J&J Amusements Go-Kart Eagle

Remove the engine (see page 8-1).

Remove the axle cover shoulder bolts.

ALWAYS MAKE SURE ALL SAFETY RELATED DECALS ARE LEGIBLE. REPLACE IF NECESSARY. WARNING DECAL (TO PREVENT INJURY OR DEATH) # 1-60-0388

Lift the rear of the axle cover and pull the cover away from both the center and wheel clips.

Sign off on the axle cover removal

Warning: This test requires trained personnel with PPE!

Special cap installed on the fuel tank

Fuel shut-off at the carburetor closed

Low-pressure air regulator attached to shop air supply

Pressure control knob turned counter-clockwise to minimize pressure

Air pressure regulator installed on the test cap

Tank pressurized to 3 psi using the control knob

Air supply shut off via the ball valve on the regulator

Turn the kart off and remove the battery covers or kart body to access the batteries.

< WARNING > Carefully remove the negative cable. Be sure to not allow the wrench to touch the positive and negative lugs of the battery at the same time.

NOTE: Always remove the negative cable first and attach it last when removing or replacing any battery or performing any electric service.

Sign off on the battery pack replacement

LOAD-TESTING THE BATTERY PACK WITH DIGITAL VOLT-OHM METER (DVOM)

The normal full-charge, open-circuit voltage reading for the battery pack will be approximately 52vdc. As a quick test, hook your DVOM with the min/max feature selected (if available). Drive the go-kart one lap or more, making sure to fully load the system with a brief, maximum acceleration and/or by sliding the go-kart along the track’s safety rail at full acceleration to “load” the battery pack.

If the pack is good, typical minimum voltage readings will be in the 47-48 volt range. Anything less requires immediate further testing (see testing individual batteries).

LOAD TESTING INDIVIDUAL BATTERIES WITH DVOM

This procedure requires a DVOM with a min/max feature. This will memorize the maximum voltage and the minimum voltage readings attained, as long as this feature is activated.

Attach the leads to the battery to be tested; secure the meter and drive a lap around the track. Fully accelerate to put maximum load on the battery, sliding the go-kart along the track rail for a few seconds with the full throttle applied. After the test lap, check the minimum voltage reading attained; a good battery will not go below 9.6vdc. If you get a lower reading, the battery has failed the test and must be replaced.

NOTE: Placing a failed battery on a separate, slow charger may bring it back.;

Warning: This procedure requires trained personnel with PPE!

Lock tabs pushed up from the sleeve jam nut index slots

Sleeve jam nut loosened with a spanner wrench. J&J # 1-60-0193

Bearing/sleeve assembly broken loose using a brass hammer and J&J bearing removal tool # 3-96-0104

NOTE: Be careful not to hit the axle with the hammer. A brass hammer is best for this procedure.

Bearing assembly removed as a whole or jam nut and lock ring removed separately

Bearing removed from the tapered sleeve; sleeve removed from the axle

Sign off on the bearing removal