American Sportworks 5210 User manual

5210 208cc FUN KART OWNER’S MANUAL / PARTS GUIDE
Potentiometer
Forward
Safety
Switch
Reverse
Safety
Switch
R
F
N
Drive/Regen
BLUE
BROWN
BLACK
BLACK
GREY
YELLOW
WHITE
GREEN
BLACK
YELLOW
WHITE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
F/N/R Switch
Battery
Discharge
Indicator
Contactor
Curtis
Controller
Plug
F1
B-
GREEN
RED
RED
WHITE
BLACK
GREEN
BLACK
RED
10A Fuse
THIS VEHICLE IS 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. 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. CHILDREN MUST BE 13+ YEARS OF AGE FOR THIS VEHICLE AND SUPERVISED BY AN ADULT AT ALL TIMES WHEN USING
THIS FUN KART. SPEED REDUCTION KITS ARE AVAILABLE FOR ALL VEHICLES. THIS VEHICLE IS NOT A TOY.
15362R1
MODEL 5210 / AGES 13+ / 24 MPH MAX SPEED
Book 2 of 2

American SportWorks (hereinafter referred to as “ASW”) hereby warrants to the original purchaser that the frame components of new ASW fun karts will be
free from defects in material and workmanship. The period of warranty is thirty (30) days from date of purchase for the component parts (except as noted
below), ninety (90) days from the date of purchase for the frame, and one (1) year from date of purchase on select engines. Some engines may carry a separate
manufacturer’s warranty and are not covered by this ASW warranty. 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, or any other uses prohibited by the Operator’s Manual. Additionally, this warranty
does not cover component failure or damage to vehicles which are leased or rented, or vehicles which are used at a concession track.
Specific Exclusions: This limited warranty does not apply to components, which are subject to normal wear and tear. These items include, but are not limited
to, the tires, brakes, throttle, shift and brake cables, drive belt, the torque converter system, chain, seat, lights, fasteners, decals, or cosmetic body panels and
natural discoloration of material due to ultraviolet light. Downtime, pick-up and delivery charges are not covered by this warranty. This warranty does not
apply to select engines covered by a separate manufacturer’s 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 APPL Y TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER LEGAL RIGHTS, WHICH VARY, FROM STATE TO STATE.
limited warranty
VEHICLE IDENTIFICATION NUMBER
Record the Vehicle Identication Number (VIN) and Model number of your American SportWorks Fun Kart
below for service and insurance records. The VIN can be found on the crossbar, behind the seat. The
Model number is located on the SKU decal near the oorboard.
VIN
MODEL
i

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
ASW Limited Warranty ...................................................................i
SECTION 1 INTRODUCTION
Forward...............................................................................1
Emissions Warranty .....................................................................1
Cell Phone Use.........................................................................1
SECTION 2 OPERATION
Kart Operation .........................................................................2
Kart Features and Locations...............................................................4
SECTION 3 SERVICE / GENERAL MAINTENANCE
Replacement Parts......................................................................5
Air Cleaner ............................................................................5
Engine lubrication.......................................................................5
Spark Plug ............................................................................6
Carburetor Adjustment ...................................................................6
Cleaning Instructions ....................................................................6
General Lubrication .....................................................................6
Chain Lubrication & Adjustment ............................................................6
Shock Adjustment.......................................................................7
Shifter Adjustment.......................................................................7
Storage Instructions .....................................................................7
SECTION 5 ILLUSTRATED PARTS LIST
Cylinder Head Assembly..................................................................10
Cylinder...............................................................................11
Engine Crankcase ......................................................................12
Transmission...........................................................................13
CVT Cover ............................................................................14
Outer Crankcase Assembly ...............................................................15
Piston, Crank & Connecting Rod ...........................................................16
Camshaft Assembly .....................................................................17
Oil Pump Assembly......................................................................18
Driven Pulley & Clutch ...................................................................19
Engine Electrical........................................................................20
Electric Start...........................................................................21
Driver Pulley...........................................................................22
Fan Cover & Shroud Assembly.............................................................23
Carburetor.............................................................................24
Frame Warning Labels ...................................................................25
Frame Group ..........................................................................26, 27
Steering & Brakes.......................................................................28
Front Suspension .......................................................................29
Rear Swingarm Assembly.................................................................30
Engine / Mufer / Air Cleaner ..............................................................31
Rear Axle .............................................................................32
Electrical..............................................................................33
TABLE OF CONTENTS

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
1
Congratulations on the purchase of your American
SportWorks / ASW Fun Kart. Please take a few moments
to get well acquainted with your vehicle by reading the
Operator Safety Manual as well as this Owners Manual /
Parts Guide. Before operating this vehicle, the owner,
and each operator, must understand that this vehicle was
not designed or manufactured to meet specications for
use on public roads, streets, highways and thoroughfares.
The owner, operator(s) and passenger(s) must read and
understand all the instructions for proper assembly and
safe operation, as well as the instructions concerning the
engine and all other portions of the vehicle as described
and illustrated in this manual, the Operator Safety Manual
and on the included Kart Safety DVD. Children must be 13
years of age or older and supervised by an adult at all times
when using the vehicle. This vehicle is not a toy.
Be sure to follow the recommended maintenance schedule
and service your machine accordingly. Preventative
maintenance is extremely important to the safe operation
and longevity of your vehicle.
Inexperienced and rst time drivers are urged to seek
instruction from a dealer or qualied instructor before and
during the initial use of this vehicle. It is also recommended
to practice in a large open area to become familiar with
the operation of the machine. This vehicle is designed for
drivers and riders 13 years and older.
For more information on American Sportworks and its
products visit our website at www.amsportworks.com.
New Vehicle Limited Warranty
For a detailed description of warranty coverage for your
vehicle, refer to the Warranty section of the Owners Manual
/ Parts Guide as supplied with the vehicle, or go to www.
amsportworks.com.
Emissions Warranty
For a detailed description of the emissions warranty for your
vehicle, refer to the Emissions Warranty section of the LCT
Engine Operation Manual as supplied with the vehicle.
Cell Phone Use
The use of Mobile Communications Equipment has become
increasingly important and prevalent in both personal
and business affairs. Drivers must not compromise their
own, or others safety when using such equipment. ASW
recommends against the use of any handheld device while
driving this vehicle.
We hope you will have a fun, safe experience with our
products and thank you again for choosing an American
SportWorks Fun Machine.
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 the Operator Safety
Manual, this manual and any accompanying manuals
before attempting to operate this vehicle. Make sure to
view the Kart Safety DVD.
FORWARD
SOME WORDS ABOUT SAFETY
WARNINGS AND CAUTIONS
Indicates a potential hazard that could result in
severe personal injury or death
Indicates a potential hazard which may result in
personal injury or damage to the machine.
NOTE: Use of the word “NOTE” will alert you to key
information or instructions.
WARNING
!
CAUTION
!
Your vehicle has been supplied with:
• OPERATOR SAFETY MANUAL (Book 1)
• OWNERS MANUAL / PARTS GUIDE (Book