J&J Amusements Falcon Go-kart 2018 User manual

Service Manual
Falcon Go-kart (2018)
2018
© 2018 J&J Amusements Inc. - All Rights Reserved
Specications subject to change without notice.
Published by J&J Amusements, Inc.
An Oregon Corporation

WARNING - Important Safety Notice
Proper service and repair procedures are vital to safe, reliable operation of J&J go karts, as well as to the personal safety
of those performing the repairs. This manual outlines procedures for servicing and repairing J&J go karts, using safe,
eective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed
(along with standard safety procedures) to reduce the possibility of personal injury or improper service, which could
damage the go kart or compromise its safety.
It is important to note that repair procedures, techniques, tools and parts for servicing J&J go karts, as well as the skill
and experience of the individual performing the work, vary widely. It is not possible to anticipate all conceivable ways,
or conditions under which J&J go karts may be serviced, or to provide cautions to all possible hazards that may result.
Standard precautions should be used when handling toxic or ammable uids, and safety goggles or other protection
should be used during cutting, grinding, chiseling, prying or any other process that can cause material removal or
projectiles. J&J recommends the use of safety goggles or approved glasses during all servicing of J&J go karts.
All information contained in this manual is based on the latest product information available at the time of printing.
We reserve the right to make changes at any time without notice. All rights reserved. Except as expressly provided
herein, no part of the manual may be reproduced, copied, transmitted, disseminated, downloaded or stored in any
storage medium, for any purpose, without prior written consent of J&J Amusements, Inc. An Oregon Corporation.
J&J Amusements, Inc. grants permission to download a single copy of this manual onto a hard drive or other
electronic storage medium to be viewed for personal use, provided that such electronic or printed copy of this
manual contains the complete text of this copyright notice. Any unauthorized commercial distribution of this
manual is strictly prohibited.
4897 Indian School Rd NE
Suite 150
Salem Oregon 97305-1126
www.jjamusements.com
Phone: [phone]
Toll Free Phone: [phone]
Fax: [phone]
Toll Free Fax: [phone]
JJ
&Amusements, Inc. Technical Contact Information
We value your feedback; technical comments and
suggestions are helpful to us. Please e-mail your
comments to [email protected].
From time to time, updates may be made to this
manual. For the latest updates, please visit our
technical website at
http://www.jjamusements.com/service-and-
technical-information/
As you read this manual, you will find information that is preceded by a NOTE symbol. The purpose of this message
is to prevent damage to the go kart, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all of the hazards associated with servicing a go kart. 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- how to service these go karts correctly and safely.

To eliminate unnecessary work, careful reading of the applicable section is recommended before starting to service a
go kart. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever
necessary.Nevertheless,even a detailed accounthaslimitations; a certain amount ofbasicknowledge is also required
for successful work.
Especially note the following:
Dirt
Before removal and disassembly, clean the go kart.Any dirt entering the engine or other parts will work as an abrasive
and shorten the life of these parts. For the same reason, before installing a new part, clean off any dust or metal 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 action will avoid distortion of the part. Conversely,
when loosening the bolts, nuts or screws, loosen each by a quarter turn, and then remove in a similar cross pattern.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts or screws must be tightened
in the order and method indicated.
Torque
When torque values are given in this Service manual, use them. Either too little or too much torque may lead to
serious damage. Use a high quality, reliable torque wrench.
Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially
difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap
lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws
held by a locking agent) in order to avoid damaging the screw heads. It also may be necessary to apply heat to some
parts that are held with a locking compound.
Edges
Watch for sharp edges, especially during major motor/engine disassembly and assembly. Protect your hands with
gloves or a piece of thick cloth when lifting the motor/engine or 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 gasket must be free of
foreign matter and perfectly smooth, which is impossible with a used gasket or o-ring.
Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturers’ directions for cleaning and preparing surfaces where these compounds will be used. Apply
sparingly,asexcessiveamountsmaycauseseriousdamage.Anexampleofanon-permanentlockingagentcommonly
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
Replace any oil or grease seals that were removed with new parts, since removal generally damages seals. When
pressing in a seal containing manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into
place using a suitable driver (which contacts evenly with the side of the seal) until the face of the seal is even with the
end of the hole. Always use assembly oil or grease on the lip (sealing edge) of any seal prior to assembly.

Circlip, Retaining Ring
Replace any removed circlips and retaining rings with new ones, as removal weakens and deforms them. When
installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.
Cotter Pin
Replace any cotter pins that were removed with new ones, since removal deforms and breaks them.
Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed. Removed
parts will be damaged and/or lose their original function.
Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage (If
there is any doubt as to their condition, replace them with new parts):
abrasions, cracks, bends, dents, scratches, wear, color changes, deterioration, hardening, warping ,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.

