GOKARTS USA JF120 User manual

JF120 • JF168 • JF200
Owner's Manual

CONTENTS
SPECIFICATIONS ........................................................................................................................ 1
IMPORTANTSAFETYINFORMATION ..................................................................................... 3
COMPONENT&CONTROLLOCATIONS ................................................................................ 4
BEFOREOPERATION ................................................................................................................ 5
GeneralConditionoftheEngine ...................................................................................... 5
ChecktheEngine............................................................................................................... 5
EquipmentPoweredbyEngine.......................................................................................... 5
SafeOperatingPrecautions............................................................................................... 5
OPERATION ................................................................................................................................. 6
StartingtheEngine............................................................................................................. 6
SettingtheEngineSpeed.................................................................................................. 8
STOPPINGTHEENGINE............................................................................................................. 9
SERVICINGTHEENGINE........................................................................................................... 10
MaintenanceSafety............................................................................................................ 10
SafetyPrecautions............................................................................................................. 10
MaintenancePrecautions................................................................................................. 11
Refueling .................................................................................................................... 12
FuelRecommendations .................................................................................................... 12
OilRecommendations ....................................................................................................... 13
OilLevel Check................................................................................................................... 13
OilChange........................................................................................................................... 14
Air Filter Inspection & Service .................................................................................... 15
SedimentCupCleaning..................................................................................................... 16
Spark PlugService ............................................................................................................ 17
IdleSpeedAdjustment....................................................................................................... 18
STORINGTHEENGINE .............................................................................................................. 19
Cleaning ............................................................................................................................. 19
Fuel ............................................................................................................... 19
AddingFuelStabilizer ................................................................................................ 19
Drainingthe Fuel................................................................................................................ 20
EngineOil............................................................................................................................ 20
StoragePrecautions........................................................................................................... 21
RemovalfromStorage........................................................................................................ 21
Transporting ............................................................................................................... 21
TROUBLESHOOTING............................................................................................................................ 22
REMOTE CONTROLLINKAGE(Optional) ................................................................................ 23
HIGHALTITUDEOPERATION.................................................................................................... 24
Replacement Parts .................................................................................................... 24

SPECIFICATIONS
JF120
Length x Widt h x Height
12.0 X13.4 X12.5 in
Dry Weig ht
28.7 Lbs
Eng ine Ty p e
4-S trok e, Ov erh ead Valv e, Sin gle Cy lind er
Displacem e nt
[Bore x Stroke]
7 . 3 c u - i n
[2.4 X1.7 in]
Valve clear a nce
IN: 0.15 ±0.02 mm (cold)
EX: 0.20+0.02 mm (cold)
Spa rk P lug
L D : F 7 R T C N G K : B P R 6 E S
Spa rk p lug g ap
0.028-0.031 in
Idle speed
1 , 4 0 0 * r p m
Max. Output
4.0 HP At 3,600 rpm
Max. Torque
5.4 ft-lbs At 2,500 rpm
Eng ine Oil
SAE 1 0W- 30, A P I S J or SL , for g e ner al u se
Eng ine O il C apac ity
0.63 qt
Fuel
Unl eaded gasoline w it h a p um p oct ane r at ing of 86 or hig her
Fue l Tan k C apac ity
0.55 gal
Fue l Consump t ion
0.51 GPH
Coo ling S yst em
Forced Air
Ignition System
Transisto r ize d M agne to
PTO Sha ft Rota tio n
Cou nter clo ckw i se
JF168
Length x Widt h x Height
12.3 X14.3 X 13.2 in
Dry Weig ht
33.1 Lbs
Engine Typ e
4 - St r o k e, O v e rh e ad V a l v e, S i n g l e C y li n d er
Displacem e nt
[Bore x Stroke]
9.9 cu-in
12.7X 1.8 in]
Valve clear a nce
IN: 0.15 ±0.02 mm (cold)
EX: 0.20±0.02 mm (cold)
Spa rk P lug
L D : F 7 R T C N G K : B P R 6 E S
Spa rk p lug g ap
0.028-0.031 in
Idle speed
1,400 T , r pm
Max. Output
5.5 HP At 3,600 rpm
Max. Torque
8.0 ft-lbs At 2,500 rpm
Engine Oil
SAE 1 0W- 30, A P I S J or SL , for g e ner al u se

