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Spiderbox 2004
Yerf-Dog Spiderbox 2004 User Manual
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2
Table of Contents
Table of Contents
3
General Specifications
4
Tightening Torque Chart
7
Model Identification
7
Engine Number
7
Starting the Engine
8
Break-In Procedure
8
Periodical Check and Services
9
Maintenance and Tune-Up Procedure
9
Checking the Engine Oil
9
Changing the Engine Oil
10
Final Gear Oil
11
Spark Plug
11
Battery Installation
12
Preparing the Battery
13
How to Initially Charge the Battery
14
Battery Charging
15
Battery Replacement
16
Air Filter
17
Nuts and Bolts
18
Valve Clearance Inspection
18
Valve Mechanism Inspection and Servicing
19
Cylinder Head Removal
19
Cylinder Head Installation
20
Camshaft Removal
21
Camshaft Inspection
23
Camshaft Installation
23
Cam Chain Tensioner
24
Cam Chain Parts Breakdown
24
Rocker Arm and Rockershaft Removal
25
Rocker Arm and Rockershaft Inspection
25
Rocker Arm and Rockershaft Installation
25
Valve and Valve Spring Removal
26
Valve and Valve Spring Inspection
26
Valve and Valve Spring Installation
26
Valve Guide
27
Cleaning the Valve Guide
28
Measuring the Valve Guide Inner Diameter
28
Valve Guide Replacement
29
Valve Seat Width Measurement
30
Valve Seat Finishing
30
Valve and Valve Seat Seal Inspection
30
Engine Components Inspection and Servicing
31
Valve and Valve Seat Lapping
31
Cylinder Removal
31
Cylinder Bore Inspection
31
Piston Pin Inspection and Servicing
32
Measuring the External Diameter of Piston Pin
32
Measuring the Inner Diameter of Piston Pin Hole
32
Inspection and Servicing Piston Rings
33
Connecting Rod and Inspection
33
Piston Ring Installation Gap
33
Piston Installation
33
Crank Connection Rod Set
34
Crankcase and Crankshaft Removal
34
Crankshaft Inspection
35
Connecting Rod Side Clearance
35
Connecting Rod Radial Clearance
35
Measuring the Runout of the Crankshaft
35
Crankshaft and Crankcase Installation
36
Lubrication System Inspection and Servicing
37
Oil System Inspection and Replacement
37
Oil Pump Removal
37
Oil Pump Inspection
37
Oil Pump Assembly
38
Oil Pump Installation
38
Transmission Components Inspection and Servicing
39
Starting Mechanims Inspection and Servicing
39
Kick Return Starting Mechanism
39
Exhaust Mounting Shaft Removal and Inspection
39
Rear Transmission Mechanism Inspection and Servicing
40
Transmission Case Oil Replacement
40
Exhaust Mounting Shaft Installation
40
Transmission Case Removal
41
Transmission Case Gear Inspection
41
Transmission Case Cover Bearing Replacement
42
Left Crankcase Body Bearing Replacement
42
Belt Driven CVT Mechanism Inspection and Servicing
43
Drive Belt Pulley Removal
44
Drive Belt Pulley Inspection
44
Drive Belt Pulley Installation
44
Clutch Removal
45
Clutch Inspection
45
Clutch Disassembly
45
Clutch Installation
46
Driven Belt Pulley Removal
46
Driven Belt Pulley Inspection
46
Transmission Belt Inspection
47
Driven Plate Bearing Replacement
47
Driven Belt Pulley Installation
47
Carburetor Removal
48
Carburetor Disassembly and Inspection
48
Carburetor Cleaning
49
Carburetor Assembly
50
Carburetor Starter System - Choke or Enrichment
51
Enrichment Inspection
51
Enrichment Testing
51
Carburetor Troubleshooting
52
Chain and Axle
53
Chain Adjustment
53
Lubrication of Chain
53
Rear Axle Removal
54
Rear Sprocket Removal
54
Axle Bearing Removal and Inspection
55
Swingarm
55
Charging System
56
Battery Drain Testing
56
Charging Status Inspection
56
Battery Removal
56
Battery Voltage Inspection
57
Primary Coil Inspection
58
Generator Removal and Inspection
59
Generator Installation
59
Ignition System Inspection and Servicing
60
Ignition Time Inspection
60
Ignition System Inspection
60
Ignition Charging Coil
61
Trigger Winding
61
CDI Component
62
Ignition Coil Removal
63
Ignition Coil Installation
63
Primary Ignition Coil Inspection
63
Secondary Ignition Coil Inspection
63
Regulator Rectifier
64
Main Wiring - Sub Electric Circuit Condition Inspection
64
Regulator Rectifier Inspection
64
Resistor Resistance Value Measurement
64
Electrical Starting Mechanism
65
Starter Motor
65
Controling Mechanism
65
Starter Relay Inspection
65
Starter Motor Removal
66
Armature Inspection
66
Carbon Brush Inspection
66
Starter Clutch
67
Starter Motor Installation
67
Reduction Gear Inspection
67
Engaging Mechanism
68
Starting Clutch Removal
68
Starting Clutch Inspection
68
Brakes
69
Starting Clutch Installation
69
Brake Performance
69
Brake Shoe and Caliper Inspection
70
Brake Bleeding Fluid Change
72
Rear Brake Disk Removal
73
Wiring Diagram
74
Replacement Parts Identification
75
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Yerf-Dog Spiderbox 2004 Specifications
General
Brand
Yerf-Dog
Model
Spiderbox 2004
Category
Utility Vehicle
Language
English
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