Yerf Dog Scout Issues

corylee03

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Greetings all. My son and I just acquired a Yerf Dog Scout. We don’t know a lot about these machines and it seems the information online is rather limited in comparison with many other yerf dog products.

It currently does not run. Here are some of the issues we have found so far.
1) The starter solenoid is not getting it’s “signal” to close.
2) Gas was very old
3) No spark
4) Fuel pick up tube inside the tank had dry rotted and broken into pieces
5) As with many old farm vehicles, the wiring has had…..modifications to be nice.
6) Very crude and home chain tensioning system.
7) Actually this one is a plus, the rear has had shocks/springs added.


It will crank over (when the starter solenoid is jumped). That’s the first issue. The starter solenoid does not appear to be getting its ”signal” to close the solenoid. The only wiring diagram I have found leaves a lot to be desired. The wiring colors do not match and a few other differences. Due to problem number 5….we found a replacement wiring harness for the engine for a good price. Figured once it came in, we would start digging further into the starter solenoid problem.

Plan on replacing the fuel filter and all fuel lines since the are old, brittle, and been sitting with old gas in them for who knows how long. After that, we will be able to see if there is anything going on with the carb. The previous owner did buy and swap a new carb onto it so Im not sure if we are going to have any issues there or not.

As far as the spark, the plug looks BRAND NEW. To the point that i dont think it has actually ever fired. We did see that the CDI box was missing too. We had another knock off cdi box and put it on the buggy to see if maybe that was the issue. No such luck, but we aren’t sold that it is necessarily the correct one. It came with another kart we got years earlier. It’s the ever so common “racing cdi box” that is online. Once again, after the wiring harness has been replaced and we can feel confident there wasnt some other broken/cut wires causing the issue, we plan to replace the cdi if necessary.

I was hoping maybe someone on here had some experience with these machines and might have a better wiring diagram for us to reference. Also, it seems there are 2 different types of wiring for the stator? Some came with 4 wires and some with 5? Can someone shed a little light on the connections for each of these wires and which came on these engines factory? Remember it had several back yard modifications so Im not sure what i can trust and what i cant. Thanks in advance.
 

corylee03

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If it has the gy6 Yamaha style engine, good luck. Not many here know about them. But be patient for help.
It does have the GY6 engine in it. Im not sure if it is a Yamaha style or not though. From what i have read, it is possibly a Howhitt?
 

corylee03

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Our collective opinion of them is rip them out and replace with a 420 and a 40 series cvt if you want the buggy reliable.
And that is likely to happen down the road. Im afraid that we would lose reverse capability at that point without purchasing another reverse gearbox which is another $400. At least that is the only one i have seen online rated for that kinda power range.
 

corylee03

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As promised….she is definitely a little rough around the edges, but I couldn’t beat the price. If anyone wants to see more or something specific on it, just let me know.
 

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corylee03

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So i did a little google searching and found that the CDI box i had laying around is an AC CDI box and i need a DC one. That is now on order. Hopefully that and the wiring harness should give me spark. Ill update more once the parts arrive.
 

corylee03

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Quick update on the yerf…

The fuel pick up tube has been replaced.
We also replaced the fuel lines and fuel filter. While doing this, the fuel pump broke and now that has been replaced as well.

We ordered a rear wiring harness. This replaced all wiring behind the seat. We did not order the harness for everything from the seat to the headlights since we didnt think this was going to be a problem and they were out of stock anyhow.

We replaced the voltage regulator since the one that was on it seemed very corroded and a new one was on sale anyhow.

The new CDI box came in and was installed.

After all of this, we naturally found more issues. Currently, when you turn the key to the on position (not the starting position), the engine starts turning over. This only happens if the headlight switch is pushed in…..yes you read that correctly. Odd i know! Due to the age and the cheap price of a front wiring harness, we have contacted them about getting a new one. It has a 5 wire ignition switch on it and of course none of the wiring diagrams i can find show an ignition switch of any type. Apparently everything was push button and kill switch operated.

Also, there is still not a good consistent spark. I do know that power is making it to the spark plug wire. This has been checked via the “DONT TOUCH THAT AGAIN” method. 😂 It will shock you but there is not a GOOD, CONSISTENT spark on the plug. I have seen it spark at the plug intermittently, but not consistently or even very often for that matter.

