J&J Amusements King Scorpion User manual

Service Manual
Single & Double Go-Karts (2014)
Published by J&J Amusements, Inc.
An Oregon Corporation
© 2013 J&J Amusements Inc. - All Rights Reserved
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Specifications subject to change without notice.

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,
effective 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 flammable fluids, 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 [e-mail].
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.
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 account has limitations; a certain amount of basic knowledge is also required for successful
work.
ESPECIALLY NOTE THE FOLLOWING:
DIRT
Before removal and disassembly, clean the go-kart. Any dirt entering the engine or other parts will work as an abrasive
and shorten the life of these parts. For the same reason, before installing a new part, clean off any dust or metal 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 good 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.
LIQUID GASKET, NON-PERMANENT LOCKING AGENT
Followmanufacturers’directionsforcleaningandpreparingsurfaceswherethesecompoundswillbeused.Applysparingly,
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
Replace any oil or grease seals that were removed with new parts, since removal generally damages seals. When pressing
in a seal containing manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a
suitable driver (which contacts evenly with the side of the seal) until the face of the seal is even with the end of the hole.
Always use assembly oil or grease on the lip (sealing edge) of any seal prior to assembly.
CIRCLIP, RETAINING RING
Replace any removed circlips and retaining rings with new ones, as removal weakens and deforms them. When installing
circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

COTTER PIN
Replace any cotter pins that were removed with new ones, since removal deforms and breaks them.
REPLACEMENT PARTS
When there is a replacement instruction, replace these parts with new ones every time they are removed. Removed parts
will be damaged and/or lose their original function.
INSPECTION
When parts have been disassembled, visually inspect these parts for the following conditions or other damage (If there is
any doubt as to their condition, replace them with new parts):
Abrasions, cracks, hardening, warping, bends, dents, scratches, wear, color changes, deterioration, seizure.
SPECIFICATIONS
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
2Frame, bumpers,
nerf bars
3Front hubs,
spindles
4Steering system
5Roll bars, pads,
seatbelts
6Axle, axle cover,
drive system
components
7Brake system
8Engine, clutch,
engine mounted
accessories
Specifications.............................................. 0-1
Scheduled maintenance..............................0-8
Service schedule - gas.................................0-9
Service schedule - electric .........................0-11
Maintenance records..................................0-12
Pre-opening checklist - gas ........................0-13
Pre-opening checklist - electric..................0-14
Go-kart track area checklist.......................0-15
Non-scheduled maintenance record..........0-16
Work order tags .........................................0-17
How a warranty is processed.................... 0-20
Product return procedures ........................ 0-20
Limited warranty....................................... 0-21
Cleaning go-karts...................................... 0-22
Unloading go-karts.................................... 0-23
Initial setup ............................................... 0-26
Tube & rim information................................1-1
Frequent questions.......................................1-2
Rotating tires................................................1-2
Disc-lock lug nuts ........................................1-3
Wheel removal ............................................1-5
Changing tires & tubes ................................ 1-6
Tire & wheel inspection.............................1-10
Troubleshooting tires..................................1-11
Frequent questions (frame)...........................2-1
Frequent questions (bumper)........................2-2 Bumper & D-rubber removal .......................2-3 Nerf bar removal..........................................2-5
Steering system ........................................... 4-1
Caster.......................................................... 4-3
Toe-in..........................................................4-6
Tie rods/ends...............................................4-8
Ackerman effect.........................................4-10
Steering shaft & cover ................................4-11
Steering wheel ...........................................4-12
Steering column pad ..................................4-13
Engine overview............................................ 8-1
Grabber plate.............................................. 8-3
Engine assembly removal.............................. 8-4
Engine-mounted items.................................8-6
Hour meter schematic (without kartrol)....... 8-7
Hour meter schematic (with kartrol)............ 8-8
Tiny tach schematic...................................... 8-9
Clutch/reduction rebuild............................8-14
Overview.....................................................7-1
Caliper assembly..........................................7-3
Brake pads - removal & installation............. 7-4
Removing brake caliper assembly ...............7-5
Master cylinder overview.............................7-9
Master cylinder removal.............................7-10
Brake pedal................................................7-13
Brake fluid level inspection........................7-14
Brake fluid change......................................7-14
Bench-bleeding master cylinder.................7-15
Bleeding the brake system..........................7-17
Brake troubleshooting................................7-18
Drum brake system overview.....................7-19
Drum brake parts identification..................7-20
Changing brake shoes ................................7-21
Drum brake adjustments............................7-27
Frequent questions...................................... 5-1
Roll bar (Eagle, Scorpion, Can-Am, F-22, Sidekick) ........ 5-2
Rollbar(Sidewinder, Sidewinderdouble)......................5-3
Seat back pads ............................................5-4
Fixing pads..................................................5-6
Seatbelts...................................................... 5-7
Cleaning seatbelts....................................... 5-9
Overview.................................................... 6-2
Axle cover................................................... 6-3
Drive cover .................................................6-4
Drive belt....................................................6-6
Drive hub...................................................6-11
Drive pulley ...............................................6-12
Floater hub.................................................6-14
Axle bearing overview ...............................6-16
Bearings .....................................................6-17
Axle - single drive ......................................6-19
Axle - two-wheel drive.............................. 6-26
Drive sprocket spreadsheet ....................... 6-27
Frequent questions (hubs & spindles).......... 3-1
Front hub removal....................................... 3-3
Spindle........................................................3-4
Tapered spindle & roller bearings................ 3-5
Spindle dissassembly...................................3-8
Spindle assembly......................................... 3-9

