Related Manuals for J&J Amusements Falcon Go-kart 2018
Summary of Contents for J&J Amusements Falcon Go-kart 2018
- Page 1 Service Manual Falcon Go-kart (2018) Specifi cations subject to change without notice. Published by J&J Amusements, Inc. An Oregon Corporation © 2018 J&J Amusements Inc. - All Rights Reserved 2018...
- Page 2 Amusements, Inc. & Technical Contact Information 4897 Indian School Rd NE We value your feedback; technical comments and Suite 150 suggestions are helpful to us. Please e-mail your Salem Oregon 97305-1126 comments to service@jjamusements.com. www.jjamusements.com Phone: 503-304-8899 From time to time, updates may be made to this Toll Free Phone: 800-854-3140 manual.
- Page 3 To eliminate unnecessary work, careful reading of the applicable section is recommended before starting to service a go kart. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations; a certain amount of basic knowledge is also required for successful work.
- Page 4 Circlip, Retaining Ring Replace any removed circlips and retaining rings with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Cotter Pin Replace any cotter pins that were removed with new ones, since removal deforms and breaks them.
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Page 5: Table Of Contents
Specifi cations ........page 7 Go kart seasonal storage ....page 14 Falcon maintenance chart .....page 8 How a warranty is processed ....page 15 General data and Pre opening checklist ......page 10 Product return procedures ....page 15 Maintenance record ......page 11 Limited warranty ........page 16 maintenance. -
Page 6: Specifi Cations
Specifications Motor type............................12-volt DC motor Battery capacity .........................2-lead acid 12-volt DC Charge time ................................6-hr Charging ............................12-VDC, 12-AMP Speed ......................... Factory set at 3-mph (4.8 km/h) Rear brakes ............................Mechanical drum Front tire ..............................11” x 3.60-5” Rear tire ..............................11” x 3.60-5” Wheel base............................32.8/840 in/mm Dry weight............................. - Page 7 Need karts for bigger kids? J&J’s Stinger & Talon go karts fit into the middle of the pack. Designed for those kids that are a little too small to drive the adult-sized go karts, but too large for the smallest go kart, the Falcon. Optional Nerf Bar Colorful fi berglass bodies Specifi cations...
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Page 8: Falcon Maintenance Chart
Falcon maintenance chart ITEM SERVICE TYPE FREQUENCY Body & fenders Check Daily Replace When damaged Warning decals Check Daily Replace When damaged or illegible Seat belt Check Daily Replace When damaged Bumpers Check Daily Replace When damaged Pads Check Daily Replace When damaged Brake system... - Page 9 Falcon maintenance chart 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: Body & fenders: Check for damage and proper installation of the fenders and body; replace as needed. Warning decals: Replace if damaged or illegible.
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Page 10: Pre Opening Checklist
Pre-opening checklist FALCON GO KART ID# Servicer must initial each empty box every day. If anything is not OK, see a supervisor. BODY COLOR ITEM # DESCRIPTION TUES BODY & FENDERS: check for proper installa- tion of the body & fenders. WARNING DECALS: replace if damaged or illegible. - Page 11 Maintenance Record Go kart ID#____________________ Date _____/______/_______ Date Maintenance performed Parts used Serviced by Finish date Make extra copies for future use.
- Page 12 Non-scheduled maintenance record Go kart ID#____________________ Date _____/______/_______ Date Maintenance performed Parts used Serviced by Finish date Make extra copies for future use.
- Page 13 Printable work order tags This sample maintenance work order tag can be copied for use in your facility. Copy and cut tag along dashed line and fold along the fold line indicated. Simply attach a maintenance work order tag to a machine in need of repair. When maintenance is complete, fi...
- Page 14 Go kart seasonal storage (electric) PROPER CARE IN THE “OFF SEASON”: Some go kart tracks do not operate all year long. For this reason, J&J Inc. has prepared this information on how to properly condition your go kart fl eet for periods of storage or inactivity. We urge you to follow the simple instructions and advice contained here, referencing specifi...
