Yerf-Dog 3203A Owner`s manual

MODEL: 3203A
OWNERS MANUAL
WARNING:
Read Tecumseh Engine Owner’s Manual and Important
Rules for Safe Operation before Operating Vehicle
WARNING:
YOU MUST ADD OIL TO THE ENGINE PRIOR TO USE!!!
20 oz. or 1 ¼ Pints (.6 Liters) OF SAE 30 MOTOR OIL
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 Fun-Kart.
For Replacements Parts Call:
1-888-389-5522 (U.S.) 1-888-707-1880 (Canada)
11/01/02
02456
Rev. L
1
NOTE: All the items (1-33) below should be read and understood by the Operator
and Parent. Failure to follow these instructions could endanger personal safety of
the operator and any passenger.
1. This vehicle is not licensable. IT IS NOT TO BE OPERATED ON ANY PUBLIC ROAD, STREET,
SIDEWALK or ALLEY. To do so would be a violation of local law. This vehicle may be operated only on
private property and upon areas approved by local law.
2. This vehicle should NEVER be operated indoors. The exhaust from the engine contains carbon monoxide,
which is tasteless, odorless, and poisonous gas.
3. This Fun-Kart is not intended nor designed for racing.
4. The operator of this vehicle should always wear a D.O.T approved helmet and other
protective equipment as recommended by state and local laws. The operator should also wear face
shields or goggles, boots, gloves, and other appropriate protective clothing.
5. Unless otherwise specified in this manual, all screws, nuts, and bolts must be kept tight to ensure that the
vehicle is in safe operating condition. The engine must be kept free of all dirt and other accumulations, paying
particular attention to throttle linkage area.
6.
Prevailing Torque type locknuts lose their locking capability with repeated use and require
replacement. Ensure locknuts are functioning properly.
7. The tire pressure should be checked prior to each use. The recommended inflation pressure is the maximum
tire pressure which is printed on the tire’s sidewall. Improper tire pressure may cause instability and may
prevent proper braking or steering.
8. Modification of this vehicle or removal of any original equipment or safety decals may render the vehicle unsafe
or illegal. Never remove any chained guard, or belt clutch guard. These covers are for the riders’
protection.
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9. The vehicle should never be started without first checking to see that the throttle is in idle position. Do not start
engine without verifying proper function of the throttle.
10. Never attempt to start this vehicle without having the operator sitting in the proper position to
ensure control of the kart.
11. The operator’s ability to operate this off-road vehicle safely is largely dependent upon the operator’s ability to
exercise proper judgment. An operator also must not be too small or too large for controlled operation. The
operator must be at least 16 years of age and have understanding, mental capacity and physical capability to
safely operate this vehicle. This vehicle should only be operated after mature, supervised instruction and
sufficient practice in non-congested areas.
12. This vehicle is designed for one operator and one passenger. A passenger on any vehicle must be
sufficient age, understanding, mental capacity, and physical capability to act to protect himself/herself, and wear
a D.O.T approved helmet at all times. This kart is not recommended cumulative weights exceeding
250 pounds.
13. The engine should be stopped when the vehicle is not in use.
14. Loose clothing, long hair, or articles worn by any riders must be fully contained, or
covered to prevent them from possibly being caught in rotating parts of the vehicle or the
surrounding environment while riding. Failure to obey could endanger the personal safety of
the Riders.
15. Do not place hands, feet, or any other part of the body or any clothing near the engine, muffler,
wheels, chain, and other rotating parts of the vehicle while riding or running the engine. Caution
must be used in performing required maintenance on or near an operating engine. Special caution should be
taken after the engine has been running, since the engine and other drive components may be extremely hot.
16. Wet, slippery, rough, or steep terrain is potentially dangerous and may result in injury if proper caution is not
observed. Slow speeds are required to safely operate this vehicle under those conditions. The Operator must
use mature judgment, skill, and experience to choose a speed suitable for the terrain and riding conditions.
17. The Governor settings for this vehicle’s engine must not be tampered with, altered or changed.
The governor is set by the engine manufacturer and limits the maximum speed of the engine (and vehicle) and
protects the engine from damage. Excessive speeds are potentially dangerous to the rider and the engine.
18. Each time before using this vehicle, the fuel supply should be checked. The fuel tank should never be
filled while the engine is running or while the engine is hot. Do not fill tank in closed area such as a
garage, while smoking, or in the vicinity of an open flame. Do not overfill the tank. Always allow at
least ¼ inch of space at the top of the tank for expansion. Never top off tank. Replace cap tightly to
prevent spillage of fuel and potential fire hazard. After filling tank, move the vehicle at least 15 feet
away from spot of filling before starting.