0General data and
maintenance.
1Tubes, tires, rims
2Wheel guards
3Batteries
4Body
5Power & drive train
6Kartrol
7Rear axle assembly
8Brakes
9Steering
Specifications ........................................page 7
Falcon maintenance chart.....................page 8
Pre opening checklist ..........................page 10
Maintenance record.............................page 11
Non-scheduled maintenance...............page 12
Printable work order tags.....................page 13
Go kart seasonal storage ....................page 14
How a warranty is processed ..............page 15
Product return procedures...................page 15
Limited warranty..................................page 16
Cleaning go karts.................................page 17
Warning decals....................................page 18
Tube & rim information ...................... page 1-1
Wheel removal................................... page 1-2
Tire changing..................................... page 1-3
Wheel guards ....................................page 2-1
Wheel guard removal ........................page 2-2
Wheel guard installation.................... page 2-2
Batteries ............................................ page 3-1
Battery removal ................................. page 3-2
Battery installation............................. page 3-3
Battery testing.................................... page 3-4
Battery charger.................................. page 3-4
Body .................................................. page 4-1
Body removal..................................... page 4-2
Fender removal .................................page 4-4
Power & drive train............................ page 5-1
Accellerator operation........................ page 5-2
Replacing accellerator switch............ page 5-2
Circuit breaker................................... page 5-3
Motor removal.................................... page 5-3
Relay ................................................. page 5-4
Resistor ............................................. page 5-5
Electrical testing ................................page 5-5
Wire diagram..................................... page 5-6
Kartrol................................................ page 6-1
Wire diagram - with Kartrol................ page 6-2
Rear axle........................................... page 7-1
Drive chain adjustment...................... page 7-2
Drive chain replacement.................... page 7-2
Sprockets........................................... page 7-2
Floater wheel..................................... page 7-3
Steering............................................. page 9-1
Steering column................................. page 9-2
Toe in adjustment ..............................page 9-4
Spindle removal................................. page 9-5
Brakes ............................................... page 8-1
Cable adjustment............................... page 8-2
Changing brake shoes....................... page 8-3

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.............................................................................................................................................131.25lbs/59kg
Length....................................................................................................................................................55/1397 in/mm
Width .....................................................................................................................................................42/1066 in/mm
Height...................................................................................................................................................24.4/620 in/mm
Ground clearance.....................................................................................................................................1.8/45 in/mm
Seat height .............................................................................................................................................8.1/205 in/mm
Specifications
Set-up anywhere!
py
Set
-
up
anywhere!
Portable, inflatable
Falcon track that
sets up in minutes
anywhere!
Dimensions:
48’x31.5’x8’
Track comes with heavy
-duty blower.
Falcon go karts not included.

Same rugged chassis
design as our adult-
sized go karts.
Colorful berglass bodies
Need karts for bigger kids?
Color-coded
control pedals
Heavy-duty seat pads
Strong, steel
rollover protection
Buttery steering
wheel (optional)
Specications
Length Width
73”(185cm) 45”(114cm)
Optional Nerf Bar
Rookie Go karts
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.

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 Check operation Daily
Check brake shoe wear Every year
Adjust When necessary
Replace When necessary
Remote shut down system
(if equipped) Check operation Daily
Replace When necessary
On/off switch Check operation Daily
Inspection Monthly
Replace When necessary
Clean terminals When necessary
Throttle lever Check operation Daily
Check return o-ring Daily
Replace When necessary
Wheels Check Daily
Torque wheels When replaced
Replace When necessary
Tires (45 psi) Check Daily
Replace When damaged
Batteries Check volts Daily
Load test Monthly
Replace When necessary
Clean terminals When necessary
Steering Check Daily
Battery charger Check Daily
Replace When necessary
Clean terminals When necessary
Axle & drive chain Check Monthly
Lube drive chain Daily
All nuts, bolts & fasteners Check Daily
Torque Yearly
Replace When damaged
General wires & connections Check for damage Monthly
Clean connections Monthly
Replace When necessary
Clean terminals When necessary

