Utility Vehicle Operators Manual Copyright January 12, 2010
INDEX Section 1 Introduction Serial Number Plate Location pages 3-4 Section 2 Safety Pre-Delivery Steps Dealer Inspection Checklist pages 5-10 Section 3 Assembly Instructions Seat Back, Brush guard, Bumper Steering wheel Cargo Bed Seat Base pages 11-13 Section 4 Operating Instructions 390cc 4X4 653cc 4X4 48 Volt Electric page 14 – 29 Section 5 Maintenance Fuel Valve Lever Air Cleaner Engine Oil / Transaxle Oil Drive Belt pages 30-33 Section 6 Troubleshooting pages 34-40 Section 7 Parts D
Section 1 Introduction American SportWorks welcomes you to its growing family of new product owners. This Utility Vehicle “UTV” is a light utility vehicle that has been designed with care and built by skilled workers using quality materials. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory use from this vehicle. Safety First American SportWorks is fully aware of the need for safe operating procedures around all of our equipment.
Section 1 Introduction The Brush Guard Bar also provides a mounting system for American SportWorks optional windshields, canopy tops and weather enclosures. It also serves as a mounting base for many other optional cargo racks, gun and bow racks. The cargo bed is for transporting accessories such as camping equipment, tree stands, hunting gear, and fishing gear. A standard hitch mounting plate enables quick installation of a rear hitch for pulling small trailers full of supplies, tools, gear, and game.
Read These Important Rules for Safe Operation Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained within this owners/operators manual before operating utility vehicle. Failure to follow these instructions could endanger the personal safety of the Operator, Passenger and any Bystanders.
Section 2 Safety It is very important to read, understand, and follow all instructions and warnings located on the decals on your Utility Vehicle.
Section 2 Safety Safe Operating Procedures The safe operation of any machinery is a big concern to all consumers. Your Utility Vehicle has been designed with many built-in safety features. However, no one should operate this vehicle before carefully reading this Operator’s Manual. Also read all instructions noted on the safety decals. * Some conditions may warrant extra safety gear to be worn such as safety helmets and/or goggles.
* Do not exceed 400 lbs. in cargo bed area (NOTE: 300lbs with rear seat kit installed), or 900 lbs. total on this vehicle. * Do not mount a receiver hitch type carrier platform to the vehicle. * Do not load the Brush Guard Bar with heavy equipment. Rollover could result from such loading. * The Brush Guard Bar is not certified ROPS (Roll Over Protection System). Always avoid rollovers. * Do not operate this vehicle on highways, public roads, or where it may be a hazard to faster moving traffic.
battery. Follow all battery safety rules outlined in this manual. __ Check tire pressure to make sure front and rear tires have 5 psi. * Avoid battery acid spills. Do not get battery acid on eyes, face, or other body parts. Flush eyes and other body parts immediately with water for at least 15 minutes if battery acid has gotten on them. __ Make sure wheel lug bolts/nuts are tightened to 90 Newton meters (65ft.lbs).
__ Check overall appearance for cleanliness and for body and molding damage. Dealer Test Ride List __ Fluid fill and lubrication points have been located and explained to the customer. __ Check engine for starting, accelerating, running smooth, and idling smoothly. __ Information on the safety decals have been reviewed with the customer. __ Check steering response. There should be no free play. Customer Acceptance List __ Check forward, neutral, and reverse shifting response.
Section 3 Assembly Instructions Utility Vehicle Assembly Instructions Your new Utility Vehicle Utility vehicle should include the following items to be assembled: Qty 1 3 7 4 4 8 12 10 4 2 Item #8 black screw (steering cap) ¼” x 1 ¾” Hex head bolts ¼” nylock nuts ¼” x ¾” carriage bolts ¼” flat washers 5/16” x 2” socket head bolts 5/16” curved washers 5/16” nylock nuts 5/16” x 2” hex head bolts 5/16” center lock nuts Qty Item 2 2 1 5/8” x 4” Hex bolt 5/8” nylock nuts set of keys 1 1 2 2 1 1 1 Steer
Section 3 Assembly Instructions Pre-Assembly Instructions 1) Read Owner’s Manual. 2) Unpack all vehicle and assembly parts. Make sure you have everything listed on the previous page. 3) If you have any questions or problems with your American SportWorks LLC product please call us, toll free 1-866-646-5278. Bumper Installation Seat / Brushguard Assembly 1) Place seat back frame on vehicle frame tubes. Insert a 5/16” x 2” socket head bolt through both bottom joints.
Cargo Bed Installation 1) Locate rear frame stubs at the rear of frame. The bed pivot tube on the stub should be at the top. Insert 5/16” x 2” socket head bolt. Loosely install 5/16” center lock nut (do not tighten until after cargo bed is installed) 7) 2) Place the cargo bed on the vehicle and insert a 5/8” x 4” hex head bolt through each pivot bracket and frame stub tube. 3) Tighten both 5/16” frame stub bolts and nuts. 4) Install the 5/8” nylock nuts on the pivot bolts.
Section 4 Operating Instructions Pre-Start Check List __ Check tire pressure as indicated. General Operation __ Make sure wheel lug bolts/nuts are tightened to 65ft. lbs. Start your Utility Vehicle by following the starting procedures as noted below. __ All nuts, bolts, screws, and fasteners should be checked. 1. Depress brake pedal with your foot and hold. Pull firmly up on the park brake lever with your hand until the lever is tight.
