J&J Amusements Bumper Boat 2014, ELECTRIC-POWERED BLASTER BOAT, GAS-POWERED WATER BUG Service Manual

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Service Manual

Bumper Boat 2014

Published by J&J Amusements, Inc.

A Corporation of Oregon

Amusements, Inc.

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

Technical Contact Information

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

www.jjamusements.com Phone: 503-304-8899 Toll Free Phone: 800-854-3140

Fax: 503-304-1899

Toll Free Fax: 800-366-7505

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.

WARNING - Important Safety Notice

Proper service and repai r pr ocedu res are v i tal t o sa f e , reliable operation of J&J bumper boa ts, as w e ll as to the personal safety of those performing the repairs. This manual outlines procedures for servicing and repairing J&J bumper boats using safe, effective methods. The procedures contain many NOTE S, CAUTIONS and WARNINGS which should be followed (along with standard safety procedures) to eliminate the possibility of personal injury or improper service, which could damage the bumper boat or compromise its safety.

It is important to note that repair procedures, techniques, tools and parts for servicing J&J bumper boats, 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 bumper boats may be serviced, or to provide cautions to all possible hazards that may result. Standard precautions should be used when handling toxic or flammable fluids, and safety goggles or other protection shou ld be used durin g cutting, grind ing, chi se ling, prying or any other process that can cause material removal or pro j ectil es. J &J recom mends the use of sa fety goggles or appro v ed gl asses du ri ng a l l servic i ng o f J &J b umper boats.

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 m ay be reproduced, copied, transmitted, diss eminated, downloaded or stored in any storage medium, for any purpose, without prior written cons ent of J&J Amusements, Inc. A Corporation of Oregon. J&J Amusements, Inc. grants p ermission 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 find information that is preceded by a NOTICE symbol. The purpose of this message is to prevent damage to the bumper boat, 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 in form ati on th roug hout th is m an ua l . Of course , it i s not pra ctica l or poss i bl e to w arn y ou abou t all the hazards associated with servicing a bumper boat. You must use your own good judgement. You will find 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

To eliminate unnecessary work, careful reading of the applicable section is recommended before starting to service a bumper boat. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Ne vertheless , ev en a deta iled accou nt h as limitations; a certain amou n t of bas i c kno w l edge i s a l so requ i red for successful work.

ESPECIALLY NOTE THE FOLLOWING:

DIRT

Before removal and disassembly, clean the bumper boat. 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 filings.

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 fit. Then tighten them evenly in a cross pattern. This will avoid distortion of the part. Conversely, when loosening the bolts, nuts or screws, loosen by a quarter turn, and then remove. 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 se ems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap ligh tly u s i ng a w ooden or pl asti c-faced mallet. Use an impa ct driv er fo r screws (pa rticu l a rl y for the remo v a l of screw s hel d by a locki n g agent) in order t o avoid damagi n g the sc rew heads. It ma y also be necessary to apply heat to some parts that are held with 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 lifting the motor/engine, or when turning it over.

HIGH-FLASH-POINT SOLVENT

A high-flash-point solvent is recommended to reduce fire 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 service. The mating surfaces around the new gasket should be free of foreign matter and perfectly smooth.

LIQUID GASKET, NON-PERMANENT LOCKING AGENT

Foll ow manufacturer’ s directions f or clean ing and prepar ing surfaces where these compoun ds will be u sed. Apply sparin gly , 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 first be coated with oil on its outer or inner circumference so that it will go into place smoothly.

OIL SEAL AND GREASE SEAL

Repla c e a ny oil or grease seals tha t w ere remo ved with new parts, sinc e remo v al generally damages seals. When pressing in a seal con ta i ning ma n ufacturer’ s ma r ks, pres s it in with the marks facing out. Seals should be pressed into place u s ing 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 remo ved circlips and retaining rings with new ones, as removal weak en s 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 change, deterioration, or seizure.

SPECIFICATIONS

Specification terms are defined as follows:

“Standards”: show dimensions or performances which brand-new parts 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.

0-7 Specifications 0-9 Monthly maintenance chart 0-13 Pre-opening daily checklist 0-17 Bumper boat area checklist 0-18 Printable work order tags 0-19 How a warranty is processed 0-20 Product return procedures 0-21 Limited warranty-bumper boat

0-22 Limited warranty-super tube II 0-23 Unpacking & setup 0-25 Tube setup 0-26 Boat assembly 0-27 Battery installation 0-31 Boat launch procedure 0-32 Motor installation

1 2 3

Boat Top Assembly

Boat Hull Lower Assembly

Motor Assembly (Electric-powered)

Basic Electrical Troubleshooting

1-2 Breaker/main cutoff switch 1-5 Volt meter 1-7 Bilge pump 1-8 Pivot receiver 1-10 Safety & dock rail hooks 1-12 Dock rail rope installation

2-1 General boat hull assembly 2-2 Main power post 2-4 Boat half protector 2-6 Bilge pump 2-11 Ba t tery- f ull kit

3-1 General information 3-2 Motor cover 3-4 Control rods/grips/handle bar 3-8 Flex wire 3-11 Motor 3-19 Magnetic trigger 3-21 Motor relay

4-1 General information 4-2 Basic electrical troubleshooting 4-4 Voltage drop test 4-6 Testing fuse 4-7 Major electrical components 4-13 Specific gravity test

1-18 Trim 1-21 Vent plate 1-23 Reinforced rubber hinge 1-27 Battery charging cable 1-30 Battery-fill quick-release coupler 1-31 Motor power supply cable

2-13 Super tube 2-14 Super tube inflation 2-16 Checking super tube for leaks 2-17 Patching super tube 2-19 Super tube valve replacement

3-25 Solid State Switch 3-27 Boat captain 3-29 Pivot 3-33 Lower unit assembly 3-37 Squirt pump Assembly 3-42 SB-120 terninal

4-15 Equalizing batteries 4-16 Battery maintenance - winter 4-17 Master charger 4-18 Wiring schematic 4-19 Motor wiring schematic 4-20 Boat Captain Wiring Schematic

Engine assembly (Gas-powered)

Decals

Care & Storage

5-1 General information 5-2 Handle bar

6-1 General information 6-2 Motor cover decals

7-1 General information 7-2 Fiberglass care & maintenance

5-3 Pivot 5-4 Prop guard

6-3 Boat top decals 6-5 Decal removal/installation

7-4 303 Aerospace protectant 7-6 Storage

0-6

NOTES:

SPECIFICATIONS: ELECTRIC-POWERED

BLASTER BOAT.

0-7

DIMENSIONS:

Overall diameter .......................................................................................................................................72”(182 cm)

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

Wet weight .............................................................................................................................................488lbs(222kg)

Total battery weight ................................................................................................................................248lbs(113kg)

Super Tube II weight...................................................................................................................................23lbs(11kg)

Hull & deck weight ..................................................................................................................................139lbs(63kg)

Minimum water depth ....................................................................................................................................3ft(.91m)

MOTOR:

Model.....................................................................................................................................................24v 1750 rpm

Type ......................................................................................Continuous duty 3/4 hp(1118w) 24v, permanent magnet

Motor weight ..............................................................................................................................................78lbs(36kg)

Cooling system ........................................................................................................................................................ Air

Maximum horsepower.......................................................................................................................3/4 hp(1750 rpm)

Maximum speed ..............................................................................................................................3.5 mph(4.8 km/h)

Throttle........................................................................................................................Green rod / push button (on/off)

Squirt.............................................................................................................................Blue rod / push button (on/off)

Squirter Type .......................................................................................................................................24v submersible

BATTERY:

Type ...................................................................................................................................6 volt deep cycle (225 AH)

Weight ....................................................................................................................................................62 lbs (28 kg)

Length .................................................................................................................................................10 3/8(264 mm)

LOWER UNIT:

Gear ratio ................................................................................................................................................................1:1

Propeller......................................................................................................................3-7.2 x 4.7 in(3-184 x 120 mm)

Rotating direction ............................................................................................................Clockwise (viewed from rear)

0-8

SPECIFICATIONS: GAS-POWERED

WATER BUG.

DIMENSIONS:

Overall diameter .......................................................................................................................................72”(182 cm)

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

Wet weight ...............................................................................................................................................194lbs(88kg)

Super Tube II weight...................................................................................................................................23lbs(11kg)

Hull & deck weight ..................................................................................................................................139lbs(63kg)

Minimum water depth ....................................................................................................................................3ft(.91m)

ENGINE:

Model..............................................................................................................................J&J equipped Honda BF2.3D

Type ............................................................................................................. 4-stroke, overhead valve, single cylinder

Engine weight.......................................................................................................................................................32.0

lbs (14.6kg)

Cooling system ............................................................................................................................................. Forced air

Starting system ....................................................................................................................................................Recoil

Lubrication system..............................................................................................................................................Splash

Fuel capacity ........................................................................................................................................1.16 US qt (1L)

LOWER UNIT:

Gear ratio ...................................................................................................................................................2.42(29/12)

Gear case oil capacity ................................................................................................................................. 0.05 US qt

Propeller......................................................................................................................3-7.2 x 4.7 in(3-184 x 120 mm)

Rotating direction ............................................................................................................Clockwise (viewed from rear)

MONTHLY SERVICE SCHEDULE (Electric)

0-9

Item # Item Service type

Check Frequency

Log hours of operation to determine proper maintenance intervals.

