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10__ Check overall appearance for cleanliness and for body and molding damage. Dealer Test Ride List __ Check engine for starting, accelerating, ru

100Reference Number Part Number Part Description 650cc Models Quantity Required 13L 30146 Rim/Tire Assembly, UTV 25/11-12" Left 1 13R 30147

101Reference Number Part Number Part Description 650cc Models Quantity Required 31 11123 master cylinder 1 50167 bolt, 5/16 x 2 2 50005

102Reference Number Part Number Part Description 650cc Models Quantity Required 42 45414 Battery strap, CW (8 3/4") - black 1 50083 bolt

103Reference Number Part Number Part Description 650cc Models Quantity Required 65 8778 Seat Belt, 3pt Retrc. 2 50025 7/16 Nylock 4 70 4542

104Reference Number Part Number Part Description 650cc Models Quantity Required 122 50021 3/4 Jam nut SAE 3 123 42093 Panhard bar, CW 4x4 - bla

105653cc CW650 & TW650 4-wheel drive Utility Vehicle Parts Breakdown MODELS MANUFACTURED BEFORE AUGUST 2009

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109Models CW-650 & TW-650 Parts List (pre August 2009) Reference Number Part Number Part Description 650cc Models Quantity Required 1 Frame,

11Section 3 Assembly Instructions Utility Vehicle Assembly Instructions Your new Utility Vehicle Utility vehicle should include the

110Reference Number Part Number Part Description 650cc Models Quantity Required 13R 30147 Rim/Tire Assembly, UTV 25/11-12" Right 1 30481

111Reference Number Part Number Part Description 650cc Models Quantity Required 31 11123 master cylinder 1 50167 bolt, 5/16 x 2 2 50005

112Reference Number Part Number Part Description 650cc Models Quantity Required 42 45414 Battery strap, CW (8 3/4") - black 1 50083 bolt

113Reference Number Part Number Part Description 650cc Models Quantity Required 65 8778 Seat Belt, 3pt Retrc. 2 50025 7/16 Nylock 4 70 4542

114Reference Number Part Number Part Description 650cc Models Quantity Required 122 50021 3/4 Jam nut SAE 3 123 42093 Panhard bar, CW 4x4 - bla

115 48 Volt CW48V & BD48V 2-wheel drive Electric Utility Vehicle Parts Breakdown

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119Reference Number Part Number Part Description – 48V Models Quantity Required 1 XXXXXX Frame, CW48V 1 2 45401 Rear frame stub, CW - black 2

12 Section 3 Assembly Instructions Pre-Assembly Instructions 1) Read Owner’s Manual. 2) Unpack all vehicle and assembly parts. Make su

120Reference Number Part Number Part Description – 48V Models Quantity Required 50060 Lug nuts, ½” 11 70301 Shock, Heavy duty #1 6 5040

121 Reference Number Part Number Part Description – 48V Models Quantity Required 31 11180 Brake Rod, with clevis 1 50215 bolt, 3/8 x 1 ¼ 1

122Reference Number Part Number Part Description – 48V Models Quantity Required 45 70080 Accessory Plug 1 70081 Accessory Plug cap 1 46 185

123Reference Number Part Number Part Description – 48V Models Quantity Required 70 45426 Cargo Bed, Green 1 45420 Cargo Bed, Red 1 45424 C

124 Part Number Part Description – 48V Models Quantity Required 106 70112 Potentiometer (Curtis) 1 107 70114 Solenoid / Contactor(Curtis) 1

125Low Speed Vehicle (LSV) Owner/Operators Manual Insert This low speed vehicle may be used on public roads (check local ordinances). This vehicle

126American SportWork’s LSV/UTV models are equipped with certain parts unique to these models only. Special care and attention may be required durin

127 Turn Signal Controls Cleaning Your LSV Windshield • • • Compatible Cleaning Agents

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 th

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13Cargo 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” s

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131 LIMITED WARRANTY Utility Vehicles (UTVs) American SportWorks (hereinafter referred to as “ASW”), hereby warrants to the original purchaser, t

132 Service and WaService and WaService and WaService and Warrantyrrantyrrantyrranty Special NoteSpecial NoteSpecial NoteSpecial Note Should

[email protected] UTILITY VEHICLE SET-UP, PRE DELIVERY CHECKLIST AND WARRANTY ACTIVATION MODEL # SERIAL # DATE OF PURCHASE DEALE

134CUSTOMER CHECKLIST VISUAL INSPECTION I understand that this product is designed for of

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14Section 4 Operating Instructions General Operation Start your Utility Vehicle by following the starting procedures as noted below. 1. Depr

154x4 Utility Vehicles This supplement covers the additional features, operation and maintenance of the 4x4 Utility Vehicles Features • 653cc Sub

16(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

1748 Volt Utility Vehicle48 Volt Utility Vehicle48 Volt Utility Vehicle48 Volt Utility Vehicle OWNERS MANUAL OWNERS MANUAL OWNERS MANUAL OWNERS M

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.

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2 INDEX Section 1 Introduction pages 3-4 Serial Number Plate Location Section 2

20WASHING YOUR 48 VOLT ELECTRIC UTV It is acceptable to wash your electric utility vehicle, though a pressure washer should not be used, and c

21Battery Charging • Your charger is equipped with a flooded / gel charge mode switch, set switch to FLOODED mode. • Plug the AC cord into a ground

22 BATTERY WATERING

23Flooded batteries need water. More importantly, watering must be done at the right time and in the right amount or else the battery's perform

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

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 vac

26Fuses Your 48V Vehicle has fused protection for the main motor circuit, along with the low amperage 48 volt circuit, and the 12 volt circuit. Pi

27Under Hood Under Bed Left Side Forward / Reverse Switch

28Located on the dash, the forward/reverse switch selects the direction of the vehicle. The operator must select the proper switch position before

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3 Section 1 Introduction American SportWorks welcomes you to its growing family of new product owners. This Utility Vehicle “UTV” is a lig

30Warning Accessories Must NOT be Grounded to Chassis. Damage to Converter Will Occur Ground to Distribution Block Ground (Neg) Terminal Only Please

31650cc Utility Vehicle650cc Utility Vehicle650cc Utility Vehicle650cc Utility Vehicle OWNERS MANUALOWNERS MANUALOWNERS MANUALOWNERS MANUAL Suppl

32Section 5 Maintenance Fuel Type The fuel tank is located under seat. TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. CW-265 & TW265

33Before installing the filter elements to make sure they have not been damaged during cleaning. Never run an engine without the filters installed.

345. Replace filler cap/dipstick and tighten securely. Engine Oil Change Warms oil drains quickly and completely. Therefore, drain used e

35 Transaxle Oil Change Warm oil drains quickly and completely. Therefore, drain used transaxle oil while transaxle housing is still warm as

36 Section 6 Troubleshooting Fuel in the Cylinder Cavity In the event that the fuel valve is left open while transporting or towing this Util

37Section 6 Troubleshooting

38Trouble Shooting Steering feels funny/pulling to one side/hard to steer (Call normally for 4wd) Probable Cause: • One side may still be engag

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 th

4Section 1 Introduction The Brush Guard Bar also provides a mounting system for American SportWorks optional windshields, canopy tops an

40 American SportWorks Utility Vehicle Shifter Trouble Shooting Notice: Always check transmission oil level. Dip a clean screwdriver straight down

41 Vehicles with serial number less than 17063. (See brass tag near top of left rear shock absorber) 1. Loosen the cable adjusters behind the da

42 Vehicles with serial number greater than 17063. (See brass tag near top of left rear shock absorber) 1. Put the vehicle in neutral. 2. Lo

43Section 7 Parts Diagrams Wiring Diagram HONDA Engine

44 Wiring Diagram SUBARU Engine Models

45 Terminal Block Wiring

46 2 Wheel Drive Dana Transaxle Parts Breakdown

47 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts

48 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts

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5 Read These Important Rules for Safe Operation Note: The Operator, Passenger, Parent or Guardian must read, study and understand a

50 265cc CW265/ TW265/ BD300 Utility Vehicle Parts Breakdown

51Body 265cc Models

52Frame 265cc Models

53 Drive Train 265cc Models

54Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 1 45419 Frame, CW11 1 2 45401 Rear frame stub, CW - black

55Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 30623 dust cap 30622 castle nut, 1” 30621 cotter p

56 Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 31 11181 Brake Rod, with clevis 1 50215 bolt, 3/8 x 1 ¼

57Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 46 18500 Terminal Block Cover – plastic 1 50625 screw, #

58Reference Number Part Number Part Description – 265cc 2WD Models Quantity Required 70a 45420 Cargo Bed, Red CW265 1 70b 45434 Flat Cargo Bed,

59Reference Number Part Number Part Description - 265cc 2WD Models Quantity Required 120 70250 Rubber Feet (Isolators) 5 - 50010 3/8 Nylock Nut

6 Section 2 Safety It is very important to read, understand, and follow all instructions and warnings located on the decals on your Utility

60 340cc CW11/ TW11/ TW11R Utility Vehicle Parts Breakdown

61 Body 340cc Models

62 Frame 340cc Models

63 Drive Train 340cc Models

64 Reference Number Part Number Part Description - 2WD Models Quantity Required 1 45419 Frame, CW11 1 2 45401 Rear frame stub, CW - black 2

65Reference Number Part Number Part Description – 2WD Models Quantity Required 50060 Lug nuts, ½” 11 70301 Shock, Heavy duty #1 6 50400

66 Reference Number Part Number Part Description – 2WD Models Quantity Required 31 11181 Brake Rod, with clevis 1 50215 bolt, 3/8 x 1 ¼ 1

67Reference Number Part Number Part Description – 2WD Models Quantity Required 42 45414 Battery strap, CW (8 ¾”) – black 1 50083 bolt, ¼ x 7

68 Reference Number Part Number Part Description – 2WD Models Quantity Required 58 55060 Fuel Tank 1 55063 Elbow Fuel Inlet w/ #200 Mesh Scree

69 Reference Number Part Number Part Description - 2WD Models Quantity Required 80 18312 Roof, green 1 18301 Roof, Red 1 18351 Roof, Camo

7Section 2 Safety Safe Operating Procedures The safe operation of any machinery is a big concern to all consumers. Your Utility Vehicle has been

70 Reference Number Part Number Part Description - 2WD Models Quantity Required 117 50722 1/2" Lock Washer 1 50721 1/2" Uss Flat Wa

71 Reference Number Part Number Part Description - 2WD Models Quantity Required 132 11086 Differential Control Assembly w/ cable all models after

72 4 Wheel Drive Dana & Hilliard Transaxle Parts Breakdown

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8* 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 rece

80Hilliard Drive Train Products Approved Lubricants list  Mobilfluid 424  Mobilfluid LT  Hytran Ultra  Hytran  HyGuard  Low Viscosity HyGuard

81Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts

82 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts

83

84 390cc CW413 & TW413 4-wheel drive Utility Vehicle Parts Breakdown

85 Body 390cc Models

86 frame 390cc Models

87 Drive Train 390cc Models

88Reference Number Part Number Part Description – 4x4models Quantity Required 1 45501 Frame, CW413 - 4x4 1 2 45401 Rear frame stub, CW - black

89Reference Number Part Number Part Description – 4x4models Quantity Required 14 20851 CV half shaft (axle) – (Left or Right) 2 20868 Boot CV

9battery. Follow all battery safety rules outlined in this manual. * Avoid battery acid spills. Do not get battery acid on eyes, face, or other bod

90Reference Number Part Number Part Description – 4x4models Quantity Required 31 11123 master cylinder 1 50167 bolt, 5/16 x 2 2 50005 Nu

91 Reference Number Part Number Part Description – 4x4models Quantity Required 42 45414 Battery strap, CW (8 3/4") - black 1 50083 bolt,

92Reference Number Part Number Part Description – 4x4models Quantity Required 60 10754 Seatback 43 1/2 x 17 1/2 1 50619 #14 X 1-3/4" Pan

93 Reference Number Part Number Part Description – 4x4models Quantity Required 103 45502 Swing arm, CW - Black 4x4 1 104 45430 Motor Plate, CW

94Reference Number Part Number Part Description – 4x4models Quantity Required 133 11804 Spring #80704 Black painted 1 136 65500 fuel hose 3/16&

95 653cc CW650/ TW650/ BD700 4-wheel drive Utility Vehicle Parts Breakdown All Vehicles Post August 2009

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99Models CW-650/TW-650/BD-700 Parts List (post August 2009) Reference Number Part Number Part Description 650cc Models Quantity Required 1 Frame