................................... 33” (84 cm)

Wheel base ........................................................................................................................................................................... 36” (91.4cm)

Ground clearance .................................................................................................................................................................... 2.5” (6cm)

MOTOR

Type ................................................................................................................. 24vdc separately excited, 24vdc permanent magnet

Cooling system .........................................................................................................................................................................forced air

Maximum horsepower ................................................................................................................................................... 9.3 hp (6.9 kw)

Speed controller ...........................................................................................................................................................................Sevcon

Power .................................................................................................................................... 24 vdc, qty 2 (12 volts Trojan T-31-AGM)

.......................................................................................................................................... 720 amps, cold-cranking amps per battery

................................................................................................................................................. 100 amps reserve capacity per battery

DRIVE TRAIN

Clutch type ............................................................................................................................................................................ direct drive

High/low (optional) .......................................................................................................................................................yes, with Kartrol

Final drive system ...................................................................................................................................520 X ring hd chain, cog belt

FRAME

Type ....................................................................................................................................................................... unitized, monocoque

Coatings ............................................................................................... phosphate-dipped and electrostatic powder-coated 425°f

Steering angle ............................................................................................................................................................. 24° to either side

Caste r ......................................................................................................................................................................adjustable, 0° to 14°

Tires ......................................................................................................................................................... 5” extended-wear pneumatic

Brake type .............................................................................................................................................. (self-adjusting) hydraulic disc

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

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 before they happen.

When following the guides in the next few pages, be sure to look over the entire kart for potential problems and address them as needed prior to allowing guests to operate the equipment. Each piece of equipment should be inspected daily for problems or needed repairs. As an example, if you find a tire that is showing a wear indicator in the morning, replace the tire; it will prevent the tire from failing in the middle of the day, requiring the kart to be taken out of service when it may be needed the most. An out-of-adjustment belt can cause extensive wear on the belt and clutch bearings, and cause premature failure. The list goes on and on, but the key is to maintain the equipment rather than react to failures.

Utilize the maintenance logs to track problems with your fleet. Log kart numbers and parts replaced to track other issues that may be causing a particular kart’s parts to be damaged more quickly than they should. As an example, you may have a kart that continually fouls a spark plug. If you do not track that type of usage, then all you know is that you go through a lot of spark plugs when it may only be one or two karts with other issues that are causing the plugs to foul. In that case, the real issue may be as simple as a dirty air cleaner that is not allowing proper air flow to the motor, causing it to run rich or have excessive carbon build up in the combustion chamber. In either case, the root of the problem is something other than the spark plug, but the result is a fouled plug. This is especially important when there is more than one maintenance person working on the equipment. If the replacement parts are not tracked, then one person could replace a part one day, another the next, and each would not know that the single kart is wearing parts out so quickly.

SPECIFICATIONS

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-8

SPECIFICATIONS

EXPLANATION OF SCHEDULED MAINTENANCE

Below are explanations of the services listed in the maintenance charts for gas-powered go karts. The proper ﬂ uids and lubricants to use are listed in this section. Make sure to always use the recommended ﬂ uids and lubricants. All parts should be replaced and all necessary repairs done before the kart is operated.

CAUTION J&J recommends use of safety goggles or approved glasses during all servicing of J&J go karts.

1. ENGINE OIL & REDUCTION GEAR OIL: Always use API service SG.SF/CC.CD. Designation shown on the container.

To determine the preferred viscosity of oil for your go-kart’s engine, see “Engine Oil” in the Honda™ Shop Manual.

AIR CLEANER FILTER REPLACEMENT: Clean, check and replace at the speciﬁ ed intervals; see the Honda™a Shop

Manual.

FUEL STRAINER: Clean at the speciﬁ ed interval or sooner if clogged.

SPARK PLUG CLEANING & REPLACEMENT: Clean and replace spark plugs with the type listed in the Honda™ Shop

Manual.

VALVE CLEARANCE: Check and adjust at the speciﬁ ed intervals; see the Honda™ Shop Manual.

COMBUSTION CHAMBER & VALVES: Decarbonize cylinder head and lap valves; see the Honda™ Shop Manual.

FUEL TANK, CAP & LINES INSPECTION: Inspect the fuel tank, cap and lines for damage or leaks. Remove the fuel

cap, inspect the gasket for an even ﬁ ller neck imprint and any damage. Replace parts as needed.

FRONT HUBS AND SPINDLES: Inspect and grease the front spindles every 2 weeks or 200 hours. Front hub nuts

should be torqued to 50 ft. lbs.

AXLE & AXLE BEARINGS: Inspect the axle for bending and cracking. Clean and grease the axle bearings at the

speciﬁ ed intervals or sooner, if operated in dirty or wet conditions.

STEERING: Check for smooth and precise movement from full turn left to full turn right. Inspect the tie rods and

10.

rod ends for loosening, damage or wear. To prevent uneven tire wear and a poor-handling kart, check the front end alignment weekly or every 100 hrs.

11.

DRIVE BELTS: Inspect the drive belts for proper deﬂ ection, alignment and tension. Twisted or cracked belts should be

replaced.

WARNING Too much tension shortens belt and bearing life.

PULLEYS & SPROCKETS: Inspect for damage and proper alignment. Replace as needed.

12.

WHEEL LUG NUTS & STUDS: Check for loose wheel lug nuts and studs daily, and torque to 35 ft. lbs.

13.

WARNING Check the tightness frequently during the ﬁ rst week or 100 hrs, and when the wheel is changed.

ALL NUTS AND BOLTS: Check for loose and/or missing nuts and bolts. Replace as needed.

14.

HYDRAULIC DISC BRAKES INSPECTION: When the engine oil is changed, inspect the lines and hoses for proper

15.

hookup, binding, leaks, cracks, chaﬁ ng, etc. Check the ﬂ uid level in the master cylinder. A low ﬂ uid level can indicate worn disc brake pads, which may need to be replaced. Inspect the disc for wear and improper alignment.

WARNING Inspect brakes more often if driving conditions result in frequent braking.

SEAT BELTS: Inspect all belts, buckles, latch plates and anchorages daily, replace if necessary.

16.

CAUTION Don’t let anyone operate the go-kart if they can’t wear a seat belt properly. If the kart is in a crash and

they are not wearing a seat belt, they could hit things inside the kart or be ejected from it; they can be seriously injured or killed. Always properly fasten customers’ seat belts, and then double-check to make certain the straps are not loose.

17.

STARTER ROPE: Check the rope for fraying. Check the air intake screen for foreign matter that could cause

overheating or ﬁ re; see the Honda™ Owner’s Manual.

TIRES: For proper wear and maximum tire life, rotate the tires and check inﬂ ation (see service schedule). A properly

18.

inﬂ ated and aligned tire should wear evenly across the tread. Replace tires when the wear indicator lines are no longer visible around the sidewalls.

19.

CHASSIS LUBRICATION: Lubricate the steering linkage, throttle linkage pedal, and throttle control arm at the

speciﬁ ed intervals, or after washing. When used in dusty or wet conditions, service more frequently.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

GO-KART SERVICE SCHEDULE (Gas)

Item # Item Service type

Log hours of operation to determine proper maintenance intervals.

1 Engine oil

1 Reduction gear oil

2 Air ﬁ lter

3 Fuel strainer Clean

4 Spark plug

5 Valve clearance Adjust

6 Combustion chamber Clean

7 Fuel tank & fuel lines

8 Front hubs & spindles

9 Axle & axle bearings

10 Steering Check Daily

11 Drive belts

12 Pulleys

14 All nuts & bolts

15 Hydraulic brakes

16 Seat belts

17 Starter rope

18 Tires (40-50psi)

19 Chassis lubrication Lubricate After every wash

20 Warning decals

(1) Service more frequently when used in dusty areas. (*) Replace paper element type only.

Wheel lug nuts & studs

Check level Daily

Change

Check level Daily

Change

Check Daily

Clean (1)

Replace (*)

Check

Replace

Check Daily

Replace lines Yearly

Replace tank When necessary

Check Daily

Torque When necessary

Grease Yearly

Check

Grease Yearly

Check Daily

Adjust When necessary

Replace When necessary

Check Daily

Adjust When necessary

Replace When necessary

Check Daily

Torque wheels(35 ft.lbs) When replaced

Replace When damaged

Check Daily

Torque Yearly

Replace When damaged

Check pad wear

Check ﬂ uid level

Fluid change Yearly

Check Daily

Replace When damaged

Check Daily

Replace When damaged

Check Daily

Rotation When necessary

Replace When damaged

Check Daily

Replace When damaged

Check Frequency

0-9

1st

20 hrs

 

  

   



 



 



 



Note: This is a sample form. Your checklist should include but not

be limited to these items. Make extra copies for future use.

Every

50 hrs



Every

100 hrs

Every

300hrs



 

Every

500hrs



SPECIFICATIONS

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-10

SPECIFICATIONS

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

Below are explanations of the services listed in the maintenance charts for electric-powered Go karts. The proper ﬂ uids and lubricants to use are listed in this section. Make sure to always use the recommended ﬂ uids and lubricants. All parts should be replaced, and all necessary repairs done before the kart is operated.

CAUTION J&J recommends use of safety goggles or approved glasses during all servicing of J&J go karts.

1. SB175 CHARGER PLUG/CHARGER BRUSHES: Make sure that the plug is lubricated with dielectric grease. Inspect

the plug for deep grooving or signs of arcing. Make sure charger brushes (if equipped) are in good condition and they both slide up and down freely in the holder. Inspect the UHMW brush holder to be sure it is tightly fastened to kart’s chassis. Look for loose or damaged cables or connections. Check that the brushes are making good contact with the ﬂ oor plates. Repair or replace as needed.

2. 4 GAUGE POWER WIRE: Check for bare wires or heavy discoloration; Replace as needed.

3. MOTOR: Check for discoloration of the motor casing and tightness of the terminal. Use compressed air to remove

dust and debris.

4. CHARGE-STOP FUNCTION: Ensure that with charger plugged in, the acceleration function does not work.

5. SWITCH BOX: Check the switch box for proper operation (see service schedule). Externally inspect the switch box

for bare or damaged wires. Check and tighten the set screw for the on/oﬀ and forward/reverse knob (see service schedule).

6. BATTERIES: Check the terminal connections for tightness.

7. COMPONENT BOARD: Remove the cover and inspect all the components. Check for bare wires, proper connection,

and any signs of excessive heat, arcing or melting.

8. FRONT HUBS AND SPINDLES: Inspect and grease the front spindles every 2 weeks or 200 hours. The front hub nuts

should be torqued to 50 ft. lbs.

9. AXLE & AXLE BEARINGS: Inspect the axle for bending and cracking. Clean and grease all axle bearings at the

speciﬁ ed intervals, or sooner if operated in dirty or wet conditions.

10. STEERING: Check for smooth and precise movement from full turn left to full turn right. Inspect the tie rods and

rod ends for loosening, damage or wear. To prevent uneven tire wear and a poor-handling kart, check the front end alignment weekly or every 100 hrs.

11. DRIVE BELTS: Inspect drive belts for proper deﬂ ection, alignment and tension. Twisted or cracked belts should be

replaced.

WARNING Too much tension shor tens belt and bearing life.

12. PULLEYS & SPROCKETS: Inspect for proper deﬂ ection and alignment.

13. WHEEL LUG NUTS & STUDS: Check for loose wheel lug nuts and studs daily, and torque to 35 ft. lbs.

WARNING Check the tightness frequently during the ﬁ rst week or 100 hrs, and when the wheel is changed.

14. ALL NUTS AND BOLTS: Check for loose and/or missing nuts and bolts. Replace as needed.

15. HYDRAULIC DISC BRAKES INSPECTION: When the engine oil is changed, inspect the lines and hoses for proper

WARNING Inspect brakes more often if driving conditions result in frequent braking.

16. SEAT BELTS: Inspect all belts, buckles, latch plates and anchorages daily, replace if necessary.

CAUTION Don’t let anyone operate the go-kart if they can’t wear a seat belt properly. If the kart is in a crash and

17. TIRES: For proper wear and maximum tire life, rotate the tires and check inﬂ ation (see service schedule). A properly

inﬂ ated and aligned tire should wear evenly across the tread. Replace tires when the wear indicator lines are no longer visible around the sidewalls.

18. CHASSIS LUBRICATION: Lubricate the steering linkage, throttle linkage, pedal, and throttle control arm at the

speciﬁ ed intervals, or after washing. When used in dusty or wet conditions, service more frequently.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

GO-KART SERVICE SCHEDULE (Electric)

0-11

Item # Item Service type

Log hours of operation to determine proper maintenance intervals.

Check Daily

2 4GA. power wire

3 Motor

4 Charge-stop function Check Daily

5 Switch box

6 Batteries

7 Component board Check

8 Front hubs & spindles

9 Axle & axle bearings

10 Steering Check Daily

11 Drive belts

12 Pulleys

14 All nuts & bolts

15 Hydraulic brakes

16 Seat belts

17 Tires (40-50psi)

18 Chassis lubrication Lubricate

(1) Service more frequently when used in dusty areas. (2) Use dielectric grease only. (*) If equipped.

SB175 charger plug/ charger brushes (*)

Wheel lug nuts & studs

Replace When damaged

Grease terminals (2) Check  

Replace When damaged

Check Daily

Clean (1)

Check operation Daily

Inspection Check knob set screw 

Check volts Daily

Load test

Replace When necessary

Clean terminals (1) When necessary

Check

Torque When necessary

Grease Yearly

Check

Grease Yearly

Check Daily

Adjust When necessary

Replace When necessary

Check Daily

Adjust When necessary

Replace When necessary

Check Daily

Torque wheels(35 ft.lbs)

Replace When damaged

Check Daily

Torque Yearly

Replace When damaged

Check pad wear

Check ﬂ uid level

Fluid change Yearly

Check Daily

Replace When damaged

Check Daily

Rotation When necessary

Replace When damaged

Check Frequency

When replaced

After every wash

1st

20 hrs

Every

50 hrs

Every

100 hrs

Every

300hrs

Every

500hrs



 



 



 



Note: This is a sample form. Your checklist should include but not

be limited to these items. Make extra copies for future use.

SPECIFICATIONS

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-12

SPECIFICATIONS

Maintenance Record

Go-kart ID# Date / /

Hour meter

reading

Maintenance performed Parts used

Serviced

Finish date

Make extra copies for future use.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Pre- opening daily checklist for gas-powered go karts

0-13

Week of / /

Go-kart ID#

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, fuel ﬁ lter, vents, ﬁ ttings, etc.

2 Covers & guards: check for proper

installation of the steering cover, axle cover, pulley guard, fenders and body.

3 Seat belts: visually check for frayed

webbing, loose stitching; check buckle and adjustment operation.

4 Safety & warning decals:

Replace if damaged or illegible.

5 Pads: check seat, seat back, seat belt,

roll bar, steering wheel and steering post pads for damage; replace as needed.

6 Accelerator: check for smooth operation

and full return when released.

7 Brakes: check pedal travel; check for

proper action during test drive.

Servicer must initial each empty

box ever y day. If anything is

not OK, see a supervisor.

SPECIFICATIONS

8 Steering: check for smooth action;

9Remote shut-oﬀ system: (if equipped);

10 Engine & reduction case: check

11 Test go-kart: drive kart to verify

12 Roll bar: check for any looseness

13 D-rubbers & bumper system:

14 Body mounts: check for looseness

15 Tires & wheels: verify tires’ psi is to speciﬁ cation;

visually check front wheel alignment.

verif y proper operation, per manufacturer’s recommendations.

oil level; ﬁ ll to proper level.

proper operation.

in roll bar system.

Check for any signs of damage. Replace when necessary.

or improper fastening.

check wheels for loose or missing lug nuts.