19. If the vehicle should start making unusual noise or vibrating abnormally, the engine should be stopped and the
spark plug wire disconnected. The vehicle should then be checked for damage. Excessive noise or vibration is
generally a warning of loose or worn parts.
20. When making repairs or adjustments to the vehicle which do not involve adjustments to the engine, the spark
plug wire must be disconnected and kept away from the spark plug to prevent accidental starting. When
working on or around or when restarting engine, use extreme caution to avoid contact with the muffler, cylinder
head, or any other potentially hot area on or around the engine.
21. Always perform a Pre-Ride Inspection before starting the engine. See Pre-Ride Inspection in the manual.
3
22. The custom brush guard assembled on this vehicle is for deflecting loose vegetation and must not be removed.
23. When storing the vehicle, it must be kept in a place where gasoline fumes will not reach an open flame or spark.
For long periods of storage, such as for winter, the fuel tank should be drained in the open, cool area. The
engine must be allowed to cool before storage in any enclosure. Read and keep all printed material supplied
with this vehicle. Timely and specific instructions and an Operators Manual revisions are included in
supplements. If any printed material included is unclear, please call 1-888-389-5522 for assistance.
24. Never operate this vehicle while under the influence of alcohol, drugs, or medication of any
kind. Such operation could be dangerous to you and/or others.
25. Always slow down while turning. High speed turning may cause loss of control, possible injury to the Operator.
26. Do not race, jump, and perform “stunt” riding or ”spinouts” when operating the Fun-Kart. The
Fun-Kart is not designed or intended for such operation.
27. This manual provides guidelines for the assembly, maintenance, and operation of this Fun-Kart and is not
intended as a service manual.
28. Assembly, maintenance, and/or repair of this Fun-Kart should only be performed by persons of sufficient
mechanical skill, experience, and judgment (such as outdoor equipment dealers, motorcycle dealer/shops, or
small engine dealers) so that no unsafe condition or modification is made.
29. Always use extreme caution when starting the engine. Avoid touching the engine, muffler, or drive components.
These areas could cause burns on contact.
30. Operator must always be appropriately supervised at all times while operating this vehicle.
31. Riding your Fun-Kart requires skill acquired through practice over a period of time. Take the time to learn the
basic techniques before attempting to ride the vehicle.
32. Ride only on safe and familiar terrain. Avoid loose gravel and rocks. Be careful on wet surfaces and allow for
extra braking distance.
33. ALWAYS mount the caution flag provided on the Fun-Kart for safety purposes. This flag could help prevent
dangerous situations.
Pay close attention to all Caution and Warning labels on the FunKart.
ASSUMPTIONS OF RISK
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
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YERF-DOG Fun-Karts by Flexible Flyer
LIMITED WARRANTY
The Limited Warranty on this vehicle is in two (2) parts:
We offer the original purchaser of this product the following warranty:
PART 1
ENGINE
Tecumseh warrants the engine for (2) years, NOT Flexible Flyer. See Tecumseh Engine Owner’s
Manual. Engine repair, replacement parts, and warranty claims must be handled through an
authorized dealer in your locality. Tecumseh has an extensive authorized sales and service dealer
network. (See yellow pages of phone directory under “Engine-Gas”).
PART 2
FRAME
The frame and related components are warranted by Flexible Flyer and are applied to any part found
to be defective due to material and/or workmanship when inspected at the Flexible Flyer factory.
Flexible Flyer will at its’ option, repair or replace the defective parts to the original purchaser at no
charge.
The warranty periods are as follows from the date of purchase:
A. Frame for 90 days, Void if:
1. Frame is broken or bent due to abuse (underside scraped abusively).
2. Wheels are bent or broken due to impact.
3. Spindles are bent due to impact.
4. Paint is worn off of rear bumper indicating an extra rider.
5. Axels are bent out of ordinary position either horizontally or vertically.
6. Non-Factory altering of engine or it’s components.
B. Bearings and sprocket for 30 days
C. Clutch for 30 days against breakage of its parts. No warranty is applied for wear of clutch shoes or
clutch bearings due to service.
D. Throttle cable, brake cable, brake band, chain, tires, seat, shocks, fasteners and other
components are not warranted because due to normal service they are subject to excessive wear
and abuse.
All Warranties are voided if the vehicle has been altered in any way or is used in racing or competition,
rented, used under abnormal conditions, or subject to abuse, misuse, neglect, or improper maintenance.