9Fuel tank &
Emission System
10 Throttle,
cable, pedal
11 Carburetor
12 Body, body
mounts, decals
13 Electrical system
Overview.................................................... 9-1
Remote fuel tank removal ........................... 9-2
Remote fuel tank bracket removal............... 9-3
Engine-mounted fuel tank removal............... 9-4
Fuel cap/vent...............................................9-5
Evaporative system.........................................9-6
Evaporative system maintenance...................9-7
Evaporative system routing............................9-9
Throttle cable.............................................10-1
Throttle cable routing (bodied go-kart).......10-2
Throttle cable routing (eagle go-kart)..........10-3
Throttle cable removal.................................10-5
Throttle cable lubrication............................10-6
Throttle cable/speed adjustment.................10-7
Throttle pedal removal................................10-9
Throttle pedal bushings...............................10-10
Overview...................................................11-1
Identifying carburetor items .......................11-3 Carburetor check sheet................................11-7
Frequent questions.....................................13-2
Basic electrical troubleshooting ................ 13-4
Voltage drop testing ...................................13-7
Testing fuse............................................... 13-8
Wire schematic..........................................13-9
Battery pack.............................................13-10
Battery pack testing..................................13-11
Battery pack replacement.........................13-12
Fuse .........................................................13-13
Relay........................................................13-17
Linear throttle potentiometer....................13-20
Throttle cable...........................................13-27
Throttle cable adjustment.........................13-29
Motor controller.......................................13-32
Interconnect board...................................13-36
Switch box .............................................. 13-44
Switch box testing................................... 13-45
Remote shutdown wire harness................13-52
Testing flash codes...................................13-54
Controller flash faults ...............................13-58
Overview...................................................12-1
Body mounts (F-22)....................................12-3
Eagle body panels ......................................12-5
Warning decals ..........................................12-7
Body seal .................................................12-12
Bigfoot tire/tube combo #007880COMBO
All weather tire #007890WET
NEED TRACTION FOR YOUR GO-KART?
Try the treaded Duckfoot tire by
J&J/FPX. Same ultra-thick tread as our slick
Bigfoot tire with the added bonus of treads
to shed water.
Ultra-thick tread for ultra
performance and long life.
Nothing will outlast a Bigfoot!