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Page 15: Product Return Procedures
How a warranty is processed The customer contacts J&J with the warranty problem. The product warranty department or parts department gathers information and makes arrangements to send the needed replacement to the customer. The parts department also gives the customer an RMA# (Return Merchandise Authorization) at that time. (Please note: RMA# must appear on the returned goods package. -
Page 16: Limited Warranty
Limited warranty - go kart J&J Amusements, Inc., Accessories, Product and Replacement Parts. This warranty is limited to J&J Amusements, Inc. Product, parts and accessories when distributed by J&J Amusements, Inc. 4897 Indian School Road NE, Suite 150, Salem, Oregon 97305- 1126 USA (J&J). -
Page 17: Cleaning Go Karts
Cleaning go karts CLEANING KART BODIES The best way to preserve your go karts’ fi nish is to keep it clean by washing it often with lukewarm or cold water. Don’t wash your kart in the direct rays of the sun. Don’t use strong soaps or chemical detergents. Use liquid hand, dish or car washing (mild detergent) soaps. -
Page 18: Warning Decals
Warning decals All go karts leave J&J Amusements with warning decals in place. All warning decals must be legible. If any warning decal cannot be read it must be replaced immediately. J&J carries all the decals you need. See section 12 for decals and placement locations. -
Page 19: Tube & Rim Information
Tires, tubes, rims Tube & rim information ........page 1-1 Tire changing .............page 1-3 Wheel removal...........page 1-2 Current production Falcon karts are fi tted with one-piece wheel/hub combination wheels. This allows the use of tubeless-style tires, which simplifi es the system. NOTE: Bearing spacer must fi... -
Page 20: Wheel Removal
Wheel removal When changing rear tires, you must remove the rear wheel guard to access the rear wheel. See “Wheel guard removal” on page 2-2. Remove rubber cap. Remove cotter pin, castle nut and washer. Wheel can now be removed from the spindle or axle. NOTE: Rear axle has spacer on the fl... -
Page 21: Tire Changing
Tire changing When changing rear tires, you must remove the rear wheel guard to access the rear wheel. See “Wheel guard removal” on page 2-2. Remove wheel. “Wheel removal” on page 1-2. Remove valve stem to release all air pressure from the tire. - Page 22 Inspect the wheel for any damage, specifi cally around the bead area. Spray a mild soap/water mix on the tire seating surface and push the new tire down onto the wheel. Vise grips can be used to keep the tire from popping off the wheel as you work the bead into place around the wheel.
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Page 23: Wheel Guards
Wheel gaurds Wheel guards ............page 2-1 Wheel guard installation ........page 2-2 Wheel guard removal ........page 2-2 The wheel guards are 1/2 inch by 4 inch virgin (not recycled), ultra-high molecular (UHMW) plastic. The guards are held in place by 1/4-20” elevator bolts. These special bolts have a large, round, fl at head and a square shank. The holes in the wheel guard bands are precut square to match the special bolts. -
Page 24: Wheel Guard Removal
Wheel guard removal Remove wheel guard “Acorn” nuts and remove the six nuts and side bolts. Leave the front or rear two bolts until last, as it makes the guard easier to remove. Note: Replacement guards are shipped folded in half with the ends tapped together to save on shipping costs. - Page 25 Batteries Batteries ............page 3-1 Battery testing............page 3-5 Battery removal ..........page 3-2 Battery charger ..........page 3-5 Battery installation ..........page 3-3 The system: Two 12VDC-50AH vent-regulated, lead acid batteries are wired in parallel to produce a 12 VDC system with superior capacity for long running time between charges. The batteries are vent-controlled and can be tipped on the side without fl...
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Page 26: Battery Removal
Battery removal First remove the hold-down strap by removing wing nuts, one on each side. WARNING: To avoid electrical short and possible explosion, DO NOT contact both the red and black battery terminals with a conductive material. Lay a shop rag or towel over the positive post to help avoid shorting between the two posts with conductive tools. -
Page 27: Battery Installation
Battery installation The batteries are wired in parallel (as shown in picture). By wiring the batteries this way, the voltage remains 12 volts, but the amperage doubles, increasing the run time of the kart. Carefully secure the battery cables. Lay the interconnect cables in the space between the batteries. - Page 28 Battery testing/charging Testing: Make sure the battery charger is working, with battery charger plugged in and switch ON (note: charger is 110 or 240 auto-detect, AC capable. Check position of switch to make certain it is in “ON” position). Check charger-to-battery connections: plug charger to AC power and make sure charger switch is “ON”.
