American Sportworks Utility Vehicl Operator'S Manual Download Page 2

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INDEX

Section 1 Introduction

pages 3-4

Serial Number Plate Location

Section 2 Safety

pages 5-10

Pre-Delivery Steps

Dealer Inspection Checklist

Section 3 Assembly Instructions

pages 11-13

Seat Back, Brush guard, Bumper

Steering wheel

Cargo Bed

Seat Base

Section 4 Operating Instructions

page 14 – 29

390cc 4X4

653cc 4X4

48 Volt Electric

Section 5 Maintenance

pages 30-33

Fuel Valve Lever

Air Cleaner

Engine Oil / Transaxle Oil

Drive Belt

Section 6 Troubleshooting

pages 34-40

Section 7 Parts Diagrams

pages 41-112

Wiring Diagram

2WD Dana Transaxle

265cc 2 wheel drive

340cc 2 wheel drive

4WD Dana / Hilliard Transaxle

390cc 4-wheel drive

653cc 4-wheel drive

48 Volt 2-Wheel Drive

Warranty Policy

page 113

Contact Information

page 114

Warranty Registration Certificate

page 115

Summary of Contents for Utility Vehicl

Page 1: ...U Ut ti il li it ty y V Ve eh hi ic cl le e O Op pe er ra at to or rs s M Ma an nu ua al l Copyright January 12 2010 ...

Page 2: ...s page 14 29 390cc 4X4 653cc 4X4 48 Volt Electric Section 5 Maintenance pages 30 33 Fuel Valve Lever Air Cleaner Engine Oil Transaxle Oil Drive Belt Section 6 Troubleshooting pages 34 40 Section 7 Parts Diagrams pages 41 112 Wiring Diagram 2WD Dana Transaxle 265cc 2 wheel drive 340cc 2 wheel drive 4WD Dana Hilliard Transaxle 390cc 4 wheel drive 653cc 4 wheel drive 48 Volt 2 Wheel Drive Warranty Po...

Page 3: ...assembly operation adjustments troubleshooting and maintenance Read this manual and follow the recommendations to help ensure safe and efficient operation The information contained within this manual was current at the 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 American SportWorks LL...

Page 4: ...e time of purchase The owner upon purchasing the vehicle should have participated in a short drivers training course with the dealer This information is necessary to provide you with quality customer service The parts on your Utility Vehicle have been specially designed and should only be replaced with genuine American SportWorks parts If customer service or repair parts are required contact a Ame...

Page 5: ...rator Passenger and any Bystanders Close adult supervision is required at all times Pay close attention to all Caution and Warning labels Located on the Utility Vehicle IMPORTANT When transporting any Utility Vehicle with an installed windshield or Color matched top DO NOT reach high speeds Assumption Of Risk The owner or operator assumes all the risks incident to or arising out of the operation o...

Page 6: ...6 Section 2 Safety It is very important to read understand and follow all instructions and warnings located on the decals on your Utility Vehicle Rear Seat Weight Limit is 300lbs ...

Page 7: ...orn such as safety helmets and or goggles Keep hands arms feet and all bodily appendages safely inside the confines of the vehicle Always be aware of and avoid 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 a safe speed that will allow you to maintai...

Page 8: ...operate vehicle on 15 degree slopes or steeper Avoid changing direction or making sharp steering corrections on slopes or rollover may occur If this vehicle begins to tip when crossing a slope turn the front wheels downhill to regain stability and control When crossing a slope on soft terrain turn the front wheels slightly uphill and maintain a constant speed to maintain a straight line of travel ...

Page 9: ...l No ___________ Date ___________ Serial No ___________ Engine Serial No Dealer Service and Inspection List __ Fully charge battery Check battery voltage to verify that it is fully charged __ Check fuel valve lever to make sure it is in the correct position __ Check tire pressure to make sure front and rear tires have 5 psi __ Make sure wheel lug bolts nuts are tightened to 90 Newton meters 65ft l...

Page 10: ...d to and reviewed by the customer __Warranty Policy limits and requirements have been explained to the customer __ Location and functions of vehicle controls have been explained __ Fuel transportation and storage procedures have been explained __ Fluid fill and lubrication points have been located and explained to the customer __ Information on the safety decals have been reviewed with the custome...