0-1
SPECIFICATIONS: GAS-POWERED DOUBLES
DOUBLE SEAT GO-KARTS, KING SCORPION, SIDEWINDER DOUBLE, F-22 DOUBLE, SIDEKICK, DOUBLE EAGLE
DIMENSIONS
Overall length............................................................................................................................................82”(208 cm)
Overall width .............................................................................................................................................55” (139cm)
Overall height...........................................................................................................................................40” (101 cm)
Wheel base ......................................................................................................................................... 44.125” (112cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
Fuel capacity....................extra-capacity fuel tanks available, model dependent, 2.2, 3.3, 3.5 or 4.75 gallon capacities
ENGINE
Model....................................................................................................Honda GX160k1, GX200, GX240k1, GX270k1
Type.......................................................................................4-stroke, overhead valve, single cylinder, inclined by 25°
Cooling system.............................................................................................................................................. forced air
Starting system...................................................................................................................recoil, optional electric start
Spark plug ..........................................................................................................................bpr6es (ngk), w20epr-u (nd)
Lubrication system...............................................................................................................................................splash
DRIVE TRAIN
Clutch type...........................................................................................................................centrifugal, wet multi-disc
Clutch engagement/lock......................................................................................engagement 1800 rpm/lock 2200rpm
Final drive system.............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................phosphate dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type..............................................................................(self-adjusting) hydraulic disc, optional mechanical drum
King Scorpion SidewinderDouble F-22 Double
Sidekick Double Eagle

0-2
SPECIFICATIONS: GAS-POWERED SINGLES
SINGLE SEAT GO-KARTS, SCORPION, SIDEWINDER, F-22, CAN-AM, EAGLE
DIMENSIONS
Overall length............................................................................................................................................82”(208 cm)
Overall width .............................................................................................................................................45” (114cm)
Overall height...........................................................................................................................................40” (101 cm)
Wheel base ......................................................................................................................................... 44.125” (112cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
Fuel capacity....................extra-capacity fuel tanks available, model dependent, 2.2, 3.3, 3.5 or 4.75 gallon capacities
ENGINE
Model....................................................................................................Honda GX160k1, GX200, GX240k1, GX270k1
Type.......................................................................................4-stroke, overhead valve, single cylinder, inclined by 25°
Cooling system.............................................................................................................................................. forced air
Starting system...................................................................................................................recoil, optional electric start
Spark plug ..........................................................................................................................bpr6es (ngk), w20epr-u (nd)
Lubrication system...............................................................................................................................................splash
DRIVE TRAIN
Clutch type............................................................................................................................centrifugal, wet multi disc
Clutch engagement/lock......................................................................................engagement 1800 rpm/lock 2200rpm
Final drive system.............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................phosphate-dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type..............................................................................(self-adjusting) hydraulic disc, optional mechanical drum
Can-Am
Scorpion Eagle
Sidewinder F-22

0-3
SPECIFICATIONS:ELECTRIC-POWEREDDOUBLES
DOUBLE GO-KARTS, SIDEWINDER DOUBLE, DOUBLE EAGLE
DIMENSIONS
Overall length............................................................................................................................................82”(208 cm)
Overall width .............................................................................................................................................55” (139cm)
Overall height...........................................................................................................................................40” (101 cm)
Wheel base ......................................................................................................................................... 44.125” (112cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
MOTOR
Model...................................................................................................................................................................D&D
Type.............................................................................................48vdc, separately excited, 48vdc permanent magnet
Cooling system.............................................................................................................................................. forced air
Maximum horsepower....................................................................................................................... 18.6 hp (13.9 kw)
Controller..........................................................................................................................................................sevcon
Speed controller ................................................................................................................................................sevcon
Power...............................................................................................48 vdc qty 4 (12 volts blue/yellow optima battery)
..................................................................................................................... 870 amps cold cranking amps per battery
...........................................................................................................................120 amps reserve capacity per battery
DRIVE TRAIN
Clutch type..................................................................................................................................................direct drive
Forward/reverse.......................................................................................................................................................yes
High/low (optional)..............................................................................................................................yes, with Kartrol
Final drive system.............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................Phosphate-dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type........................................................................................................................(self-adjusting) hydraulic disc
Sidewinder Double - ElectricDouble Eagle - Electric

