Yerf-Dog 3204 User manual

FOR MODEL: 3204
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

7/31/03
04081
Rev. D
Read Tecumseh Engine Owner’s Manual and Important
Rules for Safe Operation before Operating Vehicle
YOU MUST ADD OIL TO THE ENGINE PRIOR TO USE!!!
20 oz. or 11/4Pints (.6 Liters) OF SAE 30 MOTOR OIL
WARNING
DANGER
For Replacements Parts Call:
1-888-926-6554 (U.S.)
1-888-707-1880 (Canada)

STOP
2
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 Go-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.
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.

3
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 judgement, 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 1/4 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.
22. The custom brush guard assembled on this vehicle is for deflecting loose vegetation and must not be
removed.

4
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 Go-
Kart. The Go-Kart is not designed or intended for such operation.
27. This manual provides guidelines for the assembly, maintenance, and operation of this Go-Kart and is
not intended as a service manual.
28. Assembly, maintenance, and/or repair of this Go-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 Go-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 Go-Kart for safety purposes. This flag could help
prevent dangerous situations.
The Owner Or OperatorAssumesAll 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.
Pay close attention to all Caution and Warning labels on the Go-Kart.
ASSUMPTIONS OF RISK

5
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. Axles 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

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.
F.F. Acquisition Corp. YERF-DOG Warranty Dept.
1743 South Horne # 100
Mesa, AZ 85204
FOR REPLACEMENT PARTS PLEASE CALL:
1-888-926-6554 (U.S.) 1-888-707-1880 (Canada)
YERF-DOG Go-Karts by Flexible Flyer
LIMITED WARRANTY
The Limited Warranty on this vehicle is in two (2) parts:

6
ASSEMBLY
1. Complete the Go-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. Assemble go-kart as indicate on the following pages.
3. 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.
4. 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 11/4pints (.6 Liters) of SAE 30 weight oil.
For additional information refer to Tecumseh engine manual for servicing the engine.
5. Fill fuel tank with regular gasoline, leaded or unleaded. Do not use premium gasoline. Do
not overfill (No fuel in filler neck).
6. 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 Go-Kart for the first time, you may need to reduce the air pressure in the tires
to the specifications stated below:
Rear Tires 10 PSI
Front Tires 12 PSI
Proper tire pressures will increase the life of the tire and enhance the performance of the Go-Kart.
Driving on asphalt or concrete will significantly reduce the life of the tire!!

7
PRE-RIDE INSPECTION
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 Go-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.

8
1. Before starting the engine, the operator should be seated in the Go-Kart. If the rider is not
seated in the vehicle, it should be placed against a stationary object and started.
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 MANEUVERS
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.

9
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 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 as 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
 . 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

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:
1-888-926-6554 (U.S.) 1-888-707-1880 (Canada)

10
SUSPENSION MAINTENANCE
The Suspension System on your Go-Kart is specifically designed and set up for the smoothest possible
ride, while maintaining top performance and kart durability. Your Go-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 Go-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 Go-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 Go-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 Go-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.
Your Fun Kart has an added feature on theA-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 “Shock Absorber Adjustment” or
move 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”)
A. EXTREME OUTWARD CAMBER
(NEW SHOCKS, NOT BROKEN IN) C. INWARD CAMBER
(SHOCKS NEED TO BE
ADJUSTED OR REPLACED)
B. SLIGHT OUTWARD CAMBER
(SHOCKS BROKEN IN)
POSITION 1
OUTSIDE HOLE POSITION 2 MIDDLE HOLE POSITION 3 INSIDE HOLE
FIGURE D – THREE QUICK CAMBERADJUSTMENTS
DISPLAY POSITION RIDING POSITION

11
1. Locate the SHOCK
ABSORBERS (78) at the front
and rear of the Go-Kart.
2. The factory pre-set the
SHOCKS for normal operating
conditions.
3. Locate the SHOCK
ADJUSTMENT HOLE at the
base of the spring.
4. Place the end of a narrow
screwdriver in the SHOCK
ADJUSTMENT HOLE.
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.
SHOCK ABSORBER ADJUSTMENT
STEERING WHEEL ASSEMBLY INSTRUCTIONS
Slide 1/4” Hex Bolts (9) through holes in
steering wheel. Insert Assembly through holes of steering shaft. Attach with 1/4” (55) Nylock Nuts.
Tighten all bolts/nuts. Place steering wheel cap over center of
steering wheel. Attach with phillips head screw (A).
Item#
9
55
A
Description
Bolt: 1/4”-20 x 1-3/4”
Nut: 1/4”-20
Screw
QTY
3
3
1
STEERING WHEEL HARDWARE