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Page 29: Body
Body Body ..............page 4-1 Body removal.............page 4-2 Fender removal ..........page 4-4 Falcon 2015 Specifi cations subject to change without notice | Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com Service Manual... -
Page 30: Body Body Removal
Body removal Remove the front and rear “faux bumper” bolts (4). Remove rear hatch cover. Remove push bar/seat belt harness anchor. Remove brake lever and accelerator lever from steering wheel. Remove steering wheel (two bolts attaching to shaft fl ange). Falcon 2015 Specifi... - Page 31 Remove steering shaft cover (3 screws). Remove steering shaft down cover (3 screws). Remove nuts from underside of kart frame. Body can now be lifted off frame. Side cover accents are held on by three screws and are replaceable. Falcon 2015 Specifi...
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Page 32: Fender Removal
Fender removal Remove the (2) bolts holding the fender in place, remove fender. Falcon 2015 Specifi cations subject to change without notice | Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com Service Manual... - Page 33 Power & drive train Power & drive train ..........page 5-1 Relay ..............page 5-4 Accellerator operation........page 5-2 Resistor .............page 5-5 Replacing accellerator switch ......page 5-2 Electrical testing ..........page 5-5 Circuit breaker ...........page 5-3 Wire diagram .............page 5-6 Motor removal............page 5-3 A review of the wiring schematic for the kart shows, in graphic terms, the simplicity of the power system. The electrical circuits of the kart are totally self-contained, meaning they do not use the frame as a ground.
- Page 34 Accelerator operation The green “go” lever simply actuates a normally open, plunger-type switch mounted in the lever assembly. This is a simple on/off switch. The “O” ring serves effectively as the return spring for the lever. If free-play of the lever exceeds 5-10 mm at the ball end, replace the “O”...
- Page 35 Circuit breaker The circuit breaker (on/off) switch is located at the rear of the kart under the push bar and is held in place with (2) screws. Motor removal Disconnect electrical connections. The motor is held in place with (2) bolts and (2) allen screws.
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Page 36: Relay
Relay The relay is located on the motor mount in front of the motor and held is in place with (2) bolts. These bolts also hold the motor mount in place and are slotted to allow for motor adjustment. See “Motor removal”... -
Page 37: Resistor
Resistor The resistor wire is located on the underside of the kart. The resistor and motor are low impedance and high amperage units. Resistance across these units will be low, but there must be continuity. Use voltage drop tests, visual inspection and/or replace with known functioning unit to quickly isolate problem area. -
Page 38: Circuit Breaker
Wire diagram Throttle Switch #F030F03-34913-0 #F1-15-0001 Falcon, Throttle O-ring Return Black wire Green wire #F030F01-5317201 Note: Falcon, Right Lever Assy (Green) Wires reversed at this connector due to motor polarity. 18 Gauge 10 Gauge 18 Gauge 10 Gauge RESISTOR WIRE #F1-15-0002 (34”) 10 Gauge... -
Page 39: Kartrol
Kartrol Kartrol ..............page 6-1 Wire diagram - with Kartrol ........page 6-2 This kart-controlling device, when fi tted, pulls power just after the circuit breaker/on-off switch and, using a wireless controller, it interrupts the relay ground circuit to make the kart power system operative or inoperative, thus control the karts. -
Page 40: Wire Diagram - With Kartrol
Wire diagram - with Kartrol Throttle Switch #F030F03-34913-0 #F1-15-0001 Falcon, Throttle O-ring Return Black wire Green wire #F030F01-5317201 Note: Falcon, Right Lever Assy (Green) Wires reversed at this connector due to motor polarity. 18 Gauge 18 Gauge 10 Gauge 10 Gauge RESISTOR WIRE #F1-15-0002 (34”) -
Page 41: Rear Axle Assembly
Rear axle assembly Rear axle ............page 7-1 Sprockets............page 7-2 Drive chain adjustment ........page 7-2 Floater wheel .............page 7-3 Drive chain replacement ........page 7-2 The rear axle uses a yoke assembly (fi x seat) with two attaching points that allows it to swing from the frame. A third attaching point is a slotted stay arm fi... -
Page 42: Drive Chain Replacement
Drive chain adjustment To adjust chain tension, fi rst loosen the two upper yoke bolts that attach the axle assembly to the frame. Loosen the adjuster stay bolt that attaches to the yoke. Axle can now swing and chain tension can be set. -
Page 43: Floater Wheel
Floater wheel The Falcon go kart is equipped with single wheel drive to allow for easy steering. This is accomplished with a fl oating wheel hub on the right rear of the go kart. The fl oater wheel simply spins freely on two bearings. Note the position of collars and/or spacers during disassembly/assembly. - Page 44 We carry everything you need to maintain a fun, clean and safe bumper boat pond. Powder-coated stainless steel dock rails. These heavy-duty dock rails will withstand many years of use and can be mounted to wood or concrete docks. Want more revenue from your bumper boat pond? Try the coin-operated Master Blaster from FPX.
