Yerf-Dog 3209 Owner's Manual
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Yerf-Dog 3209 Owner's Manual

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FOR MODEL: 3209
YOU MUST DEPRESS THE BRAKE PEDAL
This vehicle is sold for OFF-ROAD USE ONLY. Before
operating this vehicle, read all the instructions for safe
assembly and operation as well as the instructions governing
the engine and other portions of the vehicle. Pay close
attention to all caution and warning labels on the Go-Kart.
Read Important Rules for Safe Operation
before Operating Vehicle
BEFORE THE ENGINE WILL START
WARNING
NOTICE
NOTICE
For
Replacement
Parts Call:
1-888-926-6554
06111 Rev B

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Summary of Contents for Yerf-Dog 3209

  • Page 1 FOR MODEL: 3209 NOTICE Read Important Rules for Safe Operation before Operating Vehicle NOTICE YOU MUST DEPRESS THE BRAKE PEDAL BEFORE THE ENGINE WILL START WARNING This vehicle is sold for OFF-ROAD USE ONLY. Before operating this vehicle, read all the instructions for safe assembly and operation as well as the instructions governing the engine and other portions of the vehicle.

  • Page 2: Rules For Safe Operation

    Modification of this vehicle or removal of any original equipment or safety decals may render the vehicle Never remove any chained guard, or belt clutch guard. unsafe or illegal. These covers are for the riders’ protection. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 3 Always perform a Pre-Ride Inspection before starting the engine. See Pre-Ride Inspection in the manual. The custom brush guard assembled on this vehicle is for deflecting loose vegetation and must not be removed. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 4 The Owner Or Operator Assumes All The Risks Incident To Or Arising Out Of The Operation Of This Vehicle. Failure To Follow And Comply With All Warnings May Cause Serious Injury Or Death. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 5: Limited Warranty

    ENGINE Your engine manufacturer (Howhit) warrants the parts for this engine for 6 months from the date of purchase. Yerf-Dog Customer Service will facilitate any warranty questions that you may have. For questions or parts please call 1-888-926-6554. PART 2...
  • Page 6 4. Tires – Verify correct air pressure in tires. 5. Drive Chain and Sprockets – Check condition, tension, lubricate as necessary. Check sprocket for broken teeth and loose fasteners. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 7 To avoid skids while traveling on slippery terrain, the rider must exercise a high degree of caution. Turning maneuvers on slippery terrain are more hazardous than those performed under full traction and must be done slowly. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 8: Preventive Maintenance

    Rear Wheel Replacement – Loosen the 4 lug nuts in order to remove the tire. For Engine Service instructions, see the Drive Train Service Section. For Replacement Parts Please Call: 1-888-926-6554 (U.S.) 1-888-707-1880 (Canada) For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 9: Nuts And Bolts

    Bolt – 5/16" x 1” Bolt – 5/16" x 1-1/2" SEAT BELT (Female) Bolt - 3/8" x 1" (Male) (Shoulder Belt) Bolt – 5/16" x 2 1/4" Bolt Fuel Tank Bolt - 5/16" x 3/4" For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 10: Suspension Maintenance

    5. Turn the SHOCK ADJUSTMENT HOLE counter-clockwise around the SHOCK to decrease shock absorption. 6. Turn the SHOCK ADJUSTMENT HOLE clockwise around the SHOCK to increase shock absorption. 7. Experiment with the adjustment until the desired effect is attained. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 11: Assembly And Installation Instructions

    Locate Center Cap in the seat belt hardware bag Place Center Cap over center of steering wheel. Attach with phillips head screw. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 12 To move the slide on the rail with the Note: The passenger seat does adjustment lever, press outward on the not have adjustable seat rails. lever. Note: Be careful not to over tighten FRONT OF SEAT For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 13: Cargo Rack

    Lock Washer - 5/16" and (4) 5/16” nylock nuts. SHOULDER BELT ATTACHMENT Attach both driver and passenger shoulder belts to the (2) 5/16”x 2-1/4” bolts, (2) 5/16” Nylock nuts and (2) 5/16” washers. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 14 REAR BRUSH GUARD FRONT BRUSH GUARD CROSS MEMBER ATTACHMENT CROSS MEMBER ATTACHMENT Attach using (2) 5/16” x 1-3/4” bolts and (2) Attach using (2) 5/16” x 1-3/4” bolts and (2) nylock nuts. nylock nuts. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 15: Fuel Tank And Hose Attachment

    To properly check for leaks - fill tank with fuel, crank engine and let it run for a few seconds to get fuel into the fuel line, kill engine, and then check for leaks. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 16 Each headlight has one RED wire and one BLACK wire (all four wires have male plugs). Plug the RED wire (one from each headlight) into the female ends of RED splitter. Plug the BLACK wire (one from each headlight) into the female ends of BLACK splitter. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 17: Battery Installation

    Internal – Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable. Call physician immediately. Eyes – Flush with water for 15 minutes and get prompt medical attention. KEEP OUT OF THE REACH OF CHILDREN For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 18 23). Note: After adding electolyte, the battery holds enough charge to start your unit. While this is the case we recommend that you continue with the charging instructions listed below, as this will enhance the life of your battery. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 19 • Once battery is firmly seated in gray tray with rubber mat under it, attach the red positive wire to the red positive terminal on the battery. (see figure 29) FIGURE 29 For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 20: Battery Charging

    (+) pole cable to the black negative (-) of the battery. pole of the battery. Note: Always keep the battery clean. Apply dielectric grease around the battery terminals to prevent corrosion. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 21: Battery Replacement