Flexible Flyer is not liable for any damage claim or liability claim, personal or otherwise
resulting from the operation of this vehicle in any way.
FLEXIBLE FLYER
100 Tubb Avenue
West Point, MS 39773
FOR REPLACEMENT PARTS PLEASE CALL:
1-888-389-5522 (U.S.) 1-888-707-1880 (Canada)
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ASSEMBLY
1. Complete the Fun-Kart registration and warranty confirmation on the back of this owner’s manual and
mail in within 10 days of purchase. The information is required when ordering parts.
2. Steering Wheel - Bolt the steering wheel to the anchor plate with fasteners provided in the parts bag
included with the Fun-Kart. See “Steering Wheel Assembly Instructions” page 12.
3. Seat - Install the seat frame to chassis frame with fasteners provided in the parts bag. See “Seat
Assembly Instructions” page 13.
4. Brush Guard - Bolt the brush guard to chassis frame with fasteners provided in the parts bag. See
“Brush Guard Instructions” page 14.
5. Foam - Attach Foam to Brush Guard. See “Foam Attachment Diagram” page 15.
6. Bolts - Check the screws, nuts and bolts on your vehicle to see that all are tightened securely. For safe
operating conditions, do periodic checks and tighten securely.
7.
Engine - Fill the crankcase with oil until it reaches the FULL mark
on the dip stick.
DO NOT fill above the FULL mark.
Approximately 20 oz. or 1¼ pints (.6 Liters) of SAE 30 weight oil.
For additional information refer to Tecumseh engine manual for servicing the engine.
8. Fill fuel tank with regular gasoline, leaded or unleaded. Do not use
premium gasoline. Do not overfill (No fuel in filler neck).
9. Tire Pressure
CHECK AIR PRESSURE IN TIRES!!
It is common industry practice to over inflate the tires. This is done to guarantee an airtight seal. Prior to
riding the Fun-Kart for the first time, you may need to reduce the air pressure in the tires to the
specifications stated below:
Rear Tires
Front Tires
10 PSI
12 PSI
Proper tire pressures will increase the life of the tire and enhance the performance of the Fun-Kart.
Driving on asphalt or concrete will significantly reduce the life of the tire!!
PRE-RIDE INSPECTION
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WARNING - Perform this pre-ride inspection everyday before riding
the vehicle. If not performed, serious damage to the vehicle and
personal injury may result.
1. Engine Oil Level – Add oil if required. Check for leaks. Tighten filler cap securely.
2. Fuel Level – Add fuel if necessary. Do not overfill (no fuel in filler neck). Replace cap tightly. Check
for leaks. Do not mix oil with gas. Only refuel when engine is off and cool.
3. Brakes – Perform a Brake Test: Sit in the vehicle with the brake actuated by pressing on the brake
pedal. Start the engine with the ignition switch on. Increase the engine RPM gradually to ensure the
brake is effective. Do not operate this Fun-Kart unless the brake is working properly.
4. Tires – Check conditions and pressure.
5. Drive Chain – Check condition, tension, lubricate as necessary.
6. Throttle – Check for smooth operation. Assure throttle “snaps” back to idle. Also, check for frayed
cable or damaged cable conduit. If either condition exists replace the cable assembly before
riding.
7. Stop Switch – Perform this stop switch test. While the engine is running, move the steering column
remote stop switch to the “OFF” position. If this does not stop the engine, move the engine remote
switch to the “OFF” position. If the engine is not equipped with an engine remote switch, pull the spark
plug wire. Check to insure that the stop switch wire is attached to the terminal on the engine. Do not
operate this vehicle with a stop switch that is not functioning properly.
8. All Nuts, Bolts and Fasteners – Check wheels to assure that all axle nuts and lug nuts are tightened
properly. Check and tighten all other fasteners as necessary. Regularly check set screws on
sprockets and drum.
9. Guards – Ensure all protective guards are in place. Never remove any chain guard, or clutch
guard. Each of these covers have a protective purpose, if removed it could endanger the personal
safety of the operator or passenger.
10. Steering System – Ensure that it turns freely.
STARTING INSTRUCTIONS
NOTE: Do not attempt to start or operate this machine without being
completely familiar with all controls necessary to operate this vehicle
safely. Do not start the engine before reading and understanding all the
rules, warnings, and instructions in this manual.
1. Before starting the engine, the operator should be seated in the Fun-Kart. If the rider is not seated in
the vehicle, it should be placed against a stationary object and started.