Check Daily

1 SB-120 Plug(s)

2 Motor

3 Batteries

4 Pivot (1)

6 Sump pump (1) Clean strainer

7 Propeller guard

8 Hull

10 Anode

11 Squirter

Motor & charger power cables

General wires & connections

Replace When damaged Grease terminals (2) Check condition Check wires Check water level Weekly Check electrolyte level Clean connections Check Daily Grease (3) Check for damage Clean and grease terminals (2) Replace When damaged

Inspect Replace When damaged Inspect & clean Safety decals Polish Check for damage Clean connections Replace When necessary Spay corrosion protectant Clean Replace When damaged Replace filter When needed Check for damage Check hose & fitting

Clean & grease terminals

1st

20 hrs



Every

50 hrs

Monthly or every

200 hrs



12 Tubes

(1) Service more frequently when used in dusty areas. (2) Use dielectric grease only. (3) Use marine grease only.

NOTE: This is a sample form. Your checklist should include but not be limited to these items. Make extra copies for future use.

Clean Check pressure Weekly Check visually Daily



0-10

MONTHLY SERVICE SCHEDULE (Electric)

Below are explanations of service listed in the monthly maintenance charts on previous page. Explanations of monthly maintenance shall include, but are not limited to the following:

1. SB-120 PLUG(S):

2. MOTOR: Remove hood and check connections. Spray motor and wiring with corrosion block (J&J #99101).

3. BATTERIES: Check for corrosion, and spray terminals with battery protectant (J&J #99101). Fill batteries with distilled

water weekly, or as needed. Make sure compartment is ventilated.

‹ DANGER › : ***READ BATTERY SAFETY PRECAUTIONS BEFORE HANDLING BATTERIES***

4. PIVOT: Turn motor and check for smooth operation. If motor doesn’t turn easily, visually inspect pivot and grease if

necessary. Electric motor can turn 270°. Motor stops must be in place and in working order.

5. MOTOR /CHARGER POWER CABLES: Disconnect and grease terminals. Look for signs of wear (Replace as needed).

6. SUMP PUMP: Clean strainer as needed. Check pump operation. If pump is not cycled periodically, check all wiring connections. Repair or replace pump as needed.

7. PROPELLER GUARD: Inspect for damage or foreign materials. Replace if damaged.

‹ SAFETY ITEM › ***WARNING: DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING***

8. HULL: Keep clean and wax every 200 hours or every 2 months. Use a UV protectant weekly to reduce color fading

(J&J part # 3-60-0034).

9. GENERAL WIRES & CONNECTIONS: Check all wires and connections for damage and corrosion. Clean or replace as needed.

Make sure that the plug is lubed with dielectric grease. Inspect the plug for deep grooving or signs of arcing.

10. ANODE: Clean monthly. For year-round parks, replace anode every 6 months. For seasonal parks, replace anode at end of the season.

11. SQUIRTER: Replace filter if necessary. Check integrity of hose, mount and pump. Check pump inlet for obstructions. Replace as needed.

12. TUBE: Clean with mild detergent. Check condition of tube daily. Check tube pressure weekly using low pressure gauge (J&J #3-96-0024) and set pressure to 2-3 PSI.

NOTE: ALL NECESSARY REPAIRS NEED TO BE DONE BEFORE BOAT IS OPERATED. USE J&J AMUSEMENTS

OR EQUIVALENT REPLACEMENT PARTS. INSPECTIONS SHOULD BE DONE BY TRAINED AND QUALIFIED PERSONNEL.

MONTHLY SERVICE SCHEDULE (Gas)

0-11

Item # Item Service type

Check Frequency

Log hours of operation to determine proper maintenance intervals.

1 Engine(*)

2 Gear case(*)

3 Spark plug(*)

4 Valve clearance(*) Check-adjust 5 Idle speed(*) Check-adjust 6 Carburetor linkage(*) Check-adjust 7 Fuel tank & tank filter(*) Clean

8 Fuel line(*)

9 Starter rope(*) Check

10 Propeller guard

11 Hull

12 Anode

13 Pivot(1)

Check level Daily Change oil Check level Change oil Check-adjust Replace

Check Replace When needed

Inspect Replace When damaged Inspect & clean Safety decals Polish Clean Replace When damaged Check Daily Grease (3)

Clean

1st

20 hrs





Every

50 hrs



Every

150 hrs



Monthly or

every

200 hrs



14 Tubes

(1) Service more frequently when used in dusty areas. (*) See Honda Shop Manual

Check pressure Weekly Check visually Daily

NOTE: This is a sample form. Your checklist should include but not be limited to these items. Make extra copies for future use.

0-12

MONTHLY SERVICE SCHEDULE (Gas)

Below are explanations of service listed in the monthly maintenance charts on previous page. Explanations of monthly maintenance shall include, but are not limited to the following:

1. ENGINE:

Manual.

2. GEAR CASE: Always use API service SG.SF/CC.CD. designation shown on the container; see “Engine Oil” in the Honda Shop

Manual.

3. SPARK PLUG: Clean and replace spark plugs with the type listed in the Honda Shop Manual.

4. VALVE CLEARANCE: Check and adjust at the specified intervals; see the Honda Shop Manual.

5. IDLE SPEED: Check and adjust at the specified intervals; see the Honda Shop Manual.

6. CARBURETOR LINKAGE: Check and adjust at the specified intervals; see the Honda Shop Manual.

7. FUEL TANK & TANK FILTER: Check and replace at the specified intervals; see the Honda Shop Manual.

8. FUEL LINE: Check and replace at the specified intervals; see the Honda Shop Manual.

9. STARTER ROPE: Check and replace at the specified intervals; see the Honda Shop Manual.

10. PROPELLER GUARD: Inspect for damage or foreign materials. Replace if damaged. ‹ SAFETY ITEM › ***WARNING: DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING***

11. HULL: Keep clean and wax every 200 hours or every 2 months. Use a UV protectant weekly to reduce color fading

(J&J part # 3-60-0034).

Always use API service SG.SF/CC.CD. designation shown on the container; see “Engine Oil” in the Honda Shop

12. ANODE: Clean monthly. For year-round parks, replace anode every 6 months. For seasonal parks, replace anode

at end of the season.

13. PIVOT: Turn motor and check for smooth operation. If motor doesn’t turn easily, visually inspect pivot and grease if necessary. Electric motor can turn 270°. Motor stops must be in place and in working order.

14. TUBE: Clean with mild detergent. Check condition of tube daily. Check tube pressure weekly using low pressure gauge (J&J #3-96-0024) and set pressure to 2-3 PSI.

NOTE: EQUIVALENT REPLACEMENT PARTS. INSPECTIONS SHOULD BE DONE BY TRAINED AND QUALIFIED PERSONNEL.

ALL NECESSARY REPAIRS NEED TO BE DONE BEFORE BOAT IS OPERATED. USE J&J AMUSEMENTS OR

Week of / /

Pre-Opening Daily Checklist (Electric)

Bumper boat ID#

Attendant must initial each

empty box every day. If any-

Body color

Item Service type Mon Tues Wed Thu Fri Sat Sun

BOAT

Tube - Check pressure

Hull - Visually inspect

Receiver - Visually inspect

thing is not OK, see a supervi-

sor.

0-13

Handrails & hardware - Visually inspect

Sump pump - Visually inspect

Batteries - Visually inspect volt meter

MOTOR

Motor -Physically inspect

Motor & charger cables - Visually inspect

Pivot -Physically inspect

Prop guard - Visually inspect

**See explanation of check procedure**

**Download extra copies of this and other check list on our web site at www.jjamusements.com**

0-14

Pre-Opening Checklist - Explanation (Electric)

Below are explanations of service listed in the Pre-Opening Checklist chart on previous page. Explanations of Pre-Opening Checklist shall include, but are not limited to the following:

BOATS: TUBE - Check air pressure using a high-quality, low-pressure gauge. Super Tube should be inflated to 2-3 PSI. HULL - Check for cracks and missing hardware.

RECEIVER - Check for loosening or missing hardware, and cracking around mount. HANDRAILS & HARDWARE - Check for loosening and missing hardware. SUMP PUMP - View through hull vent to check for excessive water. BATTERIES - Check volt meter for full charge of 24-26 volts. Viewing through hull vent, check battery terminals for vis-

ible corrosion.

MOTOR: MOTOR - Visually and physically check motor operation, “go” and “squirt” function, loose hardware, grips, handlebar

condition and abnormal noises during operation.

