American Sportworks Trail Wagon TW400 Owner'S Manual Download Page 1 | Manualshive

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TW400 UTILITY VEHICLE

O W N E R S M A N U A L

Copyright June 7, 2012

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Summary of Contents for Trail Wagon TW400

Page 1: ...TW400 UTILITY VEHICLE O W N E R S M A N U A L Copyright June 7 2012...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 3: ...Operating Instructions page 13 Section 5 Maintenance pages 14 17 Fuel Type Fuel Valve Lever 14 Foam Element Spark Plugs Air Filter 15 Engine Oil Transaxle Oil Drive Belt 15 17 Section 6 Troubleshooti...

Page 4: ...he time of printing Some parts may change slightly to assure you of the best performance To order a new Operator s or Parts Manual contact your authorized dealer Terminology Right hand and left hand a...

Page 5: ...e been specially designed and should only be replaced with genuine American SportWorks parts If customer service or repair parts are required contact a American SportWorks dealer They have trained per...

Page 6: ...hicle Failure to follow these instructions could endanger the personal safety of the Operator Passenger and any Bystanders Close adult supervision is required at all times Pay close attention to all C...

Page 7: ...ur Utility Vehicle SECTION 2 safety CAUTION USE ONLY MID GRADE UNLEADED GASOLINE 89 93 OCTANE This engine is designed to run on automotive gasoline with allowable ethanol blends from 0 10 Attempting t...

Page 8: ...id tree limbs and brush that have a potential of hitting and or poking individuals riding the vehicle Serious body harm could result Avoid sudden stops starts and turns Always operate your vehicle at...

Page 9: ...ht line of travel When descending hills or slopes apply steady pressure to the foot brake to avoid potential of freewheeling or runaway Never allow vehicle to coast or free wheel in neutral or loss of...

Page 10: ...ires have 5 psi q Make sure wheel lug bolts nuts are tightened to 90 Newton meters 65ft lbs q Check engine oil level at the dipstick Add SAE 10W30 oil if oil is below the full mark on the dipstick thi...

Page 11: ...d understood warranty policy ies q Customer has inspected the vehicle and it meets customer satisfaction q Customer understands the importance of following the owner s manual instructions IMPORTANT NO...

Page 12: ...perator Passenger safety system on this unit Do not attempt to operate the unit until all components have been properly installed WARNING Your new Utility Vehicle should include the following items to...

Page 13: ...e bolt Place a 5 16 nylock nut on the bolts but do not tighten 2 Place the cage on front vehicle frame tubes and seat back Insert a 5 16 x 2 socket head bolt through all four joints The head of the bo...

Page 14: ...d 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 2 Place the cargo bed on the vehicle and insert a 5 8 x 4 hex he...

Page 15: ...n with a flat washer and a nylock If installing fenders on a poly bed you will use x 1 hex head bolts instead of the carriage bolts Seat Installation 1 Place back of seat base underseat storage tray o...

Page 16: ...or reverse when the vehicle is stopped and press the throttle pedal to go Never shift while the vehicle is moving Braking is accomplished by simply depressing the brake pedal that is located on the fl...

Page 17: ...abilizer conditioner to the gas Follow the gas stabilizer conditioner manufacturer s directions for best results See engine operator s manual for the following Draining the fuel tank Checking fuel lin...

Page 18: ...Engine Operator s Manual for a detailed description Note Running engine low on oil can cause engine damage and void engine warranty Note Overfilling of oil level can cause loss of power engine damage...

Page 19: ...ll hole with recommended oil Engine must be level when filling 6 Replace filler cap dipstick and tighten securely SPECIAL NOTE TO DRAIN ENGINE OIL REMOVE REAR DRAIN PLUG ON ENGINE Engine Oil Drain Fil...

Page 20: ...r down a drain 5 Fill transaxle housing with 20 oz SAE 30W oil 6 Replace fill cap and tighten securely Drive Belt The dive belt is considered a wearable item Replacement intervals depend on vehicle us...

Page 21: ...ark plug And remove the spark plug from the engine See Figure 6 1 Spark Plug Wrench supplied with Operator s Manual 4 WARNING Stand away from the spark plug hole when performing step 5 Fuel can spray...

Page 22: ...t to a service center BRAKES DONT WORK WELL HARD TO PUSH NO TRAVEL IN PEDAL Brake rotors are dirty Brake rotors are dirty Clean rotors with brake cleaner and test A stiff pedal is normal for a 4WD uni...

Page 23: ...ust caps up the cable Drip or spray penetrating oil into the cable housing while working the lever Do this several times as the oil soaks into the housing Test the vehicle If this did not help move to...

Page 24: ...y turning the key to Start The engine will only turn over if the transmission is in neutral 5 Pull the slack out of both cables but do not stretch the springs and tighten the adjuster nuts or you can...

Page 25: ...WIRING DIAGRAM E N G I N E M O D E L S 22 SECTION 7 diagrams...

Page 26: ...SECTION 7 diagrams WIRING DIAGRAM T E R M I N A L B L O C K 23...

Page 27: ...SECTION 7 diagrams 2 WHEEL DRIVE 2 2 0 8 3 3 TRANSAXLE PA R T S B R E A K D O W N For units equipped with locking differential 24...

Page 28: ...12HS121 2 Spacer Flat 36 012HS126 1 Washer Thrust 37 012HS125 1 Washer Thrust 38 012GS202X 1 Gear Assembly Forward 39 012GS302 1 Gear Clutch 40 012GS200 1 Shaft Intermediate 41 012GS204X 1 Gear Assemb...

Page 29: ...SECTION 7 diagrams 26...

Page 30: ...to components which are subject to normal wear and tear These items include but are not limited to the tires brakes throttle shift and brake cables drive belt the torque converter system chain seat li...

Page 31: ...portWorks Dealers To locate the authorized dealer nearest you please call American SportWorks customer service at 1 800 643 7332 visit our website at www amsportworks com or contact your place of purc...

Page 32: ...nsure latch is adjusted properly GUARDS inspect for missing bolts nuts guards SHIFT LEVER insure working properly THROTTLE insure throttle is working properly BATTERY insure that it is fully charged B...

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