Owners Manual - American SportWorks
Contents
1. e 37 AGUS TCI a 37 Adjustment of Pront and anaes 38 Battery rac A sae ee Avatars 38 Storas 019 T 40 M Ae idle INE 40 Fastener Porque Watt Md EM dM ML 41 CEO akon Ma MM A MEM 42 REPLACEMENT PARTS AND SERVIGE 42 SPECIFICATION S 42 3 43 ELECIRICALSCHEMATI CS 45 PAGE 2 MY VEHICLE IDENTIFICATION NUMBER Record the VIN number and Model number of your American SportWorks vehicle below for service and insurance records The VIN number is hard tagged on the vehicle frame under the bed VIN 6 00 AMERICAN SPORTWORKS LIMITED WARRANTY American SportWorks hereinafter referred to as ASW hereby warrants to the original purchaser that the frame components of new ASW vehicles will be free from defects in material and workmanship The period of warranty is 1 year from date of purchase for the component parts except as noted below and 1 year from the date of2. Twin 12V 25W 12V 10W 5W Cargo Light 12V 25W Top Speed Speed Limited 18 20mph CHASSIS Brakes Front and Rear Hydraulic disc Tires Front Rear 20 x 8 0 8 I5psi 22 x 11 10 15psi Suspension Front Dual A arm with 1 8 45mm of travel Suspension Rear Spring over shock with 2 0 60mm of travel WEIGHT Dry Weight 443Kg 975165 WARRANTY Components Frame Engine year The specifications are subject to change without notice PAGE 43 Periodic Checks amp Services The maintenance intervals in the following table are based upon average driving conditions Driving in unusually dusty areas may require more frequent servicing Initial service Interval Monthly Quarterly Yearly first week A adjust C clean I inspect clean or replace if necessary L lubricate R replace PAGE 44 ELECTRICAL SCHEMATICS
3. ACID BURN HAZARD Este vehiculo no debe ser operado por ninguna persona menor Ge 16 anos edac SUPERFICIES CALIENTES Las superficies alrededor del motor y el escape pueden estar calentes Permita que las Superticies Se antes de realizar el mantenimiento USAR UN CASCO Siempre use un casco al montar este veh culo SIEMPRE USE CINTURON DE SEGURIDAD El cintur n de seguridad debe ser apropiadamente atado y ajustado para cada ocupante antes de la operaci n del vehiculo Ver Manual de Dueno A CAUTION DO NOT SHIFT WHILE IN MOTION These batteries contain an eloctrolyte made of a solution containing acid and water and can cause severe burns If contact is made with eyes face or other body parts flush with water for at least 15 minutes Call a physician immediately DISCONNECT FUSE BEFORE SERVICING Disconnect the the Main Fuse first before servicing Failure to do so may result in serious shock or burn 15285 A CHARGE IN WELL VENTILATED AREA Charging must take place in an area that is adequately ventilated To reduce the chance of battery explosion that could result in severe injury or death never smoke around the batteries or charge them in an area that has open flames or electric equipment that could cause an electric arc 15285 17 F To change direction stop the vehicle Selecting a new direction with the vehicle in moton may ca
4. ha in aate ridi 8 SOME WORDS ABOUT SAFETY antt eh e rag te eot 17 SAPER GAB ES dede 17 QUALIFICATIONS FOR USERS e 19 VEHICLE CONTROLS AND OPERATION i eese s Font ta rota to Fs eere ree Fee 21 Controls and FC ACESS oie o eu 21 Ae UE Ol E 21 ss 22 22 Pe 22 FOr COU dus pau elc 22 E 22 Ge View miller 22 Sea Adu iehi 22 Occupant Restraints 1 pd aei ior 22 6 23 K Forward Reverse Swi t a etl t t rase 23 a E n ce t eue e tL erate 24 M Carso Dump Bed 250Ib MAX R 25 Ne 19 CU fsa tae se cd hdr de RNC ha rate ie 25 O TAILGATE LATCH AND REMO
5. driving position H Seat Adjustment The unit is equipped with an adjustable seat To adjust lift the levers just in front of the seat bottom and move the seat either forward or backward Release the levers at the desired seat location ensuring that they both snap back into place to lock the seat Occupant Restraints This vehicle is equipped with automotive style 3 point retracting seat belts Insert the metal tongue into the buckle until it is securely attached Final adjustments should be made with the This vehicle is also equipped with a passenger grab bar located on the dash directly in front of the passenger seat PAGE 22 J Under seat Storage This vehicle is equipped with a storage area under the seat To access the storage area seat belts must be unlatched and the seat must be cleared of riders or objects Provision for a padlock or combination lock not included is available on the seat latch handle To open the storage area remove any lock and press the lever down With the lever depressed lift the rear of the seat and rotate forward to reveal the storage space NOTE The under seat storage area is not watertight Items that need to stay dry should be bagged or placed in a watertight container within the storage area LATCH HANDLE UNDER SEAT STORAGE ON BOARD CHARGER SEAT ADJUSTMENT LATCH 44 WARNING Failure to fully latch the seat in the closed position could result in seat movement while driving
6. 113 Kg QUALIFICATIONS FOR USERS This vehicle is recommended for use by operator and passenger with a minimum age of sixteen years Vehicles are intended for use by operators who meet the physical and cognitive capabilities set out by the manufacturer in the material provided with the vehicle Consumer Responsibility for Safe Use and Maintenance of a Vehicle Note For the purpose of the following if not specified an engine is defined as gasoline powered and motor is defined as an electrical device Vehicle shall not be modified from the manufacturer s original design and configuration 2 Vehicle 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 bystanders or both 3 Priorto each use the operator shall perform the preoperational checks specified by the manufacturer and further verify a Smooth throttle operation and positive return of the pedal and additionally for gas engines of the throttle linkage to a closed throttle position when released b Thatthe throttle cable and linkages operate properly and the throttle cable or other linkages be adjusted properly for gas engines c steering linkage is adjusted and operates smoothly d Thatthe engine stop switch is properly functioning for gas powered models or the keyed ignition switch is functioning pr
7. Brush Bars assembled to this vehicle are for decorative purpose and limited brush protection Brush Bars were not designed for roll over or to restrict all brush or tree branches from protruding into operator passenger compartment 44 CAUTION If the vehicle should start making unusual noise or vibrating abnormally the vehicle should be stopped and the batteries disconnected The vehicle should then be checked for damage Excessive noise or vibration is generally a warning of loose or worn parts PAGE 16 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 and view the Safety DVD that was included with your unit SAFETY LABELS The following labels have been applied to your unit and should be considered as permanent parts of the vehicle If a label should come off become hard to read or become damaged contact your dealer or American SportWorks Customer Service department for warning label replacements This vehicle is not to be operated by anyone under 16 years of age HOT SURFACES Surfaces around the engine and exhaust can be extremely hot Allow Surfaces to belore servicing WEAR A HELMET Always wear a helmet when riding this vehicle ALWAYS WEAR SEATBELT seatbelt must be properly fastened and adjusted for each occupant prior to operating the vehicle See Owner s Manual
8. Wheelbase 1588mm 62 5 inch Track Width Front Rear 1049mm 41 3 inch 1000mm 39 4 inch Ground Clearance 170mm 6 7 inch MOTOR 36V DC Motor Size 3 x 12V Deep Cycle Batteries Starting Keyed Electric Charger NOCO Genius CAPACITIES Maximum Load Driver Passenger amp Gear 340Kg 750165 Maximum Bed 114 Kg 250165 Bed Capacity 0 127 m 4 5 Under Seat Storage Capacity 0 09 cu m 3 25 cuft Climbing Angle 10 14 Head Light Tail Light
9. LIFE OF THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG IMPLIED WARRANTY LASTS OH THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE PAGE 4 BATTERY LIMITED WARRANTY Company WARRANTY STATEMENT U S Battery Manufacturing Company guarantees its products to be free of any manufacturing defects for a period of one year This limited warranty only covers defects in material and workmanship The free replacement one year period begins at date of purchase No labor or transportation expenses are included in this limited warranty US 1800 and all E line batteries carry a reduced six month free replacement period Any implied warranty of merchantability or fitness for a particular purpose shall be void and excluded subsequent to one year from the date of purchase The replacement of the battery is the exclusive remedy under this written warranty or any implied warranty U S Battery Manufacturing Company makes no other representation or warranty of any kind and no representative employee distributor or dealer has the authority to make or imply any representation promise or agreement which in any way varies the terms of this limited warranty All batteries being submitted for warranty must be r
10. Please note that not all circuits illustrated are included on all models Please disregard circuits that do not apply to your application JOVIS 3IHM AM OOVIS ASNO Jas 2 MOTIJA 232 O SIIHM NMONS MOTISA N33NO ae A33 dOloo AS WLAN x3 9 TO4LNOD id YOLOW Age 8M A9 Mid a 2 M M Af M A dddV Cl AM3LL 2100013 695 rIn zoo OMSL 3onvo O30N3I IWO 233 AINWINI OM qiii DJY 4 YOLOW VITA NTIAT DA YS 3190 4 03 0NIWIAO 244 t 8 SUE NIV AGE d pa o WES Z f S elf vol 3snd F LL az ea 433934513431 d33v3d LHOld pi Ul M al a 219 HOLMS 9 33 9 U 2 5 J eise AS AINO LIX9 ESA 4O4 1vNOILdO Old Y mnino 33MOd AZI HOLMS NOILINOI HOLAS 1H N ONINNNA HOLMS g 530 M l MSZ A2I am
11. Remove or secure tool Y N are fully secured Park Brake Operation Engage brake and Adjust as necessary Y N Attempt to roll the unit forward Cable Check for loose or Replace as necessary frayed cable PAGE 32 Starting Instructions The following instructions list the proper method for vehicle start up A full battery charge is recommended for best performance A full charge is indicated by all GREEN lights on the under seat battery charger e Fasten Seat Belt e Depress the brake pedal Turn the Key Switch to the position e Select the desired direction with the Forward Reverse switch e Gently depress the accelerator pedal to drive the vehicle Note If you attempt to shift gears while the throttle pedal is depressed vehicle power will be shut off The key will need to be cycled off and then on to return the vehicle to normal operation OPERATION SAFE DRIVING PRECAUTIONS Off Road Use Unless specified as a street legal LSV your vehicle and its tires are designed and manufactured for off road use only not for use on paved surfaces Driving on paved surfaces can affect the vehicle handling control and Cause excessive wear to your tires 44 WARNING Operating this vehicle on paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control When driving off road remember to always obey local off road driving laws and regulations Obta
12. 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 Call a physician immediately 44 WARNING Do NOT place metal objects or let them fall onto the top of the batteries as this may cause an electrical short and the possibility of a fire PAGE 39 44 CAUTION The electrolyte in the battery is a solution of acid and water so skin contact should be avoided 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 Call a physician immediately 44 CAUTION Electrolyte spills should be neutralized with a solution of 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and then flushed with water H Storage Instruction If you plan to store and not operate your vehicle for a period in excess of 30 days or at the end of each driving season the unit should be set up for storage as follows a Fully charge the batteries and disconnect the MAIN FUSE b Make certain that the key switch is in the OFF position c Check the batteries every 30 days and recharge as necessary to maintain the proper voltage level for the next riding season d To protect the paint plastics and upholstery it is a good idea to keep the unit covered when not in use Note A fully
13. in 1 through 6 8 Vehicle operators and passengers shall adhere to all manufacturer s recommendations and instructions as well as comply with all laws and ordinances as well as PAGE 19 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 or the motor powered down Passengers shall remain seated with arms and legs inside the vehicle at all times during vehicle operation Shall observe minimum age restrictions d Shall not ride the vehicle if long hair loose clothes or jewelry reach below or behind the seat 44 WARNING Long hair loose clothes or jewelry can get caught in moving parts below and behind the seat or surrounding environment Remove or tie back anything loose that can reach below and behind the seat before riding 10 11 12 13 14 Shall not allow smoking in vehicle Persons under the influence of drugs alcohol or intoxicants shall not Supervise operate or ride in a vehicle Vehicles shall operate only on a surface or terrain recommended by the vehicle s manufacturer sete Rit Vehicles shall not be operated on roads streets highways or any other location where road vehicles are intended to travel unless specifically designed and designated for such use i Vehicles shall be operated only with adequate lighting and under conditi
14. or your local dealer to see the full selection of accessories that are available for this vehicle 44 CAUTION The electric unit is not approved for all accessories Examples of accessories NOT approved for the electric unit are plows winches earth implements and trailers REPLACEMENT PARTS AND SERVICE Most replacement parts are typically available from your dealer Because of immediate availability and convenience it is recommended that replacement parts 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 ASW at 1 800 643 7332 Orders may be subject to a minimum fee A listing of authorized service center locations in your area is also available on our website at www amsportworks com or from our Customer Service department Record the vehicle VIN number in the spaces provided at the front of this manual The VIN number is hard tagged on the vehicle and can be found just behind the left rear tire PAGE 42 SPECIFICATIONS DIMENSIONS Overall length 2324mm 91 5 inch Overall width 1245mm 49 0inch Overall height 1765mm 69 5 inch
15. other uses prohibited by the Operator s Manual Additionally this warranty does not cover component failure or damage to vehicles which are leased rented or used at a concession track Specific Exclusions This limited warranty does not apply to components which are subject to normal wear and tear and natural discoloration of material due to ultraviolet light These items include but are not limited to the tires brakes throttle shift and brake cables drive belt seat lights fasteners decals or cosmetic body panels Downtime pick up and delivery charges are not covered by this warranty 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 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 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 PAGE 3 BATTERY CHARGER LIMITED WARRANTY _L
16. proper ventilation Five air exchanges per hour is considered the minimum requirement The battery charger is located under the seat Make certain that the power key is the OFF position Check battery fluid level to be certain that the fluid fully covers the battery plates Fill if necessary See Battery Watering on Page 38 Plug the AC cord into a grounded outlet If an extension cord is used it must be a heavy duty type of AWG 12 or heavier and no more than 25 feet in length Note A single audible may be heard This is normal and not an indication of a charging issue There are indicator lights on charger one set for each battery and represent the following conditions PAGE 30 o Red Battery is charging o Green Battery is fully charged o Alternately flashing red and green lights indicate that either the charging leads to a battery are loose not connected or connected backwards When indicator lights show a fully charged condition Green lights illuminated unplug the cord from the outlet Recheck battery fluid level See Battery Watering on Page 38 Note A fully discharged battery will take 9 12 hours to fully recharge Note Refer to the NOCO Battery Charger Users Guide for more detailed information 44 WARNING Hydrogen gas is generated as a natural part of the lead acid battery charging process 4 concentration of hydrogen gas is explosive and could cause severe injury or death Cha
17. purchase for the frame 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 Proof of Purchase must be provided to an approved ASW service center before any warranty work is performed 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 Additionally within 10 days of the discovery of an alleged defect the original purchaser must contact ASW s Customer Service Department at 1 800 643 7332 4404 Engle Ridge Drive Fort Wayne IN 46804 or via the internet at www amsportworks com The repair or replacement of any part or parts under this Limited Warranty shall not extend the term of the warranty beyond the Original term as set forth above 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 overloading or any
18. AMERICAN SPORTWORKS Owner s s Manual READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION 36V Series Light Utility Vehicle RECOMMENDED MINIMUM OPERATOR AGE 16 THIS VEHICLE IS NOT STREET LEGAL UNLESS SPECIFICALLY DESIGNATED AS SUCH AND IS INTENDED FOR OFF ROAD USE ONLY THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL TRACKS OR RACING BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST UNDERSTAND THIS VEHICLE WAS NOT DESIGNED OR MANUFACTURED TO MEET SPECIFICATIONS FOR USE ON PUBLIC ROADS STREETS HIGHWAYS AND THOROUGHFARES UNLESS SPECIFICALLY DESIGNATED AS SUCH THE OWNER AND EACH OPERATOR 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 THIS PRODUCT IS DESIGNED TO BE OPERATED BY INDIVIDUALS 16 YEARS OF AGE OR OLDER THIS PRODUCT IS NOT A TOY TABLE OF CONTENTS ae okt MY ain 3 AMERICAN SPORTWORKS LIMITED 3 BATTERY CHARGER LIMITED WARRANTY iet ane ao eas eben aee aeta aue eerte 4 BALEIERYTINMELED WARRANTY 50950520 ues bet 5 WARNINGS AND AU TIONS 5 aate t eco
19. B Front Wheel Alignment Ref Toe Adjustment Diagram The front wheels should be set with a toe in from 1 4 to 3 8 At the centerline of the tires measure the Distance and the Distance B For proper toe adjustment Dimension A should be 1 4 3 8 GREATER than Dimension B To make adjustments a Loosen the lock nuts on both sides of Front Tie Rods b Ensure the steering wheel is centered and adjust Dimension B by equally rotating the tie rods in or out with a 12mm wrench c After adjusting to the desired length tighten the lock nuts against the rod end d Recheck the dimensions for proper alignment A Tie Rod Nut PES C3 N d n a a 2 oO Ee n 4 Front of Vehicle Toe Adjustment Diagram C General Lubrication This unit has grease fittings located at several points on the suspension and should be routinely lubricated with a quality automotive style chassis lube for maximum performance Front suspension grease fittings are located at the connection points of the upper and lower Aarms Additional fittings are located on the rear suspension links just under the dump PAGE 36 D Cleaning Instructions Keep your vehicle clean by using a clean rag and a mild detergent and water solution Wipe off all dirt from around the controls Keep the motor and belt drive system clean and clear of foreign objects Use of a high pressure power washer may damage paint plast
20. ESION Esta informacion esta contenida en las Etiquetas de Advertencia Manual de Due o y Suplementos Video de Seguridad y el Manual Motor proveidos con este producto Aseg rese de comprender y seguir todas las advertencias e instrucciones suministradas Siempre lleve puesto un casco de motocicleta aprobado por D O T 105 0 5 Ge Checar inflaci n de llantas antes de operar Consulte el Manual de Due o la presi n adecuada de operaci n NO opere este vehiculo sin las barras protectoras aseguradas su lugar Mantenga todos las cubiertas y protectores apropiadamente instalados cn de controles de Irenos deben trabajar EI operador debe estar sentado Ci de seguridad debe estar atado presionar treno antes de operar el vehiculo Nunca opere a una velocidad demasiado r pida para sus habilidades las condiciones Nunca intente saltos o acrobacias Nunca maneje despues de consumir alcohol drogas u otros intoxicantes Si Usted no recibi alguno de los materiales mencionados anteriormente por favor llame al 1 800 643 7332 y solicite 5 envien sin cargo please call 1 800 643 7332 and request to If you did not receive any of the material listed above 29 have them sent to you at no charge gt PROTECTOR DEBE ESTAR EN SU LUGAR p estar en su a durante PINCH HAZARD Exercise caution when working o
21. IMITED WARR THREE YEAR WARRANTY Genius Battery Chargers are warranted to the original retail purchaser to be free of defects in material and or workmanship for a period of three 3 years from the date of purchase This warranty does not cover product damage due to abuse accidents modifications misuse damage caused by owner s failure to provide reasonable and necessary installation or care TO OBTAIN WARRANTY SERVICE Call NOCO for issuance of a returned goods authorization number before returning product UNITED STATES 800 456 6626 Factory Service P O Box 6539 Peoria AZ 85385 6539 Products returned by mail should also be carefully packaged and include a note describing ihe nature of the problem and or service requested Proof of purchase or warranty authorization card must be returned with product for warranty consideration at its discretion wil repair or replace items covered under the terms of this warranty Fhe warranty registration should be returned to NOCO within ten 10 days from the date of purchase to validate your warranty and allow you to obtain your warranty authorization card which gives immediate authorization throughout the U S and Canada Noco products requiring service not covered under the terms of this warranty may be repaired or replaced tor a reasonable feo ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY INSERT IMPLIED WARRANTIES ARE LIMITED TO THE
22. VAL 25 BASIC RADIO OPERATION gu ndo pleut 25 VEHICEE FEATURES AND EOCALIONS 35 EREN 21 AREYOUREADY M Mn ha do 28 Lom dee umbo E ca san 28 Helmetand Eye Protect om Does beet Oo 28 CIE dE ous du assa editos rae en cand 28 Driver nee came 28 INOZXICOhDOLOf d o ed cuenta 20 IS YOUR VEHICLE READY TO DRIVE ora o Mb 30 Battery Chare iNo aan a a bb 30 Pre Ride IVS CCL a tt Sri pe hs re 31 SS CaO OTIS EPIC HONS cet ne oui as 23 OPERATION SAFE DRIVING PRECAUTIONS 33 UNIFSERVI E p dq a mM LI DUE 36 Front Wheel Replacement Rb atid o RR ame pA RUP Qu eH Ud 36 A Rear Wheel Replacermelb us ume dd LED hes das 36 B Front Wheel Alignment Ref Toe Adjustment 36 C General DUDDPICOUODS 36 Ix Cleanins
23. and cause serious injury or death Always ensure that the seat is fully latched before driving K Forward Reverse Switch The Forward Reverse switch selects the vehicle s direction of travel To shift direction always bring the vehicle to acomplete stop With the brake applied press the desired direction of travel as noted on the switch and gently depress the throttle pedal If you attempt to shift gears while the throttle pedal is depressed vehicle power will be shut off The key will need to be cycled off and then on to return the vehicle to normal operation 44 CAUTION Damage to the vehicle will occur if the unit is shifted into a different gear while the vehicle is still in ALWAYS bring the vehicle to a complete stop before selecting a different gear PAGE 23 OWNER S OPERATOR S MANUAL 200 SERIES PART NUMBER 15293 L Tool Holders TOOL This vehicle is equipped with standard side mounted tool holders for safely carrying garden tools such as HOLDER rakes shovels etc The tool holders are rubber coated and spring loaded to keep the tool from e bouncing or rattling while the unit is in motion Shorter tools may be loaded into the tool holders provided the handle is long enough to protrude through the middle loop and provided the head of the tool bottoms out against the rotating loop The holders are designed to rotate the COUNTERCLOCKWISE direction only insert tool 1 Rotate the too
24. charged battery will not freeze in normal winter temperatures A temperature of 75 F 60 C is required to freeze a charged battery In comparison a battery that is low on charge will freeze at 14 F 25 C l Fuse Replacement Your unit is equipped with fuses to protect the electrical system from excessive load conditions Should any fuse need replacement a fuse of the same rating must be used The fuses are a Main Fuse 1 350 amp fuse located on the battery pack to protect the main motor circuit 1 15 amp blade style fuse is found behind the dash to protect the keyed power 1 A single 10 amp inline fuse is located on the positive battery cable 1 15 amp inline fuse is located on the controller s power lead 350 Amp Fuse for Motor Circuit PAGE 40 Fastener Torque Chart Bolt Conventional marked bolt 8 8 marked bolt Diameter 0 7 1 5 0 15 0 3 1 0 2 0 1 5 3 0 0 3 0 6 2 0 4 5 6 4 04 07 30 50 0 8 1 2 6 0 8 5 8 10 16 10 16 70 115 1 8 2 8 13 0 20 0 16 0 25 5 4 0 6 0 29 0 43 5 25 5 40 7 0 10 0 50 5 72 5 36 5 58 110 160 79 5 115 5 58 94 170 25 123 0 181 0 94 137 5 20 280 144 5 202 5 Bolt Size Prevailing Prevailing inch Standard Standard me Torque Torque lb ft lb ft lb ft lb ft PAGE 41 ACCESSORIES Although this electric unit is not approved for accessories such as a plow winch earth implement or trailer please visit our website at www amsportworks com
25. eps a through g until proper tension is reached e PAGE 37 F Adjustment of Front and Rear Shock Shock Adjustment There are five adjustable positions on each shock The center notch is the default position as set by the manufacturer Ref Figure Use a round nut spanner wrench to adjust the shock To INCREASE the shock stiffness rotate the ring to the highest longest setting DECREASE the shock stiffness rotate the ring to the lowest shortest setting Shock stiffness adjustments should be made based on the overall weight of the rider occupant and cargo G Battery Watering LEFT ROTATE SPRING ADJUSTMENT CAM The batteries supplied with this model require water Maintaining the proper water level is required for optimum battery performance and longevity If the battery has been discharged partially or fully prior to charging there should be enough water to cover the battery plates The water level should always be topped off to full after a full charge Note Use distilled or deionized water only Do NOT use water with a high mineral content Procedure 1 N cO i No Open the vent caps and look inside the fill wells Check electrolyte level the minimum level is at the top of the plates If necessary add just enough water to cover the plates at this time Replace the vent caps Put batteries on a complete charge before adding a
26. es 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 Calla physician immediately 44 WARNING This vehicle may have been supplied to you completely assembled To prevent injury or death read and follow the assembly instructions to make sure the unit was assembled properly 44 WARNING NEVER adjust repair or clean the machine while it is in motion 44 WARNING Check tire pressure before each use 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 specification section of this manual A tire pressure gauge is required to obtain accurate readings 44 WARNING Vehicle modification or removal of original equipment or safety decals can render the machine unsafe for operation PAGE 10 44 WARNING Safety decals must be replaced if they become unreadable or detached from the vehicle f decals are unreadable or missing warning of potential hazards or safety requirements may be lacking 44 WARNING The safe operation of this vehicle is dependent upon the operator s ability to exercise proper judgment Operator and passenger must not be too small or too large for controlled operation Operator and passenger must be of sufficient age understanding mental capacity and physical capacity to safely operate the vehicle Vehicle should only be ope
27. eturned to the place of purchase for testing and evaluation On site service would be available in most locations at an additional charge Service charges will vary from location to location distance traveled and number of batteries involved The provisions of this limited warranty shall not apply to failure due to Abuse or neglect such as improper fluid levels loose wiring or rusted or corroded hardware Lack of proper maintenance Damage caused by improper installation of the battery Neglect breakage freezing fire explosion wreckage the addition of any chemical operation of the battery in an overcharged or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity and battery charged by systems other than the original equipment type battery charger THIS BATTERY IS INTENDED TO BE USED BY PERSONS WITH TRAINING AND EXPERIENCE WITH BATTERIES ANY OTHER USE RENDERS THE LIMITED WARRANTIES EXPRESSED HERIN AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HERBY EXCLUDED ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVIENIENCE OR ANY OTHER ECONOMIC LOSS Warranty Limitations U S Battery s liability shall be to replace the defective battery Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the warranty term which is inciden
28. h Loads shifted towards the tailgate may cause the front of the bed to suddenly raise when unlatched causing serious injury 44 CAUTION Ensure that the bed is securely latched before driving the unit Failure to properly latch bed may result in damage to cargo or to the unit M Charge Gauge Located on the dash the charge gauge indicates the approximate state of charge of the batteries The bars illuminated to the RIGHT indicate fully charged batteries mu LE CURTIS N TAILGATE LATCH AND REMOVAL The tailgate on this unit has been fitted with cam over style latches The latches are designed to secure the tailgate to the bed while minimizing rattles To unlatch the tailgate depress the latch lock and pull the hasp away from the tailgate Once unlatched the tailgate will swing freely towards the rear bumper To latch simply close the gate securely against the bed tube and lock the wire hasp over the bed latch Removal of the tailgate requires a 10 and 12mm wrench and removal of the hinge bolts If the tailgate is removed temporarily install the hinge bolts into the tailgate to prevent loss of the fasteners Bed Latch O BASIC RADIO OPERATION An optional radio is available with this unit Basic operating instructions taken from the PRV 15 USER S MANUAL follow NOTE For more detailed radio operation instructions please refer to the PRV 15 USER S MANUAL PAGE 25 Basic Operation 1 POWER Button 09 Pres
29. he machine NOTE Use of the word NOTE will alert you to key information or instructions PAGE 8 IMPORTANT SAFETY INFORMATION 44 WARNING Hydrogen gas is generated as a natural part of the lead acid battery charging process 4 concentration of hydrogen gas is explosive and could cause severe injury or death 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 batteries or charge them in an area that has open flame or electric equipment that could cause an electric arc 44 CAUTION 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 44 WARNING Always wear a safety shield or approved safety glasses when adding water or charging batteries 44 CAUTION Electrolyte spills should be neutralized with a solution of cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and then flushed with water 44 WARNING Do NOT place metal objects or let them fall onto the top of the batteries as this may cause an electrical short and the possibility of a fire PAGE 9 44 CAUTION The electrolyte in the battery is a solution of acid and water so skin contact should be avoided Do not get battery acid on ey
30. ications and utilizing only the manufacturer s authorized replacement parts with installation performed by designated dealers or other skilled persons PAGE 20 VEHICLE CONTROLS AND OPERATION Controls and Features 44 WARNING Do not attempt to start or operate the vehicle until completely familiar with the location and use of each control necessary to operate this vehicle The operator must know how to stop this machine before starting and driving it CUP HOLDER STEERING WHEEL KEYED IGNITION BATTERY METER 12V POWER OUTLET PARK BRAKE LEVER BRAKE PEDAL THROTTLE PEDAL A Throttle The foot pedal on the right is the throttle See Figure to control the speed of the vehicle The further the throttle pedal is depressed the faster the vehicle will travel PAGE 21 OWNER S OPERATOR S MANUAL 200 SERIES PART NUMBER 15293 44 WARNING Every time prior to starting the vehicle check to ensure that when the throttle pedal is pushed all the way forward it returns to its initial position when released Do not operate this unit if pedal fails to return to the initial position unable to correct the problem through replacement of worn parts contact your dealer for assistance B Brake The brake is controlled by the foot pedal on the left See Figure Applying pressure to the pedal draws the brake pads against the brake discs at the wheels and slows or stops the vehicle C Parking Brake Thi
31. ics electric components or drive belts and is not recommended for cleaning your vehicle some of the electronics in the controller and charging system are sensitive to water and corrosion The charger and controller should be protected during washing by placing a plastic bag or other protection over the top before washing Allow for any water that does get on in the charger to dry out before using E Belt Adjustment This vehicle is equipped with a toothed belt drive comprised of a Primary Motor to Jackshaft and Secondary Jackshaft to Axle reduction system Belt tension is pre adjusted at the factory and should typically not require any further adjustments If belt slippage does occur belt adjustments may be performed by using following the procedure Apply pressure to 3 8 ratchet Primary Belt Apply pressure here Tensioner to 3 8 ratchet Allow 3 8 1 2 belt slack Secondary Belt Tensioner Allow 3 8 1 2 belt slack Primary Drive Secondary Drive If the belt has more than 72 of slack or flex then it will require adjustment To adjust Loosen Primary and Secondary Belt Tensioner nuts Insert 3 8 drive ratchet into square hole Using ratchet apply tension to belt so that there is gt to 3 8 of slack Tighten Belt Tensioner pivot nut 3 4 socket Tighten Belt Tensioner clamp nut 1 2 socket Rotate wheel and ensure that all belt teeth are engaged in pulleys Re check belt tension Repeat st
32. in permission to drive on private property Avoid posted areas and obey NO TRESPASSING signs If your vehicle is equipped with the Low Speed Vehicle LSV package for street legal use it may be used on public roads LSV requirements vary by state and may also be subject to local ordinances Be aware of your local regulations before operating the vehicle on local public roads Extreme care should be taken if you are driving 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 This vehicle does NOT have comparable crash protection to a car or truck Follow all safety procedures Avoid roads with considerable traffic Avoid driving on public roads at night or in low visibility Never Drink and drive PAGE 33 44 WARNING Operating this vehicle on public streets roads or highways could result in a collision with another vehicle This vehicle is not street legal unless specifically designated as such and should never be operated on any public streets roads or highways whether they are dirt gravel or paved surfaces Keep Hands and Feet on Controls When driving your vehicle always keep both hands on the steering wheel and feet near the foot controls It is important to remain alert and remain focused when driving the vehicle Removing hands or feet away from the controls can reduce your ability to react and maintain control
33. ing the vehicle 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 44 WARNING 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 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 44 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 PAGE 35 UNIT SERVICE A Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels It is only necessary to remove the 4 lug nuts to remove the wheel See Figure Wheel nuts should be tightened and torqued to 36lb ft A Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels It is only necessary to remove the 4 lug nuts to remove the wheel See Figure Wheel nuts should be tightened and torqued to 36lb ft WHEEL ATTACHMENT
34. l horizontally and slide the handle through the loop from the RIGHT side 2 Rotate the tool vertically ina COUNTERCLOCKWISE direction 3 Slide the tool downward through the second loop and onto lower tool rest Ensure that all tools are correctly and securely loaded into the tool holders before driving Failure to secure the tool could cause damage to the unit and cause serious injury or death 44 CAUTION Long tools will extend past the overhead brush bars increasing the overall height of the vehicle Damage to the tool unit or to surrounding structures will occur when driving into low overhead clearances PAGE 24 Cargo Dump Bed 25016 MAX LOAD This vehicle is equipped with a manual rear dump cargo bed Release levers are located on both the driver and passenger sides of the vehicle just forward and above the rear wheels Loose cargo should be secured with a cargo net or proper cargo straps to prevent shifting during transport This bed is NOT designed to transport people or animals and should be used for hauling cargo only Prior to dumping any loads the parking brake should be applied and the keyed power switch turned to the OFF position To dump the bed unlatch and lower the tailgate Standing to the side of the unit pull the release lever upwards then manually tilt the bed to dump the load After dumping the bed and tailgate should be securely latched 44 WARNING Do not lean over the bed while releasing the bed latc
35. n drive components Drive components turn when vehicle is in motion Chock wheels before removing drive cover Never remove drive cover or attempt to service with motor on PELIGRO DE PUNTO DE AGARRE Tenga precaucion cuand est trabajando en los componentes de transmission La cadena los elementos del motor Bloquee las ruedas antes de de extraer la cubierta de la unidad Nunca extraiga la cubierta o intente dar mantenimiento con el motor en marcha GUARD MUST BE IN PLACE This guard must be in place during motor operalion Keep hands feet and loose garments away from motor belt chain and other drive components A CAUTION DO NOT PUT FOOT ON DRIVE COVER entos del motor PRECAUCION NO PONGA EL PIE EN CUBIERTA DE TRANSMISI N 15285 cadena correa y otros elem 15285 R NO RIDING This cargo bed is intended for cargo only the rated weight load found in the Owner s Manual All occupants must be inside the vehicle and wearing the proper restraints and safety gear Absolutely no riding on the outside of the vehicle or in cargo bed LATCH DUMP BED Driving with the cargo bed raised is hazardous Always lower and latch bed before driving NO SUBIR Esta caja de carga esta dise ada s lo para carga supere el peso recomendado Manual Due o Todos los ocupantes deben estar adentro del vehiculo usando equipo de seguridad y restricciones adecuadas No subir af
36. ny additional water refer to the Charging section Unplug charger and wait a minimum of 30 minutes before proceeding Open the vent caps and look inside the fill wells Add water until the electrolyte level is 1 8 below the bottom of the fill well Clean replace and tighten all vent caps 44 WARNING Hydrogen gas is generated as a natural part of the lead acid battery charging process 4 concentration of hydrogen gas is explosive and could cause severe injury or death 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 batteries or charge them in an area that has open flame or electric equipment that could cause an electric arc PAGE 38 44 WARNING Always wear a safety shield or approved safety glasses when adding water or charging batteries 44 CAUTION 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 44 CAUTION Electrolyte spills should be neutralized with a solution of cup 60 ml sodium bicarbonate baking soda dissolved in 1 1 2 gallons 6 liters of water and then flushed with water 44 CAUTION The electrolyte in the battery is a solution of acid and water and can cause severe burns Skin contact should be avoided Do not
37. of a fire 44 WARNING Operating the vehicle in conditions where water mud snow dirt sand or other debris can get into the throttle mechanism can prevent throttle return This result in the motor continuing to run and result in loss of control 44 WARNING Assembly maintenance and or repair of this vehicle should only be performed by designated dealers or authorized small engine centers for engine repairs so that no unsafe conditions or modifications are made 44 WARNING Read and keep all supplied printed material Supplements to this Operators Manual contain updated information relative to your specific vehicle model It is important to keep all of these documents for reference 44 CAUTION During vehicle storage and or charging keep it in a place where hydrogen fumes from the battery will not reach an open flame spark or other source of ignition For long term storage Fully charge battery and then disconnect the MAIN FUSE PAGE 15 44 WARNING When making repairs or adjustments to the vehicle the batteries MUST be disconnected to prevent accidental starting 44 WARNING When working on or around the vehicle use extreme caution to avoid contact with any potentially hot area such as the motor and motor controller 44 WARNING NEVER operate the vehicle while under the influence of alcohol drugs or medication of any kind Such operation is dangerous to yourself and or others 44 CAUTION
38. of the vehicle 44 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 and feet near the foot controls of your vehicle during operation 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 44 WARNING Operating this vehicle at excessive speeds increases your chances of losing control of the vehicle resulting in an accident Always drive at a speed that is appropriate for your skill your vehicle the terrain visibility and other operating conditions 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 VEHICLE MAY ROLL PAGE 34 44 WARNING Failure to use extra care when operating this vehicle on unfamiliar terrain could result in the vehicle 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 operat
39. ons of suitable visibility Persons with the following conditions shall not ride in or operate a Vehicle 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 vehicle use Vehicle shall not be used to a Transport a passenger or passengers except in the seating area s provided b Transport materials or equipment in excess of the rated cargo capacity Vehicle operators always shall use appropriate protective clothing including but not limited to a motorcycle type helmet and eye protection with appropriate certification and any other equipment recommended by the vehicle manufacturer including gloves footwear long sleeve shirts and long pants No operator or other person shall contact any portion of the engine wheels or drive train for any purpose including maintenance until the engine or motor has been turned off and allowed to cool and the vehicle is in a stable and stationary position Passenger restraints must be used in accordance with and limited to the manufacturer s guidelines Vehicle components shall be maintained and repaired in accordance with the manufacturer s specif
40. operly for electric models e That all guards originally supplied by the manufacturer are in proper place in serviceable condition f Thatengine idle speed is below the point of clutch or torque converter engagement for gas models g That the gas tank is in good condition and the proper gas cap is fastened securely for gas models h Thatthe braking system is functioning properly That all safety labels are in place legible and understood That any and all axle guards as applicable to the model such as chain guards belt guards torque converter covers or other covers or guards supplied by the manufacturer are in place and in serviceable condition k Thattires are in good condition inflated properly and have sufficient tread remaining and That all fasteners are in place and tightened securely 4 Vehicle engines shall not be started or motors powered on unless the operator is seated in proper position for vehicle operations and the brake fully engaged 5 Longhair 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 Vehicles shall only be fueled or charged by an operator knowledgeable with regard to proper fueling and charging techniques 7 All operators or riders shall be knowledgeable capable and have the cognitive capacity to operate the vehicle safely including those items specified
41. or 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 and on the included safety DVD This unit is not designed for children and is not a toy Be sure to follow the recommended maintenance schedule and service your vehicle accordingly Preventative maintenance is extremely important to the longevity of your vehicle First time drivers are urged to seek instruction from a dealer or qualified instructor before and during the initial use of this unit It is also recommended to practice a large open area to become familiar with the operation of the vehicle We hope you will have a fun safe experience with our products and thank you again for choosing an American Sportworks Vehicle 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 Owner s Operator s manual and any accompanying supplements before attempting to operate this vehicle Make sure to view the Operations and oafety DVD 44 WARNING Never operate this vehicle when the seat is not securely locked into position Serious injury or death could occur due to loss of control Always make seat adjustments with the vehicle fully 44 CAUTION Indicates a potential hazard which may result in personal injury or damage to t
42. ould result in serious injury or death Never consume alcohol or drugs before or while operating this vehicle PAGE 29 IS YOUR VEHICLE READY TO DRIVE Before each drive it is important to inspect your vehicle and make sure any problems you find are corrected A pre drive inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major inconvenience 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 There may be damage or other problems that you cannot see 44 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 Battery Charging Battery charging must take place in an area that is adequately ventilated reduce the chance of battery explosion do NOT smoke around batteries or charge them in an area that has open flame or electric equipment that could cause an electric arc Pay particular attention to natural or propane gas water heaters and furnaces Never charge a vehicle in an area that is subject to flame or spark as hydrogen gas is generated in the charging of batteries and is explosive in concentrations as low as 4 Because hydrogen gas 15 lighter than air it will collect in the ceilings of buildings necessitating
43. p 7 J PAGE 45 9 2 PART NUMBER 1 C WNER S SUH M IONWAO M O aONWAO ams 1 AG ae m mw LH I 32914 31dafid 430102 30102 5 84849 dq3153NN OS 38 15433 9 100031 amp egi1n zool1n oM val 3onvo ONIAIM TOSINOS Q30N3WIWO2O33 AMANA OM ADNAN SD 31990 91313 Wi oo 3s AMANA OM FOND 31990 AOLOW gadwsaWio n3s OM AON 31990 039 3 20 Z 00f O3 8600 00 66 SSIOWLNOD 1332083 LO0f O3 OGOF L0 6E 8XI 105107231 0012 10 6 Gxz B LOf 23 OFOZ 10 6E ZFOE LO 6E ZXZ 28919 v1d32 33 LIINIW X310 W HOLAAS a 3 NIA OD DAKS Te q AS 394 VH 2334 A MS WAIHO 089 T Q4d HOLAAS 14915 199 315IH3A OL AGE AMAL ISOH OA AO ACI vol ISNA gx H 2LIAASA 331 1O3INO2 PAGE 46 PART NUMBER 15293 OWNER S OPERATOR S MANUAL 200 SERIES PAGE 47
44. peration Ensure steering Lubricate Ref page 36 Y N turns freely Toe Ensure toe is adjusted Adjust Ref page 36 properly 1 LI Frame Chassis Bent Damaged Check for Replace as necessary Y damaged components Battery Connections Ensure Tighten as necessary Y N terminals securely fastened Corrosion Ensure that no Clean as necessary corrosion 15 present Cover Strap Ensure that Replace Secure as battery is secure in holder necessary Main Fuse Connection Tighten to 7 9 to 8 8 ft lbs Ensure securely fastened Battery Fluid Level Refer to page 38 Battery Charge Ensure Charge if necessary batteries fully charged CJ Guards Location In place Replace as necessary Y Condition Ensure that Guards are not damaged g LI Lights Operation Ensure that lights Replace bulbs as necessary Y N including the brake light are So properlyfunctioning 22 Cl 0 Suspension Operation Ensure that ball Replace Lubricate as Y N joints shocks and bushings necessary with grease are moving freely Fasteners Ensure that all Tighten Ref page 41 fasteners are in place and securely tightened E LI oeat Belts Operation Ensure that belt Replace as necessary Y N extend and retract ensure that latches are operational BedandSeat Operation Ensure that seat Latch or Adjust as necessary Y N Latches and Bed latches are secured Oh Ll Tool Holders Operation Ensure that tools
45. rated after mature supervised instruction and sufficient practice in an un congested area 44 WARNING It is strongly recommended that Operator and any passengers wear a properly fitting motorcycle helmet approved by agencies such as the Department of Transportation DOT Safety Helmet Council of America SHCA or Snell Memorial Foundation SNELL Most accident fatalities are due to head injuries Operator and any passenger should also wear face shields or goggles boots gloves and other appropriate protective clothing See MACHINE OPERATION 44 WARNING Long hair loose clothes or jewelry can get caught in moving parts below and behind the seat or surrounding environment Remove or tie back anything loose that can reach below and behind the seat before riding PAGE 11 44 WARNING NEVER place hands feet or any body parts or clothing near the motor wheels belts and other rotating parts of the vehicle while riding Use caution in performing required maintenance on or near operating motor Use caution after the motor has been running since the motor and other drive components be extremely hot 44 WARNING STOP the motor and vehicle if you experience unusual noises or vibrations Check the vehicle for damage Excessive noise or vibration is a sign of loose or worn parts 44 WARNING Keep guards in place at all times Prevent accidental contact by the operator or service personnel while
46. re each drive you need to make sure that you and your vehicle are both ready to drive To help get prepared this section discusses how to evaluate your driving readiness what items you should check on your vehicle and adjustments to make for your comfort convenience or safety Before you drive your vehicle for the first time we urge you to Read this owner s manual and the labels on your vehicle carefully Make sure you understand all the safety messages Know how to operate all the controls View and understand the included safety DVD 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 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 44 WARNING Operating this vehicle without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head and or eye inj
47. rging 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 batteries or charge them in an area that has open flame or electric equipment that could cause an electric arc Pre Ride Inspection The following checklist should be utilized to inspect your vehicle before each use to ensure that it is in proper working order ENGINE STOPPED CHECKLIST Yes ITEM INSPECTION PROCEDURE ACTION Warning Decals Ensure that all warning decals Replace as necessary Y N are legible and securely attached LI Tires Tread 1 8 min depth Replace as necessary Y Pressure 15 PSI with gauge _Inflate as necessar Drivetrain Belt Tension 74 3 8 slack Ref page 37 Y N LE LI Throttle omooth Operation Ensure Replace pedal return Y N pedal snaps back to its spring initial returned position Mud Debris Ice Ensure Clean out mud debris that mechanisms are free and Move unit to warm location clear to de ice 1 LI Fasteners Wheel Fasteners Ensure all Tighten Ref page 41 Y N wheel nuts are tight Missing Loose Fasteners Replace missing fasteners ensure all fasteners are present Tighten Ref page 41 PAGE 31 and securely tightened Ll Brush Bars In place and attached Replace as necessary Y N Tighten Ref page 41 Ll Steering O
48. s the button to turn on or off the power Press long for MUTE function 2 VOLUME Button Press this button fo increase ihe volume 4 5 3 Button v Press this button to play previous track or previous AM FM step In AM FM mode press and hold this button to search previous strong signal station 4 BAND Bll Button Pause Radio switch button When radio receiving FM AM switch When playing pause 5 VOLUNE Button Press this button to decrease the voiume 6 MODE Button Press MODE to switch between AM FM and USB AUX IN 7 Button Press this button to play next track or a next AM FM siep in AM FM mode press and hold this button to search next strong signal station Note The USB has memory retention when turn off the device or switch to FM PAGE 26 OWNER S OPERATOR S MANUAL 200 SERIES PART NUMBER 15293 VEHICLE FEATURES AND LOCATIONS OVERHEAD BRUSH BARS 3PT SAFETY BELTS Lupa VIEW MIRROR b i TOOL HOLDER PASSENGER GRAB BAR STEERING WHEEL FUEL TANK MANUAL DUMP CARGO BED CUP HOLDER ee he y us 3 BED LATCH HIP GUARD ADJUSTABLE SEAT UNDER SEAT STORAGE RUNNING LIGHTS BUMPER THROTTLE PEDAL PARKING BRAKE BRAKE PEDAL F R Switch CWAI NIED C CYDEPDATOYD O MANI On CSEDIEQG DART NI INARER 14902 OWNER S OPERATOR S MANUAL 200 SERIES PART NUMBER 15293 ARE YOU READY TO DRIVE Befo
49. s vehicle is equipped with a parking brake system The parking brake lever can be found in front of the passenger seat just under the dash To apply the brake simply depress the brake pedal and pull back on the parking brake lever locking it into position To disengage depress the pedal push the thumb button located at the top of the lever and return to its original position towards the front of the vehicle D Lights This vehicle is equipped with front running lights a rear running brake lamp and a rear facing cargo light To turn the running lights on flip the lower switch located next to the keyed ignition on the dashboard of the unit The cargo light can be turned on by flipping the upper switch located next to the keyed ignition See Figure The rear brake light will activate automatically when the brake pedal is depressed E Power Outlet This vehicle also is equipped with a 12V 15amp power outlet for plugging in accessory items and comes standard with a rubber cap Do not exceed the maximum amperage rating of the plug F Keyed Ignition Switch For added security this unit is equipped with a keyed power switch As an added feature all lights rr are turned off when the key switch is in the OFF position Reference page 33 Starting Instructions for specific instructions G Rear View Mirror The unit is equipped with a rear view mirror Adjust the mirror such that objects can be easily seen while sitting in correct
50. tal or reasonably equivalent to the warranted product at no cost to the purchaser during the replacement period Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance transportation accident or alteration is excluded from this limited warranty PAGE 5 OWNER S OPERATO R S MANUAL 200 SERIES PART NUMBER 15293 RESPONSIBLE BATTERY SAFETY AND DISPOSAL BATTERY WARNING BATTERIES AND RELATED PARTS Battery posts CONTAIN LEAD terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WASH HANDS WASH HANDS AFTER HANDLING WARRING Batley posts am retatesd AFTER HANDLING eni nc esr imp Lead acid batteries are completely recyclable Return whole scrap battery to distributor manufacturer or lead smelter for recycling 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 PAGE 6 Spent Batteries are taken to recycling facility where they are broken down and Spent Batteries separated into components to begin the recycling process Plastic Lead Bat
51. tery Acid Plastic pellets recycled from old battery Lead ingots recycled from battery grids and lead Sodium Sulfate crystals separated from old cases and covers used to oxide sre used to manufacture new battery grids battery Scid are recycled and sold for usse manufacture new battery and and components textile glass and detergent manufacturing covers Crush the Melt Grids cases and Neutralize covers battery acid Lead ingots Pashe Pellats Sodium aultate C New Grids and Lead Oxide Battery grids are manufactured from recycled lead for use in mew batteries Recovered lead oxide is New covers and cases also used in new battery manufacturing Battery covers and cases are manufactured F for new batteries from recycled plastic pellets Glass textiles detergents Mew cases and lids Lead Oxide gt New Battery PAGE 7 P OWNER S OPERATOR S MANUAL 200 SERIES PART NUMBER 15293 FOREWORD Congratulations on the purchase of your ASW Vehicle Before operating this vehicle the owner and each operator must understand that unless specifically equipped and labeled as a street legal Low Speed Vehicle LSV 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 f
52. the vehicle is running The guards over the brake motor axle and drive pulleys also help prevent mud and debris from coming in contact with those items 44 WARNING Be sure the passenger restraint system i e Seat Belt is properly adjusted and fastened at all times during operation f the passenger restraint system is not properly used by the operator and or passengers loss of control and possible personal injury and or vehicle damage can occur PAGE 12 44 WARNING When there is no passenger in the vehicle the passenger seatbelt must be securely fastened within the vehicle 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 can occur 44 WARNING All screws nuts and bolts must be properly tightened to make sure the vehicle is in safe operating condition 44 WARNING Prevailing torque type locknuts must be replaced with new after the old locknuts have been removed Replace with the same type of locknut to make sure they function properly Refer to the maintenance section for more information on locknuts 44 WARNING Keep the motor free of dirt and debris especially in the drive belt area 44 WARNING NEVER operate the vehicle without the operator and passengers properly seated and the restraint system properly adjusted and secured PAGE 13 44 WARNING NEVER power on the unit unless the throt
53. tle control is in its initial fully returned position 44 WARNING NEVER tamper with alter or change the vehicle motor governor settings governor as set by the motor manufacturer limits maximum engine speed and protects the motor from damage Excessive motor speed is potentially dangerous to operator passengers bystanders and engine 44 WARNING Wet slippery rough or sloped terrain is potentially dangerous and may result in injury if proper caution is not observed ALWAYS SLOW DOWN Operator must use mature judgment skill and experience to choose a speed suitable for terrain and riding conditions in protecting operator and any bystanders Operator must use mature judgment skill and experience in choosing suitable terrain for individual operational capabilities 44 WARNING When turning on pavement loose gravel or similar surfaces there is an increased risk in loss of control ALWAYS SLOW DOWN 44 WARNING ALWAYS SLOW DOWN when turning High speed turning can cause loss of control and or possible operator injury Turning on a slope increases the risk of rollover Practice operation is required to coordinate turning skill Failure to operate this vehicle at a safe speed while turning can result in a strong possibility of severe personal injury PAGE 14 44 WARNING Do NOT place metal objects or let them fall onto the top of the batteries as this may cause an electrical short and the possibility
54. uera del veh culo o la caja de carga SEGURO DE LA CAJA DE VOLCAR Manejar caja carga levantada es peligroso Todo el tiempo mant ngala abajo y use el seguro de la caja cuando maneje Maximum Weight 250 Lbs 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 thus vetucie to over or go owt of control Read and understand Owner s Manual before operating this vehicle EL VEHICULO SE PUEDE VOLCAR Este vehiculo se maneja y se maniobra diferente de cualquier otro carro carmon comun de pasajeros Curvas cerradas maniobras bruscas en alta velocidad puede causar una volcadura p rdida del control Lea y comprenda Manual de Due o antes de operar este vebiculo 115530 rs VEHICLE MAY ROLL This vehicle will handie differently from any ordinary passenger car or truck Sharp turns or abrupt maneuvers at high speeds may cause this vehicle to over go out of control Read and understand Owner s Manual before operating this vehicle EL VEHICULO SE PUEDE VOLCAR Este vehiculo se maneja y se maniobra diferente de cualquier otro carro cami n comun pasajeros Curvas cerradas o maniobras bruscas en alta velocidad puede causar una voicadura p rdida del control Lea y comprenda el Manual de Duefio antes de operar este vehiculo 1133079 Peso Maximo
55. ury and the possibility of death in the event of a severe accident Always wear and approved motorcycle helmet that fits properly and wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Additional Driving Gear In addition to a helmet and eye protection we also recommend Sturdy boots to help protect feet ankles and lower legs Gloves to help protect your hands Driver Training Developing your driving skills is an ongoing process Even if you are and experienced driver take time to become PAGE 28 familiar with the 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 vehicle controls and feel comfortable with its size and weight 44 WARNING Operating this vehicle without your seat belt could cause you to be thrown from the unit causing serious injury or death No Alcohol or Drugs Alcohol drugs and vehicles don t mix Even small amount of alcohol can impair your ability to operate a vehicle safely Likewise drugs even if prescribed by a physician can be dangerous while operating a vehicle Consult your docior to be sure it is safe to operate a vehicle after taking medication 44 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 c
56. use drivetrain damage Shifting direction with the throttle depressed will cut power to the motor requiring the ignition key be turned OFF then back ON to reset 11330 Q OBSERVE THE FOLLOWING INSTRUCTIONS 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 amp Supplements Safety Video and Engine Manual supplied with this product Make sure that you understand and follow all Warnings and Instructions in this material Always wear a D O T approved motorcycle helmet eye protection and protective clothing Check tire pressures before operating Manual for proper operating pressure Do NOT operate the vehicle without the brush bars securely in place Keep all covers and shields properly installed Throttle and Brake Controls and Engine Stop Switch must work properly and freely before starting the engine Operator must be seated safety belt must be fastened and brake applied Delore operating the vehicle Never operate at speeds too fast for your skills or the conditions Never attempt jumps or other stunts Never ride after consuming alcohol drugs or other intoxicants Reter to Owner s OBSERVE LAS SIGUIENTES INSTRUCCIONES hecho de no comprender y seguir las Advertencias Instrucciones para uso seguro mantenimiento de este producto puede causar MUERTE L
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