MOTOR POWER CABLE - Check for bare wires, proper connection, and any signs of excessive heat or melting. ‹ WARNING › ***DO NOT OPERATE UNTIL DAMAGED CONNECTORS AND/ OR CABLE ARE REPLACED***

PIVOT - Check for smooth operation by rotating motor lock to lock. PROP GUARD - Check for damage and foreign material.

‹ WARNING › ***DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING***

NOTICE: OR EQUIVALENT REPLACEMENT PARTS IS RECOMMENDED. INSPECTIONS SHOULD BE DONE BY QUALIFIED PERSONNEL.

ALL NECESSARY REPAIRS NEED TO BE DONE BEFORE BOAT IS OPERATED. USE OF J&J AMUSEMENTS

Pre-Opening Daily Checklist (Gas)

Bumper boat ID#

Attendant must initial each

empty box every day. If any-

Body color

Item Service type Mon Tues Wed Thu Fri Sat Sun

BOAT

Tube - Check pressure.

Hull - Visually inspect.

Receiver - Visually inspect.

thing is not OK, see a supervi-

sor.

0-15

Handrails & hardware - Visually inspect.

Water in hull - Drain if needed.

ENGINE

Engine & gear case - Check oil Level.

Throttle - Check operation.

Fuel system - Visually inspect.

Pivot -Physically inspect.

Prop guard - Visually inspect.

0-16

Pre-Opening Checklist - Explanation (Gas)

Below are explanations of service listed in the Pre-Opening Checklist chart on previous page. Explanations of Pre-Opening Checklist shall include, but are not limited to the following:

BOATS: TUBE - Check air pressure using a high-quality, low-pressure gauge. Super Tube should be inflated to 2-3 PSI. HULL - Check for cracks and missing hardware.

RECEIVER - Check for loosening or missing hardware, and cracking around mount. HANDRAILS & HARDWARE - Check for loosening and missing hardware. WATER IN HULL - Drain if excessive water is present inside hull.

ENGINE: ENGINE & GEAR CASE - Visually and physically check engine operation, grips, handlebar condition and abnormal

noises during operation.

THROTTLE: Check for smooth operation and full return when released. FUEL SYSTEM: Check for any signs of fuel leaks from the tank, cap, fuel filter, etc. If no leakage, top off fuel tank. PIVOT - Check for smooth operation by rotating motor. PROP GUARD - Check for damage and foreign material.

‹ WARNING › ***DO NOT OPERATE IF PROPELLER GUARD IS DAMAGED OR MISSING***

NOTICE: OR EQUIVALENT REPLACEMENT PARTS IS RECOMMENDED. INSPECTIONS SHOULD BE DONE BY QUALIFIED PERSONNEL.

ALL NECESSARY REPAIRS NEED TO BE DONE BEFORE BOAT IS OPERATED. USE OF J&J AMUSEMENTS

Week of / /

Bumper Boat Area Checklist

Attendant must initial each

empty box every day. If any-

thing is not OK, see a supervi-

sor.

Item Service type Mon Tues Wed Thu Fri Sat Sun

POND

0-17

Boat rope & hooks

-Check for broken hooks and unsafe ropes.

Dock Rail

Pond Water

-Check for cracks or loose

hardware.

-Check chemical condition

and clarity.

FILTRATION

Pump

-Follow manufacturer’s recommendation.

SAFETY

Equipment - Visually inspect

Signage - Visually inspect

Fencing - Visually inspect

Dock area - Visually inspect

**Download extra copies of this and other checklists on our website at www.jjamusements.com**

0-18

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, file with other service and maintenance information.

Description of Work Performed:

MAINTENANCE

WORK ORDER

GO-KART # BUMPERBOAT #

Explanation of problem:

Parts Used:

Employee Name:

Front Back

Date/Time: Mechanic: Manager:

0-19

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 returned goods package. Goods may be refused if no RMA# is present.)

2. Replacement goods are shipped AND 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 difference.

3. The customer returns the warantied 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.

0-20

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

BE ADVISED THAT RMA’S ARE 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#.

0-21

LIMITED WARRANTY - BUMPER BOAT

This warranty is limited to J&J Amusements, Inc. products, parts and accessories when distributed by J&J Amusements, Inc., 4897 Indian School Road NE, Suite 150, Salem, Oregon 97305-1126 USA, hereinafter referred to as (J&J).

Products Covered By This Warranty: Length Of Warranty:

Bumper Boat hull (excluding Honda motors) 1 year** Bumper Boat tubes (textured) 90 days** Bumper Boat tubes (super tube II) 5 year prorated Parts and accessories 90 days** Honda BF2A gas powered motor 1 year - by Honda Marine* Electric motor 1 year Battery charger 1 year - by manufacturer* Battery By manufacturer **See specific exclusions

To qualify for this warranty:

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

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

3. You must provide proof of original purchase.

What J&J Amusements, Inc. will repair or replace under warranty:

J&J will repair or replace, at their option, any product, accessory or replacement parts that are proven to be defective in material or workmanship, under normal use, during the applicable warranty time period. Anything replaced under warranty becomes the property of J&J. All parts replaced under warranty will be considered as part of the original product and any warranty of those parts will expire concurrent with the original product warranty. Accessories and replacement parts, installed 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 Authorization (RMA) number from J&J, (phone number 800-854-3140 or 503- 304-8899). Return the accessory, product or part and proof of purchase, at your expense, to J&J. If the accessories, products or parts are returned to J&J without both an RMA and proof of purchase, J&J may void the warranty at its discretion.

Exclusions:

This warranty does not extend to products, accessories or parts affected or damaged by accident and/or collision, normal wear, fuel contamination, or those not sold by J&J. It also does not extend to those items used in applications for which the product was not designed, any other misuse, neglect, incorporation or use of unsuitable attachments or parts, nor any unauthorized alteration, improper installation, or any causes other than defects in material or workmanship of the product. J&J reserves the right, before having any obligations under this limited 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 and Canada (contact us for warranty questions regarding your country).

*Honda motor warranty is only covered by American Honda Motor Co., Inc. *Electric battery charger is only covered by manufacturer.

**Specific exclusions:

Normal wear and tear items, such as: throttle cables, spark plugs, fuel filers, hand grips, throttle levers,over-inflated tubes, tube wear from rough pool walls, shear pins, pivot bushings, starter rope, switches, relays and brush or communicator wear. Appearance-related damage, including but not limited to; scratches, nicks, dents, fading paint/trim and corrosion. A Magnehelic Low Pressure Gauge (part#013510) or equivalent must be used for consideration of Bumper boat tube warranty. (The customer must also use maintenance logs provided from J&J . Items will not be

covered by warranty if you cannot provide these records).

Disclaimer of consequential damage and limitation of implied warranties:

J&J disclaims any responsibility for any consequential damages of any kind or nature, including but not limited to; loss of time or loss of use of the product, or transportation, commercial loss or any other incidental or consequential damage arising out of any theory of recovery, including warranty, contract, statutory or tort. Notwithstanding the term of any limited warranty or any warranty implied by law (or in the event that any limited warranty fails its essential purpose) in no event will J&J’s entire liability exceed the 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, expressed or implied, including all warranties of merchantability and/or fitness for a particular purpose. To the extent that any implied warranties may nonetheless exist by operation of law, any such warranties are limited to the duration of this warranty. Some states/provinces do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

Any legal action arising from claims against this warranty shall be governed by and construed in accordance with the laws of Oregon, and the exclusive forum for disputes arising out of or relating to this warranty shall be the Marion County Circuit Court for the State 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 further agrees that in the event of litigation, such party shall, at its own expense, provide discovery and appear for depositions in Marion County, Oregon. Not available in all states or regions. Contact J&J for information on your area.

0-22

LIMITED WARRANTY - SUPER TUBE II

Super tube II 1st year full replacement (prorate charge will increase by twenty percent

for each subsequent year of the prorated period. Charge will be based on original purchase price).

To qualify for this warranty:

The product or replacement part must have been purchased from J&J. You must be the first retail purchaser. This warranty is not transferable to subsequent owners and you must provide proof of original purchase.

What J&J will repair or replace under warranty:

J&J will repair or replace, at their option, any Super Tube 2 that is proven to be defective in material or workmanship, under normal use, during the applicable warranty time period. Anything replaced under warranty becomes the property of J&J. All parts replaced under warranty will be considered as part of the original product and any warranty of those parts will expire concurrent with the original product warranty.

To obtain warranty service:

You must obtain a Return Merchandise Authorization (RMA) number from J&J. (phone number 800-854-3140 or 503-304-8899). Return the accessory, product or part and proof of purchase, at your expense, to J&J. If the accessories, products or parts are returned to J&J without both an RMA # and proof of purchase, J&J may void the warranty at its discretion.

