American Sportworks UTV Operator's Manual
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American Sportworks UTV Operator's Manual

American sportworks utility vehicle operators manual
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January 12, 2010
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Copyright

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Summary of Contents for American Sportworks UTV

  • Page 1 Copyright January 12, 2010...
  • Page 2 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 –...

  • Page 3: Section 1 Introduction

    Toll Free PH: 1-866-646-5278 family of new product owners. This Utility Vehicle Fax: 1-866-329-5278 “UTV” is a light utility vehicle that has been designed www.amsportworks.com with care and built by skilled workers using quality materials. Proper set-up, maintenance and safe...

  • Page 4: Serial Number Plate Location

    Serial Number:____________________________ short drivers training course with the dealer. This information is necessary to provide you with quality Your American SportWorks dealer wants you to be customer service. satisfied with your new vehicle. If you do not understand any part of this manual or you’re not satisfied with the The parts on your Utility Vehicle have been specially service received, please take the following actions.
  • Page 5 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. Close adult supervision is required at all times! Pay close attention to all Caution and Warning labels Located on the Utility Vehicle...
  • Page 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: Section 2 Safety

    * Do not allow anyone under 16 years of age to operate * Follow all towing instructions in this manual when this vehicle. towing the UTV behind another vehicle. Do not tow vehicle faster than 25 MPH. * Operator must always use both hands on the steering wheel.
  • Page 8 * Do not exceed 400 lbs. in cargo bed area (NOTE: * Avoid changing direction or making sharp steering 300lbs with rear seat kit installed), or 900 lbs. total on corrections on slopes or rollover may occur. this vehicle. * If this vehicle begins to tip when crossing a slope, turn * Do not mount a receiver hitch type carrier platform to the front wheels downhill to regain stability and control.

  • Page 9: Vehicle Information

    * Always check wheel lug nut torque values two hours *this should be done with seat (and under seat storage after initial operation and two hours after each tire repair Tray if equipped) removed, with UTV on flat level and/or replacement. Routinely check lug nut torque surface valves every 100 hours of operation.

  • Page 10: Dealer Test Ride List

    __ Engine Manual has been delivered to and reviewed by the customer. __Warranty Policy limits and requirements have been explained to the customer. American SportWorks LLC Toll Free PH: 1-866-646-5278 __ Location and functions of vehicle controls have been explained.

  • Page 11: Assembly Instructions

    Section 3 Assembly Instructions Utility Vehicle Assembly Instructions Your new Utility Vehicle Utility vehicle should include the following items to be assembled: Item #8 black screw (steering cap) Item ¼” x 1 ¾” Hex head bolts ¼” nylock nuts 5/8” x 4” Hex bolt ¼”...

  • Page 12: Section 3 Assembly Instructions

    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 1) Align the holes in the front bumper with the mounting holes in the front frame tubes.
  • Page 13 Cargo Bed Installation 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) Fenders installation (if Equipped, no fenders on TW265) Tilt the cargo bed up.

  • Page 14: Section 4 Operating Instructions

    Section 4 Operating Instructions Pre-Start Check List Check tire pressure as indicated. __ Make sure wheel lug bolts/nuts are tightened to 65ft. General Operation lbs. Start your Utility Vehicle by following the starting __ All nuts, bolts, screws, and fasteners should be procedures as noted below.
  • Page 15 Because the power transfer is automatic, you may 4x4 Utility Vehicles operate the vehicle in 4WD mode continuously without affecting steering effort or tire wear. This supplement covers the additional features, Maintenance operation and maintenance of the 4x4 Utility Vehicles Hydraulic Brakes –...
  • Page 16 6. Add 150 ml. (5 oz.) of Mobil fluid 424 discard the oil properly. American SportWorks part # 20848 (note: do 3. Be sure to clean off any debris on the drain not use any other type of oil in this system plug and reinstall.
  • Page 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 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 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°...
  • Page 20 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.

  • Page 21: Battery Charging

    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 •...
  • Page 22 BATTERY WATERING...
  • Page 23 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.
  • Page 24 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.
  • Page 25 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.
  • Page 26 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.
  • Page 27 Under Hood Under Bed Left Side Forward / Reverse Switch...
  • Page 28 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.
  • Page 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 650cc Utility Vehicle 650cc Utility Vehicle 650cc Utility Vehicle 650cc Utility Vehicle OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL Supplement Supplement Supplement 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.

  • Page 32: Section 5 Maintenance

    Section 5 Maintenance Engine Fuel Valve Lever Refer to Figure 5-1 Fuel Type The fuel tank is located under seat. The engine fuel valve opens and closes the passage between the fuel tank and carburetor. Leave fuel valve TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. lever in the OFF position when the engine is not in use to prevent carburetor flooding and reduce possibility of CW-265 &...
  • Page 33 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.

  • Page 34: Engine Oil Change

    5. Replace filler cap/dipstick and tighten securely. Engine Oil Change Section 5 Maintenance Warms oil drains quickly and completely. Therefore, drain used engine oil while engine is still warm as Transaxle Oil follows: 1. Park vehicle on a level surface, set park brake, A general description for transaxle oil maintenance, turn off ignition switch, and remove switch key.

  • Page 35: Drive Belt

    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.

  • Page 36: Section 6 Troubleshooting

    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”.
  • Page 37 Section 6 Troubleshooting...

  • Page 38: Trouble Shooting

    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. •...
  • Page 39 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.
  • Page 40 1. Apply the parking brake. 2. Turn and hold the key to start. – “Jiggle” the shift lever in the neutral slot. If the starter engages, release the key and call American SportWorks Customer service to order a neutral switch shim kit.
  • Page 41 If you have tried all of this and it is still not operating correctly, you may need new cables and a shifter update kit. Please call American SportWorks Customer Service at 1-866-646-5278. Have your Model and Serial number handy when you call.
  • Page 42 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 1-866-646-5278. Have your serial number handy when you call.
  • Page 43 Section 7 Parts Diagrams Wiring Diagram HONDA Engine Models...
  • Page 44 Wiring Diagram SUBARU Engine Models...
  • Page 45 Terminal Block Wiring...
  • Page 46 2 Wheel Drive Dana Transaxle Parts Breakdown...
  • Page 47 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 48 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 50 265cc CW265/ TW265/ BD300 Utility Vehicle Parts Breakdown...
  • Page 51 Body 265cc Models...
  • Page 52 Frame 265cc Models...
  • Page 53 Drive Train 265cc Models...
  • Page 54 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 45419 Frame, CW11 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 55 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30142 Rim/Tire Assembly, UTV 22/11-8” Front Left 30143 Rim/Tire Assembly, UTV 22/11-8” Front Right 30144 Rim/Tire Assembly, UTV 22/11-8” Rear Left 30145 Rim/Tire Assembly, UTV 22/11-8” Rear Right 10596 Rack &...
  • Page 56 #10-24 Keps nut 50616 screw, #10-24 X ¾” Pan Head Phillips 50770 Washer, #10 flat 70053 Wire Harness – 265 70000 Battery, U1L-HDJ7-UTV - 360CCA 70002 Battery Cable, Red – 17” 70010 Battery Cable, Black (24”) 70009 Battery Terminal Cover 50087 bolt, ¼”...
  • Page 57 Reflectors 10754 Seatback 43 ½ x 17 ½ 50619 #14 X 1-3/4” Pan head-Tapping screw 10803 Headrest – UTV 9 x 6 ½ 50085 bolt, ¼ x 1 ½” 10755 Seat bottom 43 ½ x 17 ½ 45416 seat bar, CW (17 ½”) – black 50609 #14 x ¾...
  • Page 58 TC, Driven Comet 40 20666 TC, Driven CVTECH – used after Serial Number # 42439 11171 Brake Shoes - Rear UTV 2WD – Dana – 1 Set required for each wheel 51101 265 Crankshaft Spacer 50795 7/16" I.D. Fender Washer 50793 7/16”...
  • Page 59 50007 5/16" Nylock Nut 11013 Throttle Cable, 265 11082 Cable, shifter 18313 Belt Guard Plastic UTV - Front 18314 Belt Guard Plastic UTV - Rear 18315 Belt Guard Plastic UTV - Bottom 50624 #10 x 3/4" Blunt Point Black 50050...
  • Page 60 340cc CW11/ TW11/ TW11R Utility Vehicle Parts Breakdown...
  • Page 61 Body 340cc Models...
  • Page 62 Frame 340cc Models...
  • Page 63 Drive Train 340cc Models...
  • Page 64 Reference Part Quantity Part Description - 2WD Models Number Number Required 45419 Frame, CW11 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 65 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30122 Rim/Tire Assembly, UTV 22/9-10” Left 30123 Rim/Tire Assembly, UTV 22/9-10” Right 30480 Wheel rim, 10” x 6” 30195 Tire, Pathfinder 22/9-10” 30124 Rim/Tire Assembly, UTV 22/11-10”...
  • Page 66 #10-24 Keps nut 50616 screw, #10-24 X ¾” Pan Head phillips 50770 Washer, #10 flat 70012 Wire Harness 70000 Battery, U1L-HDJ7-UTV - 360CCA 70002 Battery Cable, Red – 17” 70010 Battery Cable, Black (24”) 70009 Battery Terminal Cover 50087 bolt, ¼”...
  • Page 67 Reference Part Quantity Part Description – 2WD Models Number Number Required 45414 Battery strap, CW (8 ¾”) – black 50083 bolt, ¼ x 7 ½ 50002 nut, ¼” wing 70055 Light Switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081 Accessory Plug cap...
  • Page 68 Washer, 5/16 lock 10754 Seatback 43 ½ x 17 ½ 50619 #14 X 1-3/4” Pan head-Tapping screw 10803 Headrest – UTV 9 x 6 ½ 50085 bolt, ¼ x 1 ½” 10755 Seat bottom 43 ½ x 17 ½ 45416 seat bar, CW (17 ½”) –...
  • Page 69 20666 TC, Driven CVTECH – used after Serial Number # 25658 11171 Brake Shoes - Rear UTV – Dana “1 set for each wheel” 50745 1" I.D. Spacer Washer – Comet only (not used with CVTech pulley) 1/4" Key stock 3/8"...
  • Page 70 50704 5/16" Flatwasher 70250 Rubber Feet (Isolators) 50010 3/8 Nylock Nut 50740 3/8 Flatwasher USS 10581 Rod End Sphcl-UTV (4681-MPM-12) 50021 3/4 Jam nut SAE 45403 Panhard bar, CW - black 50206 bolt, 3/8 x 1 50010 3/8" Nylock Nut 50740 3/8"...
  • Page 71 Cable, shifter - used after Serial Number #15245 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18313 Belt Guard Plastic UTV - Front 18314 Belt Guard Plastic UTV - Rear 18315 Belt Guard Plastic UTV - Bottom 50624 #10 x 3/4"...
  • Page 72 4 Wheel Drive Dana & Hilliard Transaxle Parts Breakdown...
  • Page 80 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...
  • Page 81 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 82 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 84 390cc CW413 & TW413 4-wheel drive Utility Vehicle Parts Breakdown...
  • Page 85 Body 390cc Models...
  • Page 86 frame 390cc Models...
  • Page 87 Drive Train 390cc Models...
  • Page 88 Bolt, 10 mm x 40mm 50404 10 mm x 70mm bolt 50065 Nut, 10mm nylock 45150 spacer, shock 30122 Rim/Tire Assembly, UTV 22/9-10" Left 30123 Rim/Tire Assembly, UTV 22/9-10" Right 30480 Wheel rim, 10" x 6" 30195 Tire, Pathfinder 22/9-10" 30124 Rim/Tire Assembly, UTV 22/11-10"...
  • Page 89 Reference Part Quantity Part Description – 4x4models Number Number Required 20851 CV half shaft (axle) – (Left or Right) 20868 Boot CV 20839 front differential – 4x4 20848 Hilliard Front Differential Replacement Oil “8oz bottle Mobile Fluid 424” 50206 Bolt, 3/8 x 1 50740 washer, 3/8 flat 50741...
  • Page 90 1/4" Keps Nut 50159 5/16-18 x 1 1/2" Hex Hd Bolt 50005 5/16" Keps Nut 70012 Wire Harness 70000 Battery, U1L-HDJ7-UTV - 360CCA 70002 Battery Cable, Red - 17" 70010 Battery Cable, Black (24") 70009 Battery Terminal Cover 50087 bolt, 1/4" x 1 50000 nut, 1/4"...
  • Page 91 Reference Part Quantity Part Description – 4x4models Number Number Required 45414 Battery strap, CW (8 3/4") - black 50083 bolt, 1/4 x 7 1/2 50002 nut, 1/4" wing 70055 Light Switch / 4x4 switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081...
  • Page 92 Required 10754 Seatback 43 1/2 x 17 1/2 50619 #14 X 1-3/4" Pan head-Tapping screw 10803 Headrest - UTV 9 x 6 1/2 50085 bolt, 1/4 x 1 1/2" 10755 Seat bottom 43 1/2 x 17 1/2 45416 seat bar, CW (17 1/2") - black...
  • Page 93 20666 TC, Driven CVTECH – used after Serial Number #25663 11171 Brake Shoes - Rear 4WD UTV – Dana ( 1 set per wheel) 50745 1" I.D. Spacer Washer– Comet only (not used with CV Tech pulley) 1/4 x 3/16" Keystock 50742 3/8"...
  • Page 94 Spring #80704 Black painted 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18313 Belt Guard Plastic UTV - Front 18314 Belt Guard Plastic UTV - Rear 18315 Belt Guard Plastic UTV - Bottom 50624 #10 x 3/4" Blunt Point Black...
  • Page 95 653cc CW650/ TW650/ BD700 4-wheel drive Utility Vehicle Parts Breakdown All Vehicles Post August 2009...
  • Page 99 50400 Bolt, 10 mm x 40mm 50404 10 mm x 70mm bolt 50065 Nut, 10mm nylock 45150 spacer, shock 30146 Rim/Tire Assembly, UTV 25/11-12" Left 30147 Rim/Tire Assembly, UTV 25/11-12" Right 30481 Wheel rim, 12" 30199 UTV 25/11-12 Tire only...
  • Page 100 Reference Part Quantity Part Description 650cc Models Number Number Required 30146 Rim/Tire Assembly, UTV 25/11-12" Left 30147 Rim/Tire Assembly, UTV 25/11-12" Right 30481 Wheel rim, 12" 30199 UTV 25/11-12 Tire only 20851 CV half shaft (axle) 20839 front differential - 4x4...
  • Page 101 1/4" Keps Nut 50159 5/16-18 x 1 1/2" Hex Hd Bolt 50005 5/16" Keps Nut 70053 Wire Harness 265/650 70000 Battery, U1L-8250-UTV 70002 Battery Cable, Red - 17" 70010 Battery Cable, Black (24") 70009 Battery Terminal Cover 50087 bolt, 1/4" x 1 50000 nut, 1/4"...
  • Page 102 1" 14ga 10754 Seatback 43 1/2 x 17 1/2 50619 #14 X 1-3/4" Pan head-Tapping screw 10803 Headrest - UTV 9 x 6 1/2 50085 bolt, 1/4 x 1 1/2" 10755 Seat bottom 43 1/2 x 17 1/2 45416 seat bar, CW (17 1/2") - black...
  • Page 103 55043 Muffler 653cc Subaru 20644 TC, Driver Comet 780 20645 TC, Driven Comet 780 11171 Brake Shoes - Rear UTV - Dana 50745 1" I.D. Spacer Washer 1/4 x 3/16" Keystock 50742 3/8" I.D. Fender Washer 50741 3/8" Lock Washer 50219 3/8x 3"...
  • Page 104 Spring #80704 Black painted 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18324 Belt Guard Plastic 650 UTV - Front 18320 Belt Guard Plastic 650 UTV - Rear 50624 #10 x 3/4" Blunt Point Black 50050...
  • Page 105 653cc CW650 & TW650 4-wheel drive Utility Vehicle Parts Breakdown MODELS MANUFACTURED BEFORE AUGUST 2009...
  • Page 109 Bolt, 10 mm x 40mm 50404 10 mm x 70mm bolt 50065 Nut, 10mm nylock 45150 spacer, shock 30146 Rim/Tire Assembly, UTV 25/11-12" Left 30147 Rim/Tire Assembly, UTV 25/11-12" Right 30481 Wheel rim, 12" 30199 UTV 25/11-12 Tire only 30146...
  • Page 110 Reference Part Quantity Part Description 650cc Models Number Number Required 30147 Rim/Tire Assembly, UTV 25/11-12" Right 30481 Wheel rim, 12" 30199 UTV 25/11-12 Tire only 20851 CV half shaft (axle) 20839 front differential - 4x4 50206 Bolt, 3/8 x 1...
  • Page 111 1/4" Keps Nut 50159 5/16-18 x 1 1/2" Hex Hd Bolt 50005 5/16" Keps Nut 70053 Wire Harness 265/650 70000 Battery, U1L-8250-UTV 70002 Battery Cable, Red - 17" 70010 Battery Cable, Black (24") 70009 Battery Terminal Cover 50087 bolt, 1/4" x 1 50000 nut, 1/4"...
  • Page 112 1" 14ga 10754 Seatback 43 1/2 x 17 1/2 50619 #14 X 1-3/4" Pan head-Tapping screw 10803 Headrest - UTV 9 x 6 1/2 50085 bolt, 1/4 x 1 1/2" 10755 Seat bottom 43 1/2 x 17 1/2 45416 seat bar, CW (17 1/2") - black...
  • Page 113 55043 Muffler 653cc Subaru 20644 TC, Driver Comet 780 20645 TC, Driven Comet 780 11171 Brake Shoes - Rear UTV - Dana 50745 1" I.D. Spacer Washer 1/4 x 3/16" Keystock 50742 3/8" I.D. Fender Washer 50741 3/8" Lock Washer 50219 3/8x 3"...
  • Page 114 Spring #80704 Black painted 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18324 Belt Guard Plastic 650 UTV - Front 18320 Belt Guard Plastic 650 UTV - Rear 50624 #10 x 3/4" Blunt Point Black 50050...
  • Page 115 48 Volt CW48V & BD48V 2-wheel drive Electric Utility Vehicle Parts Breakdown...
  • Page 119 Reference Part Quantity Part Description – 48V Models Number Number Required XXXXXX Frame, CW48V 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 120 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30148 Rim/Tire Assembly, UTV 22/11-10” Left 30148 Rim/Tire Assembly, UTV 22/11-10” Right 30480 Wheel rim, 10” x 6” 30197 Tire, Terra Trac 30148 Rim/Tire Assembly, UTV 22/11-10”...
  • Page 121 Reference Part Quantity Part Description – 48V Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake bar, CW – black 50806 Clevis, 5/16 rod end 50170 Bolt, 5/16”-24 X 4”...
  • Page 122 Reflectors 10754 Seatback 43 ½ x 17 ½ 50619 #14 X 1-3/4” Pan head-Tapping screw 10803 Headrest – UTV 9 x 6 ½ 50085 bolt, ¼ x 1 ½” 10755 Seat bottom 43 ½ x 17 ½ 45416 seat bar, CW (17 ½”) – black 50609 #14 x ¾...
  • Page 123 Reference Part Quantity Part Description – 48V Models Number Number Required 45426 Cargo Bed, Green 45420 Cargo Bed, Red 45424 Cargo Bed, Black 18352 Camo Bed Panel Left 18353 Camo Bed Panel Right 18354 Camo Bed Panel Tail Gate 50255 5/8 x 4”...
  • Page 124 Part Description – 48V Models Number Required 70112 Potentiometer (Curtis) 70114 Solenoid / Contactor(Curtis) 70115 Converter 11171 Brake Shoes - Rear UTV –Electric Dana “1 set for each wheel” 70116 Charger 70111 Controller (Curtis) 70550 Mode Switch 70113 Charge Gauge 18318...
  • Page 125 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.
  • Page 126 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 Control Switch - part # 2-70140 • Front Amber Turn Signal Lamp - part # 2-70143 •...
  • Page 127 Turn Signal Controls Cleaning Your LSV Windshield • • • Compatible Cleaning Agents...
  • Page 128 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.
  • Page 131 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).
  • Page 132 Special Note Special Note 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.
  • Page 133 P.O. Box 649 support@amsportworks.com Roseland, LA 70456-0649 (866)-646-5278 Phone (866)-329-5278 Fax www.amsportworks.com UTILITY VEHICLE SET-UP, PRE DELIVERY CHECKLIST AND WARRANTY ACTIVATION MODEL # SERIAL # DATE OF PURCHASE DEALER SET-UP VISUALLY - inspect for damage WELDS - inspect for missing FASTENERS - inspect for missing bolts, nuts CLEAN UP - check clean up of unit CHECK ORDER - verify all items are as ordered...
  • Page 134 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. RECEIVED OWNERS MANUAL I understand that before operating this vehicle all MY DEALER DEMONSTRATED ALL CONTROLS...

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