American Sportworks CW-413, Operator'S Manual

Page 1: ...Utility Vehicle Operators Manual 6 2008 ...

Page 2: ... page 14 Maintenance pages 15 19 Fuel Valve Lever page 15 Air Cleaner Page 16 Engine Oil page 17 Transaxle Oil page 18 Drive Belt page 18 4X4 Supplement pages 20 21 48 Volt Supplement pages 22 34 650cc Supplement pages 35 38 Troubleshooting pages 39 41 Engine Wiring pages 42 44 2WD Dana Transaxle pages 45 48 265cc Parts Breakdown pages 49 58 340cc 2 wheel drive pages 59 70 4WD Dana Transaxle pages...

Page 3: ...bly operation adjustments troubleshooting and maintenance Read this manual and follow the recommendations to help ensure safe and efficient operation The information contained within this manual was current at the time of printing Some parts may change slightly to assure you of the best performance To order a new Operator s or Parts Manual contact your authorized dealer American SportWorks LLC Tol...

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

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

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

Page 7: ...uch as safety helmets and or goggles Keep hands arms feet and all bodily appendages safely inside the confines of the vehicle Always be aware of and avoid tree limbs and brush that have a potential of hitting and or poking individuals riding the vehicle Serious body harm could result Avoid sudden stops starts and turns Always operate your vehicle at a safe speed that will allow you to maintain con...

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

Page 9: ...l No ___________ Date ___________ Serial No ___________ Engine Serial No Dealer Service and Inspection List __ Fully charge battery Check battery voltage to verify that it is fully charged __ Check fuel valve lever to make sure it is in the correct position __ Check tire pressure to make sure front and rear tires have 6 psi __ Make sure wheel lug bolts nuts are tightened to 90 Newton meters 65ft l...

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

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

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

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

Page 14: ... either forward or reverse when the vehicle is stopped and press the throttle pedal to go Never shift while the vehicle is moving Braking is accomplished by simply depressing the brake pedal that is located on the floorboard left of the accelerator A lever action parking brake control is mounted on the center console located between the operator and passenger seats Depress the button on the park b...

Page 15: ...for the following Draining the fuel tank Checking fuel line for cracks and leaks Engine fuel valve lever Engine Maintenance General Information Detailed instructions and recommendations for break in and regular maintenance are specified in the engine operator s manual Engine warranty is backed by the engine manufacturer Please refer to engine manufacturer s manual for engine servicing lubricating ...

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

Page 17: ... Engine Oil Drain Fill Check Locations Figure 5 4 Maintenance Transaxle Oil A general description for transaxle oil maintenance recommendations and capacities is provided below NOTE Running vehicle low on transaxle oil can damage transaxle and void warranty Transaxle Oil Type Fill and Drain Refer to Figure 5 5B Fill cap location At rear left hand side See arrow Drain plug location At bottom center...

Page 18: ... ground or down a drain 5 Fill transaxle housing with 20 oz SAE 30W oil 6 Replace fill cap and tighten securely Figure 5 5B Maintenance Drive Belt The dive belt is considered a wearable item Replacement intervals depend on vehicle use and environment If your belt is slipping you may need to replace it 1 Park vehicle on a level surface set park brake place shifter in Neutral turn off ignition switc...

Page 19: ...e 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...

Page 20: ...r is automatically sent to the front wheels when the rear wheels lose traction Warning Bring engine to an idle before selecting 4WD mode Sudden engagement of 4X4 switch under power may damage drive train Failure to do so may void warranty Because the power transfer is automatic you may operate the vehicle in 4WD mode continuously without affecting steering effort or tire wear Maintenance Hydraulic...

Page 21: ...r 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 1 Remove the oil drain plug located on the bottom of the gear case using a hex key wrench 2 Let all the oil drain out of the unit Catch and discard the oil properly 3 Be sure to clea...