4x4 Utility Vehicles This supplement covers the additional features, operation and maintenance of the 4x4 Utility Vehicles Maintenance Hydraulic Brakes – Hydraulic Brakes use fluid pressure to transfer the braking force to the wheels. Before driving the vehicle each day, check the fluid Features • • • • • • Because the power transfer is automatic, you may operate the vehicle in 4WD mode continuously without affecting steering effort or tire wear.
(part #20843). Torque the oil drain plug to 9 ft*lbs. 5. Remove the oil fill plug using a 5/16” hex key wrench. 6. Add 150 ml. (5 oz.) of Mobil fluid 424 American SportWorks part # 20848 (note: do not use any other type of oil in this system or the 4WD will not operate properly!) 7. Reassemble the oil fill plug into the gear case and torque to 10 ft*lbs. Gear Spacing adjustment 1. Remove the oil drain plug located on the bottom of the gear case using a ¼” hex key wrench. 2.
48 Volt Utility Vehicle OWNERS MANUAL 17
Do NOT let metal objects fall from the seat onto the top of your batteries. This may cause a serious power short and possibly a fire.
Battery Prolonged Storage All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75° F (-60° C). For winter storage, the batteries must be clean, fully charged and disconnected from any source of electrical drain. Please assure that the key switch is in the off position for storage.
WASHING YOUR 48 VOLT ELECTRIC UTV It is acceptable to wash your electric utility vehicle, though a pressure washer should not be used, and common sense should be exercised. Remember that some of the electronics in the controller and charging system are sensitive to water and corrosion. The charger should be protected during washing by placing a plastic bag or other protection over the top of the charger before washing. Allow for any water that does get on/in the charger to dry out before using.
Battery Charging • • • • Your charger is equipped with a flooded / gel charge mode switch, set switch to FLOODED mode. Plug the AC cord into a grounded outlet. If an extension cord is used, a heavy duty cord of no more than 25 feet must be used. The extension cord must be AWG 12 or heavier. Turn charger on. A fully discharged battery set will take 9-12 hours to fully recharge.
BATTERY WATERING 22
Flooded batteries need water. More importantly, watering must be done at the right time and in the right amount or else the battery's performance and longevity suffers. Water should always be added after fully charging the battery. Prior to charging, there should be enough water to cover the plates. If the battery has been discharged (partially or fully), the water level should also be above the plates.
Your 48V UTV is equipped with a mode switch. These two modes allow for parental control of the speed of the vehicle. The switch is located on the left side of the vehicle, under the bed. The fast mode will allow speeds up to 18 mph. The slower mode will allow speeds up to 10 mph. “Slow Mode” also has a more gentle acceleration curve. The vehicle range is considerably greater in slow mode as well.
SAE 30W oil is used in the transaxle.. Oil should be changed after one year of normal use, and every other year after. To change the oil, a vacuum device may be used to remove the old fluid. To fill, fresh oil should be added up to the level of the plug.
Fuses Your 48V Vehicle has fused protection for the main motor circuit, along with the low amperage 48 volt circuit, and the 12 volt circuit. Pictured below is the 500 amp main fuse. This fuse will blow in the event of a short across the battery posts, or a catasatrophic failure in the motor or controller. Should this fuse blow, it must be replaced with a like 500 amp fuse. These fuses are available through your dealer. Main fuse is illustrated below.
Under Hood Under Bed Left Side Forward / Reverse Switch 27
Located on the dash, the forward/reverse switch selects the direction of the vehicle. The operator must select the proper switch position before applying the throttle. Before depressing the accelerator pedal, operator must be certain of the position of the forward / reverse switch. Unexpected movement will result if the switch is inadvertently in the incorrect position. Wiring Diagram next page. Please note that not all circuits illustrated are included on all models.
Warning Accessories Must NOT be Grounded to Chassis.
650cc Utility Vehicle OWNERS MANUAL Supplement This vehicle is capable of reaching speeds in excess of 25mph. Use caution when turning to avoid vehicle rollover. Improper operation of this vehicle may cause serious injury or death. Maintaining safe performance depends to a large extent on the operator. Read, understand and follow all warning decals as well as your entire owners manual before operating this vehicle.
Section 5 Maintenance Fuel Type The fuel tank is located under seat. TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. CW-265 & TW265 Fuel capacity is 1.6 Gal. When filling the fuel tank, place the gear shift in forward or reverse, set the park brake, turn off the engine, and remove ignition key. Clean dirt from around the fuel tank cap, remove cap, and begin filling. When finished, screw the cap back on securely and wipe up any spilled gasoline.
Before installing the filter elements to make sure they have not been damaged during cleaning. Never run an engine without the filters installed. Section 5 Maintenance Engine Oil A general description for engine oil maintenance, recommendations, and capacities is provided below. See Engine Operator’s Manual for a detailed description. Note: Running engine low on oil can cause engine damage and void engine warranty.
5. Replace filler cap/dipstick and tighten securely. Engine Oil Change Warms oil drains quickly and completely. Therefore, drain used engine oil while engine is still warm as follows: 1. Park vehicle on a level surface, set park brake, turn off ignition switch, and remove switch key. 2. Place a suitable container below engine to catch used oil. Remove filler cap/dipstick and drain plug. 3. Allow used oil to drain completely and then reinstall and tighten drain plug securely. 4.