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2. Do not start the engine before checking to make sure the throttle assembly is in the idle position.
Warning – Each time prior to starting the engine, check throttle assembly to ensure that when the
throttle pedal (right side) is pushed all the way forward the assembly is working smoothly and returns
to idle when released. Do not operate if pedal and engine throttle linkage fail to return to idle.
3. To start a cold engine, pump the engine primer “3” times. If the engine is hot, priming may not be
necessary to restart the engine.
4. Pull recoil starter rope sharply. See Tecumseh engine owner’s manual. Do not flood the engine by
continuously pulling the starter rope. If engine does not start after two or three pulls of the starter rope,
wait a few minutes then repeat the above procedures.
OPERATIONAL SAFETY TIPS
TURNING MANUEVERS
The new rider must learn to shift his weight and control the throttle to allow the rear tires to negotiate the
turn. This is the primary technique to be mastered in riding this vehicle. Practice turning at slow constant
speeds. Defer increased speeds until you are confident of your proficiency and are intimately familiar with
the terrain.
Steer in the direction of the turn, and lean your body to the inside of the turn in order to maximize front tire
traction. Use the throttle to maintain posture throughout the turn.
Incorrect turning techniques may cause the front tires to slide straight ahead without affecting the vehicles
direction of travel. If this should occur, come to a stop, then resume the technique outlined above.
If the front wheels tend to skid in mud, sand, or snow, you may be able to improve control by releasing the
throttle and allowing the vehicle to coast through the turn.
If rear wheel inadvertently skid sideways, correct your slide by steering in the direction of the skid, if you
have room to perform this maneuver safely. Avoid braking or accelerating until you have control.
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.
PREVENTIVE MAINTENANCE
STORAGE
In the event your vehicle is not to be operated for a period in excess of 30 days and at the end of riding
season prepare for storage as follows:
WARNING - Do not drain fuel while engine is hot. Be sure to move
vehicle outside before draining fuel.
1. Drain fuel tank and remove all fuel remaining in the tank by using a suction device or by soaking up
the fuel with a clean rag or towel. Remove all fuel remaining in the carburetor by allowing engine to
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run out of fuel. Do not perform any fuel removal procedure while smoking or near an open flame.
Dispose of any rags or towels properly.
2. Lubricate engine cylinder by removing the spark plug and pouring an ounce of lean lubricating oil
through the spark plug hole into the cylinder. Crank the engine slowly to spread oil and replace spark
plug.
3. Do not save or store gasoline over winter. Using old gasoline that has deteriorated from storage will
cause hard starting and affect engine performance.
4. When the vehicle is removed from storage re-read the owner’s manual, perform any assembly
required, and perform a pre-ride inspection. See Pre-Ride Inspection section of this manual.
GENERAL
Just as your automobile needs professional, mechanical maintenance from time to time, so does this
vehicle. Replacement of the spark plug and ignition points is made necessary by normal use.
Professional air-cooled engine service is easily obtained. Check your phone book yellow pages under
“Engine Gasoline”.
SERVICE INSTRUCTIONS
Engine Lubrication – You must change the oil in the crankcase after the first two hours of operating your
new engine and after each 25 hours of use thereafter. That will insure proper lubrication in internal parts
and prevent costly repairs due to excessive wear. Refer to Engine Maintenance Instructions.
Kart Lubrication – Every two or three hours of use lubricate the following items with several drops of oil;
steering bearing points, brake rod pivot points, pedal pivot points, steering spindles, and steering rod
ends. Use the same grade of lubricating oil that is used in the engine crankcase.
Chain Lubrication – For the best chain life, it should be lubricated with a graphite type of lubricant
such s the spray-on type which evaporates leaving the graphite on the chain. Using oil or grease on
the chain in dusty or sandy riding conditions may cause dirt particles to stick to the chain resulting in rapid
wear from abrasion.
Front Wheel Replacement – Care must be used when replacing wheels. Do not over tighten nuts. It is
only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum endplay. If the
wheel does not turn freely the nut is too tight.
Rear Wheel Replacement – Loosen the large locknut in the center of the wheel to remove the rear wheel.
Chain Adjustment – After the first two hours of operation, check the chain adjustment and readjust it if it
has more than 1/2” flex. Loosen the engine clamp nuts and slide the engine forward to tighten chain.
For Replacement Parts Please Call:
1-888-389-5522 (U.S.) 1-888-707-1880 (Canada)
SUSPENSION MAINTENANCE
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The Suspension System on your Fun-Kart is specifically designed and set up for the smoothest possible
ride, while maintaining top performance and kart durability. Your Fun-Karts suspension system uses four
shock absorbers, two on the front suspension and two on the rear suspension, to comfortably tackle rough
terrain.