Plans are to replace the wiring harness for the front so we know that any previous gremlins will have been removed. From there we will address the spark issue.

Also it is not pulling fuel consistently. It is DEFINITELY pulling fuel but it is not a consistent stream of fuel going through the lines. I did finally smell a little fuel on the plug so it is making it into the cylinder. The choke cable is broken on and not operating correctly on the carb. We plan to order another one to get the choke to open all the way. It is a Mikuni carb with BS25 marked on it. If anyone has any information on that, i would love to hear it since i am not familiar with these carbs.

All in all, many issues were fixed but we haven’t gotten all of it yet. If anyone also has any diagrams or anything on a 5 wire ignition switch, i would appreciate the help. We wanted a project and we have def gotten one, but my son made the comment today that he is already having a blast working on this thing and spending some time together! Gotta love that.
 

corylee03

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Yea my brother and I have been known to do this VERY often. My dad laughs at us when we are fencing because we won‘t get within arms reach of one another while working on an electric fence!
 

corylee03

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Correct me if I am wrong, but (assuming the ignition switch problems are resolved with a new front harness) since the voltage regulator is new, dc CDI is new, plug is new, and coil and wire are new, the next logical place to look at for a weak or intermittent spark would be the pick up coil on the flywheel? Possibly some type of coil/flywheel gap issue?
 

Denny

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Those would be my guesses. But at this stage the engine should be atleast popping. I would make sure it has compression and fuel to the cylinder. You did put some oil down the cylinder before cranking right?
 

corylee03

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Those would be my guesses. But at this stage the engine should be atleast popping. I would make sure it has compression and fuel to the cylinder. You did put some oil down the cylinder before cranking right?
I sure did. I checked the oil and it was very low so we put some good oil in it before we ever turned it over. I also put a little in the cylinder just for good measure. It spins over very easily with the starter so i dont think we have any worries there...unless there is a problem with the oil pump we are unaware of

I think the intermittent spark is causing it not to fire off good.
 

corylee03

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Alright, finally some more progress. I called the place i bought the harness from to see if I could get a wiring diagram of the harness they sent me. Unfortunately, they get them from China and they did not have one. Also they didnt know when they would get the front half of the wiring harness. So we decided to start doing a pin out on everything to see if we could figure out what was going on.

Apparently the New wiring harness has and extra connector on it that was meant for tail lights which the scout does not have. When connecting things, this had gotten connected to the stator wires. We corrected this correctly and the ignition switch problem is no longer a problem. It is functioning as it should.

We still didnt have spark at this time. We would get a single spark the moment the key went from off to run, but never any spark while it was in the starting position. We continued to pin everything out and then found that there was an extra wire to the CDI box (we checked it originally with the old harness and it was there) that provided a constant 12v to the pin that is suppose to be empty. Once we removed this wire from the connector, we had a strong spark and it immediately fired up! *** oh yea we checked the gap for the pick up coil while we were at it and it all checked out fine as well.

It was smoking some ( and i figure a little to be normal from sitting) at first start up. Much more than i had anticipated. We then cracked open the valve cover and went ahead and checked the gaps. The exhaust was tight so we reset it and put the cover back on. That fixed the smoking issue.

We still have to replace the choke cable on the carb and i believe the carb will need some adjusting. However, we were able to get it out and go riding today. It is def not a powerhouse by any means but we could consistently ride at 15mph without any issue. Any faster and it would start to surge a little. Im sure this is the carb needing adjusting and the choke fixed. It was also rattling very loudly at the top end of the RPMs. Im assuming it is most likely the homeade tensioning system for the chain. Either way, the kids are both excited and really enjoyed driving it and it already beats walking.
 

corylee03

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Good job! And Congratulations! You’re our new resident expert on these! :roflol:

The bar must be very low then! 😂

Thanks. We still have a decent ways to go and then of course there are the things we WANT to done to make it our own.
 

Hellion

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This is NOT a go-kart. What a let-down. 😢 It is in fact a *utility* UTV.
 
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