Transaxle Oil Change Warm oil drains quickly and completely. Therefore, drain used transaxle oil while transaxle housing is still warm as follows: 1. Park vehicle on a level surface, set park brake, turn off ignition switch, and remove switch key. 2. Place a suitable container below the transfer case to catch used oil. Remove fill cap and drain plug. 3. Allow used oil to drain completely and then reinstall drain plug and tighten it securely. 4.
Section 6 Troubleshooting Fuel in the Cylinder Cavity In the event that the fuel valve is left open while transporting or towing this Utility Vehicle it is possible that fuel has leaked down into the cylinder cavity. If this has occurred the engine will not start. With the cylinder cavity full of fuel the engine will feel like it has “locked up”. Below are the proper steps to follow if your Utility Vehicle engine seems to have fuel in the cylinder cavity.
Section 6 Troubleshooting 37
Trouble Shooting Steering feels funny/pulling to one side/hard to steer (Call normally for 4wd) Probable Cause: • One side may still be engaged in 4wd with the switch off. Possible Remedy: • Put unit in reverse and back up straight a few feet to get the axle to release. • If this does not work take the unit to a service center.
Gas in oil Probable Cause • Unit may have been transported with fuel valve on. Every time a unit is transported on a trailer or in a truck the fuel must be shut off using the shut off valve on the side of the engine. Leaving this valve open during transport could allow fuel to be deposited into the crank case locking the engine up. Possible Solution • Oil in engine must be drained completely and changed with fresh oil • Run unit and check oil again –if no gas is found in oil-unit is ready.
American SportWorks Utility Vehicle Shifter Trouble Shooting Notice: Always check transmission oil level. Dip a clean screwdriver straight down in the fill hole to the bottom of the gear case. There should be about 2 ½ inches of oil on the screw diver. If oil needs to be added, use SAE 30 motor oil. See Page 19 for Instructions • Engine will not turn over when key is turned to start. – This vehicle is equipped with a safety switch that only allows starting in neutral.
Vehicles with serial number less than 17063. (See brass tag near top of left rear shock absorber) 1. Loosen the cable adjusters behind the dash board. (photo on left) 2. Place the selector lever on the dashboard in forward. 3. Make sure the transmission is fully engaged in forward. The top of the shift lever on the transmission should be toward the passenger side. You may have to roll the rear wheels a little until it clicks in. 4.
Vehicles with serial number greater than 17063. (See brass tag near top of left rear shock absorber) 1. 2. 3. 4. Put the vehicle in neutral. Loosen the cable adjusters behind the dash board. (photo on left) Make sure the selector lever on the dashboard is in neutral. Make sure the transmission is in neutral. You can check by turning the key to Start. The engine will only turn over if the transmission is in neutral. 5.
Section 7 Parts Diagrams Wiring Diagram HONDA Engine Models 43
Wiring Diagram SUBARU Engine Models 44
Terminal Block Wiring 45
2 Wheel Drive Dana Transaxle Parts Breakdown 46
Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts 47
Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts 48
265cc CW265/ TW265/ BD300 Utility Vehicle Parts Breakdown 50
Body 265cc Models 51
Frame 265cc Models 52
Drive Train 265cc Models 53
Reference Number 1 Part Number 45419 2 45401 Rear frame stub, CW - black 2 50168 5/16 x 2-1/4" USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2 45413 bumper, CW - black 1 45432 Bumper, Trail Wagon – Black 1 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2 4a 45412 Brush Guard roof, CW265 – black 1 4b 42300 Brush Guard roof, TW265 – black 50168 5/16 x 2-1/4” USS Socket Head bolt 4 50007
Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 30623 30622 dust cap castle nut, 1” 30621 50060 70301 cotter pin Lug nuts, ½” Shock, Heavy duty #1 6 50400 Bolt, 10 mm x 40mm 12 50065 Nut, 10mm nylock 12 15L 30142 Rim/Tire Assembly, UTV 22/11-8” Front Left 1 15R 30143 Rim/Tire Assembly, UTV 22/11-8” Front Right 1 11 17L 30144 Rim/Tire Assembly, UTV 22/11-8” Rear Left 1 17R 30145 Rim/Tire Assembly, UTV 22/11-8” Rear Right 1 20 10596 Rack & p
Reference Number Part Number 31 11181 50215 Brake Rod, with clevis bolt, 3/8 x 1 ¼ 1 1 50010 nut, 3/8” nylock 1 50801 cotter pin 1/8” x 1 1 45417 50806 parking brake bar, CW – black Clevis, 5/16 rod end 1 1 50170 Bolt, 5/16”-24 X 4” SAE 1 50077 Nut, 5/16” Hex SAE 1 50087 bolt, ¼” x 1 1 50001 nut, ¼” nylock 1 11127 Parking Brake 1 50086 Bolt, ¼ x 1 ¼ 1 50001 nut, ¼” nylock 1 50163 bolt, 5/16 x ¾” NC 4 50005 Nut, 5/16 keps 4 50701 Washer, 5/16 flat 4 45415 Brake e
Reference Number Part Number 46 18500 50625 Terminal Block Cover – plastic screw, #10-24 X 1” Pan Head Phillips 1 2 50053 nut, #10-24 Keps nut 2 47a 70129 Headlights CW265 – oval 2 47b 70133 Headlights TW265 – rectangular 2 70055 Switch Headlights 1 50a 18302 Hood, plastic Red CW265 1 50b 18350 Hood, plastic Yellow TW265 1 18387 TW265 grill 1 18389 TW265 headlight bucket - left 1 18388 TW265 headlight bucket - right 1 50620 ¼” X 1 ¼” Pan Head Phillips Machine screw 2
Reference Number Part Number 70a 70b 45420 45434 Cargo Bed, Red CW265 Flat Cargo Bed, Black - TW265 1 1 50255 5/8 x 4” bolt Zinc plate 2 73 Part Description – 265cc 2WD Models Quantity Required 50015 5/8 nylock 2 18402 Bed Rubber Plug 2 50208 Bed latch bolt, 3/8 x 2 1/2" 1 50013 nut, 3/8 keps 2 50740 washer, 3/8 flat 2 45421 Tail gate, Red 1 50152 bolt, 5/16 x 1 2 50701 washer, 5/16 sae 4 50007 nut, 5/16 nylock 2 70230 rubber bump stops 4 78 50815 1/4" Lynch Pin -
Reference Number Part Number 120 - 70250 50010 Rubber Feet (Isolators) 3/8 Nylock Nut 5 10 - 50740 3/8 Flatwasher USS 5 121 10581 Rod End Sphcl-UTV (4681-MPM-12) 3 122 50021 3/4 Jam nut SAE 3 123 45403 Panhard bar, CW - black 1 124 50206 bolt, 3/8 x 1 4 - 50010 3/8" Nylock Nut 4 - 50740 3/8" Flatwasher, USS 4 125 50730 3/4' Spacer Washer 6 126 50280 3/4 x 2.
340cc CW11/ TW11/ TW11R Utility Vehicle Parts Breakdown 60
Body 340cc Models 61
Frame 340cc Models 62
Drive Train 340cc Models 63
Reference Number 1 Part Number 45419 2 45401 Rear frame stub, CW - black 2 50168 5/16 x 2-1/4" USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2 45413 bumper, CW - black 1 45432 Bumper, Trail Wagon – Black 1 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2 45412 Brush Guard roof, CW – black 1 50168 5/16 x 2-1/4” USS Socket Head bolt 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4
Reference Number 11 Part Number 50060 70301 Lug nuts, ½” Shock, Heavy duty #1 6 50400 Bolt, 10 mm x 40mm 12 50065 Nut, 10mm nylock 12 Part Description – 2WD Models Quantity Required 15L 30122 Rim/Tire Assembly, UTV 22/9-10” Left 1 15R 30123 Rim/Tire Assembly, UTV 22/9-10” Right 1 30480 Wheel rim, 10” x 6” 30195 Tire, Pathfinder 22/9-10” 17L 30124 Rim/Tire Assembly, UTV 22/11-10” Left 1 17R 30125 Rim/Tire Assembly, UTV 22/11-10” Right 1 30480 Wheel rim, 10” x 6” 30194 Tire,
Reference Number 31 32 33 36 Part Number 11181 50215 Part Description – 2WD Models Brake Rod, with clevis bolt, 3/8 x 1 ¼ Quantity Required 1 1 50010 nut, 3/8” nylock 1 50801 cotter pin 1/8” x 1 1 45417 parking brake bar, CW – black 1 50806 Clevis, 5/16 rod end 1 50170 Bolt, 5/16”-24 X 4” SAE 1 50077 Nut, 5/16” Hex SAE 1 50087 bolt, ¼” x 1 1 50001 nut, ¼” nylock 1 11127 Parking Brake 1 50086 Bolt, ¼ x 1 ¼ 1 50001 nut, ¼” nylock 1 50163 bolt, 5/16 x ¾” NC 4 50005 N
Reference Number Part Number 42 45414 Battery strap, CW (8 ¾”) – black 1 50083 bolt, ¼ x 7 ½ 2 50002 nut, ¼” wing 2 43 70055 Light Switch 1 44 70052 Key Switch 1 70060 Key, 1 pair 45 70080 Accessory Plug 1 70081 Accessory Plug cap 1 46 18500 Terminal Block Cover – plastic 1 50625 screw, #10-24 X 1” Pan Head Phillips 2 50053 nut, #10-24 Keps nut 2 70129 Headlights 2 70055 Switch Headlights 1 18311 Hood, plastic Green 1 18302 Hood, plastic Red 18350 Hood, pla