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Page 45: Brakes
Brakes Brakes ...............page 8-1 Cable adjustment..........page 8-2 Changing brake shoes........page 8-3 The right side collar/sleeve can be removed and the brake drum removed from its spline. Note the rubber dust cover (protector) that helps keep dirt out of inner brake drum surface. When installing axle nuts, torque to specifi cation and replace cottar pins. -
Page 46: Cable Adjustment
Cable adjustment The adjuster nut at the brake drum end of the cable is used to set the amount of lever travel prior to the brake shoes engaging the drum. Adjust so the brake lever moves 10-20 mm at the ball end of the lever. -
Page 47: Changing Brake Shoes
Changing brake shoes To inspect/change the brake shoes, you must fi rst remove the right rear wheel and the axle sleeve. Slide brake drum away to access the brake shoes. The brake lining thickness service limit is 2.0mm (.008”): If either lining is worn beyond the service limit, replace both brake shoes. - Page 48 Frame Frame ..............page 8-4 This welded, steel-tube frame is very strong. It is replaceable, however, if you are experiencing frame damage, you should curtail bumping. These karts are not intended as bumper cars. Speeds can also be adjusted. Call J&J service for how-to.
- Page 49 Steering Steering .............page 9-1 Spindle removal ..........page 9-5 Steering column..........page 9-2 Toe in adjustment ..........page 9-4 This solid steel shaft is machined on one end to fi t the lower ball bearing and is threaded to provide for attachment of tie rod ends. The lower shaft bearing is a light press fi t into the frame mount, providing a strong and easily-turned steering shaft.
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Page 50: Steering Column
Steering column To remove, unbolt the steering wheel and set aside, leaving cables and wiring attached. Remove the two nuts holding the “plummer block” together and remove the upper half of the block. Remove tie rod ends using 17mm wrench or socket. - Page 51 Remove 22mm self-locking nut from steering shaft end. A plastic or brass hammer may be needed to tap the shaft up and out of the bearing. If replacing the lower ball bearing, use an appropriate-sized drift and tap the bearing up and out of its frame holder.
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Page 52: Toe In Adjustment
Toe-in adjustment To adjust the toe-in, park the vehicle on a level FRONT area with front wheels facing straight ahead. Lift the front of the kart so wheels are just off the ground and able to spin freely. Use a metal scribe or awl and securing it, slowly spin each wheel and gently scribe a line near the center of the tire. -
Page 53: Spindle Removal
Spindle removal Remove front wheel. (“Wheel removal” on page 1-2) Remove fender. (“Fender removal” on page 4-4) Remove tie rod from spindle. (“Toe-in adjustment” on page 9-4) Remove rubber dust cap. Remove cotter pin and castle nut. Spindle will slide out the bottom. Inspect the king pin for damage or cracks. - Page 54 Often imitated, but never duplicated. The design philosophy we applied to our rough-and-ready go karts was developed while building our renowned bumper boats. While J&J Amusements is most widely known for its go karts, we actually started back in the seventies building bumper boats.
- Page 55 Seat belt/pads Seat belt removal..........page 9-8 Seat pad removal ..........page 9-9 Steering pad removal ........page 9-10 The harness/seat belt attaches to the frame using the push bar studs. The harness goes over the driver’s shoulders and uses a single “crotch” mount for the release mechanism. The crotch strap feeds through the body and mounts directly to the kart frame.
- Page 56 Seat belt removal To access the seat belt bolts, remove the rear battery cover. NOTE: Never operate a kart without seat belts. Remove the nuts holding the push bar/seat belt bracket in place. Remove the push bar to access the seat belt brackets.
- Page 57 Seat pad removal Access to the seat bottom nuts is under the kart. Remove (2) nuts and seat pad will pull off top of body. NOTE: When replacing pads, make sure self- locking-style nuts are used. The seat pad is held in place with (2) studs as shown.
- Page 58 9-10 Steering pad removal Steering wheel pad is attached with (4) phillips head screws. Remove screws, replace pad. NOTE: Never operate a kart without pads. Falcon 2015 Specifi cations subject to change without notice | Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com Service Manual...