The two front shock absorbers affect the camber or slant of your front tires. You may have noticed that
your new Fun-Kart has an extreme outward camber or slant of the front tires as shown in Figure A. This
is normal. They were set this way at the factory for ensuring maximum tread life on the front tires. There
are three important reasons for this outward camber:
1. The weight of the driver and/or passenger is not on the Kart.
The added weight of the driver and/or passenger pushes the front and rear suspension down.
2. The Fun-Kart is not in motion.
When the Kart is in motion, the front suspension is forced down slightly.
3. The shock absorbers are new and not “broken in”.
Your new Fun-Kart needs at least one hour of use to “break in” the shocks and level out the tires.
After the first 30 minutes of use, the outward camber may be reduced by one half. After 1 hour of use
the tires may have almost no or slight outward camber as shown in Figure B.
When your Fun-Kart gets an inward camber on the front tires from shock wear as shown in Figure C and
steering becomes difficult, the shocks will need to be readjusted. Adjust the front suspension to a slight
outward camber as shown in Figure B by increasing the shocks. Adjust the shocks by following the
“Shock Absorber Adjustment “ instructions below. When your shocks cannot be adjusted any tighter, they
must be replaced.
A. EXTREME OUTWARD CAMBER
B. SLIGHT OUTWARD CAMBER C. INWARD CAMBER
(NEW SHOCKS, NOT BROKEN IN)
(SHOCKS BROKEN IN)
(SHOCKS NEED TO BE
ADJUSTED OR REPLACED)
Your Fun Kart has an added feature on the A-Arms for three quick Camber Adjustments Figure D.
Note: The factory attaches the shocks at position 2. You may choose to move them to position 1 and
adjust shocks to set at Slight Outward Camber (Riding Position) until the shocks “break in” then either
readjust the shocks as shown in
FIGURE D – THREE QUICK CAMBER ADJUSTMENTS
“Shock Absorber Adjustment” or move
DISPLAY POSITION
RIDING POSITION
to position 2. Shocks may bottom out
(cannot be adjusted any tighter) before
you need to set to position 3.
To adjust: Remove 3/8” x 1-3/4” Bolts
and 3/8” Nylock Nuts attaching the
bottom of the Shocks to the Three
Hole Brackets and move to desired
hole then reattach Shocks. Tighten
Bolts.
NOTE: Outside holes can be used for new
kart display purposes with new shocks.
(Setting at “NO CAMBER”)
POSITION 1
OUTSIDE HOLE
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POSITION 2
MIDDLE HOLE
POSITION 3
INSIDE HOLE
SHOCK ABSORBER ADJUSTMENT
SHOCK ADJUSTMENT HOLE
(78) SHOCK ABSORBER
1. Locate
the
SHOCK
ABSORBERS (78) at the front
and rear of the FUN-KART.
5. Turn the SHOCK
ADJUSTMENT
HOLE
counter-clockwise around
the SHOCK to decrease
shock absorption.
2. The factory pre-set the
SHOCKS for normal operating
conditions.
6. Turn the SHOCK
ADJUSTMENT
HOLE
clockwise around the
SHOCK to increase shock
absorption.
3. Locate
the
SHOCK
ADJUSTMENT HOLE at the
base of the spring.
Counter
4. Place the end of a narrow
screwdriver in the SHOCK
ADJUSTMENT HOLE.
Clockwise
7. Experiment with the
adjustment
until
the
desired effect is attained.
STEERING WHEEL ASSEMBLY INSTRUCTIONS
(90) STEERING
WHEEL
(9) 1/4” - 20 x 1-3/4”
HEX HEAD BOLT
(55) 1/4” NYLOCKNUT
(89) STEERING SHAFT
(90) STEERING WHEEL
(89) STEERING SHAFT
(113) STEERING WHEEL CAP
(A) PHILLIPS HEAD SCREW
(9) 1/4” - 20 x 1-3/4”
HEX HEAD BOLT
STEERING WHEEL HARDWARE
Item Descritption
Qty
9 BOLT, 1/4"-20 X 1- 3/4"
3
55 NUT, 1/4" - 20
3
113 STEERING WHEEL CAP
1
A SCREW
1
11
SEAT FRAME ASSEMBLY INSTRUCTIONS
76
77
18
(Male End)
77
(Female End)
11
60
57
77
(Male End)
For ease of assembly, lay the seat frame on a table, seat back plate down, and seat bottom
coming up away from the table.