Reference Number Part Number 58 55060 Fuel Tank 1 55063 Elbow Fuel Inlet w/ #200 Mesh Screen 1 55062 Fuel Fitting Grommet 1 55061 Cap Fuel Tank 1 50163 bolt, 5/16 x 3/4" NC 3 50706 Washer, 5/16 fender 3 50703 Washer, 5/16 lock 3 60 10754 Seatback 43 ½ x 17 ½ 1 50619 #14 X 1-3/4” Pan head-Tapping screw 6 61 10803 Headrest – UTV 9 x 6 ½ 2 50085 bolt, ¼ x 1 ½” 4 62 10755 Seat bottom 43 ½ x 17 ½ 1 63 45416 seat bar, CW (17 ½”) – black 2 50609 #14 x ¾ Pan Head Screw
Reference Number Part Number 80 18312 Roof, green 1 18301 Roof, Red 1 18351 Roof, Camo 1 18391 Roof, Top Vinyl Trim 1 18390 Roof, Hardware bolt kit 50847 Clamp-Tube-vinyl coated 1-3/4" 4 50087 bolt, 1/4" x 1 4 50718 Washer, ¼” rubber domed 4 50001 18400 nut, 1/4" nylock Windshield - clear 4 18401 Windshield - tinted 18403 Fastener kit, windshield 85 Part Description - 2WD Models Quantity Required 88 40723 Front receiver hitch kit 101 20010 Engine, Honda 11hp 1 - 5
Reference Number Part Number 117 50722 118 119 Part Description - 2WD Models Quantity Required 1/2" Lock Washer 1 50721 1/2" Uss Flat Washer 1 10186 Key stock – Special Key – 3/16” X 1/4” X 31/2” 1 45431 Tension Mount Engine, CW - Black 1 - 50157 5/16x 3/4" Bolt Hex Hd NF 2 - 50703 5/16" Lock Washer 2 - 50704 5/16" Flatwasher 2 120 70250 Rubber Feet (Isolators) 5 - 50010 3/8 Nylock Nut 10 - 50740 3/8 Flatwasher USS 5 121 10581 Rod End Sphcl-UTV (4681-MPM-12) 3 1
Reference Number Part Number 132 11086 Differential Control Assembly w/ cable all models after serial # 22187 - 11083 Knob 1 - 11091 Differential Control Cable Only used on all models after serial # 22187 1 - 50053 nut, #10-24 Keps nut 2 - 50616 screw, #10-24 X 3/4" Pan Head phillips 2 - 50770 Washer, #10 flat 2 - 50087 1/4-20 x 1" Hex Hd Bolt 1 - 50000 1/4" Keps Nut 2 - 50159 5/16-18 x 1 1/2" Hex Hd Bolt 1 Part Description - 2WD Models Quantity Required 1 - 50005 5/
4 Wheel Drive Dana & Hilliard Transaxle Parts Breakdown 72
Hilliard Drive Train Products Approved Lubricants list Mobilfluid 424 Mobilfluid LT Hytran Ultra Hytran HyGuard Low Viscosity HyGuard John Deere J20C John Deere J20D Texaco Rando HD 46 Texaco TDH or TDH SS Chevron 1000 THF Shell Donax TD 80
Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts 81
Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts 82
390cc CW413 & TW413 4-wheel drive Utility Vehicle Parts Breakdown 84
Body 390cc Models 85
frame 390cc Models 86
Drive Train 390cc Models 87
Reference Number 1 2 3 4 5 6 7 7a 8 9 11 12L 12R 13L 13R Part Number 45501 45401 50168 50007 50702 45413 45433 50167 50007 50702 70208 45412 50168 50007 50702 45411 50168 50007 50702 43007 51100 50266 50015 45150 25001 25009 50028 50041 50801 25020 25003 50163 50005 25002 50040 30621 30623 50060 70301 50400 50404 50065 45150 30122 30123 30480 30195 30124 30125 30480 30194 Part Description – 4x4models Frame, CW413 - 4x4 Rear frame stub, CW - black 5/16 x 2-1/4" USS Socket Head bolt nut, 5/16 nylo
Reference Number 14 15 16 17 18 19 20 21 22 23 24 25 30 Part Number 20851 20868 20839 20848 50206 50740 50741 25006 25015 50092 50003 25008 25010 50163 50005 25007 25016 50631 10184 20804 10591 10593 50171 50005 10594 10598 10595 10593 10592 50402 50066 50403 50780 45422 45400 51100 50152 50005 10502 10506 50081 50001 45402 50152 50081 50159 50005 50701 Part Description – 4x4models CV half shaft (axle) – (Left or Right) Boot CV front differential – 4x4 Hilliard Front Differential Replacement Oil
Reference Number 31 32 33 34 35 36 37 38 40 41 Part Number 11123 50167 50005 50806 50077 11124 11167 11168 11169 50826 50217 50013 18030 11127 50086 50001 50163 50005 50701 18038 50152 50007 11135 11136 11085 11083 11082 50053 50616 50770 11086 11083 11091 50053 50616 50770 50087 50000 50159 50005 70012 70000 70002 70010 70009 50087 50000 50000 Part Description – 4x4models master cylinder bolt, 5/16 x 2 Nut, 5/16 keps Clevis, 5/16 rod end Nut, 5/16" Hex SAE brake caliper brake pads (2 pads required
Reference Number 42 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 59 Part Number 45414 50083 50002 70055 70052 70060 70080 70081 18500 50625 50053 70129 70055 70019 18380 18384 18381 50620 50621 50717 50001 50846 18309 50624 18308 50624 18317 18383 50624 18316 50624 18382 50624 18304 18303 70150 50091 50717 55060 55063 55062 55061 50163 50706 50703 18033 50163 50005 50171 10001 Part Description – 4x4models Battery strap, CW (8 3/4") - black bolt, 1/4 x 7 1/2 nut, 1/4" wing Light Switch / 4x4 switch K