Exclusions:

This warranty does not extend to products, accessories or parts affected, or damaged by, accident and/or collision, normal wear, fuel contamination, or over-inflation, nor does it extend to those tubes not sold by J&J, used in applications for which the product was not designed, or any other misuse, neglect, incorporation or use of unsuitable attachments or parts, unauthorized alteration, improper installation, or any causes other than defects in material or workmanship of the product. J&J reserves the right, before having any obligations under this limited 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 and Canada.

Products Covered By This Warranty: Length Of Warranty:

Disclaimer of consequential damage and limitation of implied warranties:

J&J DISCLAIMS ANY RESPONSIBILITY FOR ANY CONSEQUENTIAL DAMAGES OF ANY KIND OR NATURE, INCLUDING, BUT NOT LIMITED TO; LOSS OF TIME OR USE OF THE PRODUCT, TRANSPORTATION, COMMERCIAL LOSS, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGE ARISING OUT OF ANY THEORY OF RECOVERY, INCLUDING WARRANTY, CONTRACT, STATUTORY OR TORT. NOTWITHSTANDING THE TERM OF ANY LIMITED WARRANTY OR ANY WARRANTY IMPLIED BY LAW. (OR IN THE EVENT THAT ANY LIMITED WARRANTY FAILS ITS ESSENTIAL PURPOSE), IN NO EVENT WILL J&J’S ENTIRE LIABILITY EXCEED THE PURCHASE PRICE OF THE PARTICULAR GOOD SOLD. SOME ST A TES/PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENT AL 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, EXPRESS OR IMPLIED, INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE. TO THE EXTENT THAT ANY IMPLIED WARRANTIES MAY NONETHELESS EXIST BY OPERATION OF LAW, ANY SUCH WARRANTIES ARE LIMITED TO THE DURATION OF THIS WARRANTY. SOME STATES/PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

Any legal action arising from claims against this warranty shall be governed by and construed in accordance with the laws of Oregon, and the exclusive forum for disputes arising out of, or relating to, this warranty shall be the Marion County Circuit Court for the State 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 further agrees that in the event of litigation such party shall, at its own expense, provide discovery and appear for depositions in Marion County, Oregon. Not available in all states or regions. Contact J&J for information on your area.

UNPACKING & SETUP

0-23

General Information ..................................................1-19

Unpacking.................................................................1-20

Tube Setup ................................................................1-21

Boat Assembly ...........................................................1-22

Battery Installation (electric only)...............................1-23

Battery Fill Kit Installation (electric only)....................1-24

Battery Wiring (electric only) .....................................1-25

Boat Launch Procedure .............................................1-27

Motor Installation.............................................................

1-28

Your new J&J bumper boat is shipped in a heavy-duty cardboard box. This section of the Service Manual describes the process to get your new bumper boat(s) unpacked and ready for service.

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0-24

UNPACKING

Cut and remove the metal packing straps.

Remove the box top and place it aside for later use.

Remove the box sides and discard. Remove the tube and

place it aside with the box top.

Remove plastic wrap from the boat hull and discard. Leave

the boat hull on the cardboard base for protection from

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!

scratches.

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Protect your boat from harmful ULTRA-VIOLET rays and keep it looking like new with 303 Aerospace Protectant!

TUBE SETUP

0-25

Carefully unfold the tube and lay it flat on the boat box top.

Note: Boat hulls are normally packaged with their correctly

color-coordinated tube.

Fill the tube with a Super Tube fill adapter

(#00367) as shown in figures 1 & 2, a Super Tube pressure

test adapter/filler (#2-60-A0006) as shown in figures 3 & 4,

or a vacuum/blower (J&J #2-60-0124) as shown in figure 5.

Carefully inflate the tube to the recommended 3 PSI.

Always use a low-pressure gauge, such as J&J #3-96-0024,

to accurately measure tube pressure.

NOTICE: TUBES SHOULD BE FILLED COLD AS AIR PRES-

SURE CHANGES WHEN HOT.

Fig. 1

Fig. 3

Fig. 2

Fig. 4

(See Super Tube Inflation on page 2-14).

Fig. 5

After inflating, make sure the valve is closed by pushing the

valve in and turning it clockwise.

Check the valve for leaks by applying a solution of soapy

water.

If bubbles form, the valve needs to be tightened.

With the tube inflated, insert Super Tube valve tightening tool

(J&J #2-60-0123).

Turn nut 1/8th turn.

Recheck with soapy water solution.

Repeat as needed until no bubbles form.

Inflate and deflate boat tubes quickly with this 4hp vacuum/blower! J&J# 2-60-0124

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0-26

BOAT ASSEMBLY

Lift the hull assembly and carefully place it inside the tube.

‹ CAUTION › The hull is heavy. Use two people when lifting

the hull assembly.

Make sure to grab the lip of the boat bottom when lifting the

assembly.

USE WORK GLOVES TO PROTECT HANDS FROM FIBER-

GLASS EDGES.

Rotate the boat hull inside of the tube so the air valve on the

tube is located at the back of the hull. This allows simple maintenance to be performed from one direction on the bumper boat, as well as reducing the risks posed by guests access-

SUPERTUBE PRESSURE TEST ADAPTER AND FILLER

This adapter makes it easy to fill your supertube and check pressure. J&J # 2-60-A0006

ing the valve.

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BATTERY INSTALLATION (Electric only)

Open the boat top and use the wooden prop rod to hold the

‹ CAUTION › Place the wooden prop rod so it does not be-

come dislodged while holding the boat top in “up” position.

• Remove items provided inside boat:

• Wooden prop rod (qty 1)

• Battery cables (qty 3)

• Battery fill kit (qty 1)

• Wiring schematic (qty 1)

• Battery fill kit instructions

‹ CAUTION › Proper lifting procedures must be followed.

Carefully place batteries in the battery trays located inside

NOTICE J&J recommends using a battery carrier

(J&J #2-60-0034) when installing/moving heavy batteries.

0-27

top up.

the bottom hull.

Fig. 1

Battery 1

Battery 2

Batteries should be placed in such a position as to allow

ease of wiring. Place the batteries with terminals as shown

in Figure 1. Place battery #1 in the hull first, followed by

battery #4, #2, and finally, #3. This sequence helps keep the

boat balanced during battery installation.

Battery 4

Battery 3

SAFELY REMOVE, LIFT, AND adjust HEAVY BATTERIES WITH THIS BATTERY CARRIER, j&j # 2-60-0034

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0-28

BATTERY FILL KIT INSTALLATION (Electric only)

Remove the caps from the batteries and place aside for later

use.

‹ WARNING › Wear protective (rubberized) gloves when

handling batteries. Avoid contact with battery acid.

Remove the manifold valves from the hose T-fittings.

T-fitting

Manifold Valve

Remove kinks

Loosely install the manifold valves into the batteries.

Make sure the manifold valves are flush with the batteries

before tightening.

Push the hose T-fittings into the manifolds.

Use equal pressure until the fittings snap into place.

NOTICE

Be careful not to damage the T-fitting o-ring.

TECH TIP: Wet the T-Fitting with distilled water to help it

slip into the manifold more easily.

NOTICE

Twist the manifolds slightly to remove any kinks in the water

lines. All kinks must be removed for the watering system to

function correctly.

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visit www.jjamusements.com and download a copy of our complete accessory catalog!

Install the filler tube from the boat hull to the fill system.

Push and slightly twist the hose to install.

BATTERY WIRING (Electric only)

See the battery wiring diagram on page 4-18.

Battery 1

Positive Bat 1

Battery 2

Negative Bat 3

Battery 1

Battery 2

Battery 3

Battery 4

Negative Bat 3

Install a cable from the positive post of battery #1 to the

Install a cable from the positive post of battery #2 to the

0-29

NOTICE

Locate battery #1.

negative post of battery #2.

negative post of battery #3.

Battery 4

Battery 1

Battery 2

Negative Bat 4

Battery 3

Positive Bat 4

BATTERY FILL KIT

Save time topping off the water in your batteries with the complete battery fill kit. Easy installation that saves time when performing routine battery maintenance. J&J #2-70-0034

Install a cable from the positive post of battery #3 to the

negative post of battery #4.

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0-30

Battery 1

Install the “RED” cable from the breaker to the positive post

of battery #4.

Battery 4

Battery 2

Battery 1

Battery 2

Battery 3

Install the “BLACK” cable from the negative main power

post to the negative post of battery #1.

Battery 3

Carefully remove the wooden prop rod, place inside the

hull, and lower the boat top until it’s fully closed.

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Check the volt meter display.

If the meter is not displaying 24 volts, check the breaker.

If the breaker is “on”, then the battery wiring will need to be

rechecked.

BOAT LAUNCH PROCEDURE

Install the boat & dock rail hooks as described in the dock

Carefully move the boat to the edge of the pond.

Make sure to move the boat with the box lid underneath it to

‹ CAUTION › This is a two-person job. Do not try to launch a

0-31

rope installation on page 1-12.

NOTICE

prevent damage.

bumper boat with only one person.

Carefully slide the boat assembly (without the motor) into the

pond.