Page 11: ... screw steering cap 3 x 1 Hex head bolts 7 nylock nuts 4 x carriage bolts 4 flat washers 8 5 16 x 2 socket head bolts 12 5 16 curved washers 10 5 16 nylock nuts 4 5 16 x 2 hex head bolts 2 5 16 center lock nuts Qty Item 2 5 8 x 4 Hex bolt 2 5 8 nylock nuts 1 set of keys 1 Steering wheel with cap 1 Bumper 2 Rear fenders 2 Rear frame stubs 1 Seat back 1 Cage 1 Cargo Bed with tailgate ...

Page 12: ...t should be on the outside of the vehicle Put a curved washer on the threaded end of the bolt Place a 5 16 nylock nut on the bolts Tighten all 6 nuts including step 3 Bumper Installation 1 Align the holes in the front bumper with the mounting holes in the front frame tubes Insert the four 5 16 x 2 bolts through the bumper bracket and then into the frame tubes Put a curved washer on the threaded en...

Page 13: ...adjustment slot shown in upper right photo 6 Close the bed and position the latch pin bolt so that it is at the bottom of the latch slot to prevent rattles Tighten the latch pin 7 Fenders installation if Equipped no fenders on TW265 Tilt the cargo bed up Line up the holes in the rear fenders with the square holes in the bed The raised rectangular surface on the fender should be completely hidden u...

Page 14: ... into either forward 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 floorboard left of the accelerator A lever action parking brake control is mounted on the center console located between the operator and passenger seats Depress the button on the p...

Page 15: ... mode Sudden engagement of 4X4 switch under power may damage drive train Failure to do so may void warranty Because the power transfer is automatic you may operate the vehicle in 4WD mode continuously without affecting steering effort or tire wear Maintenance Hydraulic Brakes Hydraulic Brakes use fluid pressure to transfer the braking force to the wheels Before driving the vehicle each day check t...

Page 16: ...he oil be changed once a year or after 600 hours 1 Remove the oil drain plug located on the bottom of the gear case using a hex key wrench 2 Let all the oil drain out of the unit Catch and discard the oil properly 3 Be sure to clean off any debris on the drain plug and reinstall Torque oil drain plug to 10 ft lbs 4 Remove the oil fill plug using a hex key wrench 5 Add 200 ml 7 oz of 80W90 gear oil...

Page 17: ...17 48 Volt Utility Vehicle 48 Volt Utility Vehicle 48 Volt Utility Vehicle 48 Volt Utility Vehicle OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL ...

Page 18: ...18 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 ...

Page 19: ...ged 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 As with all electric vehicles the batteries must be checked and recharged as required or at a minimum of 30 day intervals...

Page 20: ...ould 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 Deep Water Crossings Must be Avoided Charge Gauge Before operating the 48V make sure the batteries have a full charge Located on the dash the charge gauge indicates approximately the state of charge of t...

Page 21: ...h 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 ...

Page 22: ...22 BATTERY WATERING ...

Page 23: ... damage corrode the plates 2 Do not fill the water level in the filling well to the cap This most likely will cause the battery to overflow acid consequently losing capacity and causing a corrosive mess 3 Do not use water with a high mineral content Use distilled or deionized water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by step watering ...

Page 24: ...e 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 ...

Page 25: ...n 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 ...

Page 26: ...ttery 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 In addition to the main fuse there are three smaller fuses to protect the 12volt and 48 volt circuits These fuses are illustrated below Should these fuses blow and need replacement a replace...

Page 27: ...27 Under Hood Under Bed Left Side Forward Reverse Switch ...

Page 28: ...tle 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 Please disregard circuits that do not apply to your application ...

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Page 30: ...30 Warning Accessories Must NOT be Grounded to Chassis Damage to Converter Will Occur Ground to Distribution Block Ground Neg Terminal Only Please See Illustration Below ...

Page 31: ...ell as your entire owners manual before operating this vehicle CAUTION This utility vehicle comes equipped with a Low Oil Indicator Light located on the dash panel in the center of the vehicle This light will come on when the key is turned to the on position and then go off after the engine is started While operating the vehicle if the oil light becomes illuminated immediately turn the key to the ...

Page 32: ...al for the following Draining the fuel tank Checking fuel line for cracks and leaks Engine fuel valve lever Engine Maintenance General Information Detailed instructions and recommendations for break in and regular maintenance are specified in the engine operator s manual Engine warranty is backed by the engine manufacturer Please refer to engine manufacturer s manual for engine servicing lubricati...