Page 22: ...22 48 Volt Utility Vehicle OWNERS MANUAL Supplement Do NOT let metal objects fall from the seat onto the top of your batteries This may cause a serious power short and possibly a fire ...

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Page 24: ...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 WASHING YOUR 48 ...

Page 25: ... during washing by placing a plastic bag or other protection over the top of the charger before washing Allow for any water that does get on in the charger to dry out before using Deep Water Crossings Must be Avoided Charge Gauge Before operating the 48V make sure the batteries have a full charge Located on the dash the charge gauge indicates approximately the state of charge of the batteries Far ...

Page 26: ...h set switch to FLOODED mode Plug the AC cord into a grounded outlet If an extension cord is used a heavy duty cord of no more than 25 feet must be used The extension cord must be AWG 12 or heavier Turn charger on A fully discharged battery set will take 9 12 hours to fully recharge ...

Page 27: ... 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 CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by ...

Page 28: ... of the speed of the vehicle The switch is located on the left side of the vehicle under the bed The fast mode will allow speeds up to 18 mph The slower mode will allow speeds up to 10 mph Slow Mode also has a more gentle acceleration curve The vehicle range is considerably greater in slow mode as well ...

Page 29: ...n the transaxle Oil should be changed after one year of normal use and every other year after To change the oil a vacuum device may be used to remove the old fluid To fill fresh oil should be added up to the level of the plug ...

Page 30: ...he 12 volt circuit Pictured below is the 500 amp main fuse This fuse will blow in the event of a short across the battery posts or a catasatrophic failure in the motor or controller Should this fuse blow it must be replaced with a like 500 amp fuse These fuses are available through your dealer Main fuse is illustrated below ...

Page 31: ...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 Under Hood Under Bed Left Side ...

Page 32: ...32 Forward Reverse Switch Located on the dash the forward reverse switch selects the direction of the vehicle The operator must select the proper switch position before applying the throttle ...

Page 33: ...on of the forward reverse switch Unexpected movement will result if the switch is inadvertently in the incorrect position Wiring Diagram next page Please note that not all circuits illustrated are included on all models Please disregard circuits that do not apply to your application ...

Page 34: ...34 ...

Page 35: ...This utility vehicle comes equipped with a Low Oil Indicator Light located on the dash panel in the center of the vehicle This light will come on when the key is turned to the on position and then go off after the engine is started While operating the vehicle if the oil light becomes illuminated immediately turn the key to the off position to kill the engine This utility vehicle is not equipped wi...

Page 36: ...y move the shift lever from neutral to reverse if the starter engages release the key Repeat moving the shift lever from neutral to forward If the starter did engage go to Cable adjustment procedure section If the starter did not engage call Customer Service at 1 866 646 5278 Cable adjustment procedure Stiff or sticking cables can cause the vehicle to not shift properly and it may affect starting ...

Page 37: ...ash but do not stretch the spring and tighten the adjuster nuts 5 Place the selector lever on the dashboard in reverse 6 Make sure the transmission is fully engaged in reverse The top of the shift lever on the transmission should be toward the passenger side You may have to roll the rear wheels a little until it clicks in 7 Pull the slack out of the rear most cable under the dash but do not stretc...

Page 38: ...ral 4 Make sure the transmission is in neutral You can check by turning the key to Start The engine will only turn over if the transmission is in neutral 5 Pull the slack out of both cables but do not stretch the springs and tighten the adjuster nuts If you have tried all of this and it is still not operating correctly you may need new cables Please call American SportWorks Customer Service at 1 8...

Page 39: ...39 Troubleshooting ...

Page 40: ...d excessive idling or running unit with choke engaged can cause plugs to foul or engine oil may be low Possible Remedy Make sure fuel valve is on Replace spark plug and try to restart Check oil level with unit on level ground Adding more oil or making sure the oil is completely full can help to not alert the low oil sensor Engine will not start and does not turn over with electric starter Probable...