0-4
SPECIFICATIONS: ELECTRIC-POWERED SINGLES
SINGLE SEAT GO-KARTS, SIDEWINDER, EAGLE
DIMENSIONS
Overall length............................................................................................................................................82”(208 cm)
Overall width .............................................................................................................................................45” (114cm)
Overall height...........................................................................................................................................40” (101 cm)
Wheel base ......................................................................................................................................... 44.125” (112cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
MOTOR
Model...................................................................................................................................................................D&D
Type..............................................................................................48vdc separately excited, 48vdc permanent magnet
Cooling system.............................................................................................................................................. forced air
Maximum horsepower....................................................................................................................... 18.6 hp (13.9 kw)
Controller..........................................................................................................................................................sevcon
Speed controller ................................................................................................................................................sevcon
Power...............................................................................................48 vdc qty 4 (12 volts blue/yellow optima battery)
..................................................................................................................... 870 amps cold cranking amps per battery
...........................................................................................................................120 amps reserve capacity per battery
DRIVE TRAIN
Clutch type..................................................................................................................................................direct drive
Forward/reverse.......................................................................................................................................................yes
High/low (optional)..............................................................................................................................yes, with Kartrol
Final drive system.............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................phosphate-dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type........................................................................................................................(self-adjusting) hydraulic disc
Sidewinder - Electric
Eagle Electric

0-5
SPECIFICATIONS: GAS-POWERED ROOKIES
STINGER, TALON
DIMENSIONS
Overall length............................................................................................................................................ 73”(185 cm)
Overall width .............................................................................................................................................45” (114cm)
Overall height.............................................................................................................................................33” (84 cm)
Wheel base ...............................................................................................................................................36” (91.4cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
Fuel capacity..............................................................................................................(extra-capacity)2.2 gal (8.3 liters)
ENGINE
Model....................................................................................................................................Honda GX160k1, GX200,
Type.......................................................................................4-stroke, overhead valve, single cylinder, inclined by 25°
Cooling system.............................................................................................................................................. forced air
Starting system...................................................................................................................recoil, optional electric start
Spark plug ..........................................................................................................................bpr6es (ngk), w20epr-u (nd)
Lubrication system...............................................................................................................................................splash
DRIVE TRAIN
Clutch type...........................................................................................................................centrifugal, wet multi-disc
Clutch engagement/lock......................................................................................engagement 1800 rpm/lock 2200rpm
Final Drive System............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................phosphate-dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type..............................................................................(self-adjusting) hydraulic disc, optional mechanical drum
Stinger Talon

0-6
SPECIFICATIONS:ELECTRIC-POWEREDROOKIES
TALON - ELECTRIC
DIMENSIONS
Overall length............................................................................................................................................ 73”(185 cm)
Overall width .............................................................................................................................................45” (114cm)
Overall height.............................................................................................................................................33” (84 cm)
Wheel base ...............................................................................................................................................36” (91.4cm)
Ground clearance.........................................................................................................................................2.5” (6cm)
MOTOR
Model...................................................................................................................................................................D&D
Type...............................................................................................24vdc separately excited, 24vdc permanent magnet
Cooling system.............................................................................................................................................. forced air
Maximum horsepower...........................................................................................................................9.3 hp (6.9 kw)
Controller..........................................................................................................................................................Sevcon
Speed controller ................................................................................................................................................Sevcon
Power.............................................................................................................24 vdc, qty 2 (12 volts Trojan T-31-AGM)
....................................................................................................................720 amps, cold-cranking amps per battery
.......................................................................................................................... 100 amps reserve capacity per battery
DRIVE TRAIN
Clutch type..................................................................................................................................................direct drive
Forward/reverse.......................................................................................................................................................yes
High/low (optional)..............................................................................................................................yes, with Kartrol
Final drive system.............................................................................................................520 X ring hd chain, cog belt
FRAME
Type............................................................................................................................................unitized, monocoque
Coatings................................................................................phosphate-dipped and electrostatic powder-coated 425°f
Steering angle.....................................................................................................................................24° to either side
Caster............................................................................................................................................adjustable, 0° to 14°
Tires................................................................................................................................ 5” extended-wear pneumatic
Brake type........................................................................................................................(self-adjusting) hydraulic disc
Talon - Electric