Page 33: ...e warranty Engine Oil Fill and Drain Locations Refer to Figure 5 4 REMOVE SEAT and plastic tray if equipped FOR EASY ACCESS Filler cap dipstick location At front of engine Drain plug location At rear end of engine Type of Lubrication SAE 30 API classification of SJ SL or Equivalent Honda Oil Capacity 1 16 US qts 1 1 liters Subaru 265cc Oil Capacity 1 1 US qts 1 0 liters Subaru 653cc Oil Capacity 1...

Page 34: ...e 5 4 Section 5 Maintenance Transaxle Oil A general description for transaxle oil maintenance recommendations and capacities is provided below NOTE Running vehicle low on transaxle oil can damage transaxle and void warranty Transaxle Oil Type Fill and Drain Refer to Figure 5 5B Fill cap location At rear left hand side See arrow Drain plug location At bottom center of transaxle Type of Lubrication ...

Page 35: ...nd or down a drain 5 Fill transaxle housing with 20 oz SAE 30W oil 6 Replace fill cap and tighten securely Figure 5 5B Section 5 Maintenance Drive Belt The dive belt is considered a wearable item Replacement intervals depend on vehicle use and environment If your belt is slipping you may need to replace it 1 Park vehicle on a level surface set park brake place shifter in Neutral turn off ignition ...

Page 36: ...emove the wire connected to the spark 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 several feet 5 Wearing eye protection slowly pull the recoil start grip handle See Figure 6 2 in an upward motion This should force the fuel out of the cylinder cavit...

Page 37: ...37 Section 6 Troubleshooting ...

Page 38: ...d excessive idling or running unit with choke engaged can cause plugs to foul or engine oil may be low Possible Remedy Make sure fuel valve is on Replace spark plug and try to restart Check oil level with unit on level ground Adding more oil or making sure the oil is completely full can help to not alert the low oil sensor Engine will not start and does not turn over with electric starter Probable...

Page 39: ...rty Possible Solution 4x4 units Clean the rotors with brake cleaner and test A stiff pedal is normal for our 4x4 unit A stiff pedal means good pressure in the brake lines Check brake pads and front calipers 2wd units The 2wd units have an automatic brake adjuster Put the unit in reverse back up at low speed and step hard on the brakes This should give enough brake adjustment If you continue to hav...

Page 40: ...y move the shift lever from neutral to reverse if the starter engages release the key Repeat moving the shift lever from neutral to forward If the starter did engage go to Cable adjustment procedure section If the starter did not engage call Customer Service at 1 866 646 5278 Cable adjustment procedure Stiff or sticking cables can cause the vehicle to not shift properly and it may affect starting ...

Page 41: ...ash but do not stretch the spring and tighten the adjuster nuts 5 Place the selector lever on the dashboard in reverse 6 Make sure the transmission is fully engaged in reverse 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 7 Pull the slack out of the rear most cable under the dash but do not stretc...

Page 42: ...ral 4 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 Pull the slack out of both cables but do not stretch the springs and tighten the adjuster nuts If you have tried all of this and it is still not operating correctly you may need new cables Please call American SportWorks Customer Service at 1 8...

Page 43: ...43 Section 7 Parts Diagrams Wiring Diagram HONDA Engine Models ...

Page 44: ...44 Wiring Diagram SUBARU Engine Models ...

Page 45: ...45 Terminal Block Wiring ...

Page 46: ...46 2 Wheel Drive Dana Transaxle Parts Breakdown ...

Page 47: ...47 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

Page 48: ...48 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

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Page 50: ...50 265cc CW265 TW265 BD300 Utility Vehicle Parts Breakdown ...

Page 51: ...51 Body 265cc Models ...

Page 52: ...52 Frame 265cc Models ...

Page 53: ...53 Drive Train 265cc Models ...

Page 54: ...0702 bent washer 5 16 4 5 45411 brshgrd seat back CW black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 43010 A arm upper 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 43011 A arm Lower 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 ...

Page 55: ...sold as assembly only 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steerin...

Page 56: ...CW 2 black 1 50215 bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 11085 Shifter control assembly black built after 2 1 05 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X Pan Head Phillips 2 50770 Washer 10 flat 2 40 70053 Wire Harness 265 1 41 70000 Battery U1L HDJ7 UTV 360CCA 1 70002 Ba...

Page 57: ... washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x hex black 4 55 18305 Plastic Seat Bottom wrap 1 50624 Screw 10 x hex black 5 57 18303 ...