Page 41: ...rty Possible Solution 4x4 units Clean the rotors with brake cleaner and test A stiff pedal is normal for our 4x4 unit A stiff pedal means good pressure in the brake lines Check brake pads and front calipers 2wd units The 2wd units have an automatic brake adjuster Put the unit in reverse back up at low speed and step hard on the brakes This should give enough brake adjustment If you continue to hav...

Page 42: ...42 Wiring Diagram HONDA Engine Models ...

Page 43: ...43 Wiring Diagram SUBARU Engine Models ...

Page 44: ...44 Terminal Block Wiring ...

Page 45: ...45 2 Wheel Drive Dana Transaxle Parts Breakdown ...

Page 46: ...46 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

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

Page 48: ...48 ...

Page 49: ...49 265cc CW265 TW265 Utility Vehicle Parts Breakdown ...

Page 50: ...50 Body 265cc Models ...

Page 51: ...51 Frame 265cc Models ...

Page 52: ...52 Drive Train 265cc Models ...

Page 53: ...0702 bent washer 5 16 4 5 45411 brshgrd seat back CW black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 42045 A arm upper 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 42046 A arm Lower 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 ...

Page 54: ...Rod 265 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering support CW...

Page 55: ...CW 2 black 1 50215 bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 11085 Shifter control assembly black built after 2 1 05 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X Pan Head Phillips 2 50770 Washer 10 flat 2 40 70053 Wire Harness 265 1 41 70000 Battery U1L HDJ7 UTV 360CCA 1 70002 Ba...

Page 56: ... washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x hex black 4 55 18305 Plastic Seat Bottom wrap 1 50624 Screw 10 x hex black 5 57 18303 ...

Page 57: ...e 265 models 1 70057 Neutral Safety Switch 1 51500 Shims Neutral Safety Switch 103 45423 Swing arm CW Black 1 104 45430 Motor Plate CW Black 1 107 20667 TC Driver Comet 40 1 108 20668 TC Driven Comet 40 1 109 11166 Brake Shoes Rear UTV 2WD Dana 1 Set required for each wheel 2 110 51101 265 Crankshaft Spacer 1 112 50795 7 16 I D Fender Washer 1 113 50793 7 16 Lock Washer 1 114 50302 7 16 x 2 SAE Bo...

Page 58: ...ylock 3 128 18011 Shifter cable mount 129 18012 shifter cable lever 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 1 50715 1 4 Flatwasher USS 2 130 11103 Brake Cables 2 50150 5 16 18 x 1 Hex Hd Bolt 2 50007 5 16 Nylock Nut 2 131 11013 Throttle Cable 265 1 135 11082 Cable shifter 2 138 18313 Belt Guard Plastic UTV Front 1 139 18314 Belt Guard Plastic UTV Rear 1 140 18315 Belt Guard Plastic U...

Page 59: ...59 340cc CW11 TW11 TW11R Utility Vehicle Parts Breakdown ...

Page 60: ...60 Body 340cc Models ...

Page 61: ...61 Frame 340cc Models ...

Page 62: ...62 Drive Train 340cc Models ...

Page 63: ... black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 45404 A arm upper CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 45405 A arm Lower CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 ...

Page 64: ...10590 Rack Pinion Rod 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steer...

Page 65: ... bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 11085 Shifter control assembly black built after 2 1 05 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X Pan Head Phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control assembly with cable and knob 1 11083 Knob 11090 Differential Co...

Page 66: ...ic Red 18350 Hood plastic Camo 50620 X 1 Pan Head Phillips Machine screw 2 50621 X 2 Pan Head Phillips Machine screw 2 50717 SAE Flat washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 ...