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.
Seat belt: Check for frayed webbing and loose stitching and check buckle and adjustment operation.
< CAUTION > : Don’t let anyone operate the go kart if they can’t wear a seat belt properly. If the kart is in a crash
and they are not wearing a seat belt, they could hit things inside the kart or be ejected from it and therefore can be
seriously injured or killed. Always properly fasten customers’ seat belts, and then double-check to make certain the
straps are not loose.
Bumpers: Check for any signs of damage; replace as needed.
Pads: Check seat, seat back, roll bar and steering wheel pads for damage; replace as needed.
Brake system: Check the rear brake lever and cable for excessive play or other damage; replace or repair if
necessary.
Remote shut-down system (if equipped): Verify proper operation per manufacturer’s
recommendations.
On/off switch: Check for signs of damage and proper operation; replace as needed.
Throttle lever: Inspect for smooth lever operation, full opening and automatic closing of lever. Inspect for
deterioration, damage, cuts and nicks of switch, wiring and throttle return o-ring; replace as needed.
Tires & wheels: Inspect the wheels for damage. Check the tires for cuts, nails or other sharp objects. Check
the tire pressure at cold tire conditions (45 psi); replace as needed.
Batteries: Check for corrosion and spray terminals with battery protectant (J&J #99101).
 DANGER  : ***READ BATTERY SAFETY PRECAUTIONS BEFORE HANDLING BATTERIES***
Steering: Check the free play of the steering shaft with the front wheels turned straight ahead. When there is
excessive play, inspect the tie-rod, king pin bushing and ball joints.
Battery charger: Check for proper operation. Inspect terminals for damage and corrosion. Clean and spray
terminals with battery protectant (J&J #99101). Make sure charger is securely mounted to the frame.
Axle & drive chain: Inspect the axle and drive chain for bending/binding and/or cracking/damage. Lube drive
chain daily.
All nuts, bolts & fasteners: Check for loose and/or missing nuts and bolts; replace as needed.
General wires & connections: Check all wires and connections for damage and corrosion; clean or
replace as needed.
Notice: All necessary repairs need to be done before the Falcon is operated. Use J&J Amusements or equivalent
replacement parts. Inspections should be done by trained and qualified personnel.

FALCON GO KART ID# Servicer must initial each empty
box every day. If anything is not
OK, see a supervisor.
BODY COLOR
ITEM # DESCRIPTION MON TUES WED THU FRI SAT SUN
1 BODY & FENDERS: check for proper installa-
tion of the body & fenders.
2 WARNING DECALS: replace if damaged or
illegible.
3 SEAT BELT: visually check for frayed webbing,
loose stitching, check buckle and adjustment
operation.
4 BUMPER SYSTEM: check for any signs of dam-
age. Replace when necessary.
5 PADS: check seat, seat back, rollbar & steer-
ing wheel for damage; replace as needed.
6 BRAKE LEVER & BRAKES: check lever travel;
check for proper action.
7 REMOTE SHUT DOWN SYSTEM IF
EQUIPPED: verify proper operation per
manufacturer’s recommendations.
8 ON/OFF SWITCH: Verify proper operation.
9 THROTTLE LEVER: Inspect return o-ring for
damage, smooth operation, full opening &
automatic closing of lever.
10 TIRES & WHEELS: verify tires’ PSI is to speci-
fication; check wheels for loose or missing lug
nuts.
11 BATTERIES: check battery voltage; if low,
inspect & load test battery.
12 STEERING: check for smooth action, visually
check front wheel alignment.
Pre-opening checklist

Go kart ID#____________________ Date _____/______/_______
Date Maintenance performed Parts used Serviced by Finish date
Maintenance Record
Make extra copies for future use.

Non-scheduled maintenance record
Make extra copies for future use.
Go kart ID#____________________ Date _____/______/_______
Date Maintenance performed Parts used Serviced by Finish date

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.
Printable work order tags
Make extra copies for future use.

Go kart seasonal storage (electric)
PROPER CARE IN THE “OFF SEASON”:
Some go kart tracks do not operate all year long. For this reason, J&J Inc. has prepared this information on how to
properly condition your go kart fleet for periods of storage or inactivity. We urge you to follow the simple instructions
and advice contained here, referencing specific model information from your owners service manual to maintain the
highest level of safety and preserve the value of your investment.
BATTERIES:
Fully charge batteries. Keep batteries stored in go karts. Inspect all battery terminals. Clean & apply corrosion block
to all battery terminals. Keep the batteries fully charged; the temperature of your winter determines how often you
should recharge them. Batteries self-discharge over time, and do so more quickly in colder temperatures. Charg-
ing your batteries every 5-6 weeks (3-4 weeks if your area is really cold) is a good period of time in between each
recharge until batteries go back into use.
CLEANING AND WAXING:
Storing a dirty go kart can lead to corrosion, because dirt retains moisture. Thoroughly wash and dry each go kart.
Polish and wax all painted/gelcoat surfaces. Spray the unpainted castings such as the engine, reduction gear case,
spindles and related hardware with a corrosion protectant to retard corrosion and rust.
TIRES:
Inflate tires to the recommended pressures and inspect.
CHASSIS LUBRICATION:
Grease spindles, axle bearings, rod ends, throttle arm pivot and pedal pivots to purge any water or contaminants
from these pivot points. Treat other pivots, when no grease fittings are provided, with water-displacing light lubricant
spray.
STORAGE AREA AND COVERING:
Select a storage area, such as a garage or storage room, that is free from dampness and high humidity. The daily
temperature change should be minimal. Do not store in direct sunlight or near open flames or sparks. Selecting the
proper cover is important. An unvented, airtight cover may lead to corrosion and rust due to trapped moisture/vapor.
Use a vented cover, which will allow moisture to escape rather than retaining it.