18
18
18
18
11 57
60
60
60
60
12
77
(Male End)
77
(Male End)76 76
77
(Female End)
Item #
11
18
57
60
77
76
Description
BOLT; 3/8-16 X 1” HEX
BOLT; 5/16-18 X 1-1/2 CARRIAGE
NUT; 3/8-16 NYLOCK
NUT; 5/16-18 NYLOCK
SEAT BELT; RETRACTABLE
SEAT RAIL
SEAT BELT ATTACHMENT HARDWARE Qty
1
4
1
4
2
2
SEAT FRAME ASSEMBLY INSTRUCTIONS

Front
square
mounting
holes of
seat frame
Rear
square
mounting
holes of
seat frame
13
Insert carriage bolts (18) through each of
the front square mounting holes of seat
frame, and through the front square
mounting hole of each seat adjustment
rail (76).
Place nut (60) on end of carriage bolts
(18) but do not tighten yet.
Insert carriage bolts (18) through each of
the rear square mounting holes of seat
frame; through mounting hole of each male
seat belt (77), and through the rear square
mounting hole of each seat adjustment
rail (76).
Place nut (60) on end of carriage bolts
(18) and tighten all 4 nuts (front and rear).
STEP 2
Note: Make sure the
seat belts are extending
to the outside of the seat frame.
To move the slide on
the rail with the
adjustment lever,
press outward on the
lever.
The seat rail slides
on seat adjustment
rails (76) can be
moved forward or
backward for access
to the rear or front
square mounting
holes.
TIP
For ease of assembly,
lay the seat frame on a
table, with the seat
back plate down, and
seat bottom coming
up away from the table.
seat
back plate
seat
bottom
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 at left. Tighten securely.
STEP 1
SEAT FRAME ASSEMBLY INSTRUCTIONS

14
CUSHION ATTACHMENT
SEAT ATTACHMENT
1. Align the THREADED STUDS (on the bottom of the SEATASSEMBLY)
with the SEAT BRACKET HOLES (on the Go-Kart FRAME).
2. Insert the THREADED STUDS into the SEAT BRACKET HOLES.
3. From UNDER the Go-Kart, secure the SEATASSEMBLY using four
5/16” FLAT WASHERS (101) AND four 5/16” NYLOCK NUTS (60).
Item #
60
101
Description Nut: 5/16”-18 Nylock Washer: 5/16”; Flat
SEAT ATTACHMENT HARDWARE Qty
4 4
Threaded Studs
on seat bottom
Seat Bracket
Holes
Slide SEAT CUSHION
(107) over top
of SEAT
FRAME
(75).
Push
Seat Belts
Through slit
in Cushion.
Attach bottom of
SEAT CUSHION
to SEAT FRAME
using Bolt (9) and
Lock Washer (8)
Item #
9
107
75
8
Description
BOLT; 1/4-20 X 1-3/4
CUSHION; SEAT
SEAT FRAME
WASHER; 1/4” LOCK
CUSHION ATTACHMENT HARDWARE
Qty
1
1
1
1

MAIN BRUSH GUARD
Attach MAIN BRUSH GUARD
to Gokart frame using
BOLTS (20) and
NUTS (60).
15
BRUSH GUARD ASSEMBLY INSTRUCTIONS
1. Attach all parts of Brush Guards
(which includes: Rear, Front, Main,
and Cross Brush Guards) as shown
on this page and the following page,
BEFORE tightening bolts.
2. Do not over tighten the hardware
attaching the ends of the
shoulder belt. The BELT must
rotate.
SHOULDER BELT ATTACHMENT
Attach both driver
and passenger
shoulder belts
using BOLTS (20),
WASHERS (101),
and NUTS (60).
Finished
Assembly
BRUSH GUARD CROSS ATTACHMENT
Attach both sides of the BRUSH GUARD
CROSS using BOLTS (19) and NUTS (60).
Item#
20
19
60
101
Description
Bolt; 5/16-18 x 1.75; Hex
Bolt; 5/16-18 x 1.50
Nut; 5/16-18 nylock
Washer; 5/16; Flat
QTY
4
6
10
4
BRUSH GUARD HARDWARE
FRONT BRUSH GUARDS
Attach both FRONT BRUSH GUARDS
at the rear and front of the Gokart
using BOLTS (19) and NUTS (60).