0-7
IMPORTANT INFORMATION
Throughout this manual, we will discuss the proper repair techniques for your J&J go-karts: however, the most important
job of any technician is to maintain the fleet. Properly maintained equipment, in most cases, will have fewer failures,
as the problems are addressed before they happen. When following the guides in the next few pages, be sure to look
over the entire kart for potential problems and address them as needed prior to allowing guests to operate the equipment.
Each piece of equipment should be inspected daily for problems or needed repairs. As an example, if you find a tire that
is showing a wear indicator in the morning, replace the tire; it will prevent the tire from failing in the middle of the day,
requiring the kart to be taken out of service when it may be needed the most. An out-of-adjustment belt can cause
extensive wear on the belt and clutch bearings, and cause premature failure. The list goes on and on, but the key is to
maintain the equipment rather than react to failures.
Utilize the maintenance logs to track problems with your fleet. Log kart numbers and parts replaced to track other issues
that may be causing a particular kart’s parts to be damaged more quickly than they should. As an example, you may
have a kart that continually fouls a spark plug. If you do not track that type of usage, then all you know is that you go
through a lot of spark plugs when it may only be one or two karts with other issues that are causing the plugs to foul.
In that case, the real issue may be as simple as a dirty air cleaner that is not allowing proper air flow to the motor, caus-
ing it to run rich or have excessive carbon build up in the combustion chamber. In either case, the root of the problem
is something other than the spark plug, but the result is a fouled plug. This is especially important when there is more
than one maintenance person working on the equipment. If the replacement parts are not tracked, then one person
could replace a part one day, another the next, and each would not know that the single kart is wearing parts out so
quickly.

0-8
EXPLANATION OF SCHEDULED MAINTENANCE
BELOW ARE EXPLANATIONS OF THE SERVICES LISTED IN THE MAINTENANCE CHARTS FOR
GAS-POWERED GO-KARTS.
The proper fluids and lubricants to use are listed in this section. Make sure to always use the recommended fluids and lubricants. All
parts should be replaced and all necessary repairs done before the kart is operated.
<CAUTION>J&J recommends use of safety goggles or approved glasses during all servicing of J&J go-karts.
1. ENGINE OIL & REDUCTION GEAR OIL: Always use API service SG.SF/CC.CD. designation shown on the container. To determine
the preferred viscosity of oil for your go-kart’s engine, see “Engine Oil” in the Honda Shop Manual.
2. AIR CLEANER FILTER REPLACEMENT: Clean, check and replace at the specified intervals; see the Honda Shop Manual.
3. FUEL STRAINER: Clean at the specified interval or sooner if clogged.
4. SPARK PLUG CLEANING & REPLACEMENT: C l ea n a n d re place s p ar k p l u g s w i t h t h e t y p e lis t e d i n t h e H on d a Sh o p M a n ual.
5. VALVE CLEARANCE: Check and adjust at the specified intervals; see the Honda Shop Manual.
6. COMBUSTION CHAMBER & VALVES: Decarbon cylinder head and lap valves; see the Honda Shop Manual.
7. FUEL TANK, CAP & LINES INSPECTION: Inspect the fuel tank, cap and lines for damage or leaks. Remove the fuel cap, inspect the
gasket for an even filler neck imprint and any damage. Replace parts as needed.
8. FRONT HUBS AND SPINDLES: Inspect and grease the front spindles every 2 weeks or 200 hours. Front hub nuts should be torqued
to 50 ft. lbs.
9. AXLE & AXLE BEARINGS: Inspect the axle for bending and cracking. Clean and grease the axle bearings at the specified intervals or
sooner, if operated in dirty or wet conditions.
10. STEERING: Check for smooth and precise movement from full turn left to full turn right. Inspect the tie rods and rod ends for
loosening, damage or wear. To prevent uneven tire wear and a poor-handling kart, check the front end alignment weekly or every 100
hrs.
11. DRIVE BELTS: Inspect the drive belts for proper deflection, alignment and tension. Twisted or cracked belts should be replaced.
<WARNING>Too much tension shortens belt and bearing life.
12. PULLEYS & SPROCKETS: Inspect for damage and proper alignment. Replace as needed.
13. WHEEL LUG NUTS & STUDS: Check for loose wheel lug nuts and studs daily, and torque to 35 ft. lbs.
<WARNING>Check the tightness frequently during the first week or 100 hrs, and when the wheel is changed.
14. ALL NUTS AND BOLTS:Check for loose and/or missing nuts and bolts. Replace as needed.
15. HYDRAULIC DISC BRAKES INSPECTION:When the engine oil is changed, inspect the lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc. Check the fluid level in the master cylinder. A low fluid level can indicate
worn disc brake pads, which may need to be replaced. Inspect the disc for wear and improper alignment.
<WARNING>Inspect brakes more often if driving conditions result in frequent braking.
16. SEATBELTS: Inspect all belts, buckles, latch plates and anchorages daily, replace if necessary.
<CAUTION>Don’t let anyone operate the go-kart if they can’t wear a seatbelt properly. If the kart is in a crash and they are not
wearing a seatbelt, they could hit things inside the kart or be ejected from it; they can be seriously injured or killed. Always properly
fasten customers’ seatbelts, and then double-check to make certain the straps are not loose.
17. STARTER ROPE: Check the rope for fraying. Check the air intake screen for foreign matter that could cause overheating or fire; see
the Honda Owner’s Manual.
18. TIRES: For proper wear and maximum tire life, rotate the tires and check inflation (see service schedule). A properly inflated
and aligned tire should wear evenly across the tread. Replace tires when the wear indicator lines are no longer visible around the
sidewalls.
19. CHASSIS LUBRICATION:Lubricate the steering linkage, throttle linkage pedal, and throttle control arm at the specified intervals,
or after washing. When used in dusty or wet conditions, service more frequently.