Page 58: ...Transaxle 265 models 1 70057 Neutral Safety Switch 1 51500 Shims Neutral Safety Switch 103 45423 Swing arm CW Black 1 104 45430 Motor Plate CW Black 1 107 20667 TC Driver Comet 40 1 20665 TC Driver CVTECH used after Serial Number 42439 1 108 20668 TC Driven Comet 40 1 20666 TC Driven CVTECH used after Serial Number 42439 1 109 11171 Brake Shoes Rear UTV 2WD Dana 1 Set required for each wheel 2 110...

Page 59: ...cer Washer 6 126 50280 3 4 x 2 5 SAE bolt 3 127 50020 3 4 SAE nylock 3 128 18011 Shifter cable mount 129 18012 shifter cable lever 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 1 50715 1 4 Flatwasher USS 2 130 11103 Brake Cables 2 50150 5 16 18 x 1 Hex Hd Bolt 2 50007 5 16 Nylock Nut 2 131 11013 Throttle Cable 265 1 135 11082 Cable shifter 2 138 18313 Belt Guard Plastic UTV Front 1 139 183...

Page 60: ...60 340cc CW11 TW11 TW11R Utility Vehicle Parts Breakdown ...

Page 61: ...61 Body 340cc Models ...

Page 62: ...62 Frame 340cc Models ...

Page 63: ...63 Drive Train 340cc Models ...

Page 64: ... black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 45404 A arm upper CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 45405 A arm Lower CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 ...

Page 65: ...ack Pinion Rod 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering sup...

Page 66: ... bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 11085 Shifter control assembly black built after 2 1 05 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X Pan Head Phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control assembly with cable and knob 1 11083 Knob 11090 Differential Co...

Page 67: ...ic Red 18350 Hood plastic Camo 50620 X 1 Pan Head Phillips Machine screw 2 50621 X 2 Pan Head Phillips Machine screw 2 50717 SAE Flat washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 ...

Page 68: ...16 seat bar CW 17 black 2 50609 14 x Pan Head Screw 6 65 10705 Seat Belt 2pt 2 50025 7 16 Nylock 4 70 45426 Cargo Bed Green 1 45420 Cargo Bed Red 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 50015 5 8 nylock 2 18402 Bed Rubber Plug 2 73 50208 Bed latch bolt 3 8 x 2 1 2 1 50013 nut 3 8 keps 2 5074...

Page 69: ...Throttle Guard Laser 1 50086 1 4 20 x 1 1 4 Hex Hd Bolt 3 50082 1 4 20 x 2 1 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 5 50715 1 4 Flatwasher USS 8 107 20648 TC Driver Comet 500 used before Serial Number 25658 1 20665 TC Driver CVTECH used after Serial Number 25658 1 108 20649 TC Driven Comet 500 used before Serial Number 25658 1 20666 TC Driven CVTECH used after Serial Number 25658 1 109 11171 Brake Sho...

Page 70: ...8 Flatwasher USS 4 125 50730 3 4 Spacer Washer 6 126 50280 3 4 x 2 5 SAE bolt 3 127 50020 3 4 SAE nylock 3 128 18012 shifter lever CW black used before Serial Number 15244 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 129 18011 shifter cable mount CW black used after Serial Number 15245 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 1 50715 1 4 Flatwasher USS 2 130 11103 Brake Cab...

Page 71: ...lt 1 50000 1 4 Keps Nut 2 50159 5 16 18 x 1 1 2 Hex Hd Bolt 1 50005 5 16 Keps Nut 2 133 11804 Spring 80704 Black painted 1 135 11080 Shifter Cable and Shifter Control used before Serial Number 15244 1 11082 Cable shifter used after Serial Number 15245 2 136 65500 fuel hose 3 16 dia 24 1 137 50849 hose clamps small 3 138 18313 Belt Guard Plastic UTV Front 1 139 18314 Belt Guard Plastic UTV Rear 1 1...

Page 72: ...72 4 Wheel Drive Dana Hilliard Transaxle Parts Breakdown ...

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Page 80: ...rain 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 ...

Page 81: ...81 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

Page 82: ...82 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

Page 83: ...83 ...

Page 84: ...84 390cc CW413 TW413 4 wheel drive Utility Vehicle Parts Breakdown ...

Page 85: ...85 Body 390cc Models ...

Page 86: ...86 frame 390cc Models ...

Page 87: ...87 Drive Train 390cc Models ...

Page 88: ...r right 2 51100 suspension bushings 2 ea 50266 bolt 5 8 x 9 1 2 1 ea 50015 Nut 5 8 nylock 1 ea 45150 Spacer CW A arm bushing 4x4 7 25001 Strut assembly left 1 25009 Strut assembly right 1 50028 Nut 7 16 NF jam 2 50041 Nut 3 8 NF slotted 2 50801 cotter pin 1 8 x 1 2 7a 25020 Lower ball joint 2 8 25003 strut bearing 2 50163 bolt 5 16 x 3 4 NC 8 50005 Nut 5 16 keps 8 9 25002 Hub rotor 4x4 2 50040 Nut...

Page 89: ...erial 31586 1 50631 Screw 3 8 16 x square head set 2 10184 key 3 16 x 1 3 19 20804 convoluted tubing 17 inch 20 10591 Rack pinion with rod ends 4x4 1 10593 Rack Pinion Boots 2 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 used before serial 27783 2 10598 Rod end 4x4 used after serial 27782 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4 1 5...

Page 90: ...52 bolt 5 16 x 1 4 50007 nut 5 16 nylock 1 35 11135 Brake hose front 1 36 11136 Brake hose rear 1 37 11085 Shifter control assembly black 1 11083 Knob 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control Assy 4x4 Diff Control w cable 1 11083 Knob 1 11091 cable diff lock 1 50053 nut 10 24 Keps nut 2 50616...

Page 91: ...at washer 8 50001 nut 1 4 nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x 3 4 hex black 5 52 18308 Steering Cover 1 50624 Screw 10 x 3 4 hex black 1 18317 Steering Cover Bottom 1 53 18383 Center Console 4x4 1 50624 Screw 10 x 3 4 hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x 3 4 hex black 4 55 18382 Plastic Seat Bottom wrap 4x4 1 50624 Sc...

Page 92: ...x 2 1 2 1 50013 nut 3 8 keps 2 50740 washer 3 8 flat 2 75 45427 Tail gate green 1 45421 Tail gate Red 1 45425 Tail gate Black 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 tailgate latch 2 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...

Page 93: ...nly not used with CV Tech pulley 1 115 20693 Belt Comet 300668 used before Serial Number 25663 1 20694 Belt CV TECH used after Serial Number 25663 1 116 50239 1 2 x 2 SAE 1 117 50722 1 2 Lock Washer 1 50721 1 2 Uss Flat Washer 1 118 10186 3 16 Key stock 1 119 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 Fee...

Page 94: ...1 Choke Bracket Honda Engine 1 150 25004 right angle gearbox 1 10184 Key 3 16 x 1 3 151 20852 gearbox coupling 1 152 18042 Gear box bracket torque arm long built before 10 06 1 18083 Gear box bracket short built after 10 06 1 70232 rubber washer built before 10 06 2 50163 bolt 5 16 x 3 4 NC 4 50701 Washer 5 16 flat 6 50703 Washer 5 16 lock 2 50005 Nut 5 16 keps 2 50303 Bolt 7 16 x 1 3 4 built befo...

Page 95: ...95 653cc CW650 TW650 BD700 4 wheel drive Utility Vehicle Parts Breakdown All Vehicles Post August 2009 ...

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Page 99: ...5 16 2 6 45445 A arm 4x4 Double A arm Front UPPER black 2 6a 45446 A arm 4x4 Double A arm Front LOWER black 2 51100 suspension bushings 2 ea 50225 bolt 3 8 x 8 1 ea 50010 Nut 3 8 nylock 1 ea 42114 spacer 3 8 ID 6 93 in length 1 ea 7 40554 Spindle Welded assembly left 1 40555 Spindle Welded assembly right 1 7a 10598 Rod End Heim Joint Studded 4 50801 cotter pin 1 8 x 1 2 25022 Snap Ring 2 8 25021 F...

Page 100: ... 10184 key 3 16 x 1 3 19 20804 convoluted tubing 17 inch 20 10599 Rack Pinion 4x4 Double A arm 1 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black...

Page 101: ...6 x 1 4 50007 nut 5 16 nylock 1 35 11135 Brake hose front 1 36 11136 Brake hose rear 1 37 11085 Shifter control assembly black 1 11083 Knob 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control Assy 4x4 Diff Control w cable 1 11083 Knob 11084 cable diff lock 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X ...

Page 102: ...4 2 51 18309 Glove Box 1 50624 Screw 10 x 3 4 hex black 5 52 18308 Steering Cover 1 50624 Screw 10 x 3 4 hex black 1 53 18383 Center Console 4x4 1 50624 Screw 10 x 3 4 hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x 3 4 hex black 4 55 18382 Plastic Seat Bottom wrap 4x4 1 50624 Screw 10 x 3 4 hex black 5 56 18304 Underseat storage box 1 57 18303 Rear Fender Left 1 18310 Rear Fe...

Page 103: ...nted 18403 Fastener kit windsheild 88 40729 Front reciever hitch 4x4 kit 1 50162 Bolt 5 16 x 1 3 8 U 4 50704 Washer 5 16 Flat 8 50007 Nut 5 16 Nylock 8 101 20017 Engine Subaru V Twin 653cc 1 50202 3 8 16 x 1 3 4 Hex Hd Bolt 4 50740 3 8 Flatwasher USS 4 102 20838 Dana Transaxle 1 103 45505 Swing arm 650 4x4 Black 1 104 55043 Muffler 653cc Subaru 107 20644 TC Driver Comet 780 1 108 20645 TC Driven C...

Page 104: ...ps small 3 138 18324 Belt Guard Plastic 650 UTV Front 1 139 18320 Belt Guard Plastic 650 UTV Rear 1 50624 10 x 3 4 Blunt Point Black 7 50050 10 Speed Nut for Plastic 7 50770 10 Flatwasher 7 150 25004 right angle gearbox 1 10184 Key 3 16 x 1 3 151 20852 gearbox coupling 1 50163 bolt 5 16 x 3 4 NC 2 50701 Washer 5 16 flat 2 50703 Washer 5 16 lock 2 152 18083 Gear Box Mount 1 153 18032 diff lock moun...

Page 105: ...105 653cc CW650 TW650 4 wheel drive Utility Vehicle Parts Breakdown MODELS MANUFACTURED BEFORE AUGUST 2009 ...

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Page 109: ... 43007 A arm 4x4 CW black 2 51100 suspension bushings 2 ea 50266 bolt 5 8 x 9 1 2 1 ea 50015 Nut 5 8 nylock 1 ea 10051 spacer 5 8 1 ea 7 25012 Strut assembly left 1 25013 Strut assembly right 1 50028 Nut 7 16 NF jam 2 50041 Nut 3 8 NF slotted 2 50801 cotter pin 1 8 x 1 2 7a 25020 replacement ball joint 2 8 25003 strut bearing 2 50163 bolt 5 16 x 3 4 NC 8 50005 Nut 5 16 keps 8 9 25014 Hub 8 rotor 4...

Page 110: ... 20804 convoluted tubing 17 inch 20 10591 Rack pinion with rod ends 4x4 1 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering su...

Page 111: ...152 bolt 5 16 x 1 4 50007 nut 5 16 nylock 1 35 11135 Brake hose front 1 36 11136 Brake hose rear 1 37 11085 Shifter control assembly black 1 11083 Knob 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control Assy 4x4 Diff Control w cable 1 11083 Knob 11084 cable diff lock 50053 nut 10 24 Keps nut 2 50616 sc...

Page 112: ...4 2 51 18309 Glove Box 1 50624 Screw 10 x 3 4 hex black 5 52 18308 Steering Cover 1 50624 Screw 10 x 3 4 hex black 1 53 18383 Center Console 4x4 1 50624 Screw 10 x 3 4 hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x 3 4 hex black 4 55 18382 Plastic Seat Bottom wrap 4x4 1 50624 Screw 10 x 3 4 hex black 5 56 18304 Underseat storage box 1 57 18303 Rear Fender Left 1 18310 Rear Fe...

Page 113: ...nted 18403 Fastener kit windsheild 88 40729 Front reciever hitch 4x4 kit 1 50162 Bolt 5 16 x 1 3 8 U 4 50704 Washer 5 16 Flat 8 50007 Nut 5 16 Nylock 8 101 20017 Engine Subaru V Twin 653cc 1 50202 3 8 16 x 1 3 4 Hex Hd Bolt 4 50740 3 8 Flatwasher USS 4 102 20833 Dana Transaxle 1 103 45505 Swing arm 650 4x4 Black 1 104 55043 Muffler 653cc Subaru 107 20644 TC Driver Comet 780 1 108 20645 TC Driven C...

Page 114: ...007 5 16 Nylock Nut 2 131 11010 Throttle Cable UTV 1 50087 1 4 20 x 1 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 11804 Spring 80704 Black painted 1 133 11804 Spring 80704 Black painted 1 136 65500 fuel hose 3 16 dia 24 1 137 50849 hose clamps small 3 138 18324 Belt Guard Plastic 650 UTV Front 1 139 18320 Belt Guard Plastic 650 UTV Rear 1 50624 10 x 3 4 Blunt Point Black 7 50050 10 Speed Nut for Plastic 7 ...

Page 115: ...115 48 Volt CW48V BD48V 2 wheel drive Electric Utility Vehicle Parts Breakdown ...

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Page 119: ...CW black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 45404 A arm upper CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 45405 A arm Lower CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut ...

Page 120: ...ion Rod 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering support CW...

Page 121: ...50701 Washer 5 16 flat 4 36 45415 Brake equalizer CW 2 black 1 50215 bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 69901 Battery Cable 20 x 5 16 x 5 16 1 69902 Battery Cable 20 x 5 16 x 3 8 1 69903 Battery Cable 20 x 1 4 x 1 4 2 69904 Battery Cable 16 x 5 16 x 5 16 1 69905 Battery Cable 10 5 x 5 16 x 5 16 2 69906 Battery Cable 10 5 x 5 16 x 3 8 2 40 70118 Wire Harness 48V 1 41 70001 Battery Trojan 6 7...

Page 122: ...ube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x hex black 4 55 18305 Plastic Seat Bottom wrap 1 50624 Screw 10 x hex black 5 57 18303 Rear Fender 1 50001 nut nylock 4 50091 20 ...

Page 123: ...ed 1 45425 Tail gate Black 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 tailgate latch 2 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 rubber domed 4 50001 nut 1 4 nylock 4 85 18400 Wi...

Page 124: ...ge 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 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 5 SAE bolt 3 127 50020 3 4 SAE nylock 3 130 11103 Brake Cables 2 50150 5 16 18 x 1 Hex Hd Bolt 2 50...

Page 125: ...cle 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 ...

Page 126: ...r Turn Signal Lamp part 2 70143 Rear Red Turn Signal Lamp part 2 70142 Turn Signal Control Module Grote part 2 70141 Blue Pigtail Plugs for front and rear Lamps part 2 70144 Turn Signal Wiring Harness part 2 70051 Plastic Turn Signal Switch Cover part 2 18318 Lexan Polycarbonate Windshield part 2 18410 Dana Transaxle H12 High Speed part 2 20840 SeatBelts Retractable LSV part 2 10706 RearView Mirro...

Page 127: ... o n g e t o p r e v e n t w a t e r s p o t t i n g A b u s i v e c l e a n i n g p r o c e d u r e s b y h a n d w a s h i n g o r a u t o m a t e d w a s h i n g e q u i p m e n t w i l l e v e n t u a l l y r e s u l t i n v i s u a l h a z i n g l o s s o f l i g h t t r a n s m i s s i o n a n d c o a t i n g c o n t a m i n a t i o n Compatible Cleaning Agents A q u e o u s S o l u t i o n ...

Page 128: ...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 ...

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Page 131: ...ns This limited warranty does not apply 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 lights fasteners decals or cosmetic body panels Warranty Service To obtain warranty service you must return your ASW product to the local authorized dealer or ser...

Page 132: ... 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 com or contact your place of purchase Mail Customer Support c o American SportWorks LLC 4404 Engle Ridge Drive Ft Wayne IN 46804 Telephone Customer Support American SportWorks...

Page 133: ...heck to insure cage is assembled properly AXLE inspect attachment and wheel bearings FASTENERS check all fasteners for proper torque ENGINE check engine RPM s for settings TRANSAXLE insure oil level is correct SEAT RESTRAINTS insure installed properly PARKING BRAKE insure that working correctly SEATS insure seat is installed properly DUMP BED insure latch is adjusted properly GUARDS inspect for mi...

Page 134: ...ERS MANUAL I understand that before operating this vehicle all MY DEALER DEMONSTRATED ALL CONTROLS operators and passengers must read follow and RECEIVED KEYS ENGINE MANUAL understands all safe operating instructions I have visually inspected unit and found no defects I understand this product is not designed for racing CUSTOMER WARRANTY ACTIVACTION REGISTRATION INFORMATION Name Phone Address Fax ...

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