16
REAR BRUSH GUARD ASSEMBLY INSTRUCTIONS
REAR BRUSH GUARD
Attach REAR BRUSH GUARD
to Gokart frame using
BOLT (19) and NUT (60) at the top and
BOLT (21), SPACER (82), WASHER (101)
and NUT (60) at the bottom.
Do not tighten bottom bolt untill FLAG
BRACKET IS IN PLACE. (see below).
Use BOLT (21) and
SPACER (82) as shown.
1. Attach all parts of Brush Guards
(which includes: Rear, Front, Main,
and Cross Brush Guards) as shown
on this page and the previous page,
BEFORE tightening bolts.
2. Attach flag as shown on this page.
FLAG ATTACHMENT
4. Wrap CABLE TIE (37)
around FLAG BRACKET
and REAR BRUSH GUARD.
5. Trim excess tie material.
1. Slide FLAG BRACKET
over BOLT (21). (Between
bolt and spacer)
2. Slide WASHER (101)
over BOLT (21).
3. Attach NUT (60) to
BOLT (21) and
SECURELY tighten.
BRUSH GUARD/FLAG HARDWARE
Item#
19
21
37
47
60
82
101
Description
Bolt; 5/16-18 x 1.50
Bolt; 5/16-18 x 2.00
Cable Tie; 23”
Flag; Safety
Nut; 5/16-18 Nylock
Spacer; Black Plastic
Washer; 5/16; Flat
QTY
1
1
1
1
2
1
1

17
FOAM ATTACHMENT
1. Cut FOAM (48) to fit length of each BRUSH GUARD as shown.
2. Finish splitting FOAM (48). (Foam is partially split)
3. Attach FOAM to the BRUSH GUARDS using CABLE TIES (35).
(48) (35)
Caution: Take care to not cut yourself when cutting
and splitting foam with a sharp instrument.
Note:
Trim excess tie material
after completion of foam
attachment.

18
Apply Decal kit as shown in the illustration below.
Note: The Decal shown in the illustration may NOT be the same Decal you received with your Yerf-Dog Gokart.
Before application,
1. Wipe surface with a clean cloth. Make sure surface is dry and free of dust and dirt.
2. Lay decal on floor pan 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 the decal with floor pan. Gently press adhesive to floor pan 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 floor pan.
4. Use a cotton rag working in a circular motion to press out any air bubbles.
5. Attach other Decals as shown.
SUGGESTED DECAL APPLICATION
Front Decal placement.
Place Decal on Engine Guard tube. Place Decals on Belly Pan as shown.