Reference Number 60 61 62 63 65 70 73 75 78 80 85 88 101 102 Part Number 10754 50619 10803 50085 10755 45416 50609 10705 50025 45426 45420 45424 18352 18353 18354 50255 50015 18402 50208 50013 50740 45427 45421 45425 50152 50701 50007 70230 50815 18312 18301 18351 18391 18390 50847 50087 50717 50001 50718 18400 18401 18403 40729 50162 50704 50007 20012 50202 50740 20838 Part Description – 4x4models Seatback 43 1/2 x 17 1/2 #14 X 1-3/4" Pan head-Tapping screw Headrest - UTV 9 x 6 1/2 bolt, 1/4 x 1 1
Reference Number 103 104 105 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 Part Number 45502 45430 18023 50086 50082 50000 50715 20648 20665 20649 20666 11171 50745 50742 50741 50219 20693 20694 50239 50722 50721 10186 45431 50157 50703 50704 70250 50010 50740 10581 50021 42093 50206 50010 50740 50730 50280 50020 18012 50084 50000 18011 11104 50150 50007 11010 50087 50000 11804 Part Description – 4x4models Swing arm, CW - Black 4x4 Motor Plate, C
Reference Number 133 136 137 138 139 140 141 150 151 152 153 Part Number 11804 65500 50849 18313 18314 18315 50624 50050 50770 20011 25004 10184 20852 18042 18083 70232 50163 50701 50703 50005 50303 50794 50028 18032 50163 50701 50703 Part Description – 4x4models Spring #80704 Black painted fuel hose 3/16" dia - 24" hose clamps - small Belt Guard Plastic UTV - Front Belt Guard Plastic UTV - Rear Belt Guard Plastic UTV - Bottom #10 x 3/4" Blunt Point Black #10 Speed Nut - for Plastic #10 Flatwasher Choke
653cc CW650/ TW650/ BD700 4-wheel drive Utility Vehicle Parts Breakdown All Vehicles Post August 2009 95
Models CW-650/TW-650/BD-700 Reference Number 1 1a 2 3 4 5 6 6a 7 7a 8 9 10 11 12L 12R Part Number 18112 45401 50206 50013 45413 50167 50007 50702 70208 45412 50168 50007 50702 45411 50168 50007 50702 45445 45446 51100 50225 50010 42114 40554 40555 10598 50801 25022 25021 50021 50023 25014 50073 14535 30623 50060 70301 50400 50404 50065 45150 30146 30147 30481 30199 Parts List (post August 2009) Part Description 650cc Models Frame, - CW650 4x4 Tie Bar (metal strip to connect A-arm mount front) Re
Reference Number Part Number 13L 13R 30146 30147 30481 30199 20851 20839 50206 50740 50741 25006 50092 50003 25008 50163 50005 25007 50628 10184 20804 10599 50171 50005 10594 10595 10593 10592 50402 50066 50403 50780 45422 45400 51100 50152 50005 10502 10506 50081 50001 45402 50152 50081 50159 50005 50701 14 15 16 17 18 19 20 21 22 23 24 25 30 Part Description 650cc Models Rim/Tire Assembly, UTV 25/11-12" Left Rim/Tire Assembly, UTV 25/11-12" Right Wheel rim, 12" UTV 25/11-12 Tire only CV half
Reference Number Part Number 31 11123 50167 50005 50806 50077 11124 11167 11168 11169 50826 50217 50013 master cylinder bolt, 5/16 x 2 Nut, 5/16 keps Clevis, 5/16 rod end Nut, 5/16" Hex SAE brake caliper brake pads brake pins brake clips Spacer Lock collar, 3/8 bolt, 3/8 x 1 1/2 nut, 3/8 keps 1 2 2 1 1 2 4 4 4 4 4 4 11127 50086 50001 50163 50005 50701 18038 50152 50007 11135 11136 11085 11083 11082 50053 50616 50770 11086 11083 11084 50053 50616 50770 50087 50000 50159 50005 70053 70000 70002 70010 70
Reference Number Part Number 42 45414 50083 50002 70055 70058 70060 70080 70081 18500 50625 50053 70129 70019 18380 50620 50621 50717 50001 50846 18309 50624 18308 50624 18383 50624 18316 50624 18382 50624 18304 18303 18310 50001 50091 50717 18033 50163 50005 50171 10001 10754 50619 10803 50085 10755 45416 50609 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 60 61 62 63 Part Description 650cc Models Battery strap, CW (8 3/4") - black bolt, 1/4 x 7 1/2 nut, 1/4" wing Light Switch / 4x4 switch Key Swit
Reference Number Part Number 65 8778 50025 45426 50255 50015 50208 50013 50740 45427 50152 50701 50007 70230 50815 18312 50846 50087 50717 50001 18400 18401 18403 40729 50162 50704 50007 20017 50202 50740 20838 45505 55043 20644 20645 11171 50745 50742 50741 50219 20697 50244 50722 50157 50703 50704 10581 70 73 75 78 80 85 88 101 102 103 104 107 108 109 110 111 112 113 114 115 116 117 118 121 Part Description 650cc Models Seat Belt, 3pt Retrc.