SPECIFICATIONS
- 2 -
E n g i n e O i l C a p a c i t y
0.63 qt
Fuel
U n l e ad e d g a s o l in e w i t h a p u m p o c t an e r a t i n g o f 8 6 o r h i g h er
F u e l T a n k C a p a c i t y
0.7 9 ga l
F u e l C o n s u m p t i o n
0 . 5 1 G P H
C o o l i n g S y s t e m
F o r c e d A i r
Ign i ti o n Sy s tem
T r a n s i s t o r i z e d M a g n e t o
P T O S h a f t R o t a t i o n
C o u n t e r c l o c k w i s e
J F200
L e n g t h x W i d t h x H e i g h t
12.3 X14. 8 X 1 3.2 in
D r y W e i g h t
3 5 . 3 L b s
E n g i n e Ty p e
4 - S t r o k e , O v e r h e a d V a l v e , S i n g l e C y l i n d e r
u i s p i a c e m e n t
[Bore x S troke]
1 2 c u - i n
[2.7X 2.1 in]
V a l v e c l e a r a n c e
IN: 0.1 5 ±0.02 m m (cold)
EX: 0.20 ±0 . 02 m m ( col d )
S p a r k P l u g
L D : F 7 R T C N G K : B P R 6 E S
S p a r k p l u g g a p
0.0 28- 0 .03 1 in
Idl e sp eed
1,4 00T r pm
M a x . O u tp u t
6 . 5 H P A t 3 , 6 0 0 r p m
M a x . T o r q u e
9 . 7 6 f t - l b s A t 2 , 5 0 0 r p m
E n g i n e O i l
S A E 1 0 W - 3 0 , A P I S J o r S L , f o r g e n e r al u s e
E n g i n e O i l C a p a c i t y
0.6 3 qt
Fuel
U n l e ad e d g a s o l in e w i t h a p u m p o c t an e r a t i n g o f 8 6 o r h i g h er
F u e l T a n k C a p a c i t y
0.7 9 ga l
F u e l C o n s u m p t i o n
0 . 5 1 G P H
C o o l i n g S y s t e m
F o r c e d A i r
Ign i ti o n Sy s tem
T r a n s i s t o r i z e d M a g n e t o
P T O S h a f t R o t a t i o n
C o u n t e r c l o c k w i s e
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, operating,
inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the
front cover. Keep this manual and invoice in a safe and dry place for future
reference.

-3-
IMPORTANT SAFETY INFORMATION
Most accidents with engines can be prevented if you follow all instructions in this manual and on the
engine. Some of the most common hazards are discussed below, along with the best way to protect
yourself and others.
Read and understand this owner's manual before operating the engine. Failure to do so could
result in personal injury or equipment damage.
Know how to stop the engine quickly, and understand the operation of all controls. Never permit
anyone to operate the engine without proper instructions.
Do not allow children to operate the engine. Keep children and pets away from the area of
operation.
Do not operate engine in explosive atmospheres, such as in the presence of flammable liquids, gases,
or dust. Engines create sparks, which may ignite the dust or fumes.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing,
and
gloves away from moving parts. Loose clothes, jewelry, and long hair can be caught in moving parts.
Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-
ventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and
sparks away. Always store gasoline in an approved container. If any fuel is spilled, make sure the
area is dry before starting the engine.
The muffler becomes very hot during operation and remains hot for a while after stopping the
engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing it
indoors.
To prevent fire hazards and to provide adequate ventilation for stationary equipment applications,
keep the engine at least 3 feet away from building walls and other equipment during operation. Do
not place flammable objects close to the engine.
Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the
engine in a closed garage or confined area.
Review the instructions provided with the equipment powered by this engine for any additional
safety precautions that should be observed in conjunction with engine startup, shutdown,
operation, or protective apparel that may be needed to operate the equipment.
Do not overload the engine. Use the correct engine for your application. The correct engine will do
the job better and safer at the rate for which it is designed.
The warnings, cautions and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that ma y
occur. It must be understood by the operator that COMMON SENSE AND
CAUTION ARE FACTORS WHIC H CANNOT BE BUILT INTO T H IS
WARNING! PRODUCT, BUT MUST BE SUPPLIED BY THE OPERATOR.