19
MODEL 3204 REPLACEMENT PARTS IDENTIFICATION
Item Part No. Description Item Part No. Description
60 HH1256T NUT, 5/16-18 NYLOCK
61 HH62518 NUT, 5/8-18 THIN NYLOCK
62 01226 NUT, 5/16-18 JAM
63 01225 BOLT, 5/16-18 X 5/8" HEX
64 01133 SPACER 0.78 ID DRIVE
65 04166 PITMAN ARM, BLACK
66 01528 RETAINING RING, 1" HEAVY DUTY
67 H91470W RETAINING RING, 1/4"
68 00980 THROTTLE / BRAKE ROD, BLACK
69 27000100 ROLL PIN, 1/4 X .875
70 001474P SCREW, SHEET METAL
71 02946 HXHD BOLT FLTRD 1/4-20x1-1/2
72 H93200W SCREW, 1/4-28 X 0.250 SET
73 04449 BOLT, 3/8-16 X 2 _”
75 00927 SEAT FRAME, BLACK
76 H92740W SEAT RAIL, 1 PAIR
77 26000900 SEATBELT, RETRACTABLE
78 02972B SHOCK ABSORBER BLACK
79 00951 SLEEVE, 13-1/8" BLACK PLASTIC
80 00919 SLEEVE, 2-3/8" BLACK PLASTIC
81 00983 SLEEVE, 4-5/8" BLACK PLASTIC
82 001467P SPACER, BLACK PLASTIC
83 00513 SPACER, SPINDLE
84 04159 SPINDLE, LEFT, BLACK
85 04160 SPINDLE, RIGHT, BLACK
86 H55030W SPRING, 1/2 X 3.00 COMPRESSION
87 H92541W SPROCKET, 10 TOOTH
88 23001100 SPROCKET, 60 TOOTH
89 02956 STEERING SHAFT, RED
89 04161 STEERING SHAFT, BLACK
90 H92561W STEERING WHEEL, 13"
91 04162 SWING ARM, BLACK
92 04265 THROTTLE CABLE, 40"
93 02063 TIE ROD, SHORT
94 26000209 TIE ROD, LONG
95 02451 TIRE, FRONT, TURF
96 02564 TIRE, REAR, 20" SUPER TURF
97 Q43200W TORQUE CONVERTER, DRIVEN
98 Q43201W TORQUE CONVERTER, DRIVER
100 001616P WASHER, 3/8" SPECIAL FLAT
101 001618P WASHER, 5/16" FLAT
102 H53132W WASHER, 5/16" INTERNAL TOOTH
104 H56251W WASHER, 5/8" NARROW FLAT
105 H92690W WIRE CLIP
106 00925 WIRE, 16GA X 107" KILL SWITCH
107 01079 SEAT CUSHION, WESTERN
108 05678 EYE BOLT
110 H32505W SCREW, SELF TAPPING 1/4"
111 02625 SLEEVE AXLE, 4"
112 01474 SPACER, 3/8”
113 01069 STEERING WHEEL CAP
02604 4-CYCLE ENGINE OIL
04081 OWNERS MANUAL
101263 A-ARM, LEFT, BLACK
201264 A-ARM, RIGHT, BLACK
301132 AXLE SHAFT
4H93110W BEARING RETAINER
5H92010W BEARING, 1" I.D.
7Q43203W BELT, DRIVE
8000710P 1/4" LOCK WASHER
9H32503W BOLT, 1/4-20 X 1.75 HEX
10 H33137W BOLT, 3/8-16 X 1.00 CARRIAGE
11 H61610W BOLT, 3/8-16 X 1.00 HEX
12 00922 BOLT, 3/8-16 X 1.50 HEX
13 22000300 BOLT, 3/8-16 X 1.75 HEX
15 22000900 BOLT, 3/8-16 X 2.00 HEX
16 H95188W BOLT, 5/16-18 X 0.75 CARRIAGE
18 H93290W BOLT, 5/16-18 X 1.50 CARRIAGE
19 2200030 BOLT, 5/16-18 X 1.50 HEX
20 H33135W BOLT, 5/16-18 X 1.75 HEX
21 04002 BOLT, 5/16-18 X 2.00 HEX
22 H33136W BOLT, 5/16-24 X 0.50 HEX
23 H36254W BOLT, 5/8-18 X 3.75 HEX
24 22001700 BOLT, 5/8-18 X 7.00 HEX
25 04476 BRACKET, BRAKE BAND RETAINER
26 5311015 BRACKET, FOOT PEDAL, LEFT
27 5311016 BRACKET, FOOT PEDAL, RIGHT
28 04421 BRAKE BAND
29 04446 BRAKE CABLE 18 7/8”
30 04420 BRAKE DRUM, 6” DIAMETER
31 04087 BRUSH GUARD, FRONT;BLACK
32 04088 BRUSH GUARD, CROSS BLACK
33 04093 BRUSH GUARD, MAIN, BLACK
34 31004600 CABLE ATTACHMENT, BLACK
35 M12501W CABLE TIE, 11" BLACK
36 04091 BRUSH GUARD, REAR, BLACK
37 M13501W CABLE TIE, 23"
38 M01001W CABLE TIE, 4" BLACK
39 00994 CHAIN, DRIVE, #40, 70 LINKS
40 04079 CHASSIS, FULL, BLACK
41 03191 CLUTCH MOUNT, ASSY, ZINC
42 H91480W COLLAR, 7/16" BORE X 7/8" O.D.
43 02907 COVER MOUNT BRACKET
44 01080 DECAL, WESTERN LTD
45 02908 DRIVE COVER, BLACK
46 Q43160W ENGINE, 6 H.P. TECUMSEH
47 01094 FLAG, SAFETY
48 M72038W FOAM, 2" X 72" BLACK
51 H92250W KEY, 1/4 X 1/4 X 2.00
52 01134 KEY, 3/16 X 3/16 X 3.25
53 Q33100W KILL SWITCH
55 001203P NUT, 1/4-20 NYLOCK
56 HH10014 NUT, 1-14 THIN NYLOCK
57 001205P NUT, 3/8-16 NYLOCK
59 HH37524 NUT, 3/8-24 THIN NYLOCK

20
MODEL 3204