Make extra copies for future use.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-14

SPECIFICATIONS

Pre- opening daily checklist for electric go karts

Week of / /

Go-kart ID#

Body color

Item # Description Mon Tues Wed Thu Fri Sat Sun

1 Covers & guards: check for proper

installation of the steering cover, axle cover, pulley guard, fenders and body.

2 Seat belts: visually check for frayed

webbing, loose stitching, check buckle and adjustment operation.

3 Safety & warning decals:

Replace if damaged or illegible.

4 Pads: check seat, seat back, roll bar,

steering wheel and steering post pads for damage; replace as needed.

5 Accelerator: check for smooth operation

and full return when released.

6 Brakes: check pedal travel; check

for proper action during test drive. Check brake shut-oﬀ function (1)

7 Steering: check for smooth action,

visually check front wheel alignment.

8 Remote shut oﬀ system: ((if equipped);

verif y proper operation per manufacturer’s recommendations.

Servicer must initial each empty

box ever y day. If anything is

not OK, see a supervisor.

9 Batteries: check battery voltage; if

10 Test go-kart: drive kart to verify

11 Roll bar: check for any looseness

12 Charging system: check sb175 plug for

13 D-rubbers & bumper system:

14 Body mounts: check for looseness

15 Tires & wheels: verify tires’ psi is to speciﬁ cation;

(1) Check that when brakes are applied, the motor will not engage. (2) Lube with dielectric grease.(See scheduled maintenance for details) (*) (if equipped) Check that the charger brushes make contact with the ﬂ oor charging plate and verify that the go-kart is receiving a charge from battery charger.

low, inspect & load test bat ter y.

proper operation.

in roll bar system

deep grooving or signs of arcing (2); check charger brushes for damage(*)

Check for any signs of damage. Replace when necessary.

or improper fastening.

check wheels for loose or missing lug nuts.

Make extra copies for future use.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Go-kart Track Area Checklist

0-15

Week of / /

Track #

Item # Description Mon Tues Wed Thu Fri Sat Sun

1 Fire extinguishers: verify proper placement.

2 Warning signs & restrictions:

Check for damage and/or legibility.

3 Emergenc y communication device:

Verify that communication from track to management is working.

4 Track: walk track & check for broken

or bent rails, missing bolts, etc.

5 Track surface: check that the track surface

is clean & clear of any safety hazards.

6Ride brieﬁ ng system: verif y

ride message works.

7 Shut-down system: (if equipped)

Check that the shut-down pit loops are functioning (if equipped).

Servicer must initial each empty

box ever y day. If anything is

not OK, see a supervisor.

SPECIFICATIONS

8 Pit area: check that the pit area is clean

9 Queue line: check that the queue line area

10 Gates: (if equipped): verify gates roll properly.

11 Charging area: (electric karts only) check

12 Tra ﬃ c lights: (if equipped):

& clear of any safety hazards; ensure all gates are latched & secure.

is clean & clear of any safety hazards; ensure all gates are latched & secure.

charging cords, plugs & ﬂ oor charging plates (if equipped) for damage.

Verify that stop & go caution lights work.

Make extra copies for future use.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-16

SPECIFICATIONS

NON-SCHEDULED MAINTENANCE RECORD

Go-kart ID#

Date Describe problem Maintenance performed Ser v iced byFinish date

Make extra copies for future use.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

0-17

PRINTABLE WORK ORDER TAGS

This sample maintenance work order tag can be copied for use in your facility. Copy and cut tag along dashed line and fold along the fold line indicated. Simply attach a maintenance work order tag to a machine in need of repair. When maintenance is complete, ﬁ le with other ser vice and maintenance information.

Description of Work Performed:

MAINTENANCE

WORK ORDER

GO-KART #

SPECIFICATIONS

BUMPERBOAT #

Explanation of problem:

Parts Used:

Date/Time: Mechanic:

Employee Name:

Front Back

Make extra copies for future use.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

Manager:

0-18

SPECIFICATIONS

GO-KART SEASONAL STORAGE (GAS)

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 ﬂ eet for periods of storage or inactivit y. We urge you to follow the simple instructions and advice contained here, referencing speciﬁ c model information from your owners ser vice manual to maintain the highest level of safety and preserve the value of your investment.

OIL CHANGE:

Change the engine and reduction case oil, follow the viscosity chart in your owner/service manual. Start engine and allow the clean oil to circulate throughout engine for approximately 3 minutes. Remove spark plug and pour about a tablespoon of clean engine oil into the cylinder. Crank engine several revolutions to distribute oil, then reinstall spark plug.

BRAKE FLUID:

If the annual brake ﬂ uid change has not been performed recently, it is advisable to change the brake ﬂ uid, as contaminated ﬂ uid will cause corrosion and deterioration of the hydraulic brake system. Fluid should be light amber in color. If it is dark or cloudy, the system must be ﬂ ushed and ﬂ uid renewed.

FUEL TANK:

Drain the fuel tank to remove any moisture or contaminants. Clean and drain carburetor ﬂ oat bowl before storing to prevent deposits caused by fuel that evaporates over time.

CLEANING AND WAXING:

Storing a dirty go-kart can lead to corrosion, because dirt retains moisture. Thoroughly wash and dry go-kart. Polish and wax all painted/gel coat surfaces. Spray the unpainted castings such as engine, reduction gear case, spindles and related hardware with a corrosion protectant to retard corrosion and rust.

TIRES:

Inﬂ ate tires to the recommended pressures and inspect.

CHASSIS LUBRICATION:

Grease spindles, axle bearings, rod ends, throttle arm pivot and pedal pivots to purge any water or contaminants from these pivot points. Treat other pivots, when no grease ﬁ ttings are provided, with water-displacing light lubricant spray.

STORAGE AREA AND COVERING:

Selec t a storage area such as a garage or storage room that is free from dampness and high humidity. The daily temperature change should be minimal. Do not store in direct sunlight, open ﬂ ames or sparks. Selecting the proper cover is important. A non vented, airtight cover may lead to corrosion and rust due to trapped moisture/vapor. Use a vented cover, which will allow moisture to escape rather than retaining it.

WARNING Gasoline is extremely ﬂ ammable and can be explosive under certain conditions. Make sure the area is well

ventilated and free from any source of ﬂ ame or sparks.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

0-19

GO-KART SEASONAL STORAGE (ELECTRIC)

PROPER CARE IN THE “OFF SEASON”:

BATTERIES:

Fully charge batteries. Keep batteries stored in go karts. Inspect all battery terminals. Clean & apply corrosion block to all battery terminals. Keep the batteries fully charged; the temperature of your winter determines when you should recharge them. Batteries self-discharge over time, and do so more quickly in colder temperatures. Charging your batteries every 5-6 weeks, 3-4 weeks if your area is really cold, is a good period of time in between each recharge until batteries go back into use.

BRAKE FLUID:

SPECIFICATIONS

CLEANING AND WAXING:

TIRES:

Inﬂ ate tires to the recommended pressures and inspect.

CHASSIS LUBRICATION:

STORAGE AREA AND COVERING:

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-20

SPECIFICATIONS

HOW A WARRANTY IS PROCESSED

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 time. (Please note: RMA# must appear on the returned goods package. Goods may be refused if no RMA# is present.)

2. Replacement goods are shipped AND CUSTOMER ACCOUNT IS CHARGED according to established account terms,

i.e. net 30, credit card, C.O.D. etc. J&J pays for the most economical shipping method. If the customer desires faster service, the customer account will be billed for the price diﬀ erence.

3. The customer returns the warrantied parts at their expense to J&J with RMA# on the outside of package. The warranty

manager inspects the goods and one of two things will happen:

a. Credit will be authorized to the customer’s account in the amount charged for the replacement.

NOTE: Cash refunds are not given on warranty items.

b. If part is not warrantable because of normal wear and tear, damage by accident, etc, the warranty will be denied

and no credit will be issued; shipping charges will be billed. **See limited warranty for details**

Please make sure goods are returned using a traceable and insured method. Items lost or damaged in transit cannot be the responsibility of J&J.

If this simple procedure is followed, the warranty usually goes smoothly. We seldom refuse to warranty an item. Problems come from short-paying statements or refusing to pay for new replacement items. The most common reason for a customer to not receive credit is failure to return the warranty item to J&J. If we do not receive the item, we cannot get credit from our vendors, and therefore cannot issue credit to the customer.

PRODUCT RETURN PROCEDURES

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 merchandise may not be returned (current merchandise is that which appears in the current annual parts catalog). A 15% restocking fee will be charged on all returns except for errors caused by J&J Amusements, Inc. The customer (except for errors caused by J&J Amusements, Inc) will pay freight. Returned merchandise must be in good condition, in the original package (where applicable), and cannot be altered with custom labels, stickers, numbers, etc. Merchandise that is returned without an RMA# will be refused.

WARRANTY RETURN POLICY:

All warranty item returns must be authorized by the Warranty Department and have an assigned RMA# before any adjustment or credit will be given. All merchandise that is returned to J&J and is proven defective in manufacture or workmanship upon examination will be replaced or repaired.

THE RMA# MUST APPEAR NEXT TO THE SHIPPING LABEL ON ALL RETURNED ITEMS FOR PROPER CREDIT TO BE ISSUED. IF THERE IS NO RMA# ON THE BOX/CARTON, IT WILL BE REFUSED AND RETURNED TO SHIPPER.

BE ADVISED THAT ANY RMA# IS VALID FOR 15 DAYS FROM DATE OF ISSUE. AFTER 15 DAYS, ALL RMA#S ARE VOID AND FURTHER RETURN ATTEMPTS WILL REQUIRE RE-ISSUE OF A NEW RMA#.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

LIMITED WARRANTY - GO-KART

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 warranty:............................................. Length of warranty:

Go-Karts (excluding Honda motors) Manufactured after 1/1/02 .....1 year*

Steel bumper rails .................................................................................. Limited 10 year***

UHMW bumper rails ............................................................................... 1 year**

Parts and Accessories ............................................................................90 Days**

Battery Charger ....................................................................................... 1-year By manufacturer

Battery ...................................................................................................... By manufacturer

Honda GX series engines ....................................................................... 1 year* by American Honda Motor Co. Inc.

**See Specific Exclusions

To qualify for this warranty:

1. The accessories, product, or replacement parts must be purchased from J&J Amusements, Inc.

2. You must be the ﬁ rst retail purchaser. This warranty is not transferable to subsequent owners.

3. You must provide proof of original purchase.

What J&J will repair or replace under warranty:

J&J will repair or replace, at its option, any product, accessories, or replacement parts that are proven to be defective in material or workmanship under n or mal use dur ing the ap plic able war rant y ti me per iod. A ny thing rep lace d under war rant y bec om es the property of J&J. All parts replaced under warranty will be considered as part of the original produc t and any warranty of th ose parts will expir e concurrent with the ori ginal product warranty. Accessor ies and replacement parts inst alled by J&J, will be repaired or replaced under warranty without charge for parts. If installed by anyone else, charges will be the responsibility of the purchaser.

To obtain warranty service:

You must obtain a Return Merchandise Autho rization (RMA) number from J&J, ph o ne num b er 800-8 54-3140 or 503-304-8899. Return the acc e ss o r i es, p ro duc t s o r parts and pro of of purc h ase, at your exp ense, to J&J. If the acce s so ries, product s o r parts are returned to J&J without both an RMA and proof of purchase, J&J may void the warranty at its discretion.

SPECIFICATIONS

Exclusions:

This warrant y d oes not extend to products, accessories or pa rts affected or damaged by accident and/or collision, normal wear, fuel contaminat ion, n ot sold by J& J, used in app lic ations f or whi ch th e produc t was not de signe d, or any other misus e, neglec t, incorporat ion or use of unsuitable attachments or par ts, unauthorized alterations, improper installation, or any causes other than defects in mater ial or wor kmanship of t he produc t. J& J reserves the ri ght, before having any obli gation s under this lim ited warranty, to inspect the damaged goods in order to determine compliance with this paragraph. This warranty does not extend to products, accessories or parts purchased for use outside of the United States or Canada.

**Specific Exclusions:

Normal wear and tear items, such as: tires, brake pads, brake rotors, spark plugs, ﬁ nal drive belts, ﬁ nal drive pulleys, brake ﬂ uid, and fuel ﬁ lters. Appearance-related damage, including but not limited to: scratches, nicks, dents, fading paint/trim,

and corrosion. Service Logs- The customer must use maintenance logs provided from J&J. Warranty will not be covered if you cannot provide these records. Service Logs-The customer must use maintenance logs provided from J&J. Warranty

will not be covered if you cannot provide these records.

*Honda motor warranty is only covered by American Honda Motor Co., Inc.

***Steel bumper rail warranty is voided if the thickness is below 0.250in (6.360mm).

Disclaimer of consequential damage and limitation of implied warranties:

J&J DISC LAIMS AN Y RESPONSIBILIT Y FOR ANY CON SEQUENTIAL DAM AGES OF ANY KIN D OR NATU RE, INCLUDING B UT NOT

LIMITED TO, LOSS OF TI ME OR US E OF TH E PRODUCT, TR ANSP ORTATION, COMM ERCIA L LOSS OR A NY OTHER I NCID ENTAL OR CONSEQ UENTIA L DAMAGE A RISING O UT OF ANY T HEORY OF RECOV ERY INCLUDI NG WARR ANT Y, CONTRACT, STATUTORY OR TORT. NOTWITHSTANDIN G THE TERM OF ANY LI MITED WARRAN TY OR ANY WARR ANTY IM PLIED BY LAW, OR IN THE EVEN T THAT ANY LIMIT ED WARRANT Y FAI LS OF ITS ESSENTIA L PURPOSE, IN NO EV ENT WILL J&J’S EN TIRE LIABILTIY EXCEED TH E PURCHASE PRICE OF THE PARTICULAR GOOD SOLD. SOME STATES/PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Disclaimer of Warranty

EXCEPT FOR THE LIMITED WARRANTY PROVIDED HEREIN, TO THE EXTENT PERMITTED BY LAW, J&J DISCLAIMS ALL WARRANTIES, EXPRES S OR IMPLI ED, INCLUDIN G ALL WARRANTIES OF MERCHANTABILITY AN D/ O R FI T NESS FOR A PARTICU LAR PU R P OSE. TO THE EXTENT THAT ANY IMPLI ED WA R RANT I ES MAY NONETHE LES S EXIST BY OPERATION OF LAW, ANY SUCH WA R RANT I ES A R E LIMITED TO TH E DURATION OF THIS WA RRANT Y. SOME STATES/PROVINCES D O NOT ALLOW LIMITATIO NS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

Any legal ac ti on a r is ing f r om c la ims a gai nst t hi s war ra nt y sh al l be g over ne d by and c o nst r ue d in ac c o rd anc e w it h th e law s of O re go n, and t he exclusive for um fo r dis pute s ar isi ng ou t of or r elat in g to th is war ra nt y sha ll b e the M ar i on C ount y C irc uit C o ur t f or t he St ate of Oregon, and no other state or Federal Court. Any party bringing a claim under this warranty consents to jurisdiction of such court, waives any objection to venue, and fur ther ag rees th at in the event of l itigat ion suc h par ty sh all, at its ow n expense, p rovide d iscove ry an d appea r for depo sitions in Marion County, Oregon. Contact J&J Amusements, Inc. for information on your area.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-22

SPECIFICATIONS

CLEANING Go karts

CLEANING KART BODIES

The best way to preserve your go karts’ ﬁ nish 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 (mild detergent) soaps. Don’t use cleaning agents that contain acid or abrasives. All cleaning agents should be ﬂ ushed promptly and not allowed to dry on the surface, or they could stain. Dry the ﬁ nish with a soft, clean chamois or a 100% cotton towel to avoid surface scratches and water spotting.

NOTE: Do not damage warning decals. Damaged or illegible warning decals must be replaced immediately.