Inspect the boat and latch the boat hooks to the dock rails.

Latch the dock ropes to the dock rails and the boat to secure

the boat to the dock rails. There should be two ropes and two

dock rails per boat.

CHECK TUBE PRESSURE EASILY & ACCURATELY WITH THE LOW-PRESSURE GAUGE #3-96-0024

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0-32

MOTOR INSTALLATION

Have a helper carefully pass the motor assembly to the

person in the boat.

GAS ENGINE

Check the engine and gear box oil level before installing.

“Refer to the Honda owner’s manual “

Position the lower unit of the motor so the prop guard will

clear the motor pivot. Carefully lower the motor through

the hole. Align the motor to the motor pivot and slide

down into place. There is an index hole and pin that need

to be aligned for proper positioning.

Index point

NOTE: For electric powered boats only.

Treat all SB120 plug terminals with corrosion block (J&J

part #99109).

Connect the blue SB120 plug from the boat hull into the

blue SB120 plug on the motor.

NOTICE

Boats equipped with remote shut down (Boat Captain sys-

tem) will need the system to be activated from the transmit-

ter before the boat

can operate.

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CORROSION SOLUTION! CORROSION BLOCK PRODUCTS AVAILABLE AT J&J.

0-33

WARNING DECALS (TYPICAL LOCATIONS)

Go-karts are terribly unforgiving of carelessness or neglet. To help avoid incidents and accidents, it is imperative that warning decals are legible and in place.

The following outlines the typical locations of particular warning decals on bodied and non-bodied go-karts, as installed at the time of manufacture. Inspect and replace them as needed; see the maintenance and daily checklist schedules located in section 0 of this manual.

WARNING

Keep Hands And

Feet In Boat

At All T imes.

DO NOT REMOVE THIS DECAL

00169

weight limit

Never Stand Up

While Boat

is Operating.

00170 00170S - Spanish

WARNING

DO NOT REMOVE THIS DECAL

S Q U

G O

00971010097102

450 lbs.

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0-34

001688

2-40-0001

www.jjamusements.com

009800

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001686

001681

00156

BOAT TOP ASSEMBLY

1-1

General boat top information ......................................1-1

Breaker/main cutoff switch (electric only) ...................1-2

Volt meter (electric only) .............................................1-5

Bilge pump fuse (electric only) ....................................1-7

Pivot receiver ..............................................................1-8

Safety & dock rail hooks ............................................1-10

Dock rope installation ...............................................1-12

Trim ..........................................................................1-18

Vent plate (electric only)............................................1-21

Reinforced rubber hinge (electric only) ......................1-23

Battery charging cable (electric only) .........................1-27

Battery-fill quick-release coupler (electric only) .........1-30

Motor power supply cable .........................................1-31

This section of the Service Manual describes the various components of the boat top assembly, how to diagnose problems, and the removal and replacement of parts associated with the boat top.

NOTE: The top and hull assembly for the gas bumper boat is permanently attached. Some if the information in this section will not apply.

1-2

BREAKER/MAIN CUTOFF SWITCH (Electric only)

General Information ....................................................1-2

Removal/Replacement .................................................1-3

The safety switch/breaker is a marine-grade unit that combines switching and circuit protection into a single device, which meets SAE J1171 requirements for marine application. All power out to the boat is routed through here, as well as all incoming power from the charging device and wire leads. NOTICE: If there is high resistance in the system, heat and possible fire can occur without tripping the breaker; this is why the switch/breaker is located in an easily-accessible position on the outside of the hull.

The charge line and charger feed current through the SB-120 connector, breaker and main buss to the battery pack. Keep in mind that even when disconnected, the charge line has current available at the SB-120 connector from the battery pack.

<CAUTION> Do not short across these terminals or allow the connector to hang into the water.

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BREAKER SWITCH (Electric only)

When breaker is in the off position, there will be no reading

displayed on volt meter, (The volt meter will display 0 volts)

Disconnect the (-) negative cable from battery #1.

1-3

NOTICE:

All power goes through breaker.

and the batteries cannot be charged.

REMOVAL/INSTALLATION.

Battery 1

Battery 2

Disconnect negative

Battery 3

Battery 4

Disconnect positive

Disconnect the (+) positive cable leading to the breaker from

battery #4.

Disconnect the (+) positive cable leading to the breaker from

the power post.

Note:

Your J&J Blaster Boat may be equipped with one of two types of power

posts.

The Pre-2012 version utilizes two rounded-style posts;

one for the positive feed and one for the negative feed.

Blaster Boats built during the 2012 model year changed to a single,

rectangular-style post that contains both the negative and positive feeds.

Power post, pre -2012 Power post, post-2012

2 unit fiberglass CHARGER ENCLOSURES. part # 2-80-A00062.

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1-4

Hold the inside nylock nut during the next step.

Remove the bolts.

Carefully remove the breaker.

NOTICE:

Inspect wires and connections for corrosion/ damage.

Clean off any corrosion from cable ends, and

apply corrosion block on the cable ends before re-installing.

Replace as needed.

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VISIT WWW.JJAMUSEMENTS.COM/TECHNICAL/INDEX.HTM FOR TECHNICAL INFORMATION RELATED TO OUR PRODUCTS.

VOLT METER (Electric only)

General Information ....................................................1-5

Removal/Installation ....................................................1-6

1-5

The built-in volt meter constantly monitors the overall condition of the battery pack. When in “charge mode” the typical volt meter reading will be approximately 27.6 VDC. The table below indicates load readings, showing the representative system condition of the batteries.

The volt meter is a sealed unit and therefore not serviceable. If the unit shows zero voltage, the systems breaker switch may be in the “OFF” position, the meter is inoperative, or the batteries’ charge is very low.

Limit discharging the batteries beyond 1.75 volts per cell (1.125 specific gravity per cell). 1.75 volts per cell corresponds to end-point voltages of 5.25 volts for 6-volt batteries (readings obtained at 80 degrees F).

State of Open Circuit Voltage 6 Volt Battery Charge Level (4) Battery Pack

6.30 or greater 100% 25.2

6.16 - 6.30 75% - 100% 24.64 - 25.20

6.00 - 6.16 50% - 75% 24.00 - 24.64

5.90 - 6.00 25% - 50% 23.60 - 24.00

5.80 - 5.9 0% - 25% 23.20 - 23.60

5.80 or less 0% 23.20

1-6

VOLT METER (Electric only)

The volt meter is located on the back of the boat top, to the

Remove the two nuts that hold the bracket to the boat top.

Remove the volt meter from the outside of the boat top.

left of the vent plate.

REMOVAL/INSTALLATION.

(See the wiring diagram for volt meter connections on page

4-18).

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BILGE PUMP FUSE (Electric only)

The bilge pump fuse is located on the back of the boat top to

With a flat screwdriver, push and turn counterclockwise 1/4

Remove the fuse and holder by pulling outward.

1-7

REMOVAL/INSTALLATION

the left of the vent plate.

turn.

Remove the fuse from the holder.

Check for continuity through the fuse with a multimeter

(see page 4-6 for a fuse test).

NOTE: The replaceable fuse is a 3-amp time-delay/slow-blow

cartridge-style fuse. Using any fuse type other than this specifi-

cation could result in poor performance and/or pump failure.

Replace as needed.

REPLACEMENT 3 AMP FUSES, J&J # 2-70-0104

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1-8

PIVOT RECEIVER

General Information ....................................................1-8

Pivot Receiver Removal/Installation .............................1-9

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PIVOT RECEIVER REMOVE/INSTALLATION

The pivot is attached with 8 bolts and nylock nuts, and 16 flat

REMOVAL/INSTALLATION

Remove the bolts, nylock nuts and washers.

Install a new pivot by using the existing holes.

Replace the hardware with new hardware as needed.

1-9

washers.

ID PLATE:

Remove the ID plate from the old pivot.

Install the ID plate to the new pivot with 4 stainless steel

rivets.

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1-10

SAFETY RAILS & DOCK RAIL HOOKS

General Information ..................................................1-10

Safety Rails & Dock Rail Hooks ................................1-11

Dock Rail Rope Installation .......................................1-12

Dock rails are now fully stainless steel with blue powder coat.

J&J Dockrails are made from stainless steel and powder coated for ultra protection.

We have dockrails available for both concrete or wood docks.

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SAFETY RAILS & DOCK RAIL HOOKS

The safety rails are mounted with 6 phillips head bolts, 6

Hold each screw from the outside of the boat top.

Remove the nylock nuts and flat washers.

1-11

nylock nuts and

6 flat washers.

REMOVAL/INSTALLATION

BOAT HOOKS & ROPE

Replace the hardware as needed.

Each dock rail hook is mounted with 1 U-bolt, 1 outside

plate,

1 inside plate, 4 nylock nuts and 4 lock washers.

REMOVAL/INSTALLATION

Remove the nylock nuts and the inside plate.

Replace the hardware as needed.