SEATBELT ATTACHMENT HARDWARE
Item # Description
Qty
11 BOLT;3/8-16 X 1” HEX
1
18 BOLT;5/16-18 X 1-1/2 CARRIAGE
4
57 NUT;3/8-16 NYLOCK
1
60 NUT;5/16-18 NYLOCK
4
77 SEAT BELT; RETRACTABLE
2
76 SEAT RAIL
2
57
Attach the two
female seat belt ends
(77) to the tab at the
rear center of the
seat frame with bolt
(11) and nut (57), as
shown. Tighten
securely.
11
77
(Female End)
12
The seat rail slides can be moved to allow access to the
mounting holes in the seat rail.
To move the slide on the rail with the adjustment lever,
press outward and down on the lever.
Move the slide of the seat adjustment
upward for access to the lower, square
mounting hole. Insert carriage bolt (18)
through bottom square hole of seat frame;
through mounting hole of
76
18
SEATBELT ATTACHMENT HARDWARE
Item # Description
Qty
9 BOLT; 1/4-20 X 1-3/4
1
18 BOLT;5/16-18 X 1-1/2 CARRIAGE
4
107 CUSHION; SEAT
1
60 NUT;5/16-18 NYLOCK
4
77 SEAT BELT; RETRACTABLE
2
75 SEAT FRAME
1
76 SEAT RAIL
2
8 WASHER; 1/4" LOCK
1
60
77
male seat belt (77), and through the seat
adjustment rail (76).
Place nut (60) on end of carriage bolt (18)
and tighten.
Note: Make sure the seat belt is extending
to the outside of the seat frame.
13
SEAT ASSEMBLY INSTRUCTIONS
1. Locate the SEAT ASSEMBLY with LAP BELTS, and SHOULDER BELTS. Insert the bolt(9) and
washers(8)(99) into the bottem of the SEAT ASSEMBLY as shown.
2. Align the STUDS on the bottom of the SEAT ASSEMBLY with the SEAT TAB HOLES on the FUNKART FRAME.
3. Insert the STUDS into the SEAT TAB HOLES.
4. Secure the SEAT ASSEMBLY using four 5/16” FLAT WASHERS (101) and four 5/16”
NYLOCK NUTS (60).
5. Run pull cord through Eye Bolt(108) and attach Eye bolt to frame using Nylock Nut(55)
as shown below.
NOTE: The ends of the SHOULDER BELTS will be mounted onto the sides of the RACK
BRUSH GUARD in step 6 of the BRUSH GUARD ASSEMBLY INSTRUCTIONS on page 14.
14
BRUSH GUARD ASSEMBLY INSTRUCTIONS
NOTE: Attach all parts of BRUSH GUARD BEFORE tightening bolts.
1. Attach the front portion of the RACK BRUSH
GUARD(36) to the middle tabs on the FUN- KART
FRAME, behind the SEAT, using the hardware shown.
5. Join and secure the two portions of the TOP
BRUSH GUARD(31) with the CROSS BRUSH
GUARD(32) using the hardware shown.
2. Attach the rear protion of the RACK BRUSH
GUARD(36) and SAFETY FLAG (47) to the rear
tabs on the FRAME using the hardware shown.
6.
TIGHTEN BOLTS starting at the back of the cart
working toward the front.
3. Attach the FRONT BRUSH GUARD (33) to the front
tabs on the FRAME using the hardware shown.
7. Mount the ends of the SHOULDER BELTS to the
sides of the RACK BRUSH GUARD (36)
using the hardware shown.
4. Attach the TOP BRUSH GUARDS (31) to the RACK
(36), then to FRONT BRUSH GUARD (33) using the
hardware shown.
NOTE: Do not overtighten the hardware attaching the
ends of the SHOULDER BELT. The BELT must
rotate.
( 32)
CROSS BRUSH GUARD
(31)
TOP BRUSH GUARD
(33)
FRONT BRUSH
GUARD
(36)
RACK BRUSH GUARD
(40)
FUN-KART FRAME
15
BRUSH GUARD HARDWARE
Item
Description
17
Bolt: 5/16-18x1 Hex
19
Bolt: 5/16-18x1.5 Hex
20
Bolt: 5/16-18 x 1.75; Hex
60
Nut: 5/16"-18 NYLOCK
82
Spacer: BLACK PLASTIC
101
Washer: 5/16" FLAT
Qty
5
6
2
11
1
15
FOAM ATTACHMENT DIAGRAM
Attach FOAM (48) to the BRUSH GUARDS using CABLE TIES (35) on front
sections as shown. Attach WRAPS (49) over FOAM (48).