COMPONENT & CONTROL LOCATIONS
MUFFLER
THROTTLE LEVER
RECOIL STARTER
FUEL TANK
ON/OFF SWITCH
- 4 -

-5-
BEFORE OPERATION
IS YOUR ENGINE READY TO GO?
For your safety, and to maximize the service life of your equipment, it is very important to take a few
moments before you operate the engine to check its condition. Be sure to take care of any problem
you find, or have your servicing dealer correct it, before you operate the engine.
Before beginning your pre-operation checks, be sure the engine is level and the engine switch is in
the OFF position.
CHECK THE GENERAL CONDITION OF THE ENGINE
Review the instructions provided with the equipment powered by this engine for any precautions and
procedures that should be followed before engine startup.
Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and
even kill you. Avoid any areas or actions that expose you to carbon monoxide.
WARNING!
Improperly maintaining this engine, or failing to correct a problem before
operation, could cause a malfunction in which you could be seriously injured.
Always perform a pre-operation inspection before each operation, and correct
WARNING! any problem.
Look around and underneath the engine for • Look for signs of damage.
signs of oil or gasoline leaks.
Remove any excessive dirt or debris, • Check that all shields and covers are in place,
especially around the muffler and recoil starter. and all nuts, bolts, and screws are tightened.
CHECK THE ENGINE
Check the engine oil level. Running the
engine with a low oil level can cause engine
damage.
The oil sensor will automatically stop the
engine before the oil level falls below safe
limits. However, to avoid the inconvenience
of an unexpected shutdown, always check
the engine oil level before startup.
• Check the air filter. A dirty air filter will restrict
air flow to the carburetor, reducing engine
performance.
Check the fuel level. Starting with a full tank
will help to eliminate or reduce operating
interruptions for refueling.
CHECK THE EQUIPMENT POWERED BY THIS ENGINE

-6-
OPERATION
Before operating the engine for the first time, please review the IMPORTANTSAFETY
INFORMATION on page 3 and the above information.
Review the instructions provided with the equipment powered by this engine for any safety
precautions that should be observed in conjunction with engine startup, shutdown, or operation.
STARTING THE ENGINE
1. Move the fuel valve lever to the ON
position.
The fuel valve opens and closes the
passage between the fuel tank and the
carburetor.
The fuel valve lever must be in the ON
position for the engine to run.
2. To start a cold engine, move the choke
lever to the CLOSED position. To restart
a warm engine, leave the choke lever in
the OPEN position.
The choke lever opens and closes the
choke valve in the carburetor.
The CLOSED position enriches the fuel
mixture for starting a cold engine.
The OPEN position provides the correct
fuel mixture for operation after starting,
and for restarting a warm engine.
3. Move the throttle lever away from the
SLOW position, about 1/3 of the way
toward the FAST position.
The throttle lever controls engine speed.
Moving the throttle lever in one direction
or the other, makes the engine run faster
or slower.

- 7 -
4. Turn the engine switch to the ON position.
The engine switch enables and disables
the ignition system.
The engine switch must be in the ON
position for the engine to run.
Turning the engine switch to the OFF
position stops the engine.
5. Operate the RECOIL STARTER:
Pull the starter grip lightly until you feel
resistance, then pull briskly. Return the
starter grip gently.
Pulling the starter grip operates the recoil
starter to crank the engine.
6. If the choke lever has been moved to the
CLOSED position to start the engine,
gradually move it to the OPEN position as
the engine warms up.

-8-
SETTING ENGINE SPEED
Position the throttle lever for the desired engine speed.
Moving the throttle lever in the directions shown makes the engine run faster or slower.
Some engine applications use a remote-mounted throttle control rather than the engine-mounted
throttle lever shown here.
For engine speed recommendations, refer to the instructions provided with the equipment powered by
this engine.
A
WARNING!
Carbon monoxide gas is
toxic. Breathing it can cause
unconsciousness and even
kill you. Avoid any areas or
actions that expose you to
carbon monoxide.