Each boat should have two Boat Hooks and 3 to 5 feet of bumper boat rope. (Note: Bumper boat rope is determined by how far dockrails are spaced from edge of pool.)

REPLACEMENT BOAT HOOKS AND ROPE AVAILABLE. ROPE BY THE FOOT - #00388

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BOAT HOOK(HEAVY DUTY STYLE) - #00036

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1-12

DOCK RAIL ROPE INSTALLATION

The length of rope needed varies depending on dock rail

After cutting the rope, lightly singe and melt one end of the

rope; form a point using a folded piece of cardboard (match-

book cover, for example), and cover the end to form the point

while insulating your fingers from the heat.

Insert a fid through the rope about 10 inches from the end.

placement and water level.

TECH TIP:

Fid

Next, insert the rope through the eye of the boat hook.

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STAINLESS STEEL DOCK RAILS available WITH BLUE POWDER COAT. J&J # 00716SS CALL FOR FITMENT INFORMATION.

1-13

To make the loop, insert the rope through the end of the fid

and the thread the fid through the rope.

Pull the rope, making a small loop at the hook.

Insert the fid at the first rope thread under the loop.

Thread the fid back through each side of the loop.

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1-14

Pass the fid down through the hollow core of the rope just

below the loop.

Run the fid down the hollow center of the rope for approxi-

mately six inches.

Bring the fid out through the stitching.

Tuck any excess back inside the hollow core of the rope.

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1-15

With the other end of the rope, repeat the previous steps,

without the boat hook, to permanently attach the rope to

the dock rails.

Insert the rope through the eye of the dock rail.

Insert the fid through the rope about 10 inches down.

Insert the rope through the end of the fid and thread the fid

through the rope.

Pull the rope, making a small loop at the dock rail.

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1-16

Thread the fid back through each side of the loop.

Pass the fid down the hollow core of the rope just below the

loop.

Run the fid through the penetrated rope and continue down

the hollow center for approximately six inches.

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1-17

Bring the fid out through the stitching.

Tuck the excess back inside the hollow core of the rope.

The dock rail rope should have about 2 inches of slack when

attached to the boat so the hooks can be easily connected.

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1-18

TRIM

General Information ..................................................1-18

Trim Installation/Removal ..........................................1-19

The boat trim serves to protect the tube and your hands from the exposed fiberglass edge on the bottom of the boat top.

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TRIM INSTALLATION/REMOVAL

The boat trim is mounted with 9 stainless steel rivets

To remove the old trim, first drill out the rivets and

Make sure to remove any trim adhesive and thor-

oughly clean off the surface of the fiberglass before

Line up the trim with the center of the vent plate.

Carefully wrap the trim around the boat top, pull-

ing the tape backing off in 2 inch sections at a

1-19

and double-sided tape.

REMOVAL

pull the trim off of the fiberglass.

installing the new boat trim.

INSTALLATION

Heat trim before installing. Peel off 2”of tape backing.

time.

Cut off any excess trim.

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1-20

Drill through the outside of the trim by matching the

existing rivet holes.

Insert rivets through the trim.

503-304-8899

Install a backing washer on the inside of each of the

rivets.

Install the rivets to boat top.

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VENT PLATE (Electric only)

General Information ..................................................1-21

Vent Plate Assembly ..................................................1-22

1-21

Vent Plate

The vent plate is a multi-purpose access port into the boat hull. It acts as a vent for the hull and also allows easy access to the charge cable.

1-22

VENT PLATE ASSEMBLY (Electric only)

The vent plate is located at the rear of the boat top.

Open the vent plate to access the charging cable,

and to perform visual inspections.

Vent Plate

To open, turn counterclockwise.

503-304-8899

The vent plate assembly is mounted with six 10-32

phillips-head screws with six 10-32 nylock nuts.

To replace the vent plate assembly, remove the six

screws.

Inspect the gasket for damage and replace as

needed.

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Protect your boat from harmful ULTRA VIOLET rays and keep it looking like new with 303 Aerospace Protectant!

REINFORCED RUBBER HINGE (Electric only)

General Information ..................................................1-23

Reinforced Rubber Hinge ..........................................1-24

1-23

The reinforced rubber hinge connects the boat top to the hull.

1-24

REINFORCED RUBBER HINGE (Electric only)

REMOVAL/INSTALLATION

Disconnect wiring from the boat hull to the boat top

(see wiring diagram on page 4-18).

Close the boat top.

From the rear, drill out the six rivets from the hull.

503-304-8899

Remove the top from the hull.

Place the top upright on a soft surface.

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mini golf and batting cage supplies

1-25

Drill out the rivets and remove the rubber hinge.

Insert five 3/16”x 3/4” aluminum rivets (J&J#002473)

through the bracket and rubber hinge.

Install the rivets through the backing plate of the

rubber hinge and the boat top.

J&J carries all locktite brand threadlocker and other sealants.

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1-26

Place the boat top on the hull.

Open the vent plate to access the rubber hinge.

Pre-drill through the rubber hinge.

Insert six rivets through the hull and rubber hinge.

Insert a backing washer on inside of each rivet.

503-304-8899

Holding the backing plate, insert the rivets.

Connect all wiring connections

(see wiring diagram on page 4-18).

ENDURANCE CLUTCH PLATES

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BATTERY CHARGING CABLE (Electric only)

General Information ..................................................1-27

Battery Charging Cable ..............................................1-28

1-27

The battery charging cable is approximately 15’ long and is located inside the boat. It is easily accessed through the vent plate access cover located on the back of the boat top.

1-28

BATTERY CHARGING CABLE (Electric only)

The battery charging cable is approximately 15’

long and is located inside the boat. The charging

cable feeds out through the removable vent cover,

guided by the eye bolt. A clamp-on cable stop pre-

vents over-extension of the cable.

Charging cable

eye bolt guide

REMOVING BATTERY CHARGER CABLE

Unscrew the vent plate hole cover.

Access the cable through the vent plate hole.

Vent plate hole

Note:

Cable length approximately 15 ft.

Disconnect the charger cable wiring from the main

post

(see wiring diagram Page 4-18).

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worn out cables? we’ve got the replacements you need to get up and running quickly.

Remove the ground wire from the battery to avoid

electrical shock.

Charging cable

1-29

Pull the charging cable out through the inside of the

boat top.

Loosen the rubber cable stop.

Remove the cable stop from the cable.

Pull

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J&J #2-70-0073-120

Pull the cable out through the vent plate hole.

ENDURANCE CLUTCH PLATES

Close the boat top.

503-304-8899

1-30

BATTERY-FILL QUICK-RELEASE COUPLER

The battery filling system allows easy top-off of the battery water level from the outside of the boat. Simply attach the battery fill squeeze bulb (J&J#2-70-A0021C) to the access port on the back of the boat top to fill all the batteries to equal levels.

Hold the quick-release coupler from outside so it doesn’t

spin while loosening the inside nut.

Loosen the hose clamp.

Remove the hose from the coupler.

Loosen and remove the plastic nut.

STRAIN RELIEF

This combination strain relief and plug end protector has an easy to grab hand hold for connecting and disconnecting SB-120 charger plugs from your bumperboats. No more broken plug ends from charger leads being dropped on the ground.

Remove the coupler from the outside of the boat top.

(J&J #2-70-0108)

2-70-0211

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1-31

MOTOR POWER SUPPLY CABLE (Electric only)

General Information ..................................................1-31

Motor Power Supply Cable ........................................1-32

J&J # 2-70-A0011

1-32

MOTOR POWER SUPPLY CABLE (Electric only)

REMOVAL/INSTALLATION

Disconnect wiring at the main post

(see wiring diagram page 4-18).

<<CAUTION>>

Remove the ground wire from the battery to avoid electrical

shock.

Loosen the plastic cable clamp.

Slide the cable through the loosened plastic “Adel”-style

clamp.

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THE RIGHT TOOL FOR THE JOB: HexCrimp jr terminal crimping tool. J&J #2-70-0073-120

1-33

Carefully loosen the nut from the plastic strain relief elbow.

Remove the nut by sliding it to the cable end.

Figure 1

Remove the cable through the boat top.

(Note the location of the elbow for installation. See Figure 1.)

Orientation

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1-34

REV 3/27/2012

Bumper Boat Motor

Work Bench Mount

800-854-3140 / 503-304-8899

www.FunPartsXpress.com

A Division of J&J Amusements, Inc.

A Receiver mounted to your work bench will make servicing your fleet of bumper boat motors SAFER and QUICKER. There’s no better way to hold your motors steady while servicing.

Maximize efficiency in your shop; add two or three receivers to your work bench today.

Receiver, Socket Type Part# 50011

BOAT HULL - LOWER ASSEMBLY

2-1

General boat hull assembly .........................................2-1

Main power post (electric only) ...................................2-2

Boat half protector (electric only).................................2-4

Bilge pump (electric only) .........................................2.6

Battery-full kit (electric only) .....................................2-11

Super tube .................................................................2-13

This section of the Service Manual describes the various components of the boat hull assembly, how to diagnose problems and the removal and replacement of parts associated with the boat hull.