Reference Number Part Number 122 123 124 50021 42093 50206 50010 50740 50730 50280 50020 18012 50084 50000 18011 11104 50150 50007 11010 50087 50000 11804 11804 65500 50849 18324 18320 50624 50050 50770 25004 10184 20852 50163 50701 50703 18083 18032 50163 50701 50703 125 126 127 128 129 130 131 133 136 137 138 139 150 151 152 153 Gear Transfer Grease Figure F-N-R Box 5-5A Brake Fluid FUEL Differen Copyright Gear Shift Box Reservoir fitting Oil fill January VALVE tial Oil Lever fill 12, 2010 Fram
653cc CW650 & TW650 4-wheel drive Utility Vehicle Parts Breakdown MODELS MANUFACTURED BEFORE AUGUST 2009 105
Models CW-650 & TW-650 Reference Number 1 2 3 4 5 6 7 7a 8 9 11 12L 12R 13L Part Number 45401 50206 50013 45413 50167 50007 50702 70208 45412 50168 50007 50702 45411 50168 50007 50702 43007 51100 50266 50015 10051 25012 25013 50028 50041 50801 25020 25003 50163 50005 25014 50040 30621 30623 50060 70301 50400 50404 50065 45150 30146 30147 30481 30199 30146 Parts List (pre August 2009) Part Description 650cc Models Frame, - CW650 4x4 Rear frame stub, CW - black bolt, 3/8 x 1 nut, 3/8 keps bumper,
Reference Number Part Number 13R 30147 30481 30199 20851 20839 50206 50740 50741 25006 50092 50003 25008 50163 50005 25007 50628 10184 20804 10591 50171 50005 10594 10595 10593 10592 50402 50066 50403 50780 45422 45400 51100 50152 50005 10502 10506 14 15 16 17 18 19 20 21 22 23 24 25 30 50081 50001 45402 50152 50081 50159 50005 50701 Part Description 650cc Models Rim/Tire Assembly, UTV 25/11-12" Right Wheel rim, 12" UTV 25/11-12 Tire only CV half shaft (axle) front differential - 4x4 Bolt, 3/
Reference Number Part Number 31 11123 50167 50005 50806 50077 11124 11167 11168 11169 50826 50217 50013 18030 11127 50086 50001 50163 50005 50701 18038 50152 50007 11135 11136 11085 11083 11082 50053 50616 50770 11086 11083 11084 50053 50616 50770 50087 50000 50159 50005 70053 70000 70002 70010 70009 50087 50000 32 33 34 35 36 37 38 40 41 Part Description 650cc Models master cylinder bolt, 5/16 x 2 Nut, 5/16 keps Clevis, 5/16 rod end Nut, 5/16" Hex SAE brake caliper brake pads brake pins brake cli
Reference Number Part Number 42 45414 50083 50002 70055 70058 70060 70080 70081 18500 50625 50053 70129 70019 18380 50620 50621 50717 50001 50846 18309 50624 18308 50624 18383 50624 18316 50624 18382 50624 18304 18303 18310 50001 50091 50717 18033 50163 50005 50171 10001 10754 50619 10803 50085 10755 45416 50609 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 60 61 62 63 Part Description 650cc Models Battery strap, CW (8 3/4") - black bolt, 1/4 x 7 1/2 nut, 1/4" wing Light Switch / 4x4 switch Key Swit
Reference Number Part Number 65 8778 50025 45426 50255 50015 50208 50013 50740 45427 50152 50701 50007 70230 50815 18312 50846 50087 50717 50001 18400 18401 18403 40729 50162 50704 50007 20017 50202 50740 20833 45505 55043 20644 20645 11171 50745 50742 50741 50219 20697 50244 50722 50157 50703 50704 10581 70 73 75 78 80 85 88 101 102 103 104 107 108 109 110 111 112 113 114 115 116 117 118 121 Part Description 650cc Models Seat Belt, 3pt Retrc.
Reference Number Part Number 122 123 124 50021 42093 50206 50010 50740 50730 50280 50020 18012 50084 50000 18011 11104 50150 50007 11010 50087 50000 11804 11804 65500 50849 18324 18320 50624 50050 50770 25004 10184 20852 50163 50701 50703 18083 18032 50163 50701 50703 125 126 127 128 129 130 131 133 136 137 138 139 150 151 152 153 Part Description 650cc Models 3/4 Jam nut SAE Panhard bar, CW 4x4 - black bolt, 3/8 x 1 3/8" Nylock Nut 3/8" Flatwasher, USS 3/4' Spacer Washer 3/4 x 2.