Page 67: ...16 seat bar CW 17 black 2 50609 14 x Pan Head Screw 6 65 10705 Seat Belt 2pt 2 50025 7 16 Nylock 4 70 45426 Cargo Bed Green 1 45420 Cargo Bed Red 1 45424 Cargo Bed Black 1 18352 Camo Bed Panel Left 1 18353 Camo Bed Panel Right 1 18354 Camo Bed Panel Tail Gate 1 50255 5 8 x 4 bolt Zinc plate 2 50015 5 8 nylock 2 18402 Bed Rubber Plug 2 73 50208 Bed latch bolt 3 8 x 2 1 2 1 50013 nut 3 8 keps 2 5074...

Page 68: ...Throttle Guard Laser 1 50086 1 4 20 x 1 1 4 Hex Hd Bolt 3 50082 1 4 20 x 2 1 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 5 50715 1 4 Flatwasher USS 8 107 20648 TC Driver Comet 500 used before Serial Number 25658 1 20665 TC Driver CVTECH used after Serial Number 25658 1 108 20649 TC Driven Comet 500 used before Serial Number 25658 1 20666 TC Driven CVTECH used after Serial Number 25658 1 109 11166 Brake Sho...

Page 69: ...8 Flatwasher USS 4 125 50730 3 4 Spacer Washer 6 126 50280 3 4 x 2 5 SAE bolt 3 127 50020 3 4 SAE nylock 3 128 18012 shifter lever CW black used before Serial Number 15244 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 129 18011 shifter cable mount CW black used after Serial Number 15245 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 1 50715 1 4 Flatwasher USS 2 130 11103 Brake Cab...

Page 70: ...lt 1 50000 1 4 Keps Nut 2 50159 5 16 18 x 1 1 2 Hex Hd Bolt 1 50005 5 16 Keps Nut 2 133 11804 Spring 80704 Black painted 1 135 11080 Shifter Cable and Shifter Control used before Serial Number 15244 1 11082 Cable shifter used after Serial Number 15245 2 136 65500 fuel hose 3 16 dia 24 1 137 50849 hose clamps small 3 138 18313 Belt Guard Plastic UTV Front 1 139 18314 Belt Guard Plastic UTV Rear 1 1...

Page 71: ...71 4 Wheel Drive Dana Transaxle Parts Breakdown ...

Page 72: ...72 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

Page 73: ...73 Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts ...

Page 74: ...74 ...

Page 75: ...75 390cc CW413 TW413 4 wheel drive Utility Vehicle Parts Breakdown ...

Page 76: ...76 Body 390cc Models ...

Page 77: ...77 frame 390cc Models ...

Page 78: ...78 Drive Train 390cc Models ...

Page 79: ...t or right 2 51100 suspension bushings 2 ea 50266 bolt 5 8 x 9 1 2 1 ea 50015 Nut 5 8 nylock 1 ea 45150 Spacer CW A arm bushing 4x4 7 25001 Strut assembly left 1 25009 Strut assembly right 1 50028 Nut 7 16 NF jam 2 50041 Nut 3 8 NF slotted 2 50801 cotter pin 1 8 x 1 2 7a 25020 Lower ball joint 2 8 25003 strut bearing 2 50163 bolt 5 16 x 3 4 NC 8 50005 Nut 5 16 keps 8 9 25002 Hub rotor 4x4 2 50040 ...

Page 80: ...er serial 31586 1 50631 Screw 3 8 16 x square head set 2 10184 key 3 16 x 1 3 19 20804 convoluted tubing 17 inch 20 10591 Rack pinion with rod ends 4x4 1 10593 Rack Pinion Boots 2 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 used before serial 27783 2 10598 Rod end 4x4 used after serial 27782 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4...

Page 81: ...52 bolt 5 16 x 1 4 50007 nut 5 16 nylock 1 35 11135 Brake hose front 1 36 11136 Brake hose rear 1 37 11085 Shifter control assembly black 1 11083 Knob 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control Assy 4x4 Diff Control w cable 1 11083 Knob 1 11091 cable diff lock 1 50053 nut 10 24 Keps nut 2 50616...