NOTE: The top and hull assembly for the gas bumper boat is permanently attached. Super tube information only applies in this section.

2-2

MAIN POWER POST (Electric only)

General information ....................................................2-2

Positive & negative main power post ...........................2-3

Power post, pre-2012 Power post, post-2012

Your J&J Blaster Boat may be equipped with one of two types of power posts. The pre-2012 version utilizes two rounded posts; one for the positive feed and one for the negative feed. Blaster Boats built during the 2012 model year changed to a single, rectangular post that contains both the negative and positive feeds.

MAIN POWER POST (Electric only)

(FOR BOATS MANUFACTURED BETWEEN 2008-

The positive and negative main posts are located at

Before removing wires, disconnect the main ground

wire from the negative power post.

Disconnect the negative cable from the battery.

Remove all wiring to the main power post that is be-

(See wiring diagram on page 4-18.)

2-3

2011)

the rear of boat hull.

REMOVAL:

ing replaced.

Remove the mounting screws.

Remove the power post.

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2-4

BOAT HALF PROTECTOR (Electric only)

General information ....................................................2-4

Boat half protector .......................................................2-5

The boat half protector acts as a seal for the motor cavity in the hull, preventing any water from entering the hull.

BOAT HALF PROTECTOR (Electric only)

Unscrew the clamps and remove the protector.

Carefully remove and clean any silicone from the

Install the protector and tighten the clamps securely.

2-5

boat hull.

Apply silicone between the boat hull and protector.

(For best results, use J&J #013331.)

Let the silicone cure before putting the boat back in

Silicone

Curing time varies depending on outside tempera-

ture and amount of silicone used

(see silicone instructions for details).

MARINE GOOP ADHESIVE #013331; the PERFECT SOLUTION TO ATTACH BOAT HALF PROTECTOR.

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service.

Note:

503-304-8899

2-6

BILGE PUMP (Electric only)

General information ....................................................2-6

Diagnosing problems...................................................2-7

Bilge pump assembly removal .....................................2-8

The bilge pump and fuse circuit feeds directly from the power distribution post/buss. The main power feeds via the red wire to the accessible fuse holder outside (located on the back of the boat top), then through the green/brown wire to the pump.

The bilge pump is a 24VDC sealed, brushless, automatically-activated unit. The self-contained, solid-state electronics energize the pump motor on a pulse method; if the amp draw is above a preset threshold, it indicates that water is present and the pump will continue operation until the amp draw drops, indicating that no water is present. Note: If the inlet is sufficiently blocked, no water will enter the inlet and the pump will not sense amp draw, so it will shut off, even though water continues to accumulate in the hull. It is imperative that the daily inspection includes removing the vent plate and, using a flashlight, inspecting to see if water is building up in the hull. A bilge pump fuse, which is accessible for service from the outside of the hull near the vent plate, is located in the power feed line from the main buss.

NOTE: The replaceable fuse is a 3-amp time-delay/slow-blow cartridge-style fuse. Using any fuse type other than this specification could result in poor performance and/or pump failure.

2-7

DIAGNOSING PROBLEMS (Electric only)

Most bilge pump problems are mechanical; ie: plugged screen, blocked impellor or foreign material causing impellor drag.

PROBLEM: Pump does not work, and daily inspection shows standing water in the hull. Solution: Remove water from the hull. Use a pump and discharge hose from spare parts and clip the leads to the battery pack. The new pump will have 3 leads. (The brown wire is normal “intermittent” operation, the brown/yellow wire is “pump on” constantly). With the discharge hose exiting to the pond, clip the brown/yellow wire to the positive post of the battery pack, then clip the black wire (ground) to the negative post of the battery pack. Tip: Replace/ re-charge batteries prior to testing. If the battery pack is discharged, pull up another boat with a charged system and pull the charge lead out. Use this as your power source to evacuate the water from the inoperative unit. Remove the bilge pump from the holder clips, and clean the screen and back flush the intake with a water hose. Inspect the wires for corrosion and/or damage. (You cannot test voltage drop unless current is flowing in the circuit). Replace the pump using the brown wire as the main power feed. This provides the proper “amp load” for function of the pump.

PROBLEM: Pump runs constantly. This is caused most often by a load/drag against the impellor, tricking the system into pumping all the time. Small amounts of foreign material can cause this. In some cases, a worn impellor shaft can cause excess drag. Clean/replace as needed.

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2-8

BILGE PUMP ASSEMBLY REMOVAL (Electric only)

Disconnect wiring from the main post

(see the wiring diagram for bilge pump connections on page

4-18).

Squeeze the (blue) mounting tabs located on each side of the

pump.

Remove the pump from its mount.

The screen is located between the pump and the mount.

NOTICE

Clean the screen before installing the bilge pump.

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ADD ANOTHER SOURCE OF REVENUE TO YOUR BUMPER BOAT POND. THE COIN OPERATED POND SIDE SQUIRTER. J&J #2-60-A0008

2-9

Remove the two 10-24 nylock nuts.

NOTICE:

Replacement of the pump mount and screen is needed only if

damaged.

Remove the bilge pump mount from the hull.

To disconnect the output hose, remove/loosen the plastic

hose clamp.

Pull and slightly twist the hose to remove it from the pump.

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2-10

Remove/loosen the plastic hose clamp.

Pull and slightly twist the hose to remove it from the fitting.

To remove the hose fitting, carefully hold the inside plastic

nut.

Remove the outside plastic nut.

Remove the fitting from the inside of the hull.

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KEEPING YOUR BUMPER BOAT POOL CLEAN & PERFECT HAS NEVER BEEN SO EASY.

BATTERY-FILL KIT (Electric only)

General information ..................................................2-11

Battery-Full kit installation .........................................2-12

2-11

2-12

BATTERY-FILL KIT INSTALLATION (Electric only)

Remove the caps from the batteries and place aside for later

use.

Remove the manifold valves from the hose T-fittings.

T-fitting

Manifold Valve

Remove kinks

Loosely install the manifold valves into the batteries.

Make sure the manifold valves are flush with the battery be-

fore tightening.

Push the hose T-fittings into the manifolds.

Use equal pressure until the fittings snap into place.

NOTICE Be careful not to damage the T-fitting o-ring.

TECH TIP: Wet the T-Fitting with distilled water to help it slip

more easily into the manifold.

NOTICE Twist the manifolds slightly to remove any kinks in

the water lines. All kinks must be removed for the watering

system to function correctly.

Install the filler tube from the boat hull to fill the system.

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Push and slightly twist the hose to install.

SUPER TUBE

2-13

General information ..................................................2-13

Super tube inflation ...................................................2-14

Checking super tube for leaks ....................................2-16

Patching super tube ...................................................2-17

The Super Tube II is built with a urethane-coated fabric.

2-14

SUPER TUBE INFLATION

FILL ADAPTER

Insert a fill adaptor and turn clockwise 1/2 turn.

Use a rubber-tip blow gun to fill the tube.

VALVE FILL ADAPTER

Insert a valve fill adaptor and turn clockwise 1/2 turn.

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Supertube fill adapter & pressure Test adapter & filler

2-60-A0006 00367

2-15

Use a tire inflator to fill the tube.

VACUUM/BLOWER INFLATOR

Open the tube valve and cover it with an inflator hose.

Turn the blower on to fill.

Inflate the tube to the recommended 3 PSI.

Check it with a low-pressure gauge.

Before returning the boat to service, check the valve for

leaks by applying a solution of soapy water.

If bubbles form, valve needs to be tightened.

With the tube inflated, insert the valve tighter and turn the

nut 1/8th turn.

Re-check with the soapy water solution. Repeat as needed

until no bubbles form.

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2-16

CHECKING SUPER TUBE FOR LEAKS

Place three to four drops of washing detergent in a

Check small areas of the tube at a time, spraying the

surface of the tube and looking for any bubbles.

Fully inflate the tube.

spray bottle with water.

503-304-8899

Draw a small circle around any punctures or rips

in the tube (for easy location of the repair), then

deflate tube.

NOTICE:

The glue and patch will bubble up and fail to bond

properly if the tube is fully inflated when the repair

is made.

Do not attempt to patch around or near a tube

seam, as the patch will not bond.

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SUPERTUBE PATCH KIT #003370

PATCHING SUPER TUBE

2-17

Completely clean the surface of the tube to be

patched before applying glue.

Remove any 303 or other silicone/petroleum-based

product from the tube surface.

Follow the gluing instructions closely.

Use or cut a vinyl patch from the repair kit making

sure it is large enough to cover the damaged area

with at least 1 to 2 inches of extra vinyl on all sides.

Round off any corners.

(Patch kit: J&J #003371, 003370).

(Recommended vinyl cement: J&J #2-60-0072)

Apply an even coat of cement to both of the surfaces

to be joined, and let it dry only 2-5 minutes.