0-9
Item # Item Service type Check
Frequency 1st 20 hrs Every 50 hrs Every 100 hrs Every 300hrs Every 500hrs
Log hours of operation to determine proper maintenance intervals.
1 Engine oil Check level Daily
Change 
1 Reduction gear oil Check level Daily
Change 
2 Air filter
Check Daily 
Clean (1) 
Replace (*) 
3 Fuel strainer Clean 
4 Spark plug Check 
Replace 
5 Valve clearance Adjust 
6 Combustion chamber Clean 
7 Fuel tank & fuel lines
Check Daily 
Replace lines Yearly
Replace tank When necessary
8 Front hubs & spindles
Check Daily 
Torque When necessary
Grease Yearly
9 Axle & axle bearings Check 
Grease Yearly
10 Steering Check Daily 
11 Drive belts
Check Daily 
Adjust When necessary
Replace When necessary
12 Pulleys
Check Daily 
Adjust When necessary
Replace When necessary
13 Wheel lug nuts & studs
Check Daily 
Torque wheels(35 ft.lbs) When replaced 
Replace When damaged
14 All nuts & bolts
Check Daily 
Torque Yearly
Replace When damaged
15 Hydraulic brakes
Check pad wear 
Check fluid level 
Fluid change Yearly
16 Seatbelts Check Daily 
Replace When damaged
17 Starter rope Check Daily 
Replace When damaged
18 Tires (40-50psi)
Check 
Rotation When necessary
Replace When damaged
19 Chassis lubrication Lubricate After every wash 
20 Warning decals Check Daily
Replace When damaged
GO-KART SERVICE SCHEDULE (Gas)
(1) Service more frequently when used in dusty areas.
(*) Replace paper element type only. NOTE: This is a sample form. Your checklist should include but
not be limited to these items. Make extra copies for future use.