16
SUGGESTED DECAL APPLICATION
Apply Decal kit (#44)(04197) as shown in the illustration below.
Before application,
1. Wipe surface with a clean cloth. Make sure surface is dry and free of dust and dirt.
2. Lay decal on floorpan to view the area it will cover.
To apply decals,
1. Peel from center of the backing to expose adhesive surface.
NOTE: DO NOT REMOVE DECAL BACKING COMPLETELY.
This will cause decal to curl and stick to itself.
2. Align decal with floorpan, gently press adhesive to floorpan to start application.
3. Slowly peel backing from underside of decal, gently pressing out any air bubbles.
Continue until the decal is completely adhered to floorpan.
4. Use a cotton rag working in a circular motion to press out any air bubbles.
17
3203A REPLACEMENT PARTS IDENTIFICATION
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
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Part No.
01756
01755
01132
H93110W
H92010W
H99502W
Q43203W
000710P
H32503W
H33137W
H61610W
00922
22000300
00920
22000900
H95188W
2200040
H93290W
2200030
H33135W
00996
H33136W
H36254W
22001700
04476
04251
04252
04421
04446
04420
03147
03149
03278
31004600
M12501W
03235
M13501W
M01001W
00994
02450
03191
H91480W
02907
02938
02908
02458
H92700W
M72038W
02611
01134
Q33100W
001203P
HH10014
001205P
00995
Description
Item
59
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63
64
65
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67
68
69
70
71
72
73
75
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77
78
79
80
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100
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105
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112
113
A-ARM, LEFT, RED
A-ARM, RIGHT, RED
AXLE SHAFT
BEARING RETAINER
BEARING, 1" I.D.
BEARING, 5/8" I.D.
BELT, DRIVE
1/4" LOCK WASHER
BOLT, 1/4-20 X 1.75 HEX
BOLT, 3/8-16 X 1.00 CARRIAGE
BOLT, 3/8-16 X 1.00 HEX
BOLT, 3/8-16 X 1.50 HEX
BOLT, 3/8-16 X 1.75 HEX
BOLT, 3/8-16 X 2.00 CARRIAGE
BOLT, 3/8-16 X 2.00 HEX
BOLT, 5/16-18 X 0.75 CARRIAGE
BOLT, 5/16-18 X 1.00 HEX
BOLT, 5/16-18 X 1.50 CARRIAGE
BOLT, 5/16-18 X 1.50 HEX
BOLT, 5/16-18 X 1.75 HEX
BOLT, 5/16-18 X 2.25 HEX
BOLT, 5/16-24 X 0.50 HEX
BOLT, 5/8-18 X 3.75 HEX
BOLT, 5/8-18 X 7.00 HEX
BRACKET, BRAKE BAND RETAINER
BRACKET, FOOT PEDAL, LEFT
BRACKET, FOOT PEDAL, RIGHT
BRAKE BAND
BRAKE CABLE, 18-7/8”
BRAKE DRUM, 6" DIAMETER
BRUSH GUARD, TOP RED
BRUSH GUARD, CROSS RED
BRUSH GUARD, FRONT RED
CABLE ATTACHMENT, BLACK
CABLE TIE, 11" BLACK
BRUSH GUARD, RACK RED
CABLE TIE, 23"
CABLE TIE, 3-1/4" BLACK
CHAIN, DRIVE, #40, 70 LINKS
CHASSIS, FULL, RED
CLUTCH MOUNT ASSY, ZINC
COLLAR, 7/16" BORE X 7/8" O.D.
COVER MOUNT BRACKET
CHECKERED FLOOR DECAL
DRIVE COVER, BLACK
ENGINE, 6.5 H.P. TECUMSEH
FLAG, SAFETY
FOAM, 2" X 72" BLACK
WRAP VINYL CHECKERED 14"
KEY, 3/16 X 3/16 X 3.25
KILL SWITCH
NUT, 1/4-20 NYLOCK
NUT, 1-14 THIN NYLOCK
NUT, 3/8-16 NYLOCK
NUT, 3/8-16, JAM
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Part No.