FINISH CARE

Occasional waxing or mild polishing of your karts may be necessar y to remove residue from the ﬁ nish. Use an approved ﬁ berglass polish. 303 Protectant can be used on clean go-kart bodies to act as a UV protectant.

NOTE: Machine compounding or aggressive polishing on the body may dull the ﬁ nish or leave swirl marks.

BODY TRIM

Silicone grease on body trims will make them last longer. Apply silicone grease with a clean cloth at least three times per season. During very cold, damp weather, more frequent application may be required.

FINISH DAMAGE

Any stone chips, fractures or deep scratches in the ﬁ nish should be repaired right away. Minor chips and scratches can be repaired with materials available from almost any auto parts store. Larger areas of ﬁ nish damage can be corrected by a local body and paint shop.

CHEMICAL SPOTTING & SUN FADING

Some weather and atmospheric conditions can create a chemical fallout. Airborne pollutants can fall upon and attack the surfaces on your kart. This damage can take two forms: blotchy, ringlet-shaped discolorations, and small irregular dark spots etched into the paint surface.

CLEANING FRAMES

 Remove bodies weekly for frame cleaning and inspection.  Using a pressure washer, clean the entire frame of any dirt or grease that might have collected.  After spraying oﬀ the frame and wiping it dry, grease all the zerk ﬁ ttings with good quality grease. Spray a rust inhibitor

on all linkage rods, tie rod ends, springs or any unpainted surfaces.

WARNING Do not spray brake disc or caliper. This will cause a loss of brakes and could cause an accident.

CLEANERS AND PROTECTANTS

J&J carries many cleaning and protection products to keep your go karts in top condition. From smaller spray bottles to 5 gallon containers of product, we’ve got you covered. Give us a call!

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

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 occurred during shipping.

A forklift is required to unload the truck and to remove the go karts from shipping racks.

WARNING

To ensure safe handling and unloading of equipment, the operator must be lift truck certiﬁ ed.

Each go-kart is mounted to the shipping rack with two brackets. The brackets are mounted on each side of the kart in a diagonal pattern.

SPECIFICATIONS

WARNING

Remove each bracket before attempting to unload the go karts from the shipping rack.

Remove the top kart ﬁ rst. Always remove from the rear of the kart (engine side). Run the forks between the cross bar and frame of the kart.

NOTE FOR ELECTRIC GO KARTS

Take special care to avoid damaging the electrical pick-ups on electric karts ordered with a ﬂ oor charging system. These pick-ups protrude downward from the rear of equipped go karts. Do not allow fork lift forks to damage them.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

SPECIFICATIONS

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 remaining karts.

NOTE: When removing the middle and bottom karts,

make sure to keep clearance from the steering wheel and the cross bar.

Go karts are shipped with the roll bars detached to allow karts to ﬁ t on the shipping racks 3 high. Carefully unwrap the roll bar and install. See page 5-2

NOTE: Shipping racks are included with shipping and

handling and do not need to be sent back.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

0-25

TIP: A great use for the shipping racks is to turn them

into storage racks for your maintenance facility.

SPECIFICATIONS

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-26

SPECIFICATIONS

INITIAL SETUP

Engine oil ﬁ ll

SAE viscosity grades

Check and ﬁ ll (if needed) engine with 4-stroke motor oil that meets or exceeds the requirements for API service classiﬁ cation 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-temperature use. Other viscosities shown in the Honda™ Owner’s Manual may be used when the average temperature in your area is within the indicated range.

 Be sure the go kart is in a level position.  Remove the oil ﬁ ller cap/dipstick and wipe it clean.  Insert the ﬁ ller cap/dipstick into the oil ﬁ ller neck,

but do not screw in.

 Remove the cap/dipstick and read the indicated oil

level.

 If the level is low, ﬁ ll to the top of the oil ﬁ ller neck

with the recommended oil.

 Reinstall the oil ﬁ ller cap/dipstick.

10w-30

5w-30

-20 -0 20 40 60 80 100°F

Ambient temperature

Clutch oil ﬁ ll

GEAR REDUCTION CASE WITH AUTOMATIC CENTRIFUGAL CLUTCH.

 Remove the oil ﬁ ller cap and wipe the dipstick clean.  Insert the dipstick into the ﬁ ller neck, but do not

screw in.

 Remove the cap/dipstick and read the indicated oil

level.

 If the level is low, ﬁ ll to the upper level mark with the

same oil recommended for the engine.

 Do not overﬁ ll; see diagram.

1/2 reduction

Oil filler cap

Oil level

Fill notch

Oil drain plug

WARNING

Gasoline is extremely ﬂ ammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow ﬂ ames or sparks in the area where the engine is refueled, or where gasoline is stored. Do not overﬁ ll the fuel tank (there should be no fuel in ﬁ ller neck). After refueling, make sure the tank cap is closed properly and securely. Be careful not to spill fuel when refueling; spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine. Avoid repeated or prolonged contact with skin, or the breathing of vapor.

KEEP OUT OF REACH OF THE PUBLIC.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Warning tag

0-27

FUEL

Remove the ﬁ ller cap and check the fuel level. Reﬁ ll the tank if the fuel level is low. Fill 1” from the lowest point of the ﬁ ller neck.

WARNING Do not overﬁ ll the fuel tank.

Ensure that the ﬁ ller cap is securely replaced.

Extra Capacity Fuel Tank:

 2.2 gal ......... (8.3 liters)

 3.3 gal .......(12.4 liters)

 3.5 gal .......(13.2 liters)

 4.75 gal ....(17.9 liters)

Use unleaded gasoline with a pump octane rating of 86 or higher. The Honda™ engine is certiﬁ ed to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or a premixed (oil/gasoline) mixture. Avoid getting dirt or water in the fuel tank. Read and understand the WARNING tag.

SPECIFICATIONS

Allow approximately 1” of airspace inside the tank to prevent spillage due to the sloshing of fuel.

DO NOT FILL FUEL INTO THE FILLER NECK.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE.

You can be burned or seriously injured when handling fuel.

 Keep heat, sparks, and ﬂ ame away.  Handle fuel only outdoors.  Wipe up spills immediately.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.j jamusements.com

0-28

WARNING!

Go-karts have rotating parts.

For your safety, longer hair must be secured above the shoulder and any personal items (clothing, jewelry, etc) must be secured and contained within the seating area.

Serious injury or death could occur!

DO NOT REMOVE THIS DECAL

SPECIFICATIONS

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.

#1-60-0288 #1-60-0388

TO HELP PREVENT

#00979

#00978

INJURY OR DEATH

All pads and guards must be

maintained and in place during

operation of this device.

DO NOT REMOVE THIS DECAL

#001711

GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS.

REFUEL IN A WELL-VENTILATED AREA WITH ENGINE STOPPED. DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA WHERE THE ENIGINE IS REFUELD OR WHERE GASOLINE IS STORED.

DO NOT OVERFILL THE TANK (THERE SHOULD BE NO FUEL IN THE FILLER NECK). AFTER REFUELING, MAKE SURE THE FUEL CAP IS CLOSED SECURSLY AND VENT OPEN.

BE CAREFUL NOT TO SPILL FUEL WHEN REFUELING. SPILLED FUEL OR FUEL VAPOR MAY IGNITE. IF ANY FUEL IS SPILLED, MAKE SURE THE AREA IS DRY BEFORE STARTING THE ENGINE.

NEVER REFUEL WHEN RIDERS ARE PRESENT.

#001712R #1-60-0020

! WARNING

Must meet posted height requirement. Shoes and shirt must be worn. All loose clothing must be secured. Hair longer than shoulder length must be secured above shoulder length.

Keep both hands on steering wheel and both feet in kart at all times, unless otherwise instructed by attendant. One person per restraint. Restraint must be worn at all times when in kart. Do not bump, skid or slide karts. Riders must remain seated at all times unless instructed by attendant. No one under the influence of drugs or alcohol is allowed to ride. This ride is not recommended for individuals who have heart problems, neck or back problems, or pregnant women. Participate at your own risk.

DO NOT REMOVE THIS DECAL.

Part Number

001712R

WARNING

J&J Amusements, Inc. 1(800) 854-3140

DANGER

Hair longer than shoulder

length must be secured

above shoulder.

Keep arms and legs in kart

at all times.

BRAKE GAS

DO NOT REMOVE THIS DECAL.

#00180

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

#00981

BRAKE GAS

DO NOT REMOVE THIS DECAL.

#00980

WARNING

Keep Hands And

Arms In Car

At All Times.

DO NOT REMOVE THIS DECAL

TIRES, TUBES, RIMS

1-1

Tube & rim information ........................................................... page 1-1

Frequent questions .................................................................page 1-2

Rotating tires ............................................................................page 1-2

Disc-lock lug nuts .....................................................................page 1-3

OVERVIEW

Wheel/tire assembly removal ................................................page 1-5

Changing tires & tubes ............................................................page 1-6

TUBES, TIRES, RIMS

TIRES: J&J has lead the concession go-kart industry in this area for many years. In the early stages, small-implement tires

were used. These casings (and sometimes new tires) were “capped” with an extra-thick layer of tread to increase life.

J&J was the ﬁ rst to design a new, purely concession go-kart tire by working with a large manufacturer and buying in bulk. The J&J Bigfoot tire was introduced to provide a new tire with extra-thick tread, while maintaining overall diameter in order to accommodate gearing and clearances for existing go-karts.

TUBES: J&J was the ﬁ rst to oﬀ er tire and tube combo packs; with a tube speciﬁ c to the Bigfoot tire, it made sense to do so.

J&J moved the angle and location of the valve stem to better ﬁ t the needs of concession go-karts.

RIMS: The current rim design features a special and unique-to-J&J locking-style lug nut and serrated rim for better bead

grip.

Use this specially made, thin-walled socket on go karts equipped with the Disc-lock safety wheel nut.

#1-60-A0311, Disc lock socket

Part# Description Price

3-20-A0008 Tool, Wheel Assembly 4 Lug J&J, Formula K, Johnson, AP $99.95

3-20-A0009 Tool, Wheel Assembly 3 Lug Shaller Type $99.95

3-96-A0001 Tool, Tire Bead Breaker HD J&J/Shaller $350.00

3-96-0105 Tool, Tire Iron Set - 8”, 11”, 15” $36.95

01345 Tool, Valve Core Remover $7.52

01344 Gauge, Tire Pressure (0-50 psi - Karts Only) $12.66

1-60-A0311 Tool, Socket 15mm 6pt (Machined) $14.99

TIRE TOOLS

#3-96-A0001, Tire bead breaker tool for J&J and Shaller go karts.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

1-2

Frequent tire questions:

WHAT IS THE PROPER INFLATION FOR MY BIGFOOT TIRES?

TUBES, TIRES, RIMS

J&J RECOMMENDS 40-50PSI (276-345KPA).

WHAT DOES THE DIRECTIONAL ARROW ON THE SIDE OF THE TIRE MEAN?

Nothing; the arrow was used in the early days on treaded tires. Bigfoot tires can be installed with the arrow going in either direction.

IS IT EASY TO SEE WHEN MY TIRE PRESSURE IS LOW?

Tire pressure is very diﬃ cult to judge by sight alone. Tires can be well under 30% inﬂ ated before it ’s noticeable to the eye. This is why it’s so important to check your tire pressure daily with an accurate tire gauge.

WHAT SIZE ARE MY TIRES?

There are two popular methods of identif ying tires.

1. The ﬁ rst is overall diameter x section width x rim diameter (example 12 x 4.00 -5 (A,B,C).

2. The second method is section width x section height x rim diameter (example 3.40 x 3.00-5 (B,D,C).

HOW SHOULD I ROTATE MY TIRES? WHEN SHOULD I ROTATE MY TIRES?

Size Typical use

(A) (B) (C) 12 x 4.00 x 5

(B) (D) (C)

4.10/3.50 - 4

(A) (B) 20 x 2.125

Lawn mowers and go-karts

Go-karts

High-Wheel mowers and Bicycles

Front and rear tires perform diﬀ erent jobs and can wear diﬀ erently, depending on the tracks driven. To get maximum life, rotate every two weeks or 200 hours of operation.

Wear ind icator lines

WHEN IS IT TIME FOR NEW TIRES?

 You can see cord or fabric showing.  Sidewall is cracked, cut or snagged deep enough to show cord or fabric.  Tire shows a bump, bulge or split.  Tire has puncture or shows other damage.

 Wear lines are worn down past the last line.

SHOULD I PUT NEW TIRES ONLY ON FRONT OR REAR OF KART?

You should always replace all four tires. Replacing only the front or rear will cause the go-kart to be unbalanced. Example: Placing new tires on the front and leaving worn out tires on the rear will cause the kart to ride high in front and low in the rear; this could cause the kart to ride over the containment system, or over or under other karts. When replacing tires, all four tires should be replaced at one time.

CAN I MIX AND MATCH TIRES?

Ideally, tires should be of the same type and design, have the same tread depth and be inﬂ ated to the correct pressure.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

1-3

TUBES

The J&J Bigfoot tire was designed to give maximum tread life and sidewall integrity. The tube is a key piece of the design and has a special size and valve stem conﬁ guration. Always use J&J tubes (#00780-M) for best results and to avoid possible premature failure of the tire and/or tube.

RIMS

Over the years, J&J has used two distinct styles of wheel rims. They have the same look and are the same size and basic design. The diﬀ erence lies in the style of the lug nuts used. Please note, the lug nuts are not interchangeable from one wheel design to the other.

TUBES, TIRES, RIMS

Old st yle

NOTE:

Old style: Raised lug stud holes to match the tapered lug nuts.

New st yle

New style: Rim is ﬂ at around the lug stud holes and uses a ﬂ ange type “Disc-Lock” lug nut. Rims also have a serrated bead area to help prevent tire/bead slippage.

DISC-LOCK LOCKING NUT INSTALLATION & REMOVAL

J&J uses the Disc-Lock locking nut on our bead-lock wheel rims. The Disc-lock safet y wheel nut is a free spinning, vibrationproof wheel nut, speciﬁ cally designed to prevent wheel loss on commercial vehicles such as trucks, trailers and buses with hub-piloted wheel systems. They are used only on J&J serrated bead lock rims. (#1-50 -0189) The system is essentially a double nut with ramps on two mating halves. When the inner hex of the nut tries to loosen, it works against the incline of the outer hex. This is a simple and very positive way to help insure that lug nuts will not work loose.

To install the Disc-Lock locking nut, follow the same procedure for conventional nuts and torque to normal speciﬁ cations. To remove the Disc-Lock locking nut, place the wrench or socket over both hexes and loosen. It is critical that the socket is seated over both halves of the nut as shown in the illustration below.

Outer hex

Inner hex

(Use a 15mm deep/thin wall, 6-point socket.)

J&J SPECIAL TOOL

#1-60-A0311 This 15mm socket is machined

15mm

to ﬁ t within the tight conﬁ nes of the wheel assembly.

NOTE: If the two parts “pop” apart they can usually be reassembled with a light tap. If the two halves will not stay

together, the nut must be replaced.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

1-4

TUBES, TIRES, RIMS

Proper installation of socket over both halves of Disc-Lock nut.

Improper ﬁ tting of socket over the nut causes the nut to come apart.

Disc-Lock nut showing that both halves can move independently of each other.

Two halves can come apart, but often can be reassembled.

#1-50-0189

The Disc-lock safety wheel nut

s a free spinning, vibration-

roof wheel nut, speciﬁ cally esigned to prevent wheel loss

rom commercial vehicles such

as trucks, trailers and buses with

ub-piloted wheel systems.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

#00970 #3824L

LUG STUDS / NUTS & RELATED HARDWARE

Part# Description Price

00970 Nut, 5/16-24 (Lug Nut) “Pre 98” $0.40

1-50-0189 Nut, 3/8-24 Z (Lug Nut) “Post 09” (DISC-LOCK) $1.15

3824L Nut, 3/8-24 Z (Lug Nut) “Post 98” Pre-09 $0.32

WHEEL REMOVAL

1-5

Use a ﬂ oor jack or a lift so the wheels are oﬀ the ground.