0-10
BELOW ARE EXPLANATIONS OF THE SERVICES LISTED IN THE MAINTENANCE CHARTS FOR
ELECTRIC-POWERED GO-KARTS.
The proper fluids and lubricants to use are listed in this section. Make sure to always use the recommended fluids and lubricants. All
parts should be replaced, and all necessary repairs done before the kart is operated.
‹ CAUTION › J&J recommends use of safety goggles or approved glasses during all servicing of J&J go-karts.
1. SB175 CHARGER PLUG/CHARGER BRUSHES: Make sure that the plug is lubed with dielectric grease. Inspect the plug for deep
grooving or signs of arcing. Make sure charger brushes (if equipped) are in good condition and they both slide up and down freely
in the holder. Inspect the UHMW brush holder to be sure it is tightly fastened to kart’s chassis. Look for loose or damaged cables or
connections. Check that the brushes are making good contact with the floor plates. Repair or replace as needed.
2. 4 GAUGE POWER WIRE: Check for bare wires or heavy discoloration; Replace as needed.
3. MOTOR: Check for discoloration of the motor casing and tightness of the terminal. Use compressed air to remove dust and debris
.
4. CHARGE-STOP FUNCTION: Ensure that with charger plugged in, the acceleration function does not work.
5. SWITCH BOX: Check the switch box for proper operation (see service schedule). Externally inspect the switch box for bare or
damaged wires. Check and tighten the set screw for the on/off and forward/reverse knob (see service schedule).
6. BATTERIES: Check the terminal connections for tightness.
7. COMPONENT BOARD: Remove the cover and inspect all the components. Check for bare wires, proper connection, and any signs
of excessive heat, arcing or melting.
8. FRONT HUBS AND SPINDLES: Inspect and grease the front spindles every 2 weeks or 200 hours. The front hub nuts should be
torqued to 50 ft. lbs.
9. AXLE & AXLE BEARINGS: Inspect the axle for bending and cracking. Clean and grease all axle bearings at the specified intervals, or
sooner if operated in dirty or wet conditions.
10. STEERING: Check for smooth and precise movement from full turn left to full turn right. Inspect the tie rods and rod ends for
loosening, damage or wear. To prevent uneven tire wear and a poor-handling kart, check the front end alignment weekly or every 100
hrs.
11. DRIVE BELTS: Inspect drive belts for proper deflection, alignment and tension. Twisted or cracked belts should be replaced.
< WARNING > : Too much tension shortens belt and bearing life.
12. PULLEYS & SPROCKETS: Inspect for proper deflection and alignment.
13. WHEEL LUG NUTS & STUDS: Check for loose wheel lug nuts and studs daily, and torque to 35 ft. lbs.
< WARNING > : Check the tightness frequently during the first week or 100 hrs, and when the wheel is changed.
14. ALL NUTS AND BOLTS: Check for loose and/or missing nuts and bolts. Replace as needed.
15. HYDRAULIC DISC BRAKES INSPECTION:When the engine oil is changed, inspect the lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Check the fluid level in the master cylinder. A low fluid level can indicate worn disc brake pads,
which may need to be replaced. Inspect the disc for wear and alignment.
< WARNING > : Inspect brakes more often if driving conditions result in frequent braking.
16. SEATBELTS: Inspect all belts, buckles, latch plates and anchorages daily, replace if necessary.
< CAUTION > : Don’t let anyone operate the go-kart if they can’t wear a seatbelt properly. If the kart is in a crash and they are not
wearing a seatbelt, they could hit things inside the kart or be ejected from it; they can be seriously injured or killed. Always properly
fasten customers’ seatbelts, and then double-check to make certain the straps are not loose.
17. TIRES: For proper wear and maximum tire life, rotate the tires and check inflation (see service schedule). A properly inflated
and aligned tire should wear evenly across the tread. Replace tires when the wear indicator lines are no longer visible around the
sidewalls.
18. CHASSIS LUBRICATION:Lubricate the steering linkage, throttle linkage, pedal, and throttle control arm at the specified intervals,
or after washing. When used in dusty or wet conditions, service more frequently.
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