Page 82: ...at washer 8 50001 nut 1 4 nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x 3 4 hex black 5 52 18308 Steering Cover 1 50624 Screw 10 x 3 4 hex black 1 18317 Steering Cover Bottom 1 53 18383 Center Console 4x4 1 50624 Screw 10 x 3 4 hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x 3 4 hex black 4 55 18382 Plastic Seat Bottom wrap 4x4 1 50624 Sc...

Page 83: ...x 2 1 2 1 50013 nut 3 8 keps 2 50740 washer 3 8 flat 2 75 45427 Tail gate green 1 45421 Tail gate Red 1 45425 Tail gate Black 1 50152 bolt 5 16 x 1 2 50701 washer 5 16 sae 4 50007 nut 5 16 nylock 2 70230 rubber bump stops 4 78 50815 1 4 Lynch Pin tailgate latch 2 80 18312 Roof green 1 18301 Roof Red 1 18351 Roof Camo 1 18391 Roof Top Vinyl Trim 1 18390 Roof Hardware bolt kit 50847 Clamp Tube vinyl...

Page 84: ...nly not used with CV Tech pulley 1 115 20693 Belt Comet 300668 used before Serial Number 25663 1 20694 Belt CV TECH used after Serial Number 25663 1 116 50239 1 2 x 2 SAE 1 117 50722 1 2 Lock Washer 1 50721 1 2 Uss Flat Washer 1 118 10186 3 16 Key stock 1 119 45431 Tension Mount Engine CW Black 1 50157 5 16x 3 4 Bolt Hex Hd NF 2 50703 5 16 Lock Washer 2 50704 5 16 Flatwasher 2 120 70250 Rubber Fee...

Page 85: ... Engine 1 150 25004 right angle gearbox 1 10184 Key 3 16 x 1 3 151 20852 gearbox coupling 1 152 18042 Gear box bracket torque arm long built before 10 06 1 18083 Gear box bracket short built after 10 06 1 70232 rubber washer built before 10 06 2 50163 bolt 5 16 x 3 4 NC 4 50701 Washer 5 16 flat 6 50703 Washer 5 16 lock 2 50005 Nut 5 16 keps 2 50303 Bolt 7 16 x 1 3 4 built before 10 06 1 50794 Wash...

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Page 87: ...87 ...

Page 88: ...88 ...

Page 89: ... nylock 2 50702 bent washer 5 16 2 6 43007 A arm 4x4 CW black 2 51100 suspension bushings 2 ea 50266 bolt 5 8 x 9 1 2 1 ea 50015 Nut 5 8 nylock 1 ea 10051 spacer 5 8 1 ea 7 25012 Strut assembly left 1 25013 Strut assembly right 1 50028 Nut 7 16 NF jam 2 50041 Nut 3 8 NF slotted 2 50801 cotter pin 1 8 x 1 2 7a 25020 replacement ball joint 2 8 25003 strut bearing 2 50163 bolt 5 16 x 3 4 NC 8 50005 N...

Page 90: ...7 inch 20 10591 Rack pinion with rod ends 4x4 1 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering support CW black 1 51100 sus...

Page 91: ... 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 38 11086 Differential Control Assy 4x4 Diff Control w cable 1 11083 Knob cable diff lock 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 50087 1 4 20 x 1 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 50159 5 16 18 x 1 1 2 Hex Hd Bolt 1 50005 5 16...

Page 92: ... 4 hex black 4 55 18382 Plastic Seat Bottom wrap 4x4 1 50624 Screw 10 x 3 4 hex black 5 56 18304 Underseat storage box 1 57 18303 Rear Fender Left 1 18310 Rear Fender Right 1 50001 nut 1 4 nylock 4 50091 1 4 20 X 3 4 Carriage bolt 4 50717 1 4 SAE Flat washer 4 58 18033 Shaft guard 1 50163 bolt 5 16 x 3 4 NC 3 50005 Nut 5 16 keps 4 50171 Bolt 5 16 x 3 3 4 USS 1 10001 tube 1 14ga 1 60 10754 Seatback...

Page 93: ...104 55043 Muffler 653cc Subaru 107 20644 TC Driver Comet 780 1 108 20645 TC Driven Comet 780 1 109 11166 Brake Shoes Rear UTV Dana 2 110 50745 1 I D Spacer Washer 4 111 1 4 x 3 16 Keystock 1 112 50742 3 8 I D Fender Washer 1 113 50741 3 8 Lock Washer 1 114 50219 3 8x 3 Bolt Hex Hd NF 1 115 20697 Belt Comet EX9857 1 116 50244 1 2 x 1 1 2 SAE 1 117 50722 1 2 Lock Washer 1 118 3 16 Key stock 1 50157 ...

Page 94: ...3 16 dia 24 1 137 50849 hose clamps small 3 138 18324 Belt Guard Plastic 650 UTV Front 1 139 Pending Belt Guard Plastic 650 UTV Rear 1 50624 10 x 3 4 Blunt Point Black 7 50050 10 Speed Nut for Plastic 7 50770 10 Flatwasher 7 150 25004 right angle gearbox 1 10184 Key 3 16 x 1 3 151 20852 gearbox coupling 1 50163 bolt 5 16 x 3 4 NC 2 50701 Washer 5 16 flat 2 50703 Washer 5 16 lock 2 152 18083 Gear B...

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Page 97: ...97 ...

Page 98: ...et Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 45404 A arm upper CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 45405 A arm Lower CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 8 45408 spindle mount ...

Page 99: ... USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end use before serial 27214 2 10597 Rod end use after serial 27213 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering support CW black 1 51100 suspension bus...

Page 100: ...e equalizer CW 2 black 1 50215 bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 69901 Battery Cable 20 x 5 16 x 5 16 1 69902 Battery Cable 20 x 5 16 x 3 8 1 69903 Battery Cable 20 x 1 4 x 1 4 2 69904 Battery Cable 16 x 5 16 x 5 16 1 69905 Battery Cable 10 5 x 5 16 x 5 16 2 69906 Battery Cable 10 5 x 5 16 x 3 8 2 40 70118 Wire Harness 48V 1 41 70001 Battery Trojan 6 70002 Battery Cable Red 17 1 70010 Batt...

Page 101: ...Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x hex black 4 55 18305 Plastic Seat Bottom wrap 1 50624 Screw 10 x hex black 5 57 18303 Rear Fender 1 50001 nut nylock 4 50091 20 X Carriage bolt 4 50717 SAE Flat washer ...

Page 102: ...t 1 18354 Camo Bed Panel Tail Gate 1 50255 5 8 x 4 bolt Zinc plate 2 50015 5 8 nylock 2 18402 Bed Rubber Plug 2 73 50208 Bed latch bolt 3 8 x 2 1 2 1 50013 nut 3 8 keps 2 50740 washer 3 8 flat 2 75 45427 Tail gate green 1 45421 Tail gate Red 1 45425 Tail gate Black 1 50152 bolt 5 16 x 1 2 50701 washer 5 16 sae 4 50007 nut 5 16 nylock 2 70230 rubber bump stops 4 78 50815 1 4 Lynch Pin tailgate latc...

Page 103: ... 105 70020 500 Amp Fuse 1 106 70112 Potentiometer Curtis 1 107 70114 Solenoid Contactor Curtis 1 108 70115 Converter 1 109 11166 Brake Shoes Rear UTV Electric Dana 1 set for each wheel 2 110 70116 Charger 1 111 70111 Controller Curtis 1 112 XXXXX Mode Switch 1 113 70113 Charge Gauge 1 114 18318 Plastic Cover for Controller 1 115 70119 FNR Switch 1 121 10581 Rod End Sphcl UTV 4681 MPM 12 3 122 5002...

Page 104: ...104 50087 1 4 20 x 1 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 ...

Page 105: ...105 ...