WARNING

Use extreme caution when changing a tire with a jack. Use a level place to raise a Go-Kart for tire changing, and make sure the jack is properly secured. Always add solid blocks or jack stands under the gokart to prevent a sudden fall of the go-kart due to jack failure. Avoid the possibility of injury: NEVER get under a gokart when it is supported only by a jack.

Using a 15mm deep/thin wall socket for 3/8” disc-lock lug nuts, remove the four lug nuts.

USE J&J SPECIAL TOOL #1-60-A0311

Some older model go-karts may not have the updated hub installed and will need to use a special 15mm socket designed to ﬁ t within the tight conﬁ nes of the wheel assembly.

TUBES, TIRES, RIMS

Pull the wheel assembly oﬀ the hub.

Wheel installation is in the reverse order. Torque the wheels to 35 ft. lb.

#1031, Air-operated lif t

SHOP LIFTS

Part# Description Price

1031 Lift, Assy Air Operated 24” x 80” $1,590.00

1032 Lift, Assy Electric Operated 24” x 80” $1,725.00

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

1-6

CHANGING TIRES & TUBES - DISASSEMBLY

TUBES, TIRES, RIMS

Make sure to deﬂ ate the tire completely, either by removing the valve core or depressing the valve core until all the air is released.

DANGER

Attempting to disassemble an inﬂ ated tire can result in injury.

Loosen the 3/8” nuts from the back side of the tire assembly and remove all hardware.

See the bead breaker tool (#3-96-a0001) online at http://www.youtube.com/watch?v=9o0dHeY9gnk

Tubes: J&J # 00780-M, Tube, 3.40/3.00-5” (Bent stem, 45-degree middle)

Remove the rim half from the valve stem side of the tire. ( J&J part #3-96-A0001 Bead Breaker recommended) Remove the tube from the tire so that is does not get pinched. Flip the tire over and press out the other rim half.

Pull tube out of tire.

TUBES - GO KART TIRE

Part# Description Price

00780-M Tube, 3.40/3.00-5” (Bent Stem 45 degree Middle (BEST)(FPX) $3.80

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

CHANGING TIRES & TUBES - ASSEMBLY

1-7

This is the J&J tire assembly tool (#1-20-T0001). Using this device to change tires is a major time- saver; it simply bolts to the work bench.

TUBES, TIRES, RIMS

Install the tube into the tire and inﬂ ate it slightly to help eliminate pinching the tube during assembly.

NOTE: Inspect the old tube for damage before

reusing. Place the tube in the tire and inﬂ ate the tube slightly. This will reduce the chances of the tube getting pinched during assembly.

#3-20-A0008, Wheel assembly tool for J&J, Formula K, Johnson & Amusement Products go karts.

Place the rim half bolts in the magnetic sockets of the tire assembly tool ( J&J Part#1-20-T0001).

Install the rim half (valve-stem rim half ) into the tire assembly tool, and down over the bolts.

Place the tire on the rim half; insert the tube into the tire, with the valve-stem facing down, through the valve stem hole of the rim half.

TIRE TOOLS

Part# Description Price

3-20-A0008 Tool, Wheel Assembly 4 Lug J&J, Formula K, Johnson, AP $99.95

3-20-A0009 Tool, Wheel Assembly 3 Lug Shaller Type $99.95

3-96-A0001 Tool, Tire Bead Breaker HD J&J/Shaller $350.00

3-96-0105 Tool, Tire Iron Set - 8”, 11”, 15” $36.95

01345 Tool, Valve Core Remover $7.52

01344 Gauge, Tire Pressure (0-50 psi - Karts Only) $12.66

1-60-A0311 Tool, Socket 15mm 6pt (Machined) $14.99

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

1-8

Place the second rim half onto the tool. Screw down

TUBES, TIRES, RIMS

Retaining nut

the self-centering retaining nut as far as possible by hand.

Pull on the lever on the bottom of the tool to squeeze the rim halves together.

Install the lock washers and nuts and tighten. Remove the complete wheel from the tool; you may need to tap it out with a rubber mallet.

DANGER

Never inﬂ ate the tire while it is on the assembly tool.

#1-20-A0020, New-style rims with bead lock and ﬂ at lug holes; Use Disc-lock style lug nuts. Fits most J&J, Formula K, Johnson & Amusement Products (Pacer) go karts.

RIMS

Part# Description Price

1-20-A0020 Rim Assy., 5” 4-Lug 3/8 Flat Style W/Bead Grip W/ Hardware $19.99

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

1-9

Inﬂ ate the tire to 50 psi (max) to set the beads. The tire pressure should be set at 40-50 psi. Re-mount the tire/wheel assembly onto the go-kart.

TUBES, TIRES, RIMS

Electric Lif t, #3-60-0043

These small electric or manual lifts are perfect for maintaining small equipment.

 Lawn mowers.  Track blasters.  And more.

AIR LIFT SPECIFICATIONS:

#1031, Air-operated lift

THE AIR LIFT IS DESIGNED FOR ALL SHOPS. IT IS IDEAL FOR RAISING UP TO 1000 POUNDS TO A 30-1/4” LEVEL FOR WORKING ON AN INFINITE NUMBER OF PRODUCTS.

 Go karts, Lawn Mowers, Appliance Repair, Motors, Air

Conditioners and more.

 Easy, all around access for vehicle repair. Finish your work

quickly and comfortably.

 Change tires, work on brakes, tune engines, change oil, clean,

tear down and assembly.

 If you need more than the standard 24” width, take a look at

our optional side extensions.

 Utilizing the quick detachable side extensions, you can turn

your air lift into a versatile all-purpose lifting tool for a multitude of diﬀ erent items.

Height - up 31”(78.7cm), down 7”(17.8cm) Length - Table 80”(203.2cm), ramp 20”(50.8cm) Width - Table 24”(61cm), with ext 40”(101.6cm) Weight - 310lbs(140kg)

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

SHOP LIFTS

Part# Description Price

1031 Lift, Assy Air Operated 24” x 80” $1,590.00

1032 Lift, Assy Electric Operated 24” x 80” $1,725.00

3-60-0043 Lift, Multi-Lift(Electric) $1,222.98

1-10

TIRE/WHEEL INSPECTION

TUBES, TIRES, RIMS

If a tire is properly i nﬂ ated and al igned, i t shou ld wea r evenly across the tread. A tire should be replaced if it has worn abnormally. If the ply cords are allowed to show before the tire is removed, you run a high risk of blowing the tire and damaging the tube and rim.

NOTE: Poorly maintained and improperly used tires

are dangerous.

HOW TO CHECK

Use a qualit y gauge to check the tire pressure. Simply looking at the tires will not tell you the pressure (see speciﬁ cations).

Wear lines

Tires have valve caps; Be sure to put them back on. They help prevent leaks by keeping out dirt and moisture.

WHEN IT’S TIME FOR NEW TIRES

You need a new tire if:

 You can see a cord of fabric showing.  The sidewall is cracked, cut or snagged deep

enough to show a cord of fabric.

 The tire has a bump, bulge or split.  The tire has a puncture, cut or other damage.  The wear lines are worn down past the last line.

Wheel Replacement Replace any wheel that is bent, cracked or badly rusted. If the wheel nuts loosen frequently, the wheel bolts and nuts should be replaced. Elongated stud holes can cause damage to hubs.

Each new wheel should have the same diameter, width, oﬀ set and mount position as the one it replaces.

If you need to replace any of your wheels, wheel bolts or wheel nuts, replace them only with new, J&J-original equipment parts. This will prevent a mismatch of parts and will be sure to have the right wheel, wheel bolts and wheel nuts for your J&J kart.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

TROUBLESHOOTING TIRES

1-11

UNDER-INFLATION OF TIRES CAN CAUSE:

 Too much ﬂ exing  Too much heat  Tire overloading  Poor wear  Poor handling  Rim breakage  Drive pulley breakage  Hub breakage  Tube failure

These specialized tires have their own wear characteristics. These can be used to diagnose or indicate certain maintenance procedures are needed.

OVER-INFLATED TIRES CAN CAUSE:

 Uneven tire wear  Poor handling  Rough ride  Needless damage from track hazards

FLAT TIRES:

Because of the stiﬀ sidewalls and fairly even weight distribution, a go-kart can appear to operate normally. Watch for the bead being not quite seated on the rim or the valve stem being loose, at an odd angle, or missing.

FRONT TIRE WEAR:

If the steering wheel is centered, both tires should be pointing straight ahead. If one or both tires are pointed at odd angles, the tie rods are bent. The tires will show scrubbing as well.

Due to the nature of your track and a preponderance of right turns or left turns, the tires will always roll onto the edge of the outside tire and wear this edge faster than the other. Tires should be rotated (swapped inside to outside) so that they wear evenly.

TUBES, TIRES, RIMS

DRIVE WHEEL (SINGLE WHEEL DRIVE GO-KARTS):

This tire receives more abuse and will always wear faster than the others. Rotate this tire side-to-side on a regular basis to get maximum tire wear.

Tire wear characteristics

Tire “A” depicts typical wear from cornering.

Tire “B” depicts a good, ﬂ at wear pattern.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

1-12

Buy tires in bulk and save! 20’ & 40’ containers available.

TUBES, TIRES, RIMS

We are the

Go Kart Tire Store

FPX is “The Tire Store” for concession go kart tires. We carry only the best and most popular sizes.

We stock so many tires we have another warehouse on the east coast! That’s right, we have a warehouse in Atlanta, Georgia and one at our headquar ters in Salem, Oregon!

Part# Description Price

007880COMBO Tire, 12 x 4.00 - 5” SL72 Bigfoot COMBO (W/Tube) $22.99

007880 Tire, 12 x 4.00 - 5” SL72 Bigfoot (TIRE ONLY NO TUBE!) $21.99

1-20-0037 Tire, 11 x 3.60 - 5” SL72 736HD $22.99

Quantity discounts available on 007880COMBO. QTY 100+ $21.99, 500+ $20.99

Part# Description Price

1-20-0054 Tire, 4.10/3.50 - 4” SL72 738HD $15.80

5” TIRE/TUBE COMBINATION DEALS

4” TIRES

Salem

Tire/Tube Combo’s in

Days

to most U.S. cites

We ship tire/tube combos from both coasts!

We know how important it is to keep your go karts on the track, so we opened an east coast warehouse in Atlanta to supplement our west coast warehouse in Salem, Oregon.

The Atlanta warehouse ships tire/ tube combination deals only. We do not carry a full line of parts or other tires at this warehouse.

From these two shipping locations, we can ground ship tire/tube combination deals to almost every U.S. city within 3 days.

We also ship worldwide!

Atlanta

TIRES - FALCON

Part# Description Price

1-60-0185 Tire, 4.10/3.50-5 4-ply Falcon Electric King Nob Style $18.99

1-20-0037 Tire, 11 x 3.60 - 5” SL72 736HD $22.99

TIRES - OTHER

Part# Description Price

1-60-0009 Tire, 10 x 4.50 - 5” SL72 739 Race Style Slick $16.50

1-20-0064 Tire, 11 x 4.50 - 5” SL72 739 Race Style Slick $18.99

1-60-0008 Tire, 11 x 7.10 - 5” SL72 739 Race Style Slick $39.99

TUBES - GO KART TIRE

Part# Description Price

1-20-0038 Tube, 11 x 6.00 - 5 TR87 $4.99

1-20-0045 Tube, 11 x 7.10 - 5 CS $9.50

00780-M Tube, 3.40/3.00-5” (Bent Stem 45 degree Middle (BEST)(FPX) $3.80

00778 Tube, 4.10/3.50-5” (Bent Stem)(FPX) $3.83

00782 Tube, 4.10/3.50-6” (Bent Stem) $6.35

1-20-0027 Tube, 15 x 6.00 - 6 (Used for 15 x 6.00 - 6 Tire) $4.99

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

FRAME

Frequent questions ................................................................. page 2-1

OVERVIEW

2-1

FRAME

Go kart frames are robot welded, then cleaned and powder-coated.

Frequent Frame Questions:

Q: CAN I WELD THE FRAME?

A: Due to safety concerns, it is advisable to contact J&J prior to doing any work of this type.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

2-2

B UMPERS & D-RUBBER

Frequent questions .................................................................page 2-2

Bumper removal ......................................................................page 2-3

FRAME

D-rubber installation ...............................................................page 2-3

Nerf bar removal/replacement ..............................................page 2-5

OVERVIEW

FAQ’s

Q: CAN THE BUMPER BE REPAIRED OR WELDED?

A: No. The bumper is made of a special spring steel. It can not be welded or modiﬁ ed. J&J oﬀ ers a limited lifetime warranty on its steel bumpers; attempting to modify the bumpers will void the warranty.

NOTE: Abrasive wear can result in “thinning” the bumper. Breakage after such wear is not covered under warranty.

INSPECTION

Inspect the bumper rail daily for cracks, missing hardware, sagging or ripped D-rubber. Replace components as needed. Do not weld or modify the rail.

THE MOST DURABLE, LONGEST-LASTING BUMPER SUPPORT AVAILABLE; THAT FIT MOST TYPES OF GO KARTS.

Special formulation gives these rubber bumper strips extra

long life and resistance to

cracking. Can easily be cut to

any length to suit your needs.

 Thousands of uses.  Rubber sections can be cut to

any size.

 Pre-cut and drilled, more natural

rubber compound to resist

breaking.

 The unique “A” design with

rounded edges helps prevent

cracking and splitting.

 The “A” shape ensures rubber-to-

bumper contact.

Part# Description Price

1-70-0043 Rubber, “A” 4” x 4” x 1-5/8” (Cut/Drilled)(Formula K) $5.50

00833 Rubber, “A” 4” x 4” x 3” (Cut/Drilled) $8.99

00834 Rubber, “A” 4” x 4” x 4” (Cut/Drilled) $11.30

008331 Rubber, “A” 4” x 4” x 60” (Log) $2.99

008332 Rubber, “A” 6” x 6” x 60” (Log) (Used mostly on track rails) $150.00

008555 Rubber, “D” 3” x 3” x 60” (Log) $1.28

008556 Rubber, 2”x2” (Sold by inch, Max 60”) $1.25

008577 Rubber, “U” Channel (Stocked 60” Log) $60.48

0083310 Rubber, “A” 4” x 4” x 3-1/2” (Cut/NOT Drilled) $11.99

A00831 Rubber, “A” 4” x 4” x 2-1/2” (Cut/NOT Drilled) $7.47

“A” RUBBER

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

BUMPER/D-RUBBER REMOVAL

D-rubber plate

D-rubber

2-3

When removing the bumpers, start at either the front or rear of the kart. The front has a separate bumper covering the outside of the side bumpers; the rear has a separate part inside the side bumpers. Hold the socket head from the outside and undo the nut, making sure to catch the outer d-rubber plate after removing the bolt. When the front and rear sections are unbolted and the front and rear bumpers are removed, undo the bolts holding the bumper sides, working from one side to the other. Carefully support the bumper as it is being unbolted to prevent dropping it on yourself or someone else. Note that any sections that have overlapping bumpers have longer hardware.

NOTE: Check the rail daily for any cracks; damaged

rails must be replaced. Replace any damaged hardware; because the karts regularly bump into each other, it is common for the hardware to get damaged. Replace any hardware as necessar y. Bent D-rubber plates can be straightened and reused, as long as the nut cannot pull through the hole in the plate. Inspect D-rubber for cracks and damage; replace as necessary.