48 Volt CW48V & BD48V 2-wheel drive Electric Utility Vehicle Parts Breakdown 115
Reference Number 1 Part Number XXXXXX 2 45401 Rear frame stub, CW - black 2 50168 5/16 x 2-1/4" USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2 45413 bumper, CW - black 1 45432 Bumper, Trail Wagon – Black 1 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2 45412 Brush Guard roof, CW – black 1 50168 5/16 x 2-1/4” USS Socket Head bolt 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4
Reference Number 11 Part Number 50060 70301 Lug nuts, ½” Shock, Heavy duty #1 6 50400 Bolt, 10 mm x 40mm 12 50065 Nut, 10mm nylock 12 Part Description – 48V Models Quantity Required 15L 30148 Rim/Tire Assembly, UTV 22/11-10” Left 1 15R 30148 Rim/Tire Assembly, UTV 22/11-10” Right 1 30480 Wheel rim, 10” x 6” 30197 Tire, Terra Trac 17L 30148 Rim/Tire Assembly, UTV 22/11-10” Left 1 17R 30148 Rim/Tire Assembly, UTV 22/11-10” Right 1 30480 Wheel rim, 10” x 6” 30197 Tire, Terra
Reference Number 31 32 33 36 Part Number 11180 50215 Part Description – 48V Models Brake Rod, with clevis bolt, 3/8 x 1 ¼ Quantity Required 1 1 50010 nut, 3/8” nylock 1 50801 cotter pin 1/8” x 1 1 45417 parking brake bar, CW – black 1 50806 Clevis, 5/16 rod end 1 50170 Bolt, 5/16”-24 X 4” SAE 1 50077 Nut, 5/16” Hex SAE 1 50087 bolt, ¼” x 1 1 50001 nut, ¼” nylock 1 11127 Parking Brake 1 50086 Bolt, ¼ x 1 ¼ 1 50001 nut, ¼” nylock 1 50163 bolt, 5/16 x ¾” NC 4 50005 N
Reference Number Part Number 45 70080 70081 Accessory Plug Accessory Plug cap 1 1 46 18500 Terminal Block Cover – plastic 1 50625 screw, #10-24 X 1” Pan Head Phillips 2 50053 nut, #10-24 Keps nut 2 70129 Headlights 2 70055 Switch Headlights 1 18311 Hood, plastic Green 1 18302 Hood, plastic Red 18350 Hood, plastic Camo 50620 ¼” X 1 ¼” Pan Head Phillips Machine screw 2 50621 ¼” X 2” Pan Head Phillips Machine screw 2 50717 ¼” SAE Flat washer 8 50001 nut, ¼” nylock 4 508
Reference Number Part Number 70 45426 45420 Cargo Bed, Green Cargo Bed, Red 1 1 45424 Cargo Bed, Black 1 18352 Camo Bed Panel Left 1 18353 Camo Bed Panel Right 1 18354 Camo Bed Panel Tail Gate 1 50255 5/8 x 4” bolt Zinc plate 2 73 75 Part Description – 48V Models Quantity Required 50015 5/8 nylock 2 18402 Bed Rubber Plug 2 50208 Bed latch bolt, 3/8 x 2 1/2" 1 50013 nut, 3/8 keps 2 50740 washer, 3/8 flat 2 45427 Tail gate, green 1 45421 Tail gate, Red 1 45425 Ta
Part Number Part Description – 48V Models Quantity Required 106 70112 Potentiometer (Curtis) 1 107 70114 Solenoid / Contactor(Curtis) 1 108 70115 Converter 1 109 11171 Brake Shoes - Rear UTV –Electric Dana “1 set for each wheel” 2 110 70116 Charger 1 111 70111 Controller (Curtis) 1 112 70550 Mode Switch 1 113 70113 Charge Gauge 1 114 18318 Plastic Cover for Controller 1 115 70119 FNR Switch 1 121 10581 Rod End Sphcl-UTV (4681-MPM-12) 3 122 50021 3/4 Jam nut S
Low Speed Vehicle (LSV) Owner/Operators Manual Insert This low speed vehicle may be used on public roads (check local ordinances). This vehicle does NOT have comparable crash protection to a car or truck. Follow all safety procedures. Avoid roads with considerable traffic. Avoid driving on public roads at night or in low visibility. Never drink and drive.
American SportWork’s LSV/UTV models are equipped with certain parts unique to these models only. Special care and attention may be required during maintenance of these vehicles.
Turn Signal Controls Cleaning Your LSV Windshield R • i n s e w i n d s h i e l d w i t h l a R • • b u s i v e c l i e n a s e n i a n g g s a p u o i r k f n e t l D c a c . o w e r d r o m t y w h o w u r i e r t s a s h b t p s y e o o ; n f h r e c n a g t a w l d s h .
Wiring of Tail Lights After installation of the fenders, the tail lights must be wired. The wire harness is routed through the holes in the fender. Please note that these fender holes face inward after mounting. As in the photos below, the FLAG COLOR on the harness wire is plugged into the corresponding WIRE COLOR on the taillight end. Note that these colors are not the same on the left as the right.
LIMITED WARRANTY Utility Vehicles (UTVs) American SportWorks (hereinafter referred to as “ASW”), hereby warrants to the original purchaser, that a new ASW UTV will be free from defects in material and workmanship. The period of warranty is one (1) year from date of purchase for the component parts (except as noted below) and two (2) years from the date of purchase for a Honda engine or three (years) from the date of purchase on a Subaru engine (engine warranties are covered by the engine manufacturer).
Service and Warranty Warranty Special Note Should your American SportWorks product require warranty repair, service or if you have any questions concerning assembly, replacement parts or how to care for your product please contact your local American SportWorks dealer or American SportWorks directly. American SportWorks Dealer: To locate the authorized dealer nearest you please call American SportWorks customer service at 1-800-643-7332 or (260)-432-1596, visit our website at www.amsportworks.
P.O. Box 649 Roseland, LA 70456-0649 (866)-646-5278 Phone (866)-329-5278 Fax www.amsportworks.com support@amsportworks.
CUSTOMER CHECKLIST VISUAL INSPECTION I understand that this product is designed for off RECEIVED SERVICE INSTRUCTIONS road use only and is not intended for use on public SHOWN ALL ENGINE CONTROLS roads or highways. WARRANTY EXPLAINED FULLY I have reviewed and understand the warranty policy.