1. The customer contacts J&J with the warranty problem. The product warranty department or parts department
gathers information and makes arrangements to send the needed replacement to the customer. The parts
department also gives the customer an RMA# (Return Merchandise Authorization) at that time. (Please note: RMA#
must appear on the returned goods package. Goods may be refused if no RMA# is present.)
2. Replacement goods are shipped AND CUSTOMER ACCOUNT IS CHARGED according to the 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 warrantied parts at their expense to J&J with RMA# on the outside of package. The
warranty manager inspects the goods and one of two things will happen:
a. Credit will be authorized to the customer’s account in the amount charged for the replacement.
Note: Cash refunds are not given on warranty items.
b. If the 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.
RETURNED GOODS POLICY:
No merchandise may be returned, nor any account adjustments made, unless authorized by J&J Amusements, Inc.
AReturn MerchandiseAuthorization (RMA#) is required for all returns. Only items authorized (listed) on an RMAmay
be returned. Obsolete and discontinued merchandise may not be returned (current merchandise is that which
appears in the current annual parts catalog). A 15% restocking fee will be charged on all returns except for errors
caused by J&J Amusements, Inc. The customer (except for errors caused by J&J Amusements, Inc) will pay freight.
Returned merchandise must be in good condition, in the original package (where applicable), and cannot be altered
with custom labels, stickers, numbers, etc. Merchandise that is returned without an RMA# will be refused.
WARRANTY RETURN POLICY:
All warranty item returns must be authorized by the warranty department and have an assigned RMA# before any
adjustment or credit will be given. All merchandise that is returned to J&J and is proven defective in manufacture or
workmanship upon examination will be replaced or repaired.
THE RMA# MUST APPEAR NEXT TO THE SHIPPING LABEL ON ALL RETURNED ITEMS FOR PROPER CREDIT TO BE
ISSUED. IF THERE IS NO RMA# ON THE BOX/CARTON, IT WILL BE REFUSED AND RETURNED TO SHIPPER.
BE ADVISED THAT ANY RMA# IS VALID FOR 15 DAYS FROM DATE OF ISSUE. AFTER 15 DAYS, ALL RMA#S ARE
VOID AND FURTHER RETURN ATTEMPTS WILL REQUIRE REISSUE OF A NEW RMA#.
How a warranty is processed
Product return procedures

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&JAmusements, Inc. 4897 Indian School Road NE, Suite 150, Salem, Oregon 97305-
1126 USA (J&J).
Products Covered by this warranty: Length of warranty:
Go karts (excluding Honda motors) manufactured after 1/1/02 1 year*
Bumper rails manufactured after 1/1/02 (steel only) Limited lifetime warranty
UHMW bumper rails 1 year Parts and accessories 90 Days**
Battery charger 1 year - by manufacturer*
Battery By manufacturer
Honda GX series engines 1 year by American Honda Motor Co. Inc.
**See specific exclusions
To qualify for this warranty:
1. e accessories, product, or replacement parts must be purchased from J&J Amusements, Inc.
2. You must be the rst retail purchaser. is warranty is not transferable to subsequent owners.
3. You must provide proof of original purchase.
What J&J will repair or replace under warranty:
J&J will repair or replace, at its option, any product, accessories, or replacement parts that are proven to be defective in material or workman-
ship 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
accessories, products or parts 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:
is warranty does not extend to products, accessories or parts aected or damaged by accident and/or collision, normal wear, fuel contamina-
tion, not sold by J&J, used in applications for which the product was not designed, or any other misuse, neglect, incorporation or use of unsuit-
able attachments or parts, unauthorized alterations, 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. is warranty does not extend to products, accessories or parts purchased for use outside of the United States
or Canada.
**Specific Exclusions:
Normal wear and tear items, such as: tires, brake pads, brake rotors, seat belts, pads, spark plugs, final drive belts, final drive
pulleys, brake fluid, and fuel filters. Appearance-related damage, including but not limited to: scratches, nicks, dents, fading paint/
trim, and corrosion. Service Logs-The customer must use maintenance logs provided from J&J. Warranty will not be cov-
ered if you cannot provide these records.
*Honda motor warranty is only covered by American Honda Motor Co., Inc.
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 DAM-
AGE 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 OF ITS
ESSENTIAL PURPOSE, IN NO EVENT WILL J&J’S ENTIRE LIABILTIY 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, EX-
PRESS 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 DURA-
TION 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. Contact J&J Amusements, Inc. for information on
your area.
Limited warranty - go kart