FRAME

Long bolt

To install the bumper, hold up the front section of the side bumper (curve goes towards front of kart) and match the ﬁ rst one in the middle with the ﬁ rst D-rubber on the side of the kart. Put the bolt through the bumper and D-rubber, then add the D-rubber plate, followed by the nut. Working towards the back, install the rest of the mounting hardware ﬁ nger tight. Repeat on both sides. Next, either install the front or rear bumper. Start from one side of the kart and work across. Use a punch through the mounting holes to hold up and help align the bumper with the corresponding holes as you install the mounting hardware. Once all hardware is installed, it is okay to begin tightening the bolts. Do not over-tighten hardware. You want the D-rubber to just start to bulge. Over-tightening could cause the D-rubber to split. Note that anywhere bumpers overlap each other, they take longer mounting bolts.

NOTE: Make sure proper-length bolts are used.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

2-4

NOTE: Not all D-rubbers will mount to bumper rail.

There are no mounting holes on the bumper at the corners.

FRAME

No moun t hole s

While holding the ﬂ at head bolt, install the outer plate.

Outer plate

Timing and traﬃ c control systems for your track.

Fasten the 5/16” ﬂ at washer and the 5/16” nylock nut to the bolt.

Install all bolt plates & nuts loosely before attempting to tighten any.

Tighten all bolts evenly.

Using a rubber hammer, make sure the D-rubber is level with the frame and rail.

Console, Traﬃ c Light Control With AV Messenger, PA, EXE Remote # 1-60-5003

8” Traﬃ c Light Assy # A01342

Ride timers, traﬃ c lights and Kartrol remote go kart shutdown systems are available to help keep your track operation running smoothly.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Basic Timer # 01328

#1-60-5003

NERF BAR REMOVAL AND INSTALLATION

2-5

The nerf bar (A) is mounted to the frame through four D-rubbers; two corner (B) and two center (C) D-rubbers. The corner D-rubbers are frame-mounted only.

FRAME

Remove the two corner D-rubbers.

NOTE: The two corner D-rubbers are frame-

mounted only; they do not mount to the bumper and there is no hole in the bumper at that location.

Protect your investment, add Nerf bars to your go karts today

SGL # 010126 DBL # 010127 Rear # 010129DBL

Loosen the two center D-rubber rail bolts.

Remove the two center D-rubber frame bolts.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

2-6

WARNING!

Go-karts have rotating parts.

For your safety, longer hair must be secured above the shoulder and any personal items (clothing, jewelry, etc) must be secured and contained within the seating area.

Serious injury or death could occur!

DO NOT REMOVE THIS DECAL

DANGER

Hair longer than shoulder

length must be secured

above shoulder.

Keep arms and legs in kart

at all times.

BRAKE GAS

DO NOT REMOVE THIS DECAL.

Remove the nerf bar by pulling it out of the two center D-rubbers.

FRAME

Installation is performed in the reverse order of removal. Using soap and water, lubricate the center D-rubbers to help when installing.

NOTE: Always make sure that any warning labels are

in place and clearly legible.

WARNING DECALS

# 1-60- 0288 #1-60 - 0 020-EAGLE

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

FRONT HUBS & SPINDLES

3-1

Frequent questions .................................................................page 3-2

Front hub removal ...................................................................page 3-3

Spindle ...................................................................................... page 3-4

Tapered spindle & roller bearings .........................................page 3-5

Spindle disassembly ................................................................page 3-8

Spindle assembly .....................................................................page 3-9

FRONT HUBS/SPINDLES

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

3-2

OVERVIEW

FRONT HUBS/SPINDLES

Front hubs and spindles: J&J pioneered the billet-machined hubs for concession go-karts. Easily-replaced lug studs are simply threaded through the hub ﬂ ange.

Sealed bearing design: two double-sealed bearings with an inner spacer make this the most popular conﬁ guration.

Tapered roller design: 1” tapered spindle and Timken®-style roller bearings and seals are used in severe conditions and on electric go-karts where weight is a consideration. This setup requires a special hub to accommodate bearings and seals. The spindle is fabricated from an automotive 4x4 universal joint. It is very rugged and is serviced in the same manner as its automotive counterpart.

Hub & Spindle FAQ

Q: I REMOVED MY FRONT HUB AND A SPACER FELL OFF. WHAT IS IT?

A: J&J’s 3/4 inch spindle is cut radially. The wheel bearing needs a ﬂ at surface to work against, so a spacer is used to cover the beveled edge of the spindle. Reinstall the spacer with the beveled edge facing the go kart frame: a little bit of red or green thread locker can be used to help hold the spacer in place.

Q: EVEN AFTER REPLACING THE FRONT HUB BEARINGS, THE HUB TURNS HARD AND IS GOING THROUGH BEARINGS QUICKLY.

A: When the bearings are replaced, it is a good idea to also replace the inner spacer that goes between them. If this spacer becomes worn, the bearings receive too much lateral preload when the hub is tightened to the spindle. The excess preload creates drag and causes premature bearing failure.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

3-3

FRONT HUBS

The front hubs are billet-machined from solid stock. The lug studs are 3/8” ﬁ ne-thread, allen-head-cap screws that are tightened through the threaded hub ﬂ ange and held with thread locking compound. Damaged studs can easily be replaced.

Remove the wheel from the hub. Unbolt the tie rod end from the spindle. Remove the steering cover by unfastening the screws holding it in place.

Spin the bearings by hand; check for roughness in the bearings, or any free play between the bearing and inner race. If roughness or play is found in the bearing, this indicates that it needs to be replaced. Also, inspect the spacer between the bearings; it should be snug, with little play between the two inner bearing races. The bearings for the hub of the radius-cut spindle are sealed. If the seal is damaged, the bearing should be replaced.

FRONT HUBS/SPINDLES

HUB PULLER

Works on both 5/16” and 3/8” studs on both front and rear hubs with 4 and 3 lug holes!

Part# Description Price

1-60-A1000 Tool, Hub Puller (5/16 or 3/8 Studs Rear or Front) $99.86

Undo the 3/4 inch lock nut on the end of the spindle. Slide the hub oﬀ of the spindle.

A hub puller may be necessary to pull the hub oﬀ the spindle. ( J&J#1-60- 1000)

#1-60-A1000, Hub puller.

HUB/BEARING TOOLS

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

3-4 SPINDLE

FRONT HUBS/SPINDLES

Before installing the hub, put a small amount of antiseize compound on the spindle. Slide the hub back onto the spindle; install a 3/4-inch nut and torque to spec. (50 ft-lbs). Check to see that the hub spins freely.

Check the spindle shaft for any pitting, galling or corrosion. Inspect the entire assembly for any damage. The spindle should rotate freely and smoothly in the yoke. Any free play or roughness means the spindle should be broken down further and the bearing cups inspected.

Tapered spindle shown

NOTE: See the Steering Adjustment section (page

4-6) for complete adjustment and installation.

#3-20-A0008, Wheel assembly tool for J&J, Formula K, Johnson & Amusement Products go karts.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

TIRE TOOLS

Part# Description Price

3-20-A0008 Tool, Wheel Assembly 4 Lug J&J, Formula K, Johnson, AP $99.95

3-20-A0009 Tool, Wheel Assembly 3 Lug Shaller Type $99.95

3-96-A0001 Tool, Tire Bead Breaker HD J&J/Shaller $350.00

3-96-0105 Tool, Tire Iron Set - 8”, 11”, 15” $36.95

01345 Tool, Valve Core Remover $7.52

01344 Gauge, Tire Pressure (0-50 psi - Karts Only) $12.66

1-60-A0311 Tool, Socket 15mm 6pt (Machined) $14.99

TAPERED SPINDLE & ROLLER BEARINGS

3-5

Remove the wheel from the hub. Gently tap the dust cap oﬀ of the hub to expose the end of the spindle.

Remove the cotter pin from the spindle. The castle nut and thrust washers can now come oﬀ .

FRONT HUBS/SPINDLES

Slide the hub oﬀ of the spindle; be careful not to drop the outer bearing as the hub comes oﬀ .

DO YOU NEED A CORROSION CONTROL SOLUTION? CORROSION BLOCK SOLVES YOUR PROBLEMS!

Experts estimate that protecting your equipment now is ten times cheaper than repairing it later. As a bonus, electrical and mechanical parts will run smoother and more eﬃ ciently.

SO WHAT IS IT?

Corrosion Block is a revolutionary product that:

 Kills corrosion on contact.  Stops corrosion from ever coming back.  Lubricates the area.  Is safe to nearly all electronics.

CORROSION PROTECTION

Part# Description Price

3-60-0002 Corrosion Block, Grease 2 oz. Tube $6.25

99101 Corrosion Block, Aerosol 12 oz. Protector/Penetrant $20.35

99101S Corrosion Block, Pump Spray 4 oz. Protector/Penetrant $8.15

99108 Corrosion Block, Grease 14oz Cartridge $14.99

99109 Corrosion Block, Grease 16oz $14.79

2-70-0112 Grease, Dielectric 5.3oz Tube Electrical Inulating & Protect $23.80

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

3-6

Remove the rear seal and wipe oﬀ the excess grease from the wheel bearings, as well as the hub assembly.

NOTE:

Do not use solvent to clean the bearings.

FRONT HUBS/SPINDLES

Inspect the wheel bearings and the bearing races for pitting or excess wear and replace as needed. Put a ﬁ lm of grease on both wheel bearing races and on the spindle shaft.

Pack the wheel bearings with wheel bearing grease, either by hand or with a wheel bearing packing tool.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Grease

3-7

Insert the newly-packed bearing into the appropriate race.

Put a light ﬁ lm of grease around the inner lip of the seal to keep it from tearing during installation.

NOTE: Do not grease the outer lip of the seal with

grease. Use “Gasgacinch” on the outer diameter.

FRONT HUBS/SPINDLES

Gasgacinch

Evenly tap or press the seal into the hub. Use a thin coat of “Gasgacinch” on seal outer diameter to help installation and to aid retention when it sets up.

Install the front wheel bearing, thrust washer, and castle nut. Torque the castle nut to 15 ft. lb. to seat the wheel bearings. Then, loosen the castle nut to the ﬁ rst available cross-hole that the cotter pin will push through. The hub should rotate freely.

If the hub does not turn smoothly and freely at this po in t, th en ba ck oﬀ the castle nut to the next available cross-hole. Using a drift punch, tap the head of the cotter pin down into the castle nut. When complete, the head of the cotter pin should be crushed just slightly. Fold the front half of the cotter pin over the spindle. Reinstall the dust cover.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

3-8

SPINDLE DISASSEMBLY

FRONT HUBS/SPINDLES

Break down the yoke and cross assembly

Remove the spindle assembly from the frame. Remove the hub if not done already. There is a snap ring at the top of each bearing cup; these need to be removed.

Place the spindle upside-down in a press. Support the bottom of the spindle so that the bearing cup can be pressed out (1-1/8” socket works well). Using a suitable tool, press the top bearing cup until the bottom one falls out.

Remove the spindle from the press; the u-joint can be twisted and removed from the yoke. The other bearing cup can now be removed.

Special tools made for universal joint removal can be very helpful here; for example, OTC brand 7248 or OTC 7249.

#1-50-0189 #00970 #3824L

The Disc-lock safety wheel nut is a free spinning, vibration-proof

heel nut, speciﬁ cally designed to prevent wheel loss from commercial vehicles such as trucks, trailers and buses with hub-piloted

heel systems.

Part# Description Price

00970 Nut, 5/16-24 (Lug Nut) “Pre 98” $0.40

1-50-0189 Nut, 3/8-24 Z (Lug Nut) “Post 09” (DISC-LOCK) $1.15

3824L Nut, 3/8-24 Z (Lug Nut) “Post 98” Pre-09 $0.32

LUG STUDS / NUTS & RELATED HARDWARE

Remove the spindle from the press; the u-joint can be twisted and removed from the yoke. The other bearing cup can now be removed.

NOTE: Make sure all needle bearings are in the

bearing cup. Check the bearings for wear or damage. If the grease in the bearing cup is old and/or dirty clean it out. Put the bearing cup on the end of the u-joint and check that it spins freely.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

SPINDLE ASSEMBLY

Grease

3-9

Remove all dirt and debris from the entire spindle assembly, ensuring it is completely clean.

Apply a small amount of grease to the replacement caps.

FRONT HUBS/SPINDLES

Replace the bearing cap by inserting it partially into the yoke.

U-joint

Bearing cap

Bearing

Begin installing the universal joint into the cap.

Partially insert the opposing cap.

Line up the universal joint and push both caps into place using a press, vice, or special “U” joint tool.

Press each cap into the universal joint just enough so that the clips can be installed.

After installing, make sure spindle moves freely. Add 2 to 3 pumps of grease.

 GMax GM2X open face helmet  DOT approved lightweight, injection-molded poly

carbonate shell.

 Clear-coated, painted shell.  Deluxe ear pockets for better ﬁ t and comfort.  Deluxe rubber edge molding.  Deluxe mesh crown pad.  Padded chin strap.  Dual liner for added comfort with soft brushed

nylon against skin and vents to help reduce moisture.

 Adjustable forehead vent.  3-snap bubble visor.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

3-10

FRONT HUBS/SPINDLES

#1-60-A0311,

Use this specially made, thin-walled socket on go karts equipped with the Disc-lock safety wheel nut. This socket was designed with the clearance to ﬁ t between the nut and wheel hub.

TIRE TOOLS

Part# Description Price

3-20-A0008 Tool, Wheel Assembly 4 Lug J&J, Formula K, Johnson, AP $99.95

3-20-A0009 Tool, Wheel Assembly 3 Lug Shaller Type $99.95

3-96-A0001 Tool, Tire Bead Breaker HD J&J/Shaller $350.00

3-96-0105 Tool, Tire Iron Set - 8”, 11”, 15” $36.95

01345 Tool, Valve Core Remover $7.52

01344 Gauge, Tire Pressure (0-50 psi - Karts Only) $12.66

1-60-A0311 Tool, Socket 15mm 6pt (Machined) $14.99

#3-96-0105, tire iron set #3-96-A0001, Tire bead breaker tool for J&J and Shaller go karts.

#3-20-A0008, Wheel assembly tool for J&J, Formula K, Johnson & Amusement Products go karts.

0095120 Bolt, 5/16-18 x 3/4 Grade 5 Zinc plated $0.59

1-50-0046 Stud, Front Hub Tapered Style 5/16-18 X 1-1/4 SSS Grade $0.64

00998 Stud, Lug Press In Type 5/16 Fine 1 1/8” L $1.50

#1-50-0189

The Disc-lock safety wheel nut

s a free spinning, vibration-

roof wheel nut, speciﬁ cally esigned to prevent wheel loss

rom commercial vehicles such

as trucks, trailers and buses with

ub-piloted wheel systems.

00970 Nut, 5/16-24 (Lug Nut) “Pre 98” $0.40

009512 Bolt, 5/16-24 x 1 SHCS (Wheel Stud) $0.31

009570 Bolt, 5/16-24 x 1-1/4 SHCS (Wheel Stud screw in type) $0.26

00962 Washer, 5/16 Z Lock $0.15

1-50-0189 Nut, 3/8-24 Z (Lug Nut) “Post 09” (DISC-LOCK) $1.15

3824L Nut, 3/8-24 Z (Lug Nut) “Post 98” Pre-09 $0.32

009513 Bolt, 3/8-24 x 1 SHCS (Wheel Stud for Front & Rear Hubs) $0.68

009514 Bolt, 3/8-24 x 1 1/4 SHCS (Front & Rear Hub) $0.77

1-50-0190 Bolt, 3/8-24 x 1-3/4 SHCS (Wheel Stud for Floater Hub 09-Up) $2.70

#01344, pressure gauge#01345, Valve core removal

LUG STUDS / NUTS & RELATED HARDWARE

Part# Description Price

#00970 #3824L

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Steering system adjustments - Overview ......................page 4-1

Cast er ...................................................................................page 4-3

Toe-in .................................................................................. page 4 -6

Tie rods/ends ..................................................................... page 4-8

4-1

STEERING SYSTEM

Ackerman eﬀ ect ...............................................................page 4-10

Steering shaf t/cover ........................................................page 4 -11

Steering wheel ..................................................................page 4-12

Steering column pad........................................................page 4-13

STEERING SYSTEM

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

4-2

OVERVIEW-CASTER

CASTER ANGLE

SIDE VIEW

STEERING SYSTEM

Caster is the inclination of the steering axis from vertical in the longitudinal plane (wheel viewed from the side). Positive caster is achieved when the steering axis is inclined toward the rear of the vehicle at the top in the side view. Negative caster is when the steering axis is inclined toward the front of the vehicle at the top in the side view.