HH37524
HH1256T
HH62518
01226
01225
01133
02953
01528
H91470W
01492
27000100
001474P
02946
H93200W
04449
03340
H92740W
26000900
02972B
00951
00919
00983
001467P
00513
02954
02955
H55030W
H92541W
23001100
02956
H92561W
02957
36000700
26000209
02063
02451
02564
Q43200W
Q43201W
001812P
001616P
001618P
H53132W
H56251W
H92690W
00925
02566
H12103W
H32505W
02625
04448
01069
02604
02456
H91780W
Description
NUT, 3/8-24 THIN NYLOCK
NUT, 5/16-18 NYLOCK
NUT, 5/8-18 THIN NYLOCK
NUT, 5/16-18 JAM
BOLT, 5/16-18 X 5/8" HEX
SPACER 0.78 ID DRIVE
PITMAN ARM, RED
RETAINING RING, 1" HEAVY DUTY
RETAINING RING, 1/4"
ROD, THROTTLE / BRAKE, RED
ROLL PIN, 1/4 X .875
SCREW, SHEET METAL
HXHD BOLT FLTRD 1/4-20x1-1/2
SCREW, 1/4-28 X 0.250 SET
BOLT, 3/8-16 X 2-1/2”, CARRIAGE
SEAT FRAME, RED
SEAT RAIL, 1 PAIR
SEATBELT, RETRACTABLE
SHOCK ABSORBER BLACK
SLEEVE, 13-1/8" BLACK PLASTIC
SLEEVE, 2-3/8" BLACK PLASTIC
SLEEVE, 4-5/8" BLACK PLASTIC
SPACER, BLACK PLASTIC
SPACER, SPINDLE
SPINDLE, LEFT, RED
SPINDLE, RIGHT, RED
SPRING, 1/2 X 3.00 COMPRESSION
SPROCKET, 10 TOOTH
SPROCKET, 60 TOOTH
STEERING SHAFT, RED
STEERING WHEEL, 13"
SWING ARM, RED
THROTTLE CABLE, 40"
TIE ROD, LONG
TIE ROD, SHORT
TIRE, FRONT, TURF
TIRE, REAR, 20" SUPER TURF
TORQUE CONVERTER, DRIVEN
TORQUE CONVERTER, DRIVER
WASHER, 1/4" FLAT
WASHER, 3/8" SPECIAL FLAT
WASHER, 5/16" FLAT
WASHER, 5/16" INTERNAL TOOTH
WASHER, 5/8" NARROW FLAT
WIRE CLIP
WIRE, 16GA X 107" KILL SWITCH
SEAT CUSHION
EYE BOLT
SCREW, SELF TAPPING 1/4"
SLEEVE AXLE, 4"
SPACER, 3/8”
STEERING WHEEL CAP
4-CYCLE ENGINE OIL
OWNERS MANUAL
OWNERS MANUAL, ENGINE
19
MODEL 3203 SERIES
Los MODELOS 3203
Diagram of Product / Diagrama de Producto
20
VEHICLE REGISTRATION AND WARRANTY CONFIRMATION
IMPORTANT!
Please return this information within 10 days of purchase to validate your warranty.
Return to:
F.F. Acquisition Corp.
YERF-DOG Warranty Dept.
P.O. Box 1296
West Point, MS 39773
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 of this product.
To ensure maximum safety while operating your YERF-DOG Fun Kart, observe the following precautions:
OPERATE THIS KART OFF ROAD ONLY
ADULT SUPERVISION FOR OPERATORS UNDER 16 YEARS OLD
WEAR A D.O.T. APPROVED HELMET, PROTECTIVE EYE WEAR, AND CLOTHING
SECURE LONG HAIR AND LOOSE CLOTHING; KEEP ARMS, LEGS, AND FEET INSIDE THE KART
DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL
To ensure maximum owner satisfaction and understanding of this product, you should:
READ OWNERS MANUAL BEFORE OPERATING KART
REVIEW AND FULLY UNDERSTAND THE KART AND ENGINE WARRANTIES
INSPECT THE KART UPON DELIVERY
SECURE A COMPLETED COPY OF THIS CERTIFICATE FOR YOUR RECORDS
In signing this document, the purchaser acknowledges that he/she understands the warranty limitations, safety,
and maintenance guidelines outlined above and in the owner’s manual and, therefore, agrees that all
riders/operators will adhere to these specifications.
Model No.
_______________________ Serial No.
_____________________Date of Purchase ___________
First Name _______________________ Initial _____ Last Name ____________________________________
Street Address ____________________________________________________________________________
City _____________________________________ State ___________________ Zip Code _______________
Signature (if 18 or older) or
Home Telephone Number ________________________ Parent’s Signature ___________________________
(Please enclose a copy of your proof of purchase.)
21