Cleaning go karts
CLEANING KART BODIES
The best way to preserve your go karts’ finish is to keep it clean by washing it often with lukewarm or cold water.
Don’t wash your kart in the direct rays of the sun. Don’t use strong soaps or chemical detergents. Use liquid hand,
dish or car washing (mild detergent) soaps. Don’t use cleaning agents that contain acid or abrasives. All cleaning
agents should be flushed promptly and not allowed to dry on the surface, as they could stain. Dry the finish with a
soft, clean chamois or a 100% cotton towel to avoid surface scratches and water spotting.
NOTE: Do not damage warning decals. Damaged or illegible warning decals must be replaced immediately.
FINISH CARE
Occasional waxing or mild polishing of your karts may be necessary to remove residue from the finish. Use an ap-
proved fiberglass polish. 303 Protectant can be used on clean go kart bodies to act as a UV protectant.
NOTE: Machine compounding or aggressive polishing on the body may dull the finish or leave swirl marks.
BODY TRIM
Silicone grease on body trims will make them last longer. Apply silicone grease with a clean cloth at least three
times per season. During very cold, damp weather, more frequent application may be required.
FINISH DAMAGE
Any stone chips, fractures or deep scratches in the finish should be repaired right away. Minor chips and scratches
can be repaired with materials available from almost any auto parts store. Larger areas of finish damage can be cor-
rected by a local body and paint shop.
CHEMICAL SPOTTING & SUN FADING
Some weather and atmospheric conditions can create a chemical fallout. Airborne pollutants can fall upon and at-
tack the surfaces on your kart. This damage can take two forms: blotchy, ringlet-shaped discolorations, and small
irregular dark spots etched into the paint surface.
CLEANING FRAMES
Remove bodies weekly for frame cleaning and inspection.
Using a pressure washer, clean/rinse the entire frame of any dirt or grease that might have collected.
After spraying off the frame and wiping it dry, grease all the zerk fittings with good quality grease. Spray a rust inhibi-
tor on all linkage rods, tie rod ends, springs or any unpainted surfaces.
< WARNING >
Do not spray brake disc or caliper. This will cause a loss of brakes and could cause an accident.
J&J carries many
cleaning and pro-
tection 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!
Cleaners and protectants

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.
Warning decals
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#1-40-0122 #1-40-0123 #009815
#FGD04-EST1-000 Falcon decal kit
complete. Includes all Falcon decals.

1-1
Falcon 2015
Service Manual
Specifications subject to change without notice | Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com
Tires, tubes, rims
Tube & rim information......................................page 1-1
Wheel removal...................................................page 1-2 Tire changing.....................................................page 1-3
Current production Falcon karts are fitted with one-piece wheel/hub combination wheels. This allows the use of
tubeless-style tires, which simplifies the system.
NOTE: Bearing spacer must fit snug or bearing life will be shortened.
NOTE: Tire pressures are directly related to battery life, as low tire pressures cause higher amp draw.
The wheels turn on two sealed radial ball bearings pressed into the hub; a spacer between the two bearings
contacts the inner race of each bearing and causes a “tight race” system when the axle or spindle nut is tightened.
The bearing races and spacer are captured between the spindle or axle shoulder and securing washer and nut so
that the radial ball bearings can turn freely. Any roughness or binding will adversely affect battery life.
The bearing can be removed by using a long drift and tapping them out of hub from the back side of bearings. New
bearings should always be used whenever old bearings are removed. Always use an appropriate size bearing driver
that uses the outside bearing race as the pressure point when installing new bearings.
When wheels are installed and the nut is torqued to specification, all bearing-fitted wheels must spin freely. Any
resistance to free spin must be corrected. The drive hub/wheel is splined and mounts to the left rear axle end to
drive the kart.

1-2
Falcon 2015
Service Manual Specifications subject to change without notice | Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com
Wheel removal
Remove rubber cap.
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 cotter pin, castle nut and washer. Wheel
can now be removed from the spindle or axle.
NOTE: Rear axle has spacer on the floater hub
side.