0-11
Item # Item Service type Check
Frequency 1st 20 hrs Every 50 hrs Every 100 hrs Every 300hrs Every 500hrs
Log hours of operation to determine proper maintenance intervals.
1SB175 charger plug/
charger brushes (*)
Check Daily
Replace When damaged
Grease terminals (2) 
2 4GA. power wire Check 
Replace When damaged
3 Motor Check Daily
Clean (1) 
4 Charge-stop function Check Daily
5 Switch box
Check operation Daily
Inspection 
Check knob set screw 
6 Batteries
Check volts Daily
Load test 
Replace When necessary
Clean terminals (1) When necessary
7 Component board Check 
8 Front hubs & spindles
Check 
Torque When necessary
Grease Yearly
9 Axle & axle bearings Check 
Grease Yearly
10 Steering Check Daily
11 Drive belts
Check Daily
Adjust When necessary
Replace When necessary
12 Pulleys
Check Daily
Adjust When necessary
Replace When necessary
13 Wheel lug nuts & studs
Check Daily
Torque wheels(35 ft.lbs) When replaced
Replace When damaged
14 All nuts & bolts
Check Daily
Torque Yearly
Replace When damaged
15 Hydraulic brakes
Check pad wear 
Check fluid level 
Fluid change Yearly
16 Seatbelts Check Daily
Replace When damaged
17 Tires (40-50psi)
Check Daily
Rotation When necessary
Replace When damaged
18 Chassis lubrication Lubricate After every wash 
GO-KART SERVICE SCHEDULE (Electric)
(1) Service more frequently when used in dusty areas.
(2) Use dielectric grease only.
(*) If equipped.
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
Go-kart ID#____________________ Date _____/______/_______
Hour meter
reading Maintenance performed Parts used Serviced by Finish date
Maintenance Record
Make extra copies for future use.

0-13
Pre-opening daily checklist for
gas-powered go-karts
Week of / /
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
1FUEL SYSTEM: check for any signs of fuel leaks
from the tank, cap, fuel filter, vents, fittings, etc.
2COVERS & GUARDS: check for proper
installation of the steering cover, axle
cover, pulley guard, fenders and body.
3SEAT BELTS: visually check for frayed
webbing, loose stitching; check
buckle and adjustment operation.
4SAFETY & WARNING DECALS:
replace if damaged or illegible.
5PADS: check seat, seat back, seat belt,
roll bar, steering wheel and steering post
pads for damage; replace as needed.
6ACCELERATOR: check for smooth
operation and full return when released.
7BRAKES: check pedal travel; check for
proper action during test drive.
8STEERING: check for smooth action;
visually check front wheel alignment.
9REMOTE SHUT-OFF SYSTEM: (if
equipped); verify proper operation, per
manufacturer’s recommendations.
10 ENGINE & REDUCTION CASE: check
oil level; fill to proper level.
11 TEST GO-KART: drive kart to
verify proper operation.
12 ROLL BAR: check for any
looseness in roll bar system.
13 D-RUBBERS & BUMPER SYSTEM:
check for any signs of damage.
Replace when necessary.
14 BODY MOUNTS: check for looseness
or improper fastening.
15 TIRES & WHEELS: verify tires’ PSI
is to specification; check wheels
for loose or missing lug nuts.
Make extra copies for future use.

0-14
Pre-opening daily checklist for
electric go-karts
Week of / /
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
1COVERS & GUARDS: check for proper
installation of the steering cover, axle
cover, pulley guard, fenders and body.
2SEAT BELTS: visually check for frayed
webbing, loose stitching, check
buckle and adjustment operation.
3SAFETY & WARNING DECALS:
replace if damaged or illegible.
4PADS: check seat, seat back, rollbar,
steering wheel and steering post pads
for damage; replace as needed.
5ACCELERATOR: check for smooth
operation and full return when released.
6BRAKES: check pedal travel; check
for proper action during test drive.
Check brake shut-off function (1)
7STEERING: check for smooth action,
visually check front wheel alignment.
8REMOTE SHUT OFF SYSTEM: ((if
equipped); verify proper operation per
manufacturer’s recommendations.
9BATTERIES: check battery voltage; if
low, inspect & load test battery.
10 TEST GO-KART: drive kart to
verify proper operation.
11 ROLL BAR: check for any
looseness in roll bar system
12 CHARGING SYSTEM: check SB175 plug
for deep grooving or signs of arcing (2);
check charger brushes for damage(*)
13 D-RUBBERS & BUMPER SYSTEM:
check for any signs of damage.
Replace when necessary.
14 BODY MOUNTS: check for
looseness or improper fastening.
15 TIRES & WHEELS: verify tires’ PSI
is to specification; check wheels
for loose or missing lug nuts.
(1) Check that when brakes are applied, the motor will not engage.
(2) Lube with dielectric grease.(See scheduled maintenance for details)
(*) (if equipped) Check that the charger brushes make contact with the floor charging plate and verify that the go-kart is receiving a charge from
battery charger.
Make extra copies for future use.