VINYL CEMENT #2-60-0072

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2-18

Place the patch over the damaged tube surface and

use roller or old spoon to squeeze any air out of

the patch, pressing the material together.

Wait at least 24 to 48 hours before reinflating the

tube.

Pressure test the tube by inflating it and checking

the patch with soapy water.

If desired, leave the tube inflated overnight and

recheck it before putting it back into service.

NOTICE: When patching, the relative humidity must be less than 70%, preferably as low as 40%. Temperature

should be 64°C to 77°C ( 147.2°F. to 170.6°F.).

Bond strength drops very rapidly with heat or high

humidity. Don’t patch the tube near water or in

direct sunlight.

J&J Supertube II on electric powered Blaster boat

J&J’s Supertube is a great eye pleaser for your boat pond. The Supertube is constructed of a UV resistant Urethane material. The Supertube’s material allows for easy storage, it can be folded and boxed up and then re-inflated in the spring. Patching this tube is easy with J&J’s tube patch kit. Unprecedented guarantee on seam breakage for 3 years. Individual panels can be replaced at the factory. And best of all, the

Supertube only weighs 12 pounds!

003370, Supertube repair kit 2-60-0072, 4OZ glue 003371, Supertube maintenance & repair kit

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SUPER TUBE VALVE REPLACEMENT

Insert a valve removal tool by lining up the prongs on

the tool with the corresponding slots in the valve.

With tube deflated, grasp the female fitting through

Once you have a solid grip, unscrew the valve by

2-19

tube.

turning counterclockwise.

Remove the male portion and install the replacement.

The replacement procedure is same as loosening, only

the valve is turned clockwise.

The valve needs to be hand tightened.

Tool, supertube valve tightener (plastic style) part # 2-60-0123

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2-20

Fill the tube using the Super Tube fill adapter and an

air-filler nozzle.

Inflate the tube to the recommended PSI of 3 lbs.

Before returning the boat to service, check the valve for

leaks by applying a solution of soapy water.

If bubbles form, the valve needs to be tightened.

With the tube inflated, insert the valve tightener and

turn the nut 1/8th turn.

Re-check with soapy water solution. Repeat as needed

until no bubbles form.

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iNFLATE AND DEFLATE BOAT TUBES QUICKLY WITH THIS 4HP VACUUM/BLOWER! J&J# 2-60-0124

Motor Assembly (Electric only)

3-1

General information ....................................................3-1

Motor cover.................................................................3-2

Control rods/grips/handlebars ......................................3-4

Flex wire .....................................................................3-8

Motor ........................................................................3-11

Magnetic trigger ........................................................3-19

Motor relay................................................................3-21

Solid state switch .......................................................3-25

Boat captain ..............................................................3-27

Pivot ..........................................................................3-29

Lower unit assembly ..................................................3-33

Squirt pump assembly ...............................................3-37

SB-120 Terminal replacement ...................................3-42

This section of the Service Manual describes the various components of the electric motor assembly, how to diagnose problems, and the removal and replacement of parts associated with the motor.

TECH TIP: While working on the boat motor, an easy way to make your own motor stand is to mount a pivot receiver (J&J #50011) to a sturdy work bench.

3-2

MOTOR COVER

General Information ....................................................3-2

Motor Cover And Neoprene Protector .........................3-3

3-3

MOTOR COVER AND NEOPRENE PROTECTOR

Remove the four 1/4” screws and washers to remove the mo-

tor cover.

Lift the motor cover to gain access to the squirter hose.

Disconnect the squirter hose by pushing the gray tab on the

quick-release coupler.

Lift

Carefully remove the motor cover.

Remove the neoprene protector by sliding it up the handle-

bars. It will be a little snug as it passes the hand grips.

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3-4

CONTROL RODS/GRIPS/HANDLEBARS

General Information ....................................................3-4

Control Rods ...............................................................3-5

Hand Grips..................................................................3-6

Handlebar Assembly ...................................................3-7

The control rods are color coded, anodized aluminum rods that activate the motor and squirt pump functions. The green rod controls the motor power and the blue rod controls the squirt pump.

CONTROL RODS

Spring

3-5

Each control rod has a spring located between the rod and

the bottom of the tube.

If the rod doesn’t return to the fully raised position, the

spring will need to be replaced.

Unbolt the magnetic trigger to remove the control rod.

Use a magnet to remove the spring.

The countersink hole in the control rod faces the slot on

the handlebar.

Line up the countersink hole on the control rod with the

Install the magnetic trigger and make sure to orient the trigger with the magnet facing down, so the trigger can

Apply anti-seize to the threads on the shoulder bolt.

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slot in the handlebar.

function properly.

NOTICE:

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3-6

HAND GRIPS

REMOVAL

Use a razor blade and cut down the grip.

Peel the grip away from the handlebar.

INSTALLATION

Set a new grip over the handlebar.

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Press the grip to move it down the handlebar.

Tech Tip:

To get the grip completely onto the handlebar, it may be helpful to use a blow gun to create a

cushion of air between the two as you push the grip

down the handlebar.

Hand Grips

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Replacement hand grips and hand grip cement available at J&J

Hand Grip Cement, #2963874

HANDLEBAR ASSEMBLY

3-7

The handlebar assembly has two parts and is mounted

on the motor with four 3/8” hex-head-mount bolts.

(Part # 2-10-0003 handlebar mount plate )

(Part # 2-10-0002 handlebar )

Remove the gear box

(see page 3-33).

Remove the hex-head motor-mount bolts.

After the bolts are removed, slide the plate up the drive

shaft housing.

Note

The drive shaft housing will be loose from the motor.

The handlebar is now free from the motor and can be

removed.

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3-8

FLEX WIRE

General Information ....................................................3-8

Flex Wire Removal/Installation ...................................3-9

Flex Wire

SB-120

Flex Wire

J&J# 2-70-A0038

SB-120

The flex wire consists of a 10/2 gauge wire that feeds power from the main distribution post through the hull to the SB120 connector located at the motor pivot. Simple voltage drop tests can verify the condition of this harness. NOTICE: SHOULD THERE BE ANY PROBLEMS WITH THIS HARNESS, IT IS RECOMMENDED THAT THE ENTIRE

HARNESS BE REPLACED.

The 10/2 gauge wire harness for the flex wire is unique in that it must provide power to the motor and yet allow the motor 320 degrees of rotation. This movement can eventually cause flex wire failure and must be monitored for high resistance and/or breaks in the circuit.

From the motor pivot SB-120 connector, the 10/2 gauge wire uses its OEM shielding and insulation, then transitions to an extreme wear “gorilla” loom that covers the wires where it must coil and uncoil to allow motor rotation. The wires are connected through the plates via brass bolts to feed the motor relay/squirt pump system.

A voltage drop test and/or visual inspection are easily performed here.

FLEX WIRE

3-9

Remove the SB-120 connector from the bracket.

Remove the cable clamps from the pivot cover.

Remove the pivot assembly.

(see page 3-29).

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3-10

Lift and rotate the UHMW disk up over the steering stop. This

will help with further disassembly.

Remove the flex cable from the UHMW disk.

Bushing

Remove the wire from the handlebar assembly.

Inspect all fiber washers and bushings, as they act as an insu-

lator for the flex wires. If they look compressed, heat dam-

aged, or show signs of material loss, replace them.

Bushing

Fiber washer

12 13

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MOTOR

General Information ..................................................3-11

Motor Disassembly ....................................................3-12

3-11

The high-efficiency, brush-type, permanent magnet motor seldom has problems.

MOST COMMON PROBLEMS: Symptom: The motor will not turn when the actuating rod is in the “ON” position. Most common cause: The motor circuit is open. Measure the voltage going into the motor from the main motor posi-

tive post (white wire), and measure the voltage going out of the motor (black wire). If voltage is present at the white wire, but not at the black wire, then the circuit inside the motor is open. Worn brushes are a common cause of this symptom.

Solutions: Remove and inspect the brushes, replacing with new brushes and springs as needed. Symptom: The motor turns very slowly, and the connections get hot.

Most common cause: The motor is drawing too many amps and may cause the 50 amp safety/breaker to trip. Normally

this is caused by mechanical issues with the drive system and/or motor bearings, resultant armature drag, etc. Solutions: Check the propeller for foreign objects wrapped up in the shaft/propeller. Check the gear box for wear or seized shafts, bearings, etc. Replace as needed.

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3-12

MOTOR DISASSEMBLY

Remove the motor cover and neoprene protector

(see page 3-3).

Remove the magnetic triggers

(see page 3-25).

Disconnect wiring connections at the power post

(see wiring diagram on page 4-18).

Remove the relay

(see page 3-21).

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Add another fun feature to your bumper boat pond and generate more revenue! Pondside squirter #2-60-a0008

J&J Amusements Bumper Boat 2014, ELECTRIC-POWERED BLASTER BOAT, GAS-POWERED WATER BUG Service Manual

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