    • Always shield eyes with protective eyewear when working around battery acid. • Battery acid is poisonous and can cause severe burns. • DO NOT smoke around batteries and keep away from open flame. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 22 FOAM PADDING PLACEMENT Attach foam padding to the go-kart as shown in the illustration. Estimated assembly time: 15 min 9” 17” 13-1/2” 11” 13-1/2” 13-1/4” 11” 13-1/4” 27-1/2” 27-1/2” For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 23 Place on frame facing towards the rear of the go-kart 1 decal 2 decals 2 decals 2 decals 2 decals Attach Grip Tape to the go-kart floorboard as shown in the illustration. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 24: Replacement Parts Identification

    ASSY;RACK & PINION W/TIE 05636 UNIVERSAL U JOINT 05594 ASSY;FRONT END 06019 SHOCK;FRONT;9-3/4";175LB 00513 1” ZINC SPACER 02451 ASSY;WHEEL;FRONT;TURF 05541 TUBE;FRONT;RIGHT;BGUARD; 05544 TUBE;BRUSH GUARD;CROSS;SILVER 05621 TUBE;FRONT;LEFT;BGUARD;SILVER 05547 HEADLIGHTS;FRONT 06108 WLDMT;CHASSIS COMPLETE;BLUE 05597 WRAP;VINYL;FOAM;KIT 05595 SEAT;BUCKET;ROTOCAST For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 25 HEAT SHIELD 05798 EX. PIPE ASSY. 05860 AIR CLEANER 05861 ELEMENT COMP AIR CLEANER 06049 FILTER;FUEL;OPAQUE 06069 CLAMP;WIRE;FUEL FILTER 05795 MUFFLER CAP 05799 GASKET, EX. PIPE 05706 BRAKE DISC 05707 DRIVE CHAIN For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 26 BATTERY COVER 05775 BATTERY STRAP 05969 CLEVIS;BRAKE;ROD 06055 SPRING;BRAKE;SWITCH H55030W SPRING;COMP;1/2X3.0;CZ H91470W RING;RETAINING;1/4";CZ H91480W COLLAR;7/16 BORE X 7/8 O 05737 CLEVIS;BRAKE;8MM;DRV TRN 05710 BRAKE INTERLOCK SWITCH 04147 SPRING;BRAKE;RETURN 05637 PLATE;BRAKE;MASTER;CYLINDER 05639 PLATE;BRAKE PIVOT For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 27 PART # DESCRIPTION 05518 TUBE;REAR;BRUSHGUARD;SILVER 06107 WLDMT;RACK;BLUE 05803 ROD;THROTTLE;ZINC 05942 ROD;BRAKE;THRD BOTH END; 05812 ASSY;STEERING;WHL;12-3/4 05640 STEERING SECTION 05672 PEDAL;THROTTLE;1-1/4";32 05673 PEDAL;BRAKE;1-1/4" 05708 ENGINE START SWITCH (RED) MISCELLANEOUS 03174 BAG;HDWR;SEAT;BELT/RAIL; 06110 ASSY;OWNERS PACKET For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 28 For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 29 For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 30: Engine Number

    GEAR OIL • API Classification GL – 5, GL – 4, GL – 3 (SAE 80W – 90) gear oil should be used. Note: SAE is an oil weight viscosity classification standard. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 31: Pre-Ride Inspection

    Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and / or death. Avoid prolonged inhalation. SWITCH ON For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 32: Break-In Procedure

    I t e m s Initial service Daily Monthly Quarterly Yearly Torque of nuts and bolts Air filter Carburetor Spark plug Drive Chain C,A,L Brake fluid Replace gearbox oil Battery Engine oil Valve clearance of engine For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 33: Maintenance And Tune-Up Procedure

    • Always check that there is plenty of brake fluid in the brake fluid reservoir. • Ensure that the rear brake pads are in good condition. • Check the brake rotor for abnormal wear. • DOT 3 – 4 brake fluid For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 34: Air Filter

    WARNING Before and during service, inspect the element for rips. A torn element must be replaced. Make sure that the element is seated properly and no foreign material can pass by it. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 35: Periodic Maintenance And Tune-Up Procedures

    • Start engine and check for leaks. • Shut off engine and check the oil level with dipstick, do NOT screw the dipstick in when making this check. Add oil if necessary to reach safe amount. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 36: Final Gear Oil

    Final drive capacity: 80cc (3 oz.) To drain gear oil, remove the drain plug at the rear case. It is recommended to warm the engine for 10 minutes or more before draining final gear For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 37 CHAIN ADJUSTMENT Loosen the jam nuts. Turn adjustments nut clockwise Leave 3/8 – 3/4 in. deflection in chain. to remove deflection in chain. Tighten jam nuts to 40 ft / lbs. For parts or service call 1-888-926-6554 • www.yerf-dog.com...

  • Page 38: Troubleshooting

    Procedures The following information is provided to help you identify probable question you may have out the operation of your go kart. See your dealer with any additional question you may have. For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 39 For parts or service call 1-888-926-6554 • www.yerf-dog.com...
  • Page 40 1743 South Horne #100 Mesa, Arizona 85204 Thank you for purchasing this fine YERF-DOG product. With proper use, maintenance and service this kart will bring many years of fun and enjoyment. Please complete this vehicle registration and warranty confirmation form to ensure protection under the terms and conditions of the warranty and to verify ownership...

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