Zero caster (ﬂ at)

CASTER:

To understand caster, you need to picture an imaginar y line that runs from the upper ball joint and extends through the lower ball joint. From the side view, the imaginary line will tilt forward/backward. The tilting of this imaginary line is deﬁ ned as caster.

Caster is measured in degrees by using a caster camber gauge. If the imaginary line described above tilts towards the back of the go-kart (at the top), then you will have positive caster. If the imaginar y line tilts forward, then you would have negative caster.

Positive caster provides the directional stability in your go-kart. Too much positive caster will make the steering eﬀ ort diﬃ cult. Power steering will allow you to run more positive caster. Negative caster requires less steering eﬀ ort, but can cause the car to wander down the straightaway. J&J go-karts only provide for positive caster.

Karts with single-wheel-drive are set stock at the second hole, which is approximately 4.7 degrees; two-wheel-drive karts are set stock at the third hole, which is approximately 9.2 degree caster.

HONDA 2:1 GO KART CLUTCH

Part# Description Price

1-61-0003 Clutch, GX140 160 200 Complete (See Notes) $400.00

1-61-0009 Clutch, GX240 270 Complete (See Notes) $400.00

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

4-3

STEERING ADJUSTMENTS - CASTER

The frame has four small index holes on the spindle mount. Each hole represents a diﬀ erent setting. The ﬁ rst hole closest to the front of the kart represents 0 degrees and the fourth hole farthest from the front of the kart represents approximately 14 degrees.

Factory caster settings: Single wheel drive karts: 4.7 degrees (second hole) Two wheel drive karts: 9.2 degrees (third hole)

Remove the steering cover and/or the body to access the spindle bolts.

NOTE: Check tie rods for straightness. If bent,

they can be removed and straightened. Always do this prior to any adjustments. H.D. tube-style tie rods must be replaced if damaged; they cannot be straightened.

Loosen all four 3/8” bolts holding the spindle to the frame.

NOTE:

Do not remove the bolts, only loosen them enough to allow the spindle to rotate.

STEERING SYSTEM

Heavy-duty, tube-style tie rods & rod ends

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

GO KART TIE RODS

Part# Description Price

A00589 Tie Rod, Assy 11” Shaft Style L/R Male Threads $44.83

A00591 Tie Rod, Assy 21” Shaft Style L/R Male Threads $50.95

1-10-A0099 Tie Rod, Assy HD 11” Tube Style L/R Female Threads $65.00

1-10-A0100 Tie Rod, Assy HD 21” Tube Style L/R Female Threads $65.00

1-10-0083 Rod End, 3/8” Male Stud x 3/8” Male Stud (Right Hand Thread) $11.17

1-10-0084 Rod End, 3/8” Male Stud x 3/8” Male Stud (Left Hand Thread) $16.00

STEERING SYSTEM

4-4

Spindles installed from the factory have been marked to make the correct caster adjustments. If the mark is not visible, or the spindle is being replaced, the spindle will need to be marked prior to adjustment.

Mark here

With the 3/8” spindle bolts loose, rotate the spindle by lifting up the spindle arm until it stops. Use a permanent marker and mark the spindle at the hole closest to the front of the kart. This will set the caster at 0 degrees.

To increase the amount of caster, rotate the spindle arm downward.

TIRE & TUBE COMBO PACKAGES AND WHEELS AVAILABLE!

If you’ve got a busy track, then you are fully aware that changing tires is a regular occurrence at your facility. J&J/FPX carries many sizes of tires and tubes to ﬁ t your go-karts. Our legendary Bigfoot tire with its extra thick tread will help keep your karts on track, generating the revenue! Bigfoot tires and tubes ship from either our west coast or east coast location, so they get to you fast.

007880combo - Tire, 12 x 4.00 - 5” SL72 Bigfoot COMBO (W/Tube)

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

OVERVIEW-TOE

TOE - IN

TOP VIEW

4-5

STEERING SYSTEM

Toe -in is t he diﬀ erence in distance between the front and rear axle measurements of the tires on the same axle in the center of the tread surface at spindle height, where the front measurement is less than the rear. Toe-out is the opposite.

TOE - IN:

Toe is the pointing in or pointing out of the front wheels as viewed from the top of the kart. If the front wheels point in (toward the front of the kart) at the front edge of the wheels, then you have toe-in. If the front wheels point out at the front edge, then you have toe-out.

In general, dune buggies and race cars are set with a small amount of toe-out. The toe-out provides directional stability. Toe-out pulls on the tie rods taking out the tiny clearances that are built into the tie rod ends. Depending on the type of car, typical toe readings are 1/16” to 1/4” out for tracks under 1/2 mile in length. J&J go-karts are set with 1/4” toe -in to provide self-centering stability for the general public.

Toe can be set with a tape measure on the side walls of the tires. A tape is placed on the inside front of the tire, as near to the rim as possible, (as close to center horizontal as possible) and then measured in the same location on the front edge of the other front tire. Remember to measure from the same locations each time you check the toe. Now check the rear side of the front tires as close to the center rear of the tires, as possible. If this number is a smaller tape reading on the back edge, this indicates toe-out.

NOTE:

The system can be held stable for this procedure on J&J go-karts by clamping the steering shaft to the steering column.

For a very precise reading, you can scribe a line in each front tire. Use a tire scribe and spin each of the front tires to get your straight line. You can then measure between the two scribed lines with a tape measure, or with a toe bar or toe plates; again a smaller measurement at the backside of the tire, indicates toe out.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

4-6

STEERING ADJUSTMENTS - TOE

Angle iron

STEERING SYSTEM

Using a C-clamp, lock the steering shaft in the center position. This can be done by clamping two D-rubber plates to the steering shaft, or by using a Angle iron to lock the steering shaft.

NOTE:

The steering shaft must be at the center position before toe can be set correctly.

Place a straight edge across hub ﬂ ange. From the rear of the spindle (facing the rear of gokart), measure the distance from the frame rail to the straight edge.

Now from the front of the spindle (facing the front of the go-kart), measure the distance from the frame rail to the straight edge.

Subtract the measurement reading from the rear of the spindle to the measurement reading received from the front of the spindle; this measurement equals the toe-in.

Standard tow-in is 0”-1/8” with a service limit of 1/4” of total toe-in.

Used to inject lubricant into cable housing. Clamps over housing and wire allowing an aerosol can to be connected. Once lube runs out the far end, the cable is lubricated.

Cable lube provides the smoothest operation

and longest cable life. Our special blend of Red

Line synthetic lubricant and rust inhibitors keep #00122 - Cable lube tool #3-60-0029 - Cable Life lubricant

your cables working smoothly in any weather

conditions from hot to cold, wet or dry.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

4-7

If the measurement is not within speciﬁ cations, loosen the two retaining lock nuts that are located on each end of the tie rod.

Turn the left and right tie rods equal amounts until the measurements are within speciﬁ cations. Tighten the lock nuts and then recheck measurements. Make sure that when the wheels are straight, the steering wheel is in the center position.

STEERING SYSTEM

A threadlocker is an anaerobic adhesive used on threaded metals that cures at room temperature in the absence of air. The adhesive completely ﬁ lls the gaps between mating threads to lock and seal the threaded assembly. LOCTITE® Threadlockers come in a wide variety of strengths and specialty formulations, including permanent and removable threadlockers.

THREAD LOCKERS & GLUES

Part# Description Price

3-20-0001 Loctite, Threadlocker 10ml Bottle (Blue) $28.05

3-20-0002 Loctite, Threadlocker 50ml Bottle (Blue) $83.73

3-20-0003 Loctite, Threadlocker 250ml Bottle (Blue) $191.76

3-20-0004 Loctite, Threadlocker 10ml Bottle (Red) $28.05

3-20-0005 Loctite, Threadlocker 50ml Bottle (Red) $76.60

3-20-0006 Loctite, Threadlocker 250ml Bottle (Red) $191.76

4-95-0011 Loctite, High Strength “Red” 10ml. Bottle $29.17

4-95-0044 Loctite, 50ML “Green” $94.07

81790 Loctite, Blue 250 ml $217.14

81793 Loctite, Red 250 ml $232.74

013330 Glue, 3.7oz Tube (Goop) $10.81

013331 Glue, Goop Cartridge $11.22

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

4-8

TIE RODS/ TIE ROD ENDS

STEERING SYSTEM

REMOVAL- Remove the body from the kart (if

applicable). Unbolt and remove the steering cover. Unfasten the rod ends from the steering shaft and spindle; using an open-end wrench, hold the hex section of the rod end stud, and then loosen the nut from the rod end.

INSPECTION- Check the tie rod ends for wear or

damage. Rod ends should pivot freely and have no slop at the ball (see arrow). Check the tie rod for straightness and damage.

NOTE: Tie rods can be bent during heavy impacts.

Bent tie rods can be removed, straightened and reinstalled.

The tie rod ends can be removed by holding them with an open-end wrench, or appropriate adjustable wrench, on the machined ﬂ at, then loosening the locknut holding it in place (one rod end is right-hand threaded, the other is left-hand threaded.)

REINSTALLATION- Install the tie rod assembly by

reversing the procedure used to remove them.

NOTE: A spray lubricant can be used to silence

squeaky tie rod ends.

MECHANIX WEAR GLOVE SIZE CHART

Place the hand on the gauge as shown for proper sizing. A snug ﬁ t is preferred for optimum glove performance.

PROTECTIVE CLOTHING/GEAR

Part# Description Price

3-00-5000 Glove, Original 8 Small Mechanix Black $37.01

3-00-5001 Glove, Original 9 Medium Mechanix Black $37.01

3-00-5002 Glove, Original 10 Large Mechanix Black $37.01

3-00-5003 Glove, Original 11 X-Large Mechanix Black $37.01

3-00-5004 Glove, Original 12 XX-Large Mechanix Black $33.64

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

4-9

TIE ROD ENDS

Removing the tie rod ends requires two open-end wrenches. There is a machined spot to use a wrench on each tie rod end. Hold the rod end with a wrench and loosen the locknut. The tie rod end can now be unscrewed from the tie rod (one tie rod is righthand threaded, the other is left-hand threaded). Installation of the rod end is the reverse of removing one.

FAQ’s

Q: THERE IS A HARD SPOT IN MY K ART’S STEERING. EVEN AFTER REPLACING THE TIE ROD ENDS, THE PROBLEM REMAINS. WHAT IS CAUSING THIS?

A: When installing the tie rod ends and setting the toe-in, it is important that the rod ends be positioned properly. The rod ends should be perpendicular to their mounting surface at rest. When the kart is steered, the tie rods twist. If the tie rod ends are installed and are tilted, they may reach their working limit as they pivot when the kart is steered. This can create binding in the steering system.

STEERING SYSTEM

NOTE: Any excess clearance (slop) in a rod end will adversely aﬀ ect steering. Excess clearance can only worsen; keep it

tight by replacing worn ends.

SHOP TOOLS AVAILABLE FROM J&J!

Compression tester, #3-96-0009

Chain riveting tool, #3-96- 0018

Thread repair kits, inserts and tooling

Metric or standard Socket T-handle set Metric #3-96-0002 Stand #3-96-0003

Spanner wrench, #2-70-0076

T-handle drives in 1/4" & 3/8" 1/4" #3-96-0004 3/8" #3-96-0005

1/4" Mini L-handle #3-96 -0016 1/4" L-handle drive #3-96-0015 3/8" Mini L-handle #3-96- 0014 3/8" L-handle drive #3-96-0013

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

Terminal crimper for SB-50 & SB-120 plugs #2-70-0073-120

Ball-end allen set (Metric) #3-96- 0026

4-10

OVERVIEW- ACKERMAN EFFECT

STEERING SYSTEM

Ackerman Eﬀ ect

TOP VIEW

ACKERMAN EFFECT:

Ackerman is the diﬀ erence in turn radius between the front tires. On oval-track cars, it can be desirable to create a situation where the left front tire turns faster than the right front tire. The Ackerman eﬀ ect can help the car turn better through the center of the turn. You can measure the amount of Ackerman you currently have by using a set of turn plates. Typically, Ackerman is measured by turning the right front tire 10 degrees to the left. If you have Ackerman, the left front will travel further than the right front. A typical amount would be three degrees in 10 degrees of steering. To simplify, moving the right front from zero through 10 degrees of steering will cause the left front to move 13 degrees in this scenario.

Ackerman is created by your front end geometry. Tie rods that angle forward from the inner pivot point out to the spindle will have more Ackerman.

You will note that J&J go-karts use this feature. When you turn the wheels all the way in either direction, the inside wheel will “tuck” (turn) more than the outside wheel.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

4-11

STEERING COLUMN & COVER

Q: THE STEERING SHAFT IS BENT ON THE LOWER END WHERE THE TIE ROD TAB IS WELDED TO THE END OF THE SHAFT. CAN I STRAIGHTEN THE SHAFT?

A: If the go-kart has suﬀ ered an impact suﬃ cient to bend the 3/4” steering shaft, it is recommended that a new part be installed. Be sure to visually inspect the complete steering system for any other damage.

Remove the 4 allen-head cap screws from the steering cover.

NOTE: The nut is welded to the frame on the bottom

side, so you will not need a wrench under the go-kart.

Remove the steering cover.

STEERING SYSTEM

Use Gra de 8 bol ts on ly. Do no t substitute with lesser grade.

Undo the tie rods from the bottom of the steering shaft. Remove the four 5/16” bolts holding the steering bushings. The steering shaft, bushings, and hardware can now be removed from the kart.

Check the steering shaft for straightness. Clean and inspect the steering bushings for damage and wear; bushings should ﬁ t snugly to the shaft while still allowing the shaft to pivot with only slight resistance. Check that the bushing sleeves are no shorter than the two bushing halves. If the bushing sleeves are shorter than the steering bushings, it will cause the steering shaft to bind.

Before installing the steering shaft, lightly grease the inside of the steering bushings. Place some red thread-locker on the 5/16” mounting bolts, install the locking and ﬂ at washer on the bolts and set them aside. Place the steering shaft onto the bottom bushings and set the top bushings on the shaft. Holding the two sets of bushings together with the shaft between them, set the assembly against the steering column. Holding the assembly against the steering column by the top bushing, install the four sleeves into the steering bushings, followed by the mounting bolts. Snugly run in the mounting bolts until they bottom out on the sleeves, and then torque them all to 15 ft-lbs. Recheck the steering assembly to verify that it turns with slight resistance.

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

4-12

STEERING WHEEL

STEERING SYSTEM

Steering wheel

mounting bolts

Steering pad mounting screws

To remove the steering wheel, undo the three acorn nuts (round steering wheel only), then undo the locknuts underneath.

Check the steering wheel and pad for damage. Replace as needed.

SAFETY ITEM

All J&J karts use a pad on the steering wheel/column to help reduce the possibility of injur y to the rider(s) in the event of a collision. These pads should be in place and in good condition at all times.

#008642, steering column pad.

Installation is the reverse of removal.

NOTE: Your go-kart may be equipped with a butterﬂ y

steering wheel. Removal/installation procedures are virtually the same as the round wheel described above.

00864A, Butterﬂ y

steering wheel pad.

PADS - STEERING

Part# Description Price

008642 Pad, Steering Column (Formed) 3/4” Steering Column $25.00

00864A Pad, Steering Wheel (Butterﬂ y) Formed $26.47

1-90-0020 Pad, Steering Wheel (Butterﬂ y) Formed (Soft Type) $41.78

00862A Pad, Steering Wheel (Round) Formed $21.32

00862A, Round

steering wheel pad.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

4-13

STEERING COLUMN PAD

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

Unbolt the 5/16” nylock nut to remove the steering column pad.

Installation is performed in the reverse order of removal.

NOTE: When installing the steering pad, be careful

not to over-tighten the nut.

STEERING SYSTEM

REPLACEMENT STEERING WHEELS

CAUTION

If any part of the pad is torn or damaged enough to expose the steering column, the pad should be replaced.

SAFETY ITEM

All J&J karts use a pad on the steering wheel/column to help reduce possibility of injury to the rider(s) in the event of a collision. These pad should be in place and in good condition at all times.

#A00863, Butterﬂ y style.

#A01098, Round style.

STEERING WHEELS

Part# Description Price

A00863 Steering Wheel Assy, Butterﬂ y W/Pad and Bolts $79.80

00863 Steering Wheel Assy, Round 10” W/Pad (Current) $44.83

01098 Steering Wheel, Round 10” (Current) $40.00

00863 Steering Wheel, Butterﬂ y $56.99

1-10-0102 Steering Wheel, Butterﬂ y 2 (Softer Grip Style) $18.00

phone: 1-800 -854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

4-14

SHOP SUPPLIES

GAS CADDY

 UL-approved, 2-way, heavy-duty rotary pump.  Non-conductive aluminum feet for proper grounding and spark resistance.  8ft. suction/discharge hose with anti-static ground.  2in. ﬁ ll neck for safe addition of outside fuel/ﬂ uids.  Fill level gauge shows tank levels.  10in. heavy-duty steel wheels with semi-pneumatic tires.  30 gallons capacity.  Durable, powder-coat ﬁ nish.

Note: Nozzle is not included with Gas Caddy

STEERING SYSTEM

#C200 #002172

GAS CADDY

Part# Description Price

00223 Gas Caddy, Complete 30 Gal. $565.00

3-60-0066 Pump, Gas Caddy (Blackmer) Optional for Gas Caddy One Way Fl $209.59

C200 Pump, Gas Caddy $202.00

C203 Gas Caddy, Vent Dome Assy $28.65

C204 Hose, Assembly (Gas Caddy) $58.14

C205 Gas Caddy, Gauge Assembly $63.21

C206 Gas Caddy, Ground Wire Assembly $21.45

C207 Gas Caddy, Filler Neck $16.07

3-60-0047 Gas Caddy, Wheel Kit (two wheels per kit) $37.99

C618 Gas Caddy, Cap $12.24

C629 Gas Caddy, O-Ring (Large) $4.55

002172 Gas Caddy, Repair Kit For Tank Gauge $33.66

3-60-0071 Gas Caddy, Wheel Retaining Clip $1.12

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

ROLL BARS/PADS/Seat beltS

5-1

Frequent questions ..................................................................page 5-1

Roll bar (Eagle, Scorpion, F-22, Can-am, Sidekick) ........................page 5-2

Roll bar (Sidewinder, Sidewinder double) .............................. page 5-3

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

OVERVIEW

Fixing pads .................................................................................page 5-6

Seat belts....................................................................................page 5-7

Cleaning seat belts .................................................................... page 5-9

ROLL BARS & PADS

Roll bar shown is for Eagle, Scorpion, F-22, Can-Am, and Sidekick only.

The roll bar assembly ﬁ ts tube-inside-tube receptacles on the go kart frame. The roll bar is then bolted and cross-bolted to ﬁ rmly attach it to the frame. Additionally, bolts attach the roll bar to the backrest panel at the bottom side of the roll bar

pad. When all of these bolts are properly tightened, the assembly is very solid.

FAQS Q: CAN I WELD THE ROLL BAR SOLIDLY TO THE FRAME?

A: Yes; using proper safety and welding techniques, (in addition to mounting bolts) the roll bar of the type shown above can be welded to frame.

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

5-2

ROLL BAR

(EAGLE, SCORPION, F22, CAN-AM, SIDEKICK)

ROLL BAR & PADS

There are two cross bolts that secure the roll bar to the frame-mounted receivers.

NOTE: The holes on the back side of the receiver are

larger to allow nuts to draw directly against the roll bar, thus cinching it tight to the receiver.

1/4” bolts attach the roll bar to the seat back.

NOTE: A center bolt is not used in this application.

Seam

NOTE: Keep the seam side of the pad away from the

rider and towards the outside of the go kart.

Seat belt pads are captured underneath the seat belt bracket to prevent twisting of the pads on the belt.

Pad

Bracket

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

ROLL BAR / REMOVABLE TO ALLOW BODY SERVICE

(SIDEWINDER, DOUBLE AND SINGLE)

Some roll bars are mounted through the body (Sidewinder go karts) and are detachable to allow for body removal. A clipped hitch pin secures the roll bar.

A locking set screw holds the roll bar in place and prevents it from rattling.

5-3

Bracket

Acorn nut

Pad

ROLL BARS & PADS

Acorn nuts are used to help reduce the possibility of injury from exposed threads.

NOTE:

Make sure acorn nuts are installed and the seat belt pads are secured in their proper position with the seam away from the rider.

Seat belt pads are captured underneath the seat belt bracket to prevent twisting of the pads on the belt.

#1-60-0069C 12” seat belt extension, push button style.

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

#010771 12” seat belt extension, Flip style.

SEAT BELTS

Part# Description Price

010771 Seatbelt Extension, 12” (Flip Buckle) $49.99

1-60-0069C Seatbelt Extension, 12”(Push Button Style Canada & Kreative) $45.00

5-4

PADS/ BACK/ ROLL BAR/SEAT

ROLL BAR & PADS

Pad

Any pad with damage that exposes the underlying part should be replaced. Torn pads that do not completely cover parts such as the roll bar, back panel, or steering column can cause injury. All pads should be inspected daily for damage. Karts should always be operated with all pads and safety covers in place.

CAUTION

The seat pad takes high abuse from loading and unloading riders. Holes, rips and tears can catch shoes and cause trips and falls.

The steering column pad is held on by one 5/16” nut on the inside of the steering column. When installing the steering pad, be careful not to over-tighten the nut. If any part of the pad is torn or damaged enough to expose the steering column, the pad should be replaced.

Hidden nut

Underside of steering column

Roll bar pads are held on by two nuts on the back side of the roll bar. In most cases, there is an acorn nut on the end of the roll bar pad stud to prevent injury to the guests. When installing the roll bar pad, do not over-tighten the mounting nuts.

NOTE: Pad studs are mounted to plywood inside the

pad by “T” nuts. Tighten the bolts carefully to “snug” to avoid pulling the “T” nuts through the plywood.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Glued to body

5-5

The back pad is held on by four nuts on the back side of the back panel for a single kart, and six nuts for a double. The back pad serves multiple purposes; most karts utilize the upper back pad bolts to mount the top of the seat belts. When installing the pad, take care not to over-tighten the nuts. Replace torn or damaged pads that expose any part of the back panel assembly.

The Sidewinder and Sidewinder Double seat back pads are glued onto the body; there are no bolts holding them to the frame or body.

When replacing, make sure all of the pad is removed; the body must be free of old adhesive and debris. Lightly sand the body surface to remove old glue. Wipe and clean the surface. Apply contact adhesive to the body and to the back of the new seat pad and let it sit until tacky (see adhesive label instructions).

ROLL BARS & PADS

Roll bar pad

Seat back pad

Seat pad

Carefully apply the new seat pad to the body, taking care to make sure it is aligned properly before it touches the body, as the glue will adhere instantly.

We have replacement pads. Call our parts department today.

800-854-3140 OR 503-304-8899

PADS - HEAVY-DUTY & STANDARD SEAT PADS

Part# Description Price

008600A Pad, Single (Seat) Formed $82.00

008580A Pad, Single (Back) Formed (Bolt On) $90.00

008560A Pad, Single (Rollbar) Formed (Bolt On) $58.00

1-90-0013 Pad, Single (Seat) Formed Heavy Duty $100.98

1-90-0006 Pad, Single (Back) Formed (Bolt On) Heavy Duty $109.00

1-90-0008 Pad, Single (Rollbar) Formed (Bolt On) Heavy Duty $84.00

1-90-0014 Pad, Single (Back) Formed (Glue On) Heavy Duty $103.02

008590A Pad, Double (Back) Formed (Bolt On) $110.00

008570A Pad, Double (Rollbar) Formed (Bolt On) $100.00

1-90-0009 Pad, Double (Seat) Formed Heavy Duty $170.77

1-90-0005 Pad, Double (Back) Formed (Bolt On) Heavy Duty $126.67

1-90-0007 Pad, Double (Rollbar) Formed (Bolt On) Heavy Duty $107.98

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

5-6

FIXING PADS

ROLL BAR & PADS

Sometimes pads get small tears or rips in the outer skin. If the pad has one of these you can easily repair it with Rapid Patch, J&J #1-60-0071

Clean the area to be patched with mild soap and water, rinse and dry thoroughly.

Apply Rapid Patch to the tear and allow it to dry for 15 minutes.

Simply sand the patch down ﬂ ush with the pad.

URETHANE REPAIR KIT FOR GO KART SEAT PADS

 Prolong the life of your go kart pads!  Do you have rips and tears in your seat pads?  Would you like to ﬁ x them in 15 easy minutes?  Now you can with Rapid Patch!  It’s the easy, inexpensive way to ﬁ x rips and tears

before they ruin your pads.

REPAIR KIT - SEAT PADS

Part# Description Price

1-60-0071 Patch, Rapid (For Seat Pads)(Maxim Fast Urethane) $71.00

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Seat beltS

Smooth side

5-7

Seat belts must be inspected and maintained on a regular basis. Follow the maintenance schedule provided on pages 0-14 of this manual.

Inspect all seat belt pads frequently; frayed, worn or split pads must be replaced. The pads are held in place with the smooth side toward the rider’s neck by capturing the pad end under the seat belt bracket when it is bolted to the go kart.

SAFETY ITEM Neck injuries can occur from frayed or

missing seat belt pads. Replace worn out seat belts with original J&J equipment only.

ROLL BARS & PADS

Seamed side

Bracket

Single seat “bodiless” go karts have the lap belt attached directly to the seat pan of the chassis. Be sure to orient the belt brackets as shown.

The photo below shows the reinforcement plate used on the bottom side of the chassis seat belt mounting point.

Bracket

NEW HEAVY-DUTY SEAT BELT SHOULDER PADS. Say good-bye to

those stinky, cracked vinyl pads. These

new molded rubber pads will not

absorb moisture. This feature keeps the

pads from absorbing perspiration and

will outlast any other pads.

#110779R. Rubber shoulder pad

SEAT BELT PADS

Part# Description Price

11077R Pad, Seatbelt Shoulder 15” (Pair)(Rubber) $25.50

110779R Pad, Seatbelt Shoulder 19”(Pair) (Orange Tab)(Rubber) $29.99

110777 Pad, Seatbelt Shoulder 23” (Pair) $29.00

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

5-8

Lap belts on bodied go karts

ROLL BAR & PADS

Bodied go karts such as Sidewinder, Sidewinder Double, and Stinger have the lap belt attached to the body instead of the chassis.

NOTE: Orient the seat belt mounting tabs as shown.

The backside of the lap belt attachment utilizes a fender-style washer (large/ﬂ at) to keep the bolt from pulling through the body.

Seat belt pads

new pads pic

When installing new seat belt pads, it’s easiest to use a stiﬀ wire or coat hanger to pull the belt through the pad. Just bend a small hook in the stiﬀ wire to grab the hole in the seat belt mounting bracket.

NOTE: Tape the hook end so it does not tear the

inside of the new pad as you pull it through.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

Cleaning seat belts

#3-60-0010, pressure washer

The seat belt manufacturer recommends a mild soap/water solution when cleaning the seat belts.

CAUTION

No chemicals should be used to clean the seat belts or their mechanism.

MAINTENANCE & GROUND TOOLS

Part# Description Price

3-00-0006 Blower, Track Blaster 9HP Honda F902H Force 2 $1,629.99

3-00-0006 Blower, Track Blaster 16hp 2400cfm Call

9-60-0010 Pressure, Washer GX200 2900 PSI $719.99

9-60-0011 Pressure, Washer GX270 3500 PSI $1,049.99

5-9

ROLL BARS & PADS

The Track Blaster

IMAGINE CLEANING AND DRYING YOUR GO KART TRACK IN THE TIME IT TAKES TO WALK IT. WELL, NOW YOU CAN WITH THE TRACK BLASTER FROM FPX!

We oﬀ er the most powerful walk-behind blower on the

market today. The hurricane-force wind is created by

a Honda 13 hp or Honda/Robin 9hp commercial grade

engine. The Track Blaster is capable of producing wind

speeds of up to 180mph and over 2,400cfm which

allows you to get the job done fast.

The Track Blaster is easy to start and operate. Its large

15-inch pneumatic rear tires make pushing it a breeze. There is also a self-propelled version for tracks with bridges.

The Track Blaster is great for all your cleaning and drying needs. Use it on your track, parking lots, or your landscape.

With a throttle control arm, you can adjust the wind speed to ﬁ t any of these cleaning tasks.

Order yours today, and don’t let the rain shut you down.

When comparing the blowing force of FPX Track Blaster blowers to other blowers on the market that claim more “CFM”,

Track Blaster blowers move debris farther. Here’s the rest of the story:

 A ceiling fan puts out a lot of CFM but does little work.  It’s the combination of CFM and Pressure that does work.

For example:

- Pneumatics (cfm x psi = work)

- Hydraulics (ﬂ ow x pressure = work)

 The combination of CFM and Track Blasters’ necked-down discharge creates the highest pressure and discharge

velocity in the industry, which produces the most work when compared to other blowers on the market.

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

5-10

ROLL BAR & PADS

ADVERTISING, REDEMPTION, AND PROMOTIONS ARE ALL PART OF GENERATING REVENUE.

DISPLAY

Part# Description Price

1-00-0100 Display, Digit (88 88.888) RED 58” H x 63.2” L x 9” D 6-Line $9,600.00

1-60-3000 Display, Main Board DSUB-M0078 DPCB-M0101 AMD $434.78

1-60-3001 Display, Power Supply S-150-7.5UL $336.60

1-60-3003 Display, Surge Protector RS-232 RJ-11 $89.76

1-60-3004 Display, Main Board DSUB-M0076 AMB V0.2 $478.26

1-00-0101-OP Converter RS 232/485 W/Built In data surge protector $245.00

GO KART TIMING HARDWARE

Part# Description Price

1-60-0093TX140 Timing, Transponder AMB140 TX (One Per Kart) $437.99

1-60-0093BRACKT Bracket, Timing Transponder (J&J Karts)/Axle Guard $16.07

1-60-0093CLAMP Timing, Clamps Hose Transponder (pack of ten) $19.07

The XPRESSTRACK System provides

these and more in one simple-to-

set-up system.

Vision is one of the most important

senses we have. They say a picture

is worth a thousand words... How

much is motion worth?

Generate revenue from outside

sales on an active matrix display.

What would you pay to advertise

your business on the radio or TV?

Sell time on your display to local

businesses and the system will pay

for itself in no time.

One of the most important aspects

of a system of this kind is its ease of

use and maintenance-free opera-

tion. The XPRESSTRACK System uti-

lizes top-of-the-line components to

ensure long, maintenance-free life.

Our timing system transponders

and decoders are the same units

used in world-class racing venues

from Formula-1 to NASCAR and

everything in between.

TIMING SOFTWARE

Part# Description Price

1-60-0094 Timing, Software Xpress Track Pit W/Scoreboard $4,500.00

1-60-0094KEY Timing, Software Key Only (no software) $504.90

1-60-0094TV Timing, Software Xpress TV Score $504.90

TRACK HARDWARE

Part# Description Price

1-60-0092 Timing, Active Detection Loop 12m/39ft Track,20m/65ft Coax $1,100.00

1-60-0117 Timing, Light Controller (Hardware for Xpress Track) $408.00

1-60-0189 Timing, Coax Extension 100m 75ohm W/ BNC Connectors $714.00

1-60-0190 Timing, Coax Extension 20m 75ohm W/ BNC Connectors $83.64

1-60-0191 Timing, Coax Extension 10m 75ohm W/ BNC Connectors $59.16

1-60-0090TX140 Timing, Decoder (1 L) TransX140 SL, RS232 Cable, Headphone $5,457.00

1-60-0090POWER Timing, Power Adapter 110V (US) for decoder 12V Pre-2004 $89.76

1-60-0090POWER2 Timing, Power Adapter 110V (US) decoder 12V Post-2004 LED $119.00

1-60-0090POWER3 Timing, Power Adapter 110V (US) Activator 20m Type Black Pls $95.00

1-60-0090POWER4 Timing, Power Adapter 110V (US) Activator 100m Type $95.00

TICKET PRINTER

Part# Description Price

1-60-0108 Printer, Mini MB Boca (Specify Interface) USB, Parallel $2,999.00

THE TRANSPONDERS ARE VIRTUALLY MAINTENANCE-FREE AND FEATURE A NEW, “NO-RECHARGE” BATTERY, GOOD FOR A MINIMUM OF HALF A MILLION LAPS!

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

AXLE/AXLE COVER/DRIVE SYSTEM COMPONENTS

6-1

Overview .................................................................................... page 6-2

Axle cover ................................................................................... page 6-3

Drive cover .................................................................................page 6-4

Drive belt .................................................................................... page 6-6

Drive hub .................................................................................page 6-11

Drive pulley ..............................................................................page 6-12

Floater hub ..............................................................................page 6-14

Axle bearing overview ............................................................ page 6-16

Bearings ...................................................................................page 6-17

Axle - single drive ....................................................................page 6-19

Axle-two wheel drive ..............................................................page 6-26

Drive sprocket spreadsheet...................................................page 6-27

SINGLE DRIVE AXLE

AXLES

LIVE AXLE (2 wheel drive)

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

6-2

WARNING!

Go-karts have rotating parts.

For your safety, longer hair must be secured above the shoulder and any personal items (clothing, jewelry, etc) must be secured and contained within the seating area.

Serious injury or death could occur!

AXLES

OVERVIEW

Axle cover

Shown without engine for clarity

Axle/drive system cover - to address safety concerns with regards to exposed, rotating parts, J&J has developed an integrated axle cover. This cover may consist of one or more sections designed to reduce rider exposure to rotating parts, while still allowing access for maintenance. The vacuum-formed system is made from high-impact TPO plastic for long life. It is purposely rubber-mounted to the frame to avoid cracking from vibration.

FREQUENT QUESTIONS

Q: CAN I REMOVE THE COVER AND OPERATE THE GO-KARTS?

A: Go-karts should not be operated without the factory-installed guards & covers in place.

Q: CAN I DRILL HOLES OR MAKE CUT OUTS IN THE COVER?

A: No; holes and/or gaps where hair, drawstrings, clothing, etc, could enter are to be avoided.

QUEUE LINE WARNING TO BE PROMINENTLY DISPLAYED SO GUESTS ARE AWARE OF POTENTIAL HAZARDS.

It is strongly urged that go kart operators adopt the “graphic” warning advising guests of the

potential hazards and dangers of long hair, loose clothing and the proximity to rotating machin-

ery. Guest with hair longer than shoulder length MUST be secured above shoulder.

Rubber bands, hair pins etc, should be provided for this purpose. Particular attention must be

paid to items of loose clothing such as draw strings that could become entangled in moving

parts. If a guest refuses to comply, they should not be allowed to operate the kart.

USE DECAL #1-60-0288 on each go kart where it is easily read by each patron.



USE DECAL #1-60-0282 in the pit area where it is easily read by each patron.



Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

#1-60-0282

AXLE COVER REMOVAL

6-3

Remove the engine (see page 8-1).

Remove the axle cover shoulder bolts.

Pull

AXLES

ALWAYS MAKE SURE ALL SAFETY RELATED DECALS ARE LEGIBLE. REPLACE IF NECESSARY. WARNING DECAL (TO PREVENT INJURY OR DEATH) # 1-60-0388

Remove the wheel and fender.

Lift the rear of the axle cover and pull the cover away from both the center and wheel clips. Remover the axle cover.

Lift

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

6-4

DRIVE COVER REMOVAL

AXLES

Remove the drive wheel.

Remove the lower wing support bolts.

Wing support

Move the wing support up and tighten the upper wing support bolt to hold it out of the way.

GREAT PRODUCT FOR SMALLER FLEETS!

Requires just 4 to 15 strokes to create a powerful vacuum. The integrated container (6.5

liters) then neatly captures the oil, preventing messy spills. The calibrated walls allow

easy measurement of the oil extracted. A built-in ﬂ oat switch automatically stops extrac-

tion as soon as capacity is reached. A pour spout facilitates emptying. The Big PELA is a

durable, maintenance-free unit. It is ideal for professional use.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

#5958434, Hand operated oil extractor

Drive cover

6-5

Remove the drive cover Allen bolts.

Pull the drive cover rubber ﬂ ap away from engine.

Pull

AXLES

Pull the drive cover from the front support clip.

POWER BLEEDER FEATURES:

 Single person operation.  Quick and clean, forward bleeding. It’s the same

way we do it here at the factory.

 Male 1 5/8” adaptor cap included, ﬁ ts FPX master

cylinder.

 Optional catch bottle is available. Part# 3-96-0033  Optional Wilwood rectangle adaptor. Part# 3-96-

0035

#3-96-0032

BRAKE TOOLS (POWER BLEEDER)

Part# Description Price

3-96-0032 Tool, Brake Bleeder Power (Includes 1 5/8 Male Cap) $84.99

3-96-0034 Tool, Brake Bleeder Power Cap Assy Only 1 5/8” Male $43.99

3-96-0036 Tool, Brake Bleeder Power Cap Only 45mm threaded round $30.25

3-96-0035 Tool, Brake Bleeder Power Cap Only Wilwood Adapter Rectangle $43.25

3-96-0033 Tool, Brake Bleeder Power Catch Bottle $15.99

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

6-6

AXLES

Twist the drive cover down and away from the engine.

Remove the drive cover.

DRIVE BELT REPLACEMENT

GX270 Long Block

NOTE: Before engine can be moved or removed, the

grabber plate must be loosened (see page 8-3).

Using a 9/16” oﬀ set-ratcheting box wrench, loosen the engine-mount lock-down bolts.

ENGINE LONG BLOCKS

Part# Description Price

1-61-0001LONG Longblock, GX160 Complete (See Notes) $459.00

1-61-0005LONG Longblock, GX200 Complete (See Notes) $459.00

1-61-0007LONG Longblock, GX270 Complete (See Notes) $599.00

LONG BLOCK COMPLETE, ASSEMBLED

Includes: Barrel, piston, rings, crank, rod, cover comp, governor kit, seals, crankcase

Cover, camshaft, valves, valve cover, valve cover gasket, exhaust studs, rods,

Breather tube, carburetor studs, spark plug & hardware.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

6-7

Use a 9/16” oﬀ set-ratcheting-box wrench and loosen the engine-mount lock-down bolts. Use a 3/4” socket and turn the belt adjuster bolt clockwise until the engine is all the way forward and the drive belt is loose.

NOTE:

Before the engine can be moved, the grabber plate must be loosened (see page 8-3).

Remove the drive belt.

NOTE: Do not use a crowbar to pry the belt. It should

slip oﬀ .

STANDARD BELT TENSIONING PROCEDURE

Adjust the drive belt tension by turning the motor adjusting bolt clockwise (to loosen belt tension) and counterclockwise (to tighten belt tension) by using a 3/4” socket with an extension.

Adjusting bolt

NOTE:

Make sure the drive belt is tensioned to prevent jumping of the teeth under the most severe load conditions that the drive belt will encounter during operation.

Tighten the engine-mount lock-down bolts and make sure the drive belt is properly aligned.

STANDARD BELT ALIGNMENT PROCEDURE

A straight edge can be used to aid in belt alignment during reassembly. Place a straight edge along the axle pulley and hold the straight edge ﬁ rmly against both sides of the pulley. The straight edge should line up just inside the ﬂ ange of the engine pulley.

AXLES

ENDURANCE CLUTCH PLATES

COOL-TEK ENDURANCE CLUTCH PLATES, LAST LONGER AND COST LESS THAN OEM!

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

COOL-TEK ENDURANCE CLUTCH

Part# Description Price

1-00-K0001CT Clutch Kit, GX/G240-270 CoolTek Complete $92.45

1-00-K0002CT Clutch Kit, GX/G160-200 CoolTek Complete $87.95

The greatest enemy of any clutch material is heat, with sludge and foreign material a

close second. To combat these wear elements, FPX sought out the latest in high tech

material and coupled this with a cooler-running, segmented design, resulting in a

truly revolutionary product.

6-8

CHAIN DRIVE REMOVAL

AXLES

CABLE CARE

Part# Description Price

00122 Cable Lubricator Luber $20.74

3-60-0029 Cable Life (Lube Only) $11.99

KEEP YOUR THROTTLE CABLES OPERATING SMOOTHLY WITH CABLE LIFE LUBRICANT!

#00121

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

#00122

DRIVE CHAIN/SPROCKET REPLACEMENT

6-9

Loosen the engine mount and slide the engine all the way forward (procedure is the same as the drive belt; (see page 6-7.)

Remove the drive chain.

Install the drive chain on the top and bottom pulley.

Turn the axle to guide the drive chain onto the sprocket.

HD 520 X-RING CHAIN

FPX 520 drive system chain is

the new choice for concession

go karts, where a combination of

long life, high strength, and excel-

lent impact load resistance are

very important.

AXLES

The tension adjustment procedure is the same as for the cog belt. 1/2” of deﬂ ection (up or down) is the correct tension.

CHAIN DRIVE COMPONENTS

Part# Description Price

1-20-0093 Chain Loop, 520 RK XSO-Ring (52 links) Endless - Rivet $40.00

1-20-0099 Chain Loop, 520 RK XSO-Ring (54 links) Endless - Rivet $44.00

1-20-0094 Chain Loop, 520 RK XSO-Ring (56 links) Endless - Rivet $55.07

Close up view of 520 X-ring chain

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

6-10

AXLES

If adjustment is needed, use a 1/4” Allen wrench and loosen the two 5/16” x 1-1/2” Allen bolts on the drive hub.

Remove the six nuts with a 1/4” ratchet 7/16” short socket on the back side of lower sprocket assy.

Remove the drive chain sprocket.

Electric Lift, #3-60-0043

These small electric or

manual lifts are perfect for

maintaining small equipment.

 Lawn mowers.  Track blasters.  And more.

#1032, Electric lift

SHOP LIFTS

Part# Description Price

1031 Lift, Assy Air Operated 24” x 80” $1,590.00

1032 Lift, Assy Electric Operated 24” x 80” $1,725.00

3-60-0043 Lift, Multi-Lift(Electric) $1,222.98

#1031, Air-operated lift

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

DRIVE HUB

6-11

Remove the drive wheel.

Use a 1-1/8” socket and remove the drive-hub axle nut and lock washer.

Use 1-1/4” open end wrench to prevent axle from turning.

Loosen the two set screws.

Remove the drive hub from the axle. If you need a puller, use J&J #1-60-A1000.

The axle should be straight and free of burrs. Apply a dab of anti-seize to the axle (coat the area where the hub will cover), then slide the drive hub onto the axle. Install axle lock washer/nut and torque to 50 ft.lbs. Apply one drop of Loctite Blue to each set screw and install them into the drive hub; torque to 12 ft.lbs.

AXLES

REMOVE HUBS THE EASY WAY WITH THE J&J HUB PULLER

#1-60-A1000

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6-12

DRIVE PULLEY REMOVAL

AXLES

Remove the drive wheel/tire (see page 1-29). Remove the drive belt or chain (see page 6-78). Using a 1/4” Allen wrench, loosen the two 5/16” x 1-1/2” Allen bolts on the drive hub.

Insert a ﬂ at-tip screwdriver into the drive hub pulley slot and lightly tap it in. This will loosen the drive hub and allow for easy removal.

In some cases, it may be necessary to carefully use a propane torch to heat the hub to aid removal.

WARNING Always use proper safety clothing and

techniques when using open-ﬂ ame torches. Follow the manufacturer’s guidelines for safe operation. Keep ﬂ ames away from fuel sources and combustible materials.

Use a dead blow or rubber mallet to remove the drive hub pulley.

NOTE: Rotate the drive hub pulley a 1/4 turn

between taps of the mallet.

WE CARRY REPLACEMENT DRIVE BELTS. MOST MAKES AND MODELS. CALL US FOR DETAILS.

The 2 most common sizes: 8m-800-36 #1-20-0077 8m-896-36 #1-20-0078

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

DRIVE BELTS)

Part# Description Price

1-20-0077 Belt, Drive 8M-800-36 GTC $78.85

1-20-0078 Belt, Drive 8M-896-36 GTC $79.05

6-13

Remove the drive hub pulley from the axle.

Before installing the drive hub, inspect the key stock and the drive hub keyway. If the drive hub keyway or the key stock show any signs of damage, the drive hub and/or the key stock must be replaced.

Install the drive hub in the reverse order of removal.

Before tightening the two Allen bolts, the drive hub will need to be aligned with the engine driven pulley. Loosen the 8 bolts holding the sprocket to ensure proper clamping to the axle.

A straight edge can be used to aid in belt alignment during reassembly. Place a straight edge along the bottom pulley and hold it ﬁ rmly against two sides of the pulley. The top pulley should line up just inside the ﬂ ange edge.

AXLES

RPM/SPEED GAUGES

SOME OF THE FEATURES OF THE VORTEX PRO:

 Simple - The display will automatically “wake up” and show the current speed once the wheel is turning: no on/oﬀ

buttons to worry about. Checking the max speed, average speed, and other stored items is simple and easy: there is

almost nothing to learn.

 Rugged - The Vortex is drop-proof and intended for use in a demanding environment.  Accurate - The Vortex is accurate to within 0.5 mph (0.8 kph) from 2 to 60 mph (3 to 100 kph).  Inexpensive - The Vortex is priced for maximum value: quality, hand-made parts and elegant design at a very attractive price.

phone: 1-800-854-3140 | 1-503-304-8899 fax: 1-800-366-7505 | 1-503-304-1899 www.jjamusements.com

Part# Description Price

1-60-0206 Gauge, MPH Go-Kart (Vortex) 0-60 mph $179.00

6-14

FLOATER HUB REMOVAL

AXLES

Use a 1-1/4” open end wrench on the axle keyway. This will keep the axle from turning.

Use 1-1/4” open-end wrench to prevent the axle from turning.

Using a 1-1/16” socket, remove the ﬂ oater hub nut and recessed washer.

Axle

Floater Hub

Spacer

Bearing

Recessed washer

Axle Nut

NOTE:

The special, recessed washer is cut out on one side; this recess always goes toward, and contacts, the bearing inner race. This allows the entire ﬂ oater hub to be tightened through the bearing races and inner spacer, and against the axle shoulder to allow the hub to spin freely (thus the name “tight race” design). Remove the ﬂ oater hub assembly.

Speciﬁ cations and prices subject to change without notice. Download latest update to this manual on-line.

J&J Amusements KING SCORPION, SIDEKICK, SIDEWINDER DOUBLE, F-22 DOUBLE, DOUBLE EAGLE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual