American Sportworks UTV Operating instructions

UTILITY VEHICLE
O P E R ATO R ’ S
SAFETY
MANUAL
Gasoline, Gas/Electric Hybrid & Electric Utility Vehicles
This manual applies the following brands:
LANDmaster UTVs
BULLDOG UTVs
Trail Wagon UTVs
Chuck Wagon UTVs
All of our Illustrated
Parts Lists are
now online at:
amsportworks.com/manuals_UTV.php
Copyright August 23, 2013
15571R1
INDEX
Table of Contents
Section 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 4-5
Section 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 6-12
Section 3
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 13-16
Section 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Your Vehicle’s Model, VIN and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning Labels / Safe Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Electric / Hybrid Vehicle Specific Warnings & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Before You Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Section 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 18-24
Responsible Operation and Rider Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
Replacement Parts, Accessories and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2WD and 4WD Gas UTV Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electric UTV Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gas / Electric Hybrid UTV Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 25-32
Section 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 33-35
Section 8
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 36-41
Section 9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages 42-44
General UTV Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
Electric / Hybrid UTV Specific Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Honda / Subaru / Briggs & Stratton Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37
48V Wiring Diagrams / Hybrid Wiring Diagrams / Terminal Block Wiring . . . . . . . . . . . . . . . . . . . . . . 38-41
Full Size UTV Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service and Warranty Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
UTV Setup and Pre-Delivery Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pre Drive Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
4404 Engle Ridge Drive
Fort Wayne IN 46804
62194 Commercial Street
Roseland, LA 70456
Toll Free 800-643-7332
Fax 800-399-1399
www.amsportworks.com
SECTION 1
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. We hope you will make a
sincere effort to put safety above all other priorities. The Utility Vehicle
was designed and built for work, recreation, and enjoyment; however,
improper and irresponsible operation could result in serious injury
or death. Since this is an off-road vehicle, operators will seldom see
the road safety and warning signs they are accustomed to seeing on
highways and public streets. This places additional responsibility on
the driver to operate this vehicle well within the safe operational limits
and capabilities of the unit.
This manual has been prepared to instruct you in the safe and
responsible operation of your Utility Vehicle. Read and abide by all
safety alert information about this vehicle. If you do not understand any
part of this manual, contact your local dealer for additional information
and clarification. As the operator of this piece of equipment, you are in
complete control. Only you can prevent an accident from happening.
Using This Manual
• Prior to any vehicle operation it is absolutely essential that you
read and comprehend each section in this manual to develop an
understanding of your vehicle and for your safety. After reviewing
this manual, store it in a dry and easily accessible place for future
reference.
• The Operator’s Section is designed to help familiarize you with safety,
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 or contact American SportWorks Customer Service at 800-6437332 or visit us on the web at www.amsportworks.com.
4
introduction
Terminology
Right-hand and left-hand as used in this manual are determined by
facing the direction the vehicle will travel while in use unless otherwise
stated.
Getting Acquainted with your Utility Vehicle
This utility vehicle is designed exclusively for off-road use. It is not
designed, properly equipped, or licensed to be safely operated on
public streets and highways unless equipped with an LSV package.
An ASW Low Speed Vehicle (LSV) is street legal where allowed when
properly licensed and plated. Although street legal, the LSV is not
designed for, nor allowed on highways. Refer to your local ordinances
regarding the use of Low Speed Vehicles in your area.
Unlike an ATV’s one person “straddle saddle” seat, the Utility Vehicle
sports dual headrests, cushioned seats with seat belts and a protective
full length body. Two passengers can ride comfortably in this vehicle
protected from splashing water and mud. The Brush Guard mounted
to the vehicle’s frame provides protection against low hanging limbs
and briars.
The Brush Guard 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 accessories.
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. Please
visit our website at www.amsportworks.com for a full list of available
accessories.
introduction
The Utility Vehicle has some similarities to an ATV. Your Utility Vehicle
has a short wheelbase, narrow stance, and high center clearance all
which provide for narrow and difficult trail access. This combination
also enables this vehicle to be loaded in the back of most full to midsized pickups for transport.
SECTION 1
Always use the serial and model number when ordering
parts for your Utility Vehicle. The serial-number plate
is located under the cargo bed on the driver’s side just
above the engine, on the frame as shown in figure 1
below.
The Utility Vehicle’s ground compaction and is very gentle on the ground
and surrounding vegetation. The engine is EPA certified and will meet
California Air Resources Board (CARB) certification standards, when
so equipped.
Owner Assistance
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 an American
SportWorks dealer or our customer service department toll free at 800643-7332 or by email at feedback@amsportworks.com. Our dealers
have trained personnel, genuine repair parts and equipment specially
designed to repair American SportWorks products.
Fig. 1 Serial
Number Plate Location
Record your Utility Vehicle Model, VIN and Serial Number here for quick reference:
The model and vehicle identification number (VIN) are located in the cab under the steering column / the serial number is located under the dump bed (see figure 1)
MODEL:
VIN:
SERIAL NUMBER:
American SportWorks wants you to be satisfied with your new
vehicle. If you do not understand any part of this manual or you’re not
satisfied with the service received, please take the following actions:
4404 Engle Ridge Drive
Fort Wayne IN 46804
• Discuss the matter with your dealership service manager. Make sure
they are aware of any problems so they can assist you.
62194 Commercial Street
Roseland, LA 70456
• If you are still unsatisfied, please call American SportWorks customer
service at 800-643-7332 or email us at feedback@amsportworks.com.
Toll Free 800-643-7332 • Fax 800-399-1399
www.amsportworks.com
5
SECTION 2
safety
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 operator’s
manual before operating the Utility Vehicle. Failure to follow these
instructions could endanger the personal safety of the Operator,
Passenger and any Bystanders.
Recommended minimum age of
operator is 16 years of age. Close adult
supervision is required at all times!
Pay close attention to all Caution and
Warning labels located on the Utility
Vehicle
CAUTION
Transporting vehicle at a high rate of speed may cause damage
to component parts. When transporting any utility vehicle with an
installed windshield or roof DO NOT travel at high speeds!
Assumption Of Risk:
The owner or operator assumes all the risks incident to or
arising out of the operation of this Utility Vehicle
FAILURE TO FOLLOW AND COMPLY WITH ALL WARNINGS
MAY CAUSE SERIOUS INJURY OR DEATH
SOME WORDS ABOUT SAFETY
The following pages present important information and recommendations to help you drive your vehicle safely. Please read through these pages
thoroughly.
WARNINGS AND CAUTIONS
! This is the safety alert symbol. When you see this symbol on your
machine or in this manual, be alert to the potential for personal injury.
Read and follow all instructions in this Operator’s Safety Manual,
Owners Manual / Parts Guide and any accompanying manuals before
attempting to operate this vehicle.
!
WARNING
Indicates a potential hazard that could result in severe
personal injury or death
!
CAUTION
Indicates a potential hazard which may result in
personal injury or damage to the machine.
NOTE
6
will alert you to key information or instructions.
Before operating this vehicle
The owner, and each operator, must understand that this vehicle was
not designed or manufactured to meet specifications for use on public
roads, streets, highways and thoroughfares. The owner, operator(s)
and passenger(s) must read and understand all the instructions
for proper assembly and safe operation, as well as the instructions
concerning the engine and all other portions of the vehicle as described
and illustrated in this manual. Children must be of the specified age or
older and supervised by an adult at all times when using the vehicle.
This vehicle is not a toy.
Cell Phone Use
The use of Mobile Communications Equipment has become increasingly
important and prevalent in both personal and business affairs. Drivers
must not compromise their own, or others safety when using such
equipment. ASW recommends against the use of any handheld device
while driving this vehicle.
We hope you will have a fun, safe experience with our products and
thank you again for choosing an American SportWorks utility vehicle.
SECTION 2
safety
It is very important to read, understand, and follow all
instructions and warnings located on the decals on your
Utility Vehicle.
WARNING
WARNING
OBSERVE THE FOLLOWING INSTRUCTIONS
ALWAYS WEAR SEATBELT
Failure to understand and follow Warnings and Instructions for
the safe use and maintenance of this product may result in
Death or Injury! This information is contained in the Warning
Labels, Owner’s Manual & Supplements, Safety Video, and
Engine Manual supplied with this product. Make sure that you
understand and follow all Warnings and Instructions in this
material.
Seatbelt must be properly fastened and
adjusted for each occupant prior to operating
the vehicle; See Owner’s Manual.
Always wear a D.O.T.-approved motorcycle helmet, eye
protection, and protective clothing.
under
This vehicle is not to be operated by
Age
anyone under 16 years of age.
Do NOT operate the vehicle without the brush bars securely in
place. Keep all covers and shields properly installed.
Never ride after consuming alcohol, drugs, or other intoxicants.
Throttle and Brake Controls must work properly and freely
before starting the engine.
Operator must be seated, safety belt must be fastened before
operating the vehicle.
Never operate at speeds too fast for your skills or the
conditions. Never attempt jumps or other stunts.
Check tire pressures before operating. Refer to Owner’s
Manual for proper operating pressure.
If you did not receive any of the material listed above,
please call 1-800-643-7332 and request to
have them sent to you at no charge.
WARNING
HOT SURFACES
Surfaces around the engine and exhaust can be
extremely hot. Allow surfaces to cool before
servicing.
WARNING
EXHAUST GAS HARMFUL
Engine exhaust from this product contains
chemicals, known in certain quantities to cause
cancer, birth defects, or other reproductive harm.
ADVERTENCIA
SIEMPRE USE CINTURON DE SEGURIDAD
El cinturón de seguridad debe ser apropiadamente atado y
ajustado para cada ocupante antes de la operación del
vehículo; Ver Manual de Dueño.
2-60057 ES
ADVERTENCIA
SUPERFICIES CALIENTES
Las superficies alrededor del motor y el escape pueden estar
extremadamente calientes. Permita que las superficies se enfríen
antes de realizar el mantenimiento.
2-60057 FS
ADVERTENCIA
GASES DE ESCAPE NOCIVOS
Gases de motor de este producto contienen productos químicos,
conocidos que en determinadas cantidades pueden causar cáncer,
defectos de nacimiento u otros daños reproductivos.
2-60057 GS
2-60057 A
ADVERTENCIA
OBSERVE LAS SIGUIENTES INSTRUCCIONES
El hecho de no comprender y seguir las Advertencias y
Instrucciones para el uso seguro y el mantenimiento de este
producto puede causar ¡MUERTE O LESION!. Esta información
esta contenida en las Etiquetas de Advertencia, Manual de Dueño
y Suplementos, Video de Seguridad, y el Manual del Motor
proveídos con este producto. Asegúrese de comprender y seguir
todas las advertencias e instrucciones suministradas.
Siempre lleve puesto un casco de motocicleta aprobado por D.O.T.,
protección en los ojos, y ropa de protección.
under
Este vehículo no debe ser operado por ninguna persona
Age
menor de 16 años de edad.
NO opere este vehículo sin las barras protectoras aseguradas en su
lugar. Mantenga todos las cubiertas y protectores apropiadamente
instalados.
Nunca maneje después de consumir alcohol, drogas, u otros
intoxicantes.
Acelerador, y controles de frenos deben trabajar
apropiada y libremente antes de encender el motor.
El operador debe estar sentado, el cinturón de seguridad
antes de operar el vehículo.
Nunca opera a una. Nunca intente saltos o acrobacias. Sus habilidades
o las condiciones.
Checar inflación de IIantas antes de operar. Consulte el Manual de
Dueño para la presión adecuada de operación.
Si Usted no recibió alguno de los materiales mencionados
anteriormente, por favor llame al 1-800-643-7332 y solicite
que se le envíen sin cargo.
2-60057 AS
CAUTION
USE ONLY MID-GRADE UNLEADED GASOLINE (89 – 93 OCTANE)
PRECAUCION
USE SOLO GASOLINA DE MEDIO-GRADO SIN PLOMO (OCTANO 89-93)
E15
This engine is designed to run on automotive gasoline with allowable ethanol
blends from 0% - 10%.
E15
Este motor fue diseñado para funcionar con gasolina de automobil con mezclas
de etanol permitidos de 0% a 10%.
E85
Attempting to use anything other than this will cause damage to the engine
and void the manufacturer warranty.
E85
El intentar utilizar otro tipo del que se requiere, causara daños al motor
y no sera valida la garantia del fabricante.
ADVERTENCIA
WARNING
NO SUBIR
NO RIDERS
2-60057 HS
WARNING
ADVERTENCIA
Todos los ocupantes deben estar
All occupants must be inside
adentro del vehículo usando equipo de
the vehicle and wearing the
proper restraints and safety gear. seguridad y restricciones adecuadas.
2-60057 JS
CAUTION
PRECAUCION
SHUT OFF FUEL VALVE
Always shut off fuel valve before transporting this vehicle.
APAGE LA VÀLVULA DE COMBUSTIBLE
Todo el tiempo apague la válvula de combustible antes de que
transporte este vehículo.
2-60057 CS
WARNING
ADVERTENCIA
TURN OFF ENGINE
Always turn off engine before refueling. Refuel in a well
ventilated area. Keep away from flame or sparks.
APAGE EL MOTOR
Todo el tiempo APAGE el motor antes de poner combustibles.
Ponga combustible en un área bien ventilada. Aleje de las
llamas o chispas.
WARNING
2-60057 DS
ADVERTENCIA
LATCH DUMP BED
Driving with the cargo bed raised is hazardous. Always
lower and latch bed before driving.
SEGURO DE LA CAJA DE VOLCAR
VEHICLE MAY
ROLL
This vehicle will handle
differently from any
ordinary passenger car
or truck. Sharp turns or
abrupt maneuvers at
high speeds may cause
this vehicle to roll over
or go out of control.
Read and understand
Owner’s Manual before
operating this vehicle.
EL VEHÍCULO SE
PUEDE VOLCAR
Este vehiculo se maneja
y se maniobra diferente
de cualquier otro carro o
camión común de
pasajeros. Curvas
cerradas o maniobras
bruscas en alta
velocidad puede causar
una volcadura o pérdida
del control. Lea y
comprenda el Manual de
Dueño antes de operar
este vehículo.
2-60057 BS
Manejar con la caja de carga levantada es peligroso.
Todo el tiempo manténgala abajo y use el seguro de la
caja cuando maneje.
2-60057 IS
7
SECTION 2
Safe Operating Procedures
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.
WARNING
• Be familiar with all functions of this vehicle.
• Keep all bystanders away from this vehicle during operation.
• Do not allow anyone to operate this vehicle who has not fully read
and comprehended this manual and who has not been properly
trained in the safe operation of this vehicle.
• Do not operate a vehicle with damaged or defective parts. Repair
all damages and defective parts before putting vehicle back in to
service.
• Do not allow anyone under 16 years of age to operate this vehicle.
• Operator must always use both hands on the steering wheel.
• No riders allowed except in factory designed and supplied seating.
• Operate this vehicle from the driver’s seat only.
• Do not leave this vehicle unattended with engine running.
• Do not dismount a moving vehicle as serious injury or death could
occur.
• Always operate vehicle with belt guard installed. Do not leave
pulleys and belts exposed.
• Do not touch engine, engine exhaust pipe and/or muffler while they
are hot.
• Always wear seatbelt - seatbelt must be properly fastened and
adjusted for each occupant prior to operating this vehicle.
• Do not exceed total payload capacity of this vehicle.
• Do not pull a trailer or implement exceeding 1100 pound towing
capacity or loss of control may result.
• Do not attach an implement, trailer or other device to the hitch that
will produce negative tongue weight.
• Follow all towing instructions in this manual when towing the UTV
behind another vehicle. Do not tow vehicle faster than 25 MPH.
• Do not use the vehicle as an anchor device.
• Beware, tow ropes, cables and chains can break when pulling
another vehicle or object causing serious injury or death to anyone
in line with the whipping action created when they break. Never jerk
when pulling, always ease into a pull gently. Always stay clear of the
tow line. Never be in line with the tow line.
• Reduce speed when loaded with cargo. Heavy cargo load takes
longer to stop.
• Reduce speed and payload on hilly, rough, wet, slick or unstable
ground.
• Always make turns at a speed that will maintain control of vehicle.
Never make turns at full speed. Reduce speed when turning empty
and reduce speed even more when turning loaded with cargo or when
pulling a cargo load. The heavier the cargo load, the slower the turn
should be.
• Make sure all gear or cargo is properly secured and tied down.
• 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.
• Keep hands, feet, long hair, clothing, and jewelry away from moving
parts and obvious pinch points to avoid getting caught.
• Do not load the Brush Guard Bar with heavy equipment. Rollover
could result from such loading.
• Wear snug-fitting clothing to avoid entanglement with moving
parts.
• The Brush Guard is not certified ROPS (Roll Over Protection System).
Always avoid rollovers.
• Use of a D.O.T. approved helmet is recommended when operating
this vehicle on uneven surfaces or rough terrain. Most fatalities are
due to head injuries.
• Do not operate this vehicle on highways, public roads, or where it
may be a hazard to faster moving traffic.
• 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
maintain control.
8
safety
• Do not operate this vehicle while drinking or under the influence of
alcohol and drugs.
• Never attempt wheelies, jumps, or other stunts. Never drive
recklessly. Always operate your vehicle at a safe speed that will allow
you to maintain control.
• Never use vehicle for racing and never modify the engine to exceed
25 MPH vehicle speed.
• Never modify any parts on the vehicle without authorization.
Unauthorized modifications will void warranty to all parts directly and
indirectly affected by the modification.
safety
SECTION 2
• Always make sure the vehicle pathway is clear of all objects when
backing up. Know location of personnel around vehicle and especially
location of small children. Take extra precautions when rear view is
hindered by cargo.
• Do not smoke or use electrical devices including cell phones while
refueling.
• Always park on level ground, stop engine, set parking brake and
remove ignition key before leaving the vehicle. Chock tires if condition
warrants.
• Always disconnect the negative battery terminal before making
adjustments to the vehicle electrical system or welding on this
vehicle.
• Use extreme caution when cresting hills or when visibility is limited.
Proceed slowly until you are sure trail conditions immediately ahead
are safe.
• Battery fumes are explosive. A spark will ignite battery fumes. Wear
a face shield when charging or jumping a battery. Follow all battery
safety rules outlined in this manual.
• Keep front wheels straight when cresting hills or going over bumps.
• 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.
• Do not stop, start suddenly or over accelerate on hills. Loss of control
and rollover could result.
• Always maintain proper tire inflation.
• Do not operate vehicle on 15 degree slopes or steeper.
• Always check wheel lug nut torque values two hours after initial
operation and two hours after each tire repair and/or replacement.
Routinely check lug nut torque valves every 100 hours of operation.
• Support this vehicle securely before working beneath. Chock the
wheels to prevent the vehicle from rolling.
• Avoid changing direction or making sharp steering corrections on
slopes or rollover may occur.
• Do not shift transaxle unless this vehicle is fully stopped and the
engine is at idle or damage may occur.
• Use extreme caution when descending hills or running on loose slippery
surfaces. Towing, braking, and traction are greatly diminished.
• 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.
• 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 control
may result.
• If your vehicle loses power and stops on a hill, immediately engage
the foot brake and back slowly down the hill maintaining a straight
downhill line of travel. Do not attempt to turn the vehicle sideways on
the hill or a rollover could result.
• When traveling at night always use your headlights and reduce speed
according to visibility, trail, and terrain conditions.
• Avoid water crossings when possible and never cross a body of water
where depth is unknown. Loss of power will occur if the drive belt
becomes submerged or wet. Unnecessary crossing of streams and
waterways erodes shore line and damages water-born habitat. If you
must cross, do it at a point where banks are not steep and proceed at
a slow and steady speed.
• Front bumper and brush guards are not designed as pusher bars.
Do not attempt to push other vehicles or implements or damage may
result.
• When refueling use an (UL) approved non-metallic container that has
no screen or filter. Set the container on the ground before fueling to
eliminate static discharge and do not use Methanol fuel.
CAUTION
When transporting any utility vehicle with a windshield or
roof installed do NOT exceed 55 mph.
CAUTION
This utility vehicle may be equipped with a Low Oil Indicator
Light located on the left hand side of the dash panel. 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 “off” position to kill the
engine.
NOTICE
For all models with the Subaru 653cc motors,
the EH65 High Altitude Jet Kit (Part# 2-20160
for single barrel and Part# 2-20164 for dual
barrel) is required in order to be operated at an
altitude of 5000 feet or higher.
9
SECTION 2
safety
48 Volt / Gas-Electric Hybrid Utility Vehicle
Specific Warnings & Cautions
BEFORE INITIAL USE
NOTE
LIMITED ELECTRIC RUNTIME: Plan carefully before
using this vehicle to go significant distances over
questionable terrain. Remember that a one hour drive
may take many hours to walk out should you run out
of battery power or be stranded by becoming stuck on
unsuitable terrain.
WARNING
• 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.
• Hydrogen gas is generated as a natural part of the lead acid battery
charging process. A 4% concentration of hydrogen gas is explosive and
could cause severe injury or death. Because hydrogen gas is lighter
that air, it will collect in the ceiling of buildings necessitating proper
ventilation. Charging must take place in an area that is adequately
ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could result in severe
injury or death, never smoke around or charge batteries in an area
that has an open flame or electrical equipment that could cause an
electrical arc. Pay particular attention to natural gas or propane gas
water heaters and furnaces.
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.
As with all electric vehicles, the batteries must be checked and recharged as
required or at a minimum of 30 day intervals.
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 the batteries. Far right (as shown) indicates batteries are fully charged, far left
indicates a low charge.
0
1
BATTERY GAUGE: Showing a full charge.
Washing Your Vehicle
• Always wear a safety shield or approved safety goggles when
adding water or charging batteries.
Any electrolyte spills should be neutralized with a solution of 1/4 cup
(60ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6
liters) of water and flushed with water.
Overfilling batteries may result in electrolyte being expelled from
the battery during the charge cycle. Expelled electrolyte may cause
damage to the vehicle and storage facility.
Aerosol containers of battery terminal protectant must be used with
extreme care. Insulate metal container to prevent can from contacting
battery terminals which could result in an explosion.
• Deep water crossings MUST be avaoided.
10
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.
SECTION 2
safety
!
WARNING
BEFORE YOU DRIVE
1. Check tire pressure before each use.
a. Prior to operating the vehicle check and adjust tire pressure to the proper operating pressure as indicated on the sidewall of
each tire or in the Specifications section of the Operator’s Safety Manual. A tire pressure gauge is required to obtain
accurate readings.
2. Check fuel supply before each use.
a. NEVER fill fuel tank while the engine is running or hot.
b. DO NOT overfill tank.
c. ALWAYS allow at least ½” of expansion space at the top of tank.
d. There should not be any fuel in the filler neck.
e. Replace cap tightly to prevent a fuel spillage fire hazard.
NOTE: Always use an original gas cap or OEM (Original Equipment Manufacturer) replacement.
f. NEVER fill fuel tank while the vehicle is inside a building.
g. After filling the tank, move the vehicle at least ten feet before attempting to start the engine.
3. NEVER start the engine without the operator properly seated and the restraint system properly
adjusted and secured with the brake applied and the vehicle in neutral.
4. Be sure the passenger restraint system (i.e. Seat Belt) is properly adjusted and fastened at all times during operation.
a. If the passenger restraint system is not properly used by the operator and/or passenger, loss of control and possible
personal injury and/or vehicle damage may occur.
5. When there is no passenger in the vehicle, the passenger seatbelt must be securely fastened within the vehicle.
a. If the passenger restraint system is not properly used by the operator and/or passenger, loss of control and possible
personal injury and/or vehicle damage may occur.
6. Keep the engine free of dirt and debris, especially in the throttle linkage area.
7. NEVER start the engine without checking to see that the throttle control is in idle position.
8. ALWAYS use extreme caution when starting the engine.
a. Hot engine, muffler, or drive components can burn on contact.
9. NEVER operate the machine while under the influence of alcohol, drugs, or medication of any kind.
a. Such operation is dangerous to yourself and/or others.
10. NEVER use hand held electronic devices while driving this vehicle.
a. Driving while distracted can result in loss of vehicle control, accident and injury.
11. Long hair, loose clothes, or jewelry can get caught in moving parts below and behind the seat or surrounding
environment.
a. Remove or tie back anything loose that can reach below and behind the seat before riding.
11
SECTION 2
!
safety
WARNING
WHILE OPERATING THIS VEHICLE
1.
NEVER place hands, feet, or any body parts or clothing near the engine, wheels, and other rotating parts of the
vehicle while riding or running the engine.
a. Use caution in performing required maintenance on or near operating engine.
b. Use caution after the engine has been running, since the engine and other drive components may be extremely hot.
2. Wet, slippery, rough, or sloped terrain is potentially dangerous and may result in injury if proper caution is not
observed.
a. ALWAYS SLOW DOWN
b. Operator must use mature judgment, skill, and experience to choose a speed suitable for terrain and riding conditions in
protecting operator, passenger, and/or any bystanders.
c. Operator must use mature judgment, skill and experience in choosing suitable terrain for individual operational capabilities.
3. ALWAYS SLOW DOWN when turning.
a. This vehicle is not a passenger car. High-speed turning and failure to operate this vehicle correctly may cause loss of
control, vehicle rollover and/or possible death or injury to the vehicle occupant(s).
b. Turning on a slope increases the risk of rollover.
c. Practice driving in a safe open area to develop a feel for the vehicles performance and handling characteristics, size and
weight.
4. When turning on pavement, loose gravel, or similar surfaces, there is an increased risk in loss of control. ** ALWAYS
SLOW DOWN! **
5. Operating the vehicle in conditions where water, mud, snow, dirt, sand, or other debris can get into the throttle cable
conduit and/or on the throttle mechanism may cause binding of the cable and/or the throttle mechanism.
a. This may result in the throttle sticking which can cause the engine to continue to run and result in loss of control.
6. Keep hands, feet, and all body parts in the vehicle at all times.
7. STOP the vehicle and back slowly down any hill that the vehicle lacks the power or traction to climb. Do NOT turn
across the slope or try to turn around.
a. Turning on a slope increases the risk of rollover.
b. Control the descent speed with the brake (left foot pedal).
c. Re-applying the throttle when facing up a steep hill increases the risk of the front tires leaving the ground and the vehicle
over-turning.
8.
!
12
STOP the engine if the machine makes unusual noises or vibrations.
a. Check the vehicle for damage.
b. Excessive noise or vibration is a sign of loose or worn parts.
c. Do not attempt to use the vehicle until it has been serviced to correct the issue.
CAUTION
1.
Vehicle must be stored where gasoline fumes will not reach an open flame, spark, or other source of ignition.
a. For long-term storage, fuel tank should be drained in an open, cool area.
b. Engine must be allowed to cool before storage in any enclosure.
c. NEVER store the vehicle in close proximity to appliances such as hot water heaters or furnaces.
2.
NEVER use E-15 or E-85 fuel or blends with Ethanol content in excess of 10%. Ethanol blends in excess of 10% will cause damage to the engine and void manufacturer warranty
a. Use regular unleaded 87 octane gasoline with up to a 10% ethanol blend.
b. This engine supplied with this vehicle is NOT designed for Flex Fuel operation.
assembly
SECTION 3
A S S E M B LY I N S T R U C T I O N S
Cargo bed
! WARNING
Brush guard
Other items are located
under the unit
Wear proper eye protection during the uncrating
and assembly process to avoid potential eye injuries.
! WARNING
RISK OF SERIOUS INJURY OR DEATH
The Brush Bars and the Seat and Shoulder Belt
are critical parts of the Operator / Passenger safety
system on this unit. Do not attempt to operate the
unit until all components have been properly installed.
Your new Utility Vehicle should include
the following items to be assembled:
Qty
Item
6
6
4
10
4
4
6
12
12 4
2
2
2
2
1
1
1
2
2
1
1
1
1
1
¼” x ¾” Socket head bolts (steering cap)
¼” – 20 Nylock nuts (steering cap)
¼” x 1” hex head bolts (poly bed)
¼” Nylock nuts
¼” x ¾” Carriage bolts (steel bed)
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” x 2 ¼” Socket head bolts (LM)
5/16” Nylock nuts (LM)
5/8” x 4” Hex bolt
5/8” nylock nuts
Set of keys
Steering wheel (with cap)
Bumper
Rear fenders
Rear frame stubs
Seat back
Cage
Cargo Bed with tailgate
Seat Back Frame
Seat Bottom
1 Uncrating the vehicle
• Wear your Safety Glasses to prevent eye injury.
• Using the Hammer and Pry Bar, remove cross supports at each end
of the crate and discard.
• Carefully pry and remove crate top and sides then discard.
2 Remove crate sides and discard
• Using Box Cutters, cut and remove the hold down ties.
• Remove seat back and other loose items from underneath unit and set
aside
• Remove the unit from the crate base and discard base.
NOTE: Some models may require installing front tires prior to removing
from crate.
3 Unpacking the components
• Unpack all of the loose components from the unit and set aside.
• Remove protective plastic from each component and discard.
Step 2 Crate Top
Step 1 End
Cross Supports
Step 3 Sides
Step 3 Sides
Step 1 End
Cross Supports
13
SECTION 3
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.
assembly
4) Then secure the plastic hood onto the same bolt with the
second nylock nut located beneath the hood, until the bolt head
is flush with the end of the nut.
5) Tighten all brush guard fasteners.
3) If you have any questions or problems with your American SportWorks product please call us, toll
free at 1-800-643-7332.
Seat / Brushguard Assembly
Your new American SportWorks UTV uses two socket head 5/16” x
2 ¼” bolts to hold the hood as well as the Brushguard in place, with
an additional nylock behind the plastic as shown
1)
Place seat back bar on vehicle frame tubes. Insert a 5/16” x 2”
socket head bolt through both bottom joints. The head of the
bolt 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 but do not tighten.
Bumper Installation
1)
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 bolt 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.
3) Tighten the nylock against the bent washer VERY tightly to
secure the Brushguard.
14
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 end of the bolt. Place a 5/16”
nylock nut on the bolts and verify bumper is level before
tightening.
SECTION 3
assembly
Steering Wheel Installation
1)
Turn vehicle steering so that the tires are pointed
straight forward. There should be a mark showing the
top of the steering hub. Line up holes in steering wheel
with mounting holes so that the center spoke is pointing
down.
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. The bolt heads should be facing the
center of the vehicle with the nuts facing the ouside.
2) Install ¼” x ¾” socket head bolts through the center
cap, then into the steering wheel and steering hub.
Tighten with ¼” nylock nuts.
3) Tighten both 5/16” frame stub bolts and nuts.
4) Install the 5/8” nylock nuts on the pivot bolts. Tighten the
pivots and then loosen ¼ turn.
Cargo Bed Installation
1)
Locate and install 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)
5) Loosen the bed latch pin bolt on the frame just enough
for it to slide in the adjustment slot.
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.
Note: Rear frame stubs not applicable on the LM700
with Independent Rear Suspension (IRS).
15
SECTION 3
assembly
Rear Fender Installation
1)
Fenders installation 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 under the bed. If not,
turn the fender around. Insert a ¼” x ¾” carriage bolt
through the bed and into the fender. Fasten with a ¼”
flat washer and a ¼” nylock. (If installing fenders on a
poly bed, you will use ¼” x 1” hex head bolts instead of
the carriage bolts.)
2) Secure underseat storage tray by pushing down firmly
around the plastic seat bottom wrap.
Seat Installation
1) Place back of seat base / underseat storage
tray over seat frame bar and lower seat base into
position.
16
3)
Place front tabs of seat bottom into the slots on the
underseat storage tray and lower seat into position.
Rear tabs of seat should fit into slots at the rear of seat
base / underseat storage tray.
SECTION 4
inspection
IS YOUR VEHICLE READY TO DRIVE?
PRE-RIDE INSPECTION
Before each drive, it is important to inspect your vehicle and make sure any problems you find are corrected. A PRE-RIDE INSPECTION is a must, not only for safety, but because
having a breakdown, or even a flat tire, can be a major inconvenience.
Perform a PRE-RIDE INSPECTION using the list on the back cover of this book before each use to ensure that your vehicle is in proper working order.
Correct any discrepancies according to this Operator’s Safety Manual before riding. If the problem cannot be corrected, contact an authorized dealer for assistance or call
1-800-643-7332 for Customer Service.
If your vehicle has overturned or has been involved in a collision, do not drive it until your vehicle has been inspected by your dealer or an authorized service center. There may
be damage or other problems that you cannot see.
!
WARNING
Improperly maintaining this vehicle or failing to correct a problem before driving can cause an accident resulting in
serious injury or death. Always perform a pre-drive inspection before every drive and correct any problems.
ARE YOU READY TO DRIVE?
Driver Readiness
Before each drive, you also need to make sure that you, along with your vehicle are ready to drive. To help get you prepared, this section discusses how to evaluate your
driving readiness. Before you drive your vehicle for the first time, we urge you to:
- Read this Operator’s Safety Manual and the labels on your vehicle carefully.
- Make sure you understand all the safety messages.
- Know how to operate all the controls.
Protective Apparel
Although complete protection is not possible, wearing proper gear can reduce the chance of injury should you have an accident. The following suggestions will help you
choose the proper protective gear.
• Helmet and Eye Protection
• Additional Riding Gear
- Your helmet is your most important piece of protective gear because it offers the best protection against head injuries. A helmet should fit your head comfortably
and securely.
- Open-face helmets offer some protection, but a full-face helmet offers more. Regardless of the style, look for a D.O.T. (Department of Transportation) or Snell
Memorial Foundation (SNELL) sticker on any helmet you buy. Always wear a face shield or goggles to protect your eyes and help your vision.
- Sturdy boots, such as an off-road motorcycle boot, to help protect feet, ankles, and lower legs.
- Gloves, such as off-road motorcycle gloves, to help protect your hands.
- Long pants, preferably with knee and hip pads, and a long-sleeved shirt or jacket.
Training and Driver Development
Developing good driving skills and habits is an ongoing process. Even if you are an experienced driver, take time to become familiar with the vehicle controls and how the
vehicle handles. Practice driving in a safe, open area to develop your skills. Do not drive on rough terrain until you get accustomed to the controls and feel comfortable with
its size and weight.
Inexperienced drivers of specified age must be supervised by an adult and should practice in an open, uncongested area.
!
WARNING
• Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing could
increase your chances of head and/or eye injury, and the possibility of death in the event of a severe accident.
• Always wear an approved motorcycle helmet that fits properly, eye protection (goggles or face shield), gloves, boots,
long-sleeved shirt or jacket and long pants.
17
SECTION 5
operation
SOME WORDS ABOUT RESPONSIBLE OPERATION AND RIDER SAFETY
The following pages present important information and recommendations to help you operate your vehicle responsibly and safely. Forming good habits and developing driving
skills is an ongoing process. Even if you are an experienced driver, take time to become familiar with the controls, handling
characteristics, capabilities, size and weight of your vehicle. Please read through these pages thoroughly.
Qualifications for Utility Vehicle (UTV) Users
This vehicle is restricted to use by operator and passenger with a minimum age of thirteen (16) years as indicated on the vehicle and vehicle specific literature. UTV’s are
intended for use by operators who meet the physical and cognitive capabilities set out by the manufacturer in this manual and in the material provided with the vehicle.
Consumer Responsibility for Safe Use and Maintenance of a UTV
1. UTV’s shall not be modified from the manufacturer’s original design and configuration.
2. UTV’s shall not be used to perform racing, stunt riding, jumps, spinouts, donuts, or other maneuvers as they may
cause loss of control. As such, these activities are likely to result in possible injury to the operator, passenger,
bystanders, or all.
3. Prior to each use, the operator shall perform the pre-operational checks specified by the manufacturer, and further verify:
a. Smooth throttle operation and positive return of the throttle linkage to a closed throttle position when released;
b. That the throttle cable and linkages operate properly and the throttle cable or other linkages are adjusted properly;
c. That the steering mechanism(s) is adjusted and operates smoothly;
d. That the engine stop switch is properly functioning;
e. That all guards originally supplied by the manufacturer are in proper place in serviceable condition;
f. That engine idle speed is below the point of clutch or torque converter engagement;
g. That the gas tank is in good condition and the proper gas cap is fastened securely;
h. That the braking system is functioning properly;
i. That all safety labels are in place, legible and understood;
j. That any and all guards, torque converter covers, or other covers or guards supplied by the manufacturer are in place and in serviceable condition;
k. That tires are in good condition, inflated properly, and have sufficient tread remaining; and
l. That all fasteners are in place and tightened securely.
4. UTV engines shall not be started unless the operator is seated and restrained in proper position for vehicle operation and the brake is fully engaged and
locked with the park brake mechanism.
5. Long hair, loose clothes, or jewelry can get caught in moving parts below the seat or surrounding environment. Remove
or tie back anything loose that can reach below or behind the seat before riding.
6. UTV’s shall only be fueled by personnel knowledgeable with regard to proper fuel selection and fueling techniques.
7. UTV operators and passengers shall adhere to all manufacturer’s recommendations and instructions, as well as
comply with all laws and ordinances, and the following:
a. Operators shall stay seated with both hands on the steering wheel and both feet in the vehicle at all times, whether moving or stationary, unless the vehicle is stopped
completely and the engine has been shut off.
b. Passengers shall remain seated with arms and legs inside the vehicle at all times during operation.
c. Shall observe minimum age restrictions.
d. Shall not allow smoking in the vehicle.
e. Persons under the influence of drugs, alcohol, or intoxicants shall not supervise, operate, or ride in a UTV.
g. UTV’s shall operate only on a surface or terrain recommended by the UTV’s manufacturer.
h. UTV’s shall not be operated on roads, streets, highways, or any other location where road vehicles are intended to travel.
8. Persons with the following conditions shall not ride in or operate a UTV:
a. Those with heart conditions
b. Pregnant women
c. Persons with head, back, or neck ailments, or prior surgeries to those areas of the body.
d. Persons with any mental or physical conditions, which may make them susceptible to injury or impair their physical dexterity or mental capabilities to recognize,
understand, and perform all of the safety instructions, and be able to assume the hazards inherent in motor vehicle use.
9. No operator or other person shall contact any portion of the engine, wheels, or drive train for any purpose including maintenance until the engine has been
turned off and allowed to cool, and the UTV is in a stable and stationary position.
10. Passenger restraints must be used in accordance with, and limited to, the manufacturer’s guidelines.
11. UTV components shall be maintained and repaired in accordance with the manufacturer’s specifications and utilizing only the manufacturer’s
authorized replacement parts with installation performed by designated dealers or other skilled persons.
!
WARNING
Long hair, loose clothes, or unsecured cargo can get caught in moving parts below and behind the seat or surrounding
environment. Remove or tie back anything loose that can reach below or behind the seat before riding.
18
operation
SECTION 5
Off-Road Use Only:
Your UTV and its tires are designed and manufactured for off-road use only and not for use on paved surfaces. Driving on paved surfaces can affect the handling, control, and
cause excessive wear to your tires.
When driving off-road, also remember to always obey local off-road driving laws and regulations. Obtain permission to drive on private property. Avoid posted areas and obey
“NO TRESPASSING” signs.
Unless equipped for such, you should never drive your vehicle on public streets, roads or highways, even if they are not paved. Drivers of street vehicles may have difficulty
seeing and avoiding you, which could lead to a collision.
!
WARNING
• Operating this UTV on paved surfaces may seriously affect handling and control of the vehicle, and may cause the
vehicle to go out of control.
• Operating this UTV on public streets, roads or highways could result in a collision with another vehicle. Never
operate this UTV on any public streets, roads or highways, whether they are dirt, gravel or paved surfaces unless
properly equipped.
Keep Hands and Feet on Controls
When driving your vehicle, always keep both hands on the steering wheel. It is important to remain alert and remain focused when driving the vehicle. Removing hands or feet
from the controls can reduce your ability to react and maintain control of the vehicle.
!
WARNING
• Removing your hands from the steering wheel or feet from the foot controls during operation can reduce your ability
to control the vehicle and could result in a collision. Always keep both hands on the steering wheel during operation.
• Keep hands, feet, and all body parts in the vehicle at all times.
- In the event of a vehicle roll-over, do NOT extend arms, legs or any other extremity outside the vehicle as possible personal injury can occur.
Control Speed
Driving at excessive speeds increases the likelihood of an accident. In choosing an appropriate speed, you must consider the capability of your vehicle, the terrain, visibility,
and other operating conditions, in addition to the skill and experience of the driver.
!
WARNING
Operating this vehicle at excessive speeds increases your chances of losing control, resulting in an accident. Always
drive at a speed that is appropriate for your skill, your vehicle, the terrain, visibility and other operating conditions.
19
SECTION 5
operation
Use of this Vehicle on Unfamiliar or Rough Terrain
Before driving in an unfamiliar area, always check the terrain thoroughly. Don’t drive fast on unfamiliar terrain or when visibility is limited (it is often difficult to react to hidden
obstructions like rocks, bumps, or holes).
Never drive past the limit of visibility. Maintain a safe distance between your vehicle and other off-road vehicles. Always exercise caution and use extreme care on rough,
slippery and loose terrain.
!
WARNING
• Failure to use extra care when operating this vehicle on unfamiliar terrain could result in the unit overturning or
going out of control. Go slowly and use extreme caution when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the vehicle.
• Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction
or vehicle control, resulting in an accident or overturn. Do not operate on excessively rough, slippery or loose terrain
until you have learned and practiced the skills necessary to control the vehicle on such terrain. Always be especially
cautious on these types of terrain.
• STOP the vehicle and back slowly down any hill that the vehicle lacks the power or traction to climb. Do NOT turn
across the slope or try to turn around.
a) Turning on a slope increases the risk of rollover.
b) Control the descent speed with the brake (left foot pedal).
c) Re-applying the throttle when facing a steep up-hill increases the risk of the front tires leaving the
ground and the vehicle over-turning.
Do Not Perform Stunts
You should always operate your vehicle in a safe and reasonable manner. When driving, always keep all four wheels on the ground.
!
WARNING
Attempting wheelies, jumps, and other stunts increase the chances of an accident, including an overturn. Never
attempt stunt riding of any type and ride responsibly. Don’t try to show off.
!
WARNING
Operating this vehicle without your seat belt could cause you to be thrown from the vehicle, causing serious injury or
death.
NO ALCOHOL OR DRUGS
Alcohol, drugs, and UTV’s DO NOT mix. Even a small amount of alcohol can impair your ability to operate this vehicle safely. Likewise, drugs, even if prescribed by a
physician, can be dangerous while operating a UTV. Consult your doctor to be sure it is safe to operate a vehicle after taking medication.
!
WARNING
Operating this vehicle after consuming alcohol or drugs can seriously affect your judgment, cause you to react more
slowly, affect your balance and perception, and could result in serious injury or death. Never consume alcohol or
drugs before or while operating this vehicle.
20
SECTION 5
operation
REPLACEMENT PARTS, ACCESSORIES AND SERVICE
Most replacement parts and accessories are typically available from your dealer. Because of immediate availability and convenience, it is recommended that items be
ordered from an authorized dealer. Take this manual and all supplements to the dealer when ordering parts in person.
If replacement parts are not available from a dealer, they may be ordered directly from American SportWorks by contacting ASW at 1-800-643-7332 or online at www.
amsportworks.com. Orders may be subject to a minimum fee. A listing of authorized service center locations in your area is also available from our Customer Service
department.
Record the Model, Vehicle Identification Number (VIN) and Serial Number in the spaces provided at the front of this Manual.
Periodic Checks & Services
The general maintenance intervals in the following table are based upon average driving conditions. Driving in unusually dusty areas may require more frequent
servicing. Refer to the engine operation manual for detailed information specific to engine maintenance.
ITEM
EACH USE
Tire Pressure / Wear
INSPECT
Brake System
INSPECT
Brake Fluid
INSPECT
Chassis
INSPECT
Fastener Tightness
INSPECT
Air Cleaner
INSPECT
Engine Oil Level
INSPECT
FIRST 10 HOURS
EVERY 20 HOURS
EVERY 40 HOURS
REPLACE
CLEAN
CLEAN
Engine Oil
REPLACE
REPLACE
Carburetor
CLEAN
Spark plug
CLEAN / ADJUST
Drive Belt
REPLACE
INSPECT
Air Filter Elements Replacement Parts
Spark Plug Replacement Parts
Description
Briggs & Stratton Air Filter
Honda Paper Filter Element
Honda Foam Filter Element
Subaru Paper & Foam Element (653cc)
Subaru Paper & Foam Element (265cc)
Description
BRIGGS & STRATTON 479cc
NGK
HONDA 390cc
NGK
CHAMPION
AUTOLITE
DENSO
SUBARU 265cc
NGK
CHAMPION
SUBARU 653cc
NGK
Part No.
2-20165
2-20153
2-20154
2-20158
12374
Oil Filter Replacement Parts
Description
653cc Spin-on
REPLACE
Part No.
2-20159
Part No.
BPR6ES
BPR6ES
RN9YC
4263 / 63
W20EPR-U
BR6HS
RLH6C
BPR2ES
21
SECTION 5
operation
Gasoline Utility Vehicles
This section covers the operation of the gasoline powered 2WD and 4WD Utility Vehicles.
NOTE
Perform a Pre-Ride Inspection using the list on the back
cover of this book before each use to ensure that your
vehicle is in proper working order
4WD Models
This section covers the additional features, operation and maintenance of the 4x4
Utility Vehicles.
Operation of Four Wheel Drive Features
General Operation
The rear axle is equipped with a manually operated differential lock on all models
except for the LM700 with Independent Rear Suspension which features an auto
locking differential. It is engaged (locked) by moving the differential lever to the
left and down. Locking the differential sends equal power to both rear wheels for
better traction. It may be used in both 2WD and 4WD modes.
Start your Utility Vehicle by following the starting procedures as noted below.
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.
2.Place gearshift in neutral
3.Apply choke fully when engine is cold.
4.Turn ignition key fully clockwise and hold to start engine.
5.Release ignition key to run position and choke to normal operating
position immediately after engine starts.
6.Turn ignition key counterclockwise to stop engine.
NOTE
Locking the differential on paved or hard surfaces
may increase steering effort and tire wear.
To switch to four wheel drive, the front wheels are
engaged simply by flipping the dashboard switch to
4WD. In 4WD mode power is automatically sent to
the front wheels when the rear wheels lose traction.
Driving is as easy as driving a car with an automatic transmission. A simple forward
and reverse shifter provides direction control. Never shift while the vehicle is moving.
For convenience, on some models a back-up pull-rope starter mechanism is provided
on the engine.
Braking is accomplished by simply releasing the throttle pedal and 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 park brake control lever to release the
park brake.
HEADLIGHT SWITCH:
This switch turns
the Running lights /
Headlights on or off.
HEADLIGHT
ON/OFF SWITCH
WARNING
Engine should be idle before selecting 4WD mode. Sudden
engagement of 4X4 switch under power may damage the
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.
OIL PRESSURE LIGHT:
When illuminated
while engine is
running indicates low
oil pressure (not on all
models).
OIL PRESSURE
WARNING LIGHT
(Not on all models)
F-N-R LEVER:
This lever controls
the direction of the
vehicle. Moving the
lever upward puts
the transmission into
FORWARD, the center
is NEUTRAL and the
bottom position is
REVERSE.
F
N
R
TRANSMISSION
LEVER
GAS ENGINE
IGNITION
Diff
DIFFERENTIAL:
This lever controls
the rear locking
differential if it is
applicable to your
vehicle.
MANUAL LOCKING
DIFFERENTIAL
(Not on all models*)
F
N
R
Diff
* The LM700 with Independent Rear Suspension
features an auto locking differential
22
SECTION 5
operation
Electric Utility Vehicles
0
This section covers the operation of the Electric 2WD Utility Vehicles.
Some ASW models are configured as street legal Low Speed Vehicles (LSV). Low Speed
Vehicles may be used on public roads (check local ordinances). Low Speed Vehicles do 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. Check local laws and ordinances about the use of LSV’s in your area.
1
BATTERY GAUGE: Showing a full charge.
NOTE
STALK CONTROL
Keyswitch must be in the “RUN” position for vehicle to
operate.
HEADLIGHT SWITCH: This
switch turns the Running
lights / Headlights on or off.
FWD
REV
FWD / REV SWITCH: selects
the direction of the vehicle.
when the keyswitch is
turned to the “RUN” position.
The operator must select
the proper switch position
before applying the throttle.
NOTE: When the switch is
set to the center position,
the vehicle is in NEUTRAL.
HEADLIGHTS
MODE SWITCH: This switch
is used for “FAST” mode
(M1) with speeds up to 18
mph, or “SLOW” mode (M2)
with speeds up to 10 mph.
“SLOW” mode has a more
gentle acceleration and a
greater vehicle range.
Note: on some models this
switch may be labeled as
M1 and M2.
TURN
HORN
TURN
Multi Function Stalk
Turn Signal / Horn / Headlights
The Multi-Function Stalk is a multiple feature control. It is
located on the left side of the steering wheel and functions
similar to an automobile for turn signaling but also includes the
headlamp and horn control.
Turn Signal
Pushing down on the stalk indicates a left turn, pushing up
indicates a right turn. Note: the turn signal stalk will not
automatically return to the off position after a turn. The
operator should move the stalk to the center position after
completing each turn.
HEADLIGHT
ON/OFF SWITCH
BATTERY
GAUGE
ELECTRIC MOTOR
FWD / REV SWITCH
MULTI-FUNCTION
STALK
Not on all models
ELECTRIC MOTOR
KEY SWITCH
Turns the electric motor
functionality on or off
MODE SWITCH
Selects the speed mode
of the electric motor
FWD
0
1
REV
23
SECTION 5
operation
Hybrid Utility Vehicles
GAS ONLY MODE
This section covers the operation of the Gas/Electric 4WD Hybrid Utility Vehicles.
DRIVE
FWD
REGEN
REV
There are 4 different modes to use when operating an ASW Hybrid Utility Vehicle:
OFF
ON
• GAS ONLY MODE: utilizes the gasoline engine only with the rear wheels.
• ELECTRIC ONLY MODE: utilizes the 48v motor only with the front wheels.
• GAS / REGEN MODE: utilizes the gasoline engine only with the rear wheels while recharging the 48v motors batteries.
• 4WD MODE: utilizes both the gasoline engine and the 48v motor in tandem for superior power with all 4 wheels.
HEADLIGHT SWITCH:
This switch turns
the Running lights /
Headlights on or off.
DRIVE
DRIVE / REGEN SWITCH: When
switched to “DRIVE” and the
electirc motor keyswitch to “ON”,
vehicle is ready to run on electric
power. When switched to REGEN
with the electric motor in Neutral
the batteries are recharged as
the vehicle moves
REGEN
F
N
R
Diff
F-N-R LEVER:
This lever controls
the direction of the
vehicle. Moving the
lever upward puts
the transmission into
FORWARD, the center
is NEUTRAL and the
bottom position is
REVERSE.
REV
DIFFERENTIAL:
This lever controls
the rear locking
differential if it is
applicable to your
vehicle.
0
BATTERY
GAUGE
OIL PRESSURE
WARNING LIGHT
0
FWD
REV
NEUTRAL
ONLY
F
N
R
ON
GAS / REGEN MODE
DRIVE
FWD
REGEN
REV
FOR
RECHARGING
BATTERIES
F
N
R
OFF
ON
4WD (GAS + ELECTRIC)
DRIVE
FWD
REGEN
REV
SAME
DIRECTION
F
N
R
1
ON
BATTERY GAUGE:
Showing a full charge.
APPLICABLE CONTROLS / ACTIONS
SHOWN IN DARK GREY
DRIVE / REGEN
SWITCH
ELECTRIC MOTOR Switches the transmission
FWD / REV SWITCH direction when in electric mode
DRIVE mode: batteries are not being charged
REGEN mode: batteries are being recharged
ELECTRIC MOTOR
KEY SWITCH
Turns the electric motor
functionality on or off
TRANSMISSION
LEVER
GAS ENGINE
IGNITION
Starts the gasoline engine
DRIVE
FWD
REGEN
REV
1
F
N
R
24
DRIVE
REGEN
OFF
OIL PRESSURE LIGHT:
When illuminated
while engine is
running indicates low
oil pressure.
HEADLIGHT
ON/OFF SWITCH
ELECTRIC ONLY MODE
OFF
FWD / REV SWITCH: selects the
direction of the vehicle.
when the keyswitch is turned to
the “RUN” position. The operator
must select the proper switch
position before applying the
throttle. NOTE: When the switch
is set to the center position,
the vehicle is in NEUTRAL.
FWD
F
N
R
Diff
MANUAL LOCKING
DIFFERENTIAL
maintenance
Vehicle Maintenance
The following section covers routine maintenance procedures for your utility vehicle.
SECTION 6
Rear Transaxle Gear Box – It is recommended that the oil be
changed once a year or after 600 hours. See page 18 of owner’s manual.
90˚ Transfer Gear Box – It is recommended that the oil be changed
once a year or after 600 hours.
Front Differential Gear Box – It is recommended that the oil be
changed once every 2000 miles (about 150 to 200 hours). To change the oil, follow
each step on the procedure listed below.
1. Remove the oil drain plug located on the bottom of the gear case using a ¼” 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 ¼” hex key wrench.
5. Add 200 ml. (7 oz.) of 80W90 gear oil.
6. Reassemble the oil fill plug into the gearcase and torque to 10 ft*lbs.
1. Remove the oil drain plug located on the bottom of the gear case using a 7/16”
socket.
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 using a new nylon
washer (part #20843). Torque the oil drain plug to 9 ft*lbs.
4. Remove the oil fill plug using a 5/16” hex key wrench.
5. 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!)
6. Reassemble the oil fill plug into the gear case and torque to 10 ft*lbs.
Gear Spacing adjustment
1. Locate set screw on front gear box.
2. Turn clockwise until you feel resistance.
3. Turn back counter clockwise ¼ turn.
Hydraulic Brakes – Hydraulic Brakes use fluid pressure to transfer the
braking force to the wheels. Before driving the vehicle each day, check the fluid
level in the reservoir. The reservoir is located under the hood behind the front
differential gear box. Fill to the MAX line with DOT 3 brake fluid. If you notice that
the brake pedal feels spongy or the vehicle is not stopping well, take the vehicle to
a qualified service center.
Authorized ASW service centers in your area can be found by visiting
www.amsportworks.com or by calling customer service toll free at 800-643-7332
25
SECTION 6
maintenance
Fuel Type
Engine Fuel Valve Lever
390cc, 479cc & 653cc Fuel Capacity is 5 Gallons.
On single cylinder models the engine has a fuel valve that opens and closes the
passage between the fuel tank and carburetor. Leave fuel valve lever in the OFF
position when the engine is not in use to prevent carburetor flooding and reduce
possibility of fuel leakage into the cylinder cavity and engine oil reservoir. Turn fuel
valve lever to the ON position when running the engine.
The fuel tank is located under seat.
265cc Fuel capacity is 1.6 Gallons.
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. Use regular unleaded gasoline with an
octane rating of 87 or higher.
Refer to Figure 5-1 and images below
CAUTION
Never use methanol, gasoline containing methanol, or
gasohol containing more than 10% ethanol because the fuel
system could be damaged. Do NOT mix oil with gasoline.
Using a fuel stabilizer/conditioner in the vehicle can provide benefits such as:
•Keeps gasoline fresh during storage of 90 days or less. For longer
storage, drain the fuel tank.
• Cleans the engine during operation.
• Eliminates gum-like varnish build-up in the fuel system.
Add the correct amount of gas stabilizer/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 line for cracks and leaks.
• Engine fuel valve lever (if applicable).
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, lubricating oil levels, oil quality and viscosity recommendations, bolt
torques, etc. Special attention should be paid to applicable data that is not
duplicated here.
NOTICE
For all models with the Subaru 653cc motors,
the EH65 High Altitude Jet Kit (Part# 2-20160
for single barrel and Part# 2-20164 for dual
barrel) is required in order to be operated at an
altitude of 5000 feet or higher.
26
figure 5.1
SECTION 6
maintenance
Foam element
Clean foam element with detergent in warm water or in a nonflammable solvent.
Do not wring element. Squeeze excess cleaning fluids out. Allow time for the
element to dry and then soak it with clean engine oil. Squeeze excess oil out.
Excess oil left in the filter will cause engine to smoke briefly when first started.
Before installing the filter elements to make sure they have not been damaged
during cleaning.
Never run an engine without the filters installed.
Fuel Hose
Inspect fuel hose monthly for cracks, leaks or other damage. Replace immediately
if any damage is suspected.
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.
• Overfilling of oil level can cause loss of power,
engine damage and void engine warranty.
Oil Filter Replacement Parts
Description
653cc Spin-on
Part No.
2-20159
Engine Oil Fill and Drain Locations
Refer to Figure 5.4 and images on opposite page
figure 5.2
Air Filter Elements Replacement Parts
Description
Briggs & Stratton Air Filter
Honda Paper Filter Element
Honda Foam Filter Element
Subaru Paper & Foam Element (653cc)
Subaru Paper & Foam Element (265cc)
Part No.
2-20165
2-20153
2-20154
2-20158
12374
figure 5.4
REMOVE SEAT AND PLASTIC TRAY (if equipped) TO ACCESS
Spark Plug Replacement Parts
Description
BRIGGS & STRATTON 479cc
NGK
HONDA 390cc
NGK
CHAMPION
AUTOLITE
DENSO
SUBARU 265cc
NGK
CHAMPION
SUBARU 653cc
NGK
Part No.
BPR6ES
BPR6ES
RN9YC
4263 / 63
W20EPR-U
•
•
•
•
•
•
•
•
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: 1.64 US qts. / 1.55 liters
Briggs 479cc Oil Capacity: 1.5 US qts. / 1.42 liters
Engine Oil Maintenance Schedule
* Check oil level after each use.
BR6HS
RLH6C
BPR2ES
* Make first oil change after the first month of operation or at 20 hours of operation
(whichever comes first).
* Make all subsequent oil changes every 6 months or every 50 hours of operation
(whichever comes first).
27
SECTION 6
maintenance
Engine Oil Level Check
Refer to Figure 5.4 and images below
Check engine oil daily with filler cap/dipstick located at the engine rear end as
follows:
1. Park Vehicle on a level surface, set park brake, turn off ignition switch, and
remove key.
2. Remove filler cap/dipstick and wipe it clean.
3. Insert and remove dipstick without screwing it into the fill neck. Check oil level
shown on dipstick.
4. Fill to edge of oil fill hole with recommended oil when oil levels are low.
5. Replace filler cap/dipstick and tighten securely.
Engine Oil Change
Warm 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 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. Dispose of used motor oil in a manner that is compatible with the environment.
Do not throw used oil in the trash. Do not pour it on the
ground, or down a drain.
5. Fill oil to the outer edge of the oil fill hole, using a funnel, with recommended oil.
Engine must be level when filling.
6. Replace filler cap/dipstick and tighten securely.
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 on figure 5.5b)
* Drain plug location: At bottom center of transaxle.
* Type of Lubrication: SAE 30W oil.
* Transaxle Lubrication Capacity: 20 oz.
Transaxle Oil Maintenance Schedule
* Check transaxle housing for damage and possible oil leakage after each use.
* Check transaxle oil level every 6 months or every 200 hours (whichever comes
first).
Park vehicle on a level surface, set park brake, turn off ignition switch, and remove
key. Use a clean long bladed screw driver (or similar object) insert into filler hole
until it touches the bottom of gear case. Remove the screw driver. There should be
approximately 2.1/4” to 2.1/2” of oil visible on screw driver. Refer to Figure 5.5a
* Change transaxle oil once a year or every 600 hours (whichever comes first).
figure 5.5a
28
maintenance
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 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. Dispose of used transaxle case oil in a manner that is compatible with the
environment. Do not throw used oil in the trash, pour it on the ground, or down a
drain.
5. Fill transaxle housing with 20 oz. SAE 30W oil.
6. Replace fill cap and tighten securely.
SECTION 6
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 switch, and remove key.
2. Remove the upper belt covers. (It is not necessary to remove the bottom cover.
3. “Walk” the belt off of the rear pulley as shown in Figure 5.6.
4. Install the new belt on the front pulley first and “walk” it onto the rear pulley.
5. Reinstall the belt guards. Figure 5.7.
Attention: Failure to reinstall the belt guards may void
your warranty.
figure 5.6
figure 5.5b
figure 5.7
Cleaning the Windshield (if applicable)
•
•
•
Rinse windshield with lukewarm water; wash gently with mild soap or detergent
and lukewarm water, using a soft cloth or sponge. DO NOT SCRUB or use
brushes or squeegees.
Rinse again. Dry with soft cloth or moist cellulose sponge to prevent water
spotting.
Abusive cleaning procedures by hand washing or automated washing equipment
will eventually result in visual hazing, loss of light transmission and coating
contamination.
Compatible Cleaning Agents
Aqueous Solutions (Mix With Water) of Soaps and Detergents
Fantastik, Formula 409, Hexcel, F.O. 554, Joy, Lysol, Mr. Clean, Neleco-Placer, PineSol, Top Job, Windex.
29
SECTION 6
ELECTRIC OR HYBRID VEHICLES ONLY
maintenance
Battery Charging
Refer to Figure 5.8
• On-Board battery charger is located under the dump bed or under the seat on
select models.
• Put the adapter into the AC cord then 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.
•The charger will come on and begin to charge on its own.
•A fully discharged battery set will take 9-12 hours to fully recharge.
Battery Watering
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.
Keeping the water at the correct level after a full charge will prevent having to
worry about the water level at a different state of charge.
Depending on the local climate, charging methods, application, etc. Trojan
recommends that batteries be checked once a month until you get a feel for how
thirsty your batteries are.
Important things to remember:
1.Do not let the plates get exposed to air. This will 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.
figure 5.8
Battery Disposal
Lead-acid batteries are completely recyclable. Return whole scrap battery
to distributor, manufacturer or lead smelter for recycling. For information on
returning batteries to Trojan Battery Company for recycling call 800-423-6569.
For neutralized spills, place residue in acid-resistant containers with sorbent
material, sand or earth and dispose of in accordance with local, state and
federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.
Transaxle Oil
Refer to Figure 5.9
WARNING
The electrolyte is a solution of acid and water so skin
contact should be avoided.
Step by step watering procedure:
REMEMBER: Always wear a safety shield
or approved safety goggles when adding
water or charging batteries.
1.Open the vent caps and look inside the fill wells.
2.Check electrolyte level; the minimum level is at the top of the plates.
3.If necessary add just enough water to cover the plates at this time.
4.Put batteries on a complete charge before adding any additional water
(refer to the Charging section).
5.Once charging is completed, open the vent caps and look inside the fill wells.
6.Add water until the electrolyte level is 1/8” below the bottom of the fill well.
7.A piece of rubber can be used safely as a dipstick to help determine this level.
8.Clean, replace, and tighten all vent caps.
30
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 or
remove the differential cover from the bottom in order to get all of the old oil out
of the housing. To fill, some fresh oil should be put in the differential cover then
installed back to the housing, then fill up to the level of the plug. (figure 5.9)
figure 5.9
SECTION 6
ELECTRIC OR HYBRID VEHICLES ONLY
maintenance
Mode Switch
figure 5.11
Refer to Figures 5.10a & 5.10b
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 either on the dash or on the left side of the vehicle, under the
bed. The fast mode (M1) will allow speeds up to 18 mph. The slower mode (M2)
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.
figure 5.10a
NOTE
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 replacement
fuse of the same rating must be used.
figure 5.12
figure 5.10b
figure 5.13
Fuses
Refer to Figures 5.11, 5.12 & 5.13
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 to the right sbove
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.
31
SECTION 6
ELECTRIC OR HYBRID VEHICLES ONLY
maintenance
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
• 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 Mirror - part # 2-55081
• Horn - part # 2-55033
Wiring of Tail Lights
Refer to Figures 5.14
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 diagram 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.
TAIL LIGHT WIRING
figure 5.14
32
BLACK FLAG
WHITE FLAG
Harness
RED FLAG
Flags on harnesses must match wire color on tail light
If no flags are present, match the wire colors
Tail Light
RED WIRE
BLACK WIRE
CAUTION
Accessories Must NOT be Grounded to Chassis. Damage to
Converter Will Occur Ground to Distribution Block Ground
(Neg) Terminal Only (see fig. 5.15 below)
WHITE WIRE
figure 5.15
SECTION 7
troubleshoooting
SYMPTOMS
PROBABLE CAUSES
SUGGESTED REMEDIES
DEAD BATTERY
Key switch left on
Turn key off, recharge battery
Bad battery
Replace battery
Shorted starter solenoid
Replace starter solenoid
Loose or corroded battery connection
Clean and tighten connections
Defective voltage regulator
Contact local service center
BATTERY
WONT CHARGE
Turn key on and pull rope to start engine.
Replace battery as soon as possible
Turn key on and pull rope to start engine.
Replace battery as soon as possible
Dead battery cell
Worn out or defective battery
ELECTRICAL
SYSTEM NOT
WORKING
Bad magnet on engine
Contact local Honda service center
Blown or missing fuse
Replace fuse
Loose or corroded battery connection
Clean and tighten connections
Worn out or defective battery
Replace battery
Defective ignition switch
Replace ignition switch
Bad connection in wire harness
Replace or replace wire harness
Fouled sparkplug
Replace or clean sparkplug
Missing or incorrectly installed
air intake restrictor
Replace or correctly install air intake restrictor
Throttle cable is defective or out
of adjustment
Clean and oil or replace cable
Engine idle speed too low
Adjust engine idle
Overloaded engine
Avoid overloading engine
Stale or dirty fuel
Replace fuel with new fuel
ENGINE SHUTS DOWN WHILE
TURNING, ON INCLINES, OR
ON UNEVEN TERRAIN
Low engine oil
Check oil level with unit on level ground
Honda oil sensor is bad
Get Honda low oil sensor changed by authorized
Honda service center
STEERING FEELS FUNNY /
PULLING TO ONE SIDE /
HARD TO STEER
One side may still be engaged in
4WD with the switch off
Put unit in reverse and back up straight a few feet
to get the axle to release
One side may still be engaged in
4WD with the switch off
Take unit to a service center
Low tire pressure
Inflate tires to proper inflation levels
ENGINE
BACKFIRES
ENGINE KNOCKS
(CALL NORMALLY FOR 4WD)
BRAKES DONT WORK
WELL / HARD TO PUSH /
NO TRAVEL IN PEDAL
BELT SLIPPING /
WILL NOT PULL
UPHILL
Brake rotors are dirty
4WD
Clean rotors with brake cleaner and test. A stiff
pedal is normal for a 4WD unit
Brake rotors are dirty
2WD
Put unit in reverse, back up at low speed and step
hard on the brake (2WD units have an auto brake adjuster)
Too much weight
Lighten load
The belt is wet
Dry the belt
Torque converter pulleys are dirty
Clean the torque converter
Belt may have stretched or have a
low spot causing slipping
Replace the belt
33
SECTION 7
Fuel in the Cylinder Cavity (applies only to single
cylinder engines)
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.
WARNING
Use EXTREME CAUTION when performing the activity
below. Gasoline is EXTREMELY FLAMABLE!
1. Move the vehicle to a well ventilated area, away from sparks or flame.
2. Park Vehicle on a level surface, set park brake, turn off ignition switch, and
remove key.
3. Remove 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 cavity through
the spark plug hole. Caution: This gasoline spraying out of the
cylinder cavity is very flammable, use extreme caution and
make sure there are no sparks or flames nearby.
6. Repeat step 3 until only air escapes out of the spark plug hole.
7. Properly replace the spark plug back into the cylinder head, move the vehicle
away from any spilled fuel. If there is fuel on the vehicle itself, allow for it to
evaporate before continuing.
8. Connect the plug wire. Your Utility Vehicle is now ready to start.
figure 6.1
figure 6.2
34
troubleshooting
ASW 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.
Go to Neutral switch diagnostic procedure below.
• Gears grind when going into a gear or vehicle stays in gear when shifted
to neutral.
– Cables need to be lubricated or adjusted.
Go to Cable adjustment procedure below.
Neutral Switch Diagnostic Procedure
If starter does not engage when shift lever is in neutral:
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.
3. If the starter did not engage in step 2, turn and hold the key to start – slowly
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 1-800-643-7332.
troubleshooting
SECTION 7
Cable Adjustment Procedure
Stiff or sticking cables can cause the vehicle to not shift properly and it may affect
starting since the vehicle must go to neutral to start. Before attempting to adjust
the cables there are several steps that can be taken to insure the cables are
operating properly.
•
•
Lubricate the cables. Behind the dash board there are two cables attached to
the gear selector lever. Slide the rubber dust 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 the next step.
Remove the center console (with cup holders). Find the shifter cables and cut
the plastic ties that fasten them to the frame tube. Over tight cable ties can
cause the cable to bind. Replace cable ties but leave them loose so that the
cable can move in them. Test the vehicle. If it is still not performing correctly,
move to the adjustment procedures that follow.
1. Put the vehicle in neutral.
2. Loosen the cable adjusters behind the dash board. (figure 6.3)
3. Make sure the selector lever on the dashboard is in neutral.
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 or you can also use the adjuster nuts on the cable bracket located
on the transmission. (figure 6.4)
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 1-800-643-7332.
Have your serial number when you call.
figure 6.3
figure 6.4
35
SECTION 8
WIRING DIAGRAM
ENGINE MODELS
36
diagrams
diagrams
SECTION 8
WIRING DIAGRAM
ENGINE MODELS
ENGINE MODELS
37
12V
B+
black
red
+
bank
battery
48V
48V
Neg
48V
A-2
F-2
48V
A-1
red
to contactor
motor
F-1
A-2
Battery
discharge indicator
48V
black
red
green
orange plug to motor
Headlight
switch
1/4” loom x 34” L
3/8” loom x 16” L
red
1/4” loom x 34” L
black
12V+
12V-
Not Used
A/H
S/H
grey
green
grey
power to controller
F/R switch
48V
48V
keyswitch
red
brown
48V
8” pigtail to
F/R switch
brown
white
yellow
grey
J-1
black
1/4” loom x 17” L
black
Reverse
horn
1/4” loom x 44” L
red
red
48V
green
20A fuse
B+
horn button
To B+ on Motor Control
Forward
black
from A/H post terminal block
12V
red
12V accessory plug
black
red
to optional horn button
black
1/4” loom x 48” L
grey
red
black
black
fuse
10A
Pos
48V
48v to 12v
converter
blue
F-2
to main cont.
on to A-2
black
to A-1
headlights
48V
48V
12V
48V
48V
M-
4 pin
6 pin
24 pin
yellow
B-
white
red
b F-1
red
black
4 5 6
green to neg.
blue to pos.
red
red
J-2 contactor plug
brown
J-2 J-3
grey
J-1
green
black
green
red
grey
A-2
Neg
Pos
3/8”
pigtail
4
#6 battery
8 volts
Bk up switch
Back up alarm
2 1
17 15 4 13
T-19 @ J-1 plug
Rev 7-19-13
bottom of firewall
top of firewall
white
blue
brown
red
yellow
grey
black
green
S/H = switched hot
A/H = always hot
1/4”
To Throttle Position
Potentiometer
Throttle Position Potientiometer
1/4” loom x 12” L
blue
blue
blue 20.375” L
blue
1/4” loom x 11.5”
blue
white
T 24-13 24
2019
J-1 plug
1110 8
T 12-1
1/4” loom x 11.5”
brown
green
for optional backup alarm
black
Hi/Low switch
to + battery
Main contactor
coil
blue
black
white
red
DC motor control
red
yellow
green
38
brown
Please note that not all
circuits illustrated are
included on all models.
Please disregard circuits
that do not apply to your
application.
blue
48 VOLT DC MOTOR CONTROL & TERMINAL BLOCK WIRING
SECTION 8
diagrams
48VOLT 2WD Wiring Diagram
Rear Left
Signal
Black
Red
White
Red
Red
Brown
Red
Gray
Brown
Red / Blue Stripe
Red / Black Stripe
White
Black
Blue
Red / Black Stripe
Black
White
1
3
5
Red
Green
White
Black
White
Green
Red
White
4
6
LSV 48V Wiring Harness
10A
2
Distribution Block
Yellow
Black
White
1 = 12V Pos
2 = 12V Neg
3 = Switched 12V Pos
Red
Red / Black Stripe
Green
Black
A
F
Module
B
G
C
H
D
J
E
K
Left as viewed from front of vehicle
Red / Black Stripe
ground
into existing
harness
Note wire color change @ rear lights on early models
Red / Black
Green
White
Red
White
Red / Brown Stripe
Green
Signal / Horn / Headlight
Switch
Red / Black Stripe
A
B
C
D
A
B
C
Black
Red / Black Stripe
Red
Red / Black Stripe
Horn
Black
Black
ground
into existing
harness
Yellow
Black
Green
Red
White
Hazard
Switch
Yellow
Headlight
Rear Right
Signal
Brake Switch
Front Right
Signal
Black
Black
Headlight
Black
Front Left
Signal
Black
diagrams
SECTION 8
48VOLT 2WD Wiring Harness Diagram
39
N
F
Reverse
Safety
Switch
GREEN
BLACK
Starter Solenoid
20A Fuse
20A Fuse
Motor Ground
GREY
WHITE
STOP WIRE
To Carburetor Wire
GREEN
BROWN
GREY
WHITE
Headlight Switch
RED
Large 12v
Battery
87
86
85
87a
BLACK
Converter
YELLOW
A2
F2
BROWN
Speed
Sensor
RED
GREY
GREEN
2wd/4wd Switch
Differential Plug
GREEN
YELLOW
BLACK/WHITE
RED
BLACK
Large 12v
Battery
BLACK
GREEN
YELLOW
Large 12v
Battery
BLACK
Charger
BROWN
GREEN
4wd
Relay
30
BLUE
BLACK
Large 12v
Battery
GREEN
WHITE
BLUE
BROWN
RED
YELLOW
GREEN
RED
Curtis
Controller
A1
GREEN
RED
RED
R
RED
GREEN
BLACK
F/N/R Switch
Forward
Safety
Switch
BLACK
BLACK
10A Fuse
YELLOW
WHITE
PINK = WHITE
BLUE
Battery
Discharge
Indicator
BLUE
Drive/Regen
Contactor
BLACK
RED
F1 B- M1 B+ F2
F1
GREY
Motor Ground
Headlight Plug
Headlight Plug
RED
Small 12v Battery
12v Outlet Negative
12v Outlet Positive
500A Fuse
Neutral Safety
Switch
RED
Key Switch
BROWN
BLUE
Potentiometer
BLUE
Curtis
Controller
Plug
GREEN
BLUE
WIRING DIAGRAM Gas / Electric Hybrid
WHITE
BLUE
WHITE
BLACK
BLUE
YELLOW
BLACK
BLACK
40
BLACK
Electric Motor
SECTION 8
diagrams
RED
BROWN
diagrams
WIRING DIAGRAM Terminal Blocks
SECTION 8
650cc / 479cc
Honda
GASOLINE MODELS
GASOLINE MODELS
GRN
GRN
GRY GRY YEL
RED BRN
RED RED
BLK RED
BRN RED
YEL
GRN
GRN
GRY GRY YEL
RED BRN
RED
RED
RED
GRN BLK
BLK
GRN
BLK
BLK
GRN
YEL
-GROUND
-GROUND
+12V CONSTANT ACC*
SWITCHED +12V (LIGHTS)
SWITCHED +12V
+12V CONSTANT
-GROUND
-GROUND
+12V CONSTANT ACC*
SWITCHED +12V (LIGHTS)
SWITCHED +12V
+12V CONSTANT
265cc
48 Volt
GASOLINE MODELS
ELECTRIC MODELS
RED GRY GRY YEL
RED BRN
RED
RED
RED
GRN
GRN
BLK
BLK
RED
BLK
ORNG
BLK
GREY
RED
GRN
BLUE
BLUE
BLK
BLK
GRN
YEL
RED
RED
GRN
BRN
GREY
SWITCHED + 48V
– 48V GROUND
SWITCHED + 12V
– 12V GROUND
+ 12V CONSTANT
-GROUND
-GROUND
+12V CONSTANT ACC*
SWITCHED +12V (LIGHTS)
SWITCHED +12V
+12V CONSTANT
RED
GREY
41
SECTION 9
warranty
limited warranty
Full Size Utility Vehicle
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 three (3) years from the date of purchase for a Honda engine or Briggs & Stratton
Vanguard Engine and five (5) years from the date of purchase on a Subaru engine (engine warranties are covered by the engine
manufacturer). Please refer to the engine manufactures warranty policy included with your ASW product.
ASW, if notified of a defect in material or workmanship during the period of warranty, will repair or replace, at its option,
defective parts at no charge, other than the reasonable cost for the transportation of the component(s). ASW will also agree to
pay reasonable charges for labor, if necessary, to perform a warranty repair.
The original purchaser must operate the vehicle and maintain the vehicle in accordance with the instructions provided in the
Operator’s Manual, the supplements hereto, and labels affixed to the vehicle.
General Exclusions: This limited warranty does not cover component failure or damage caused by any of the following:
abnormal strain or stress, neglect; abuse; improper assembly of components which were supplied in the factory sealed carton
after the vehicle left ASW; improper maintenance, improper use of the vehicle, including, but not limited to racing, jumping,
stunt driving, or any other uses prohibited by the Operator’s Manual. Additionally, this warranty does not cover component
failure or damage to vehicles which are leased or rented, or vehicles which are used at a concession track.
Specific Exclusions: 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 and natural discoloration of material due to ultraviolet light.
Downtime, pick-up and delivery charges are not covered by this warranty. This warranty does not apply to the engine, which
is covered by its manufacturers warranty, unless otherwise noted above.
Warranty Service: To obtain warranty service you must return your ASW product to the local authorized dealer or service
center, you must inform them of your warranty problem and provide proof of purchase before any warranty service is provided.
The authorized dealer or service center will inspect the product to determine what warranty repairs or parts are needed and if
the problem meets the requirements of ASW’s Limited Warranty Policy. To locate the authorized dealer or service center
nearest you please call ASW customer service at 800-643-7332, or visit our website at www.amsportworks.com for more
information.
ASW MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITATIONS SPECIFIED IN THE WARRANTY ABOVE ARE HEREBY
DISCLAIMED BY ASW AND EXCLUDED FROM THIS WARRANTY. ADDITIONALLY, THIS WARRANTY
EXCLUDES ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO
LOSS OF USE. SOME STATES, PROVINCES OR COUNTRIES DO NOT ALLOW A MANUFACTURER TO
EXCLUDE OR LIMIT INCIDENTAL OR CONSEQUENTIAL DAMAGES AND, THEREFORE, THE ABOVE
EXCLUSION MAY NOT APPLY TO YOU.
SOME STATES, PROVINCES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN
IMPLIED WARRANTY WILL LAST; IT IS POSSIBLE THAT THE ABOVE LIMITATION MAY NOT APPLY
TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER LEGAL RIGHTS, WHICH VARY, FROM STATE TO STATE PROVINCE TO PROVINCE OR
COUNTRY TO COUNTRY.
42
ASW, LLC, 4404 Engle Ridge Dr., Fort Wayne, IN 46804 • 62194 Commercial St., Roseland, LA 70456 • Phone 800-643-7332
warranty
SECTION 9
Service and 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 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 purchase.
Mail:
Customer Support
c/o American SportWorks
4404 Engle Ridge Drive
Ft. Wayne, IN 46804
Telephone:
Customer Support
American SportWorks
1-800-643-7332
Fax:
Customer Support
American SportWorks
1-800-399-1399
e-mail:
Customer Support
American SportWorks
feedback@amsportworks.com
43
SECTION 9
warranty
UTILITY VEHICLE SET-UP /
PRE DELIVERY CHECKLIST
MODEL #
SERIAL #
DATE OF PURCHASE
DEALER SET-UP
SET UP BY:
 VISUALLY - inspect for damage
 FASTENERS - inspect for missing bolts, nuts


 CHECK ORDER - verify all items are as ordered
 LOOSE COMPONENTS - verify all are there


MANUALS - operators safety manual / engine manual
WELDS - inspect for missing
CLEAN UP - check clean up of unit
DECALS - inspect for missing decals
PRE DELIVERY
DATE:
CHECKED BY:
 TIRES - adjust pressure to proper specification
 WHEELS - check lug and axle nut for proper torque


BATTERY - insure that it is fully charged
 CAGE - check to insure cage is assembled properly
 FASTENERS - check all fasteners for proper torque


LIGHTS - verify proper operation of all lights
 TRANSAXLE - insure oil level is correct

ENGINE - check engine RPM’s for settings
 PARKING BRAKE - insure that working correctly

SEAT RESTRAINTS - insure installed properly
 DUMP BED - insure latch is adjusted properly
 SHIFT LEVER - insure working properly
 BRAKE - insure brake is adjusted and working
 OIL - insure that engine oil level is correct



SEATS - insure seat is installed properly
KEYS - verify operations of key switch
AXLE - inspect attachment and wheel bearings
GUARDS - inspect for missing bolts, nuts, guards
THROTTLE - insure throttle is working properly
DATE:
DEALER INFORMATION
NAME
PHONE
ADDRESS
FAX
CITY, STATE, ZIP
EMAIL
CUSTOMER CHECKLIST
44
 VISUAL INSPECTION
 RECEIVED SERVICE INSTRUCTIONS
 MY DEALER DEMONSTRATED ALL CONTROLS
 RECEIVED KEYS & ENGINE MANUAL
 SHOWN ALL ENGINE CONTROLS
 WARRANTY EXPLAINED FULLY


I have visually inspected unit and found no defects
 RECEIVED OWNERS MANUAL

I understand this vehicle product is not designed for racing
I have reviewed and understand the warranty policy

I understand that this product is designed for off
road use only and is NOT intended for use on
public roads or highways unless equipped with
an LSV package.*

I understand that before operating this vehicle all
operators and passengers must read, follow and
understand all safe operating instructions
* American SportWorks Low Speed Vehicle (LSV) models are street
legal where allowed when properly licensed and plated. No ASW
vehicles are designed for, nor allowed on highways. Check local
ordinances regarding the use of Low Speed Vehicles in your area.
07/23/2013
notes
45
notes
46
PRE DRIVE INSPECTION CHECKLIST
ITEM
INSPECTION PROCEDURE
ACTION
Engine Oil Level
Add oil if required.
Check for leaks.
Tighten filler cap securely.
Refer to operator's or engine manual.
Fuel Level
Add fuel if necessary.
DO NOT overfill.
DO NOT mix oil with gas.
Replace cap tightly.
Refer to operator's or engine manual.
DO NOT refuel a hot engine. Allow engine to cool before
adding fuel.
Warning Decals
Make sure all warning decals are legible and securely attached.
Replace as necessary.
Tires
Tread must have a minimum height of 1/8" at center of tire.
Prior to operating vehicle, check and adjust tire pressure as indicated
on the sidewall of each tire, or in the vehicle manual. A tire pressure
gauge is required to obtain accurate readings.
Replace tires if tread height is less than 1/8" at center of
tire.
Add or remove air as necessary to meet requirements
indicated on sidewall of each tire or in the specifications
section of the vehicle manual.
Drive Train
Check condition and fluid levels
Lubricate, adjust as necessary.
Throttle
Check for smooth operation.
Ensure throttle 'snaps' back to idle.
Check for frayed or loose cable.
Check for mud, debris, and ice in throttle mechanism
Check idle adjustment
Replace damaged cable.
Clean out any mud and debris. If ice is present, move
vehicle to a warm place and allow the ice to melt and
water to dry.
Adjust as necessary
Fasteners
Check wheels to see that all wheel nuts are tightened securely at 65
ft. Lbs.
Check for missing fasteners.
Check that all other fasteners are secure.
Tighten fasteners as necessary.
Replace fasteners as necessary.
Brush Bars
Make sure all brush bars are in place and securely attached.
Replace damaged bars or fasteners and tighten as
necessary.
Steering
Make sure steering turns freely.
Check for proper 'toe-in' of wheels.
Lubricate and adjust as necessary.
Frame / Chassis
Check for bent or otherwise damaged frame and/or other chassis
components.
Replace as necessary.
Guards
Check all guards covering moving parts.
Tighten fasteners on loose guards. Replace worn or
damaged guards.
Lights
Check for proper operation
Suspension and
Ball Joints
Check for ball looseness
Replace as necessary
Keyswitch
Perform switch test and ensure that engine shuts off when key is
turned to the “OFF” position.
Repair / replace as necessary
Brakes
Ensure brakes function properly.
Adjust / replace as necessary
See OPERATION section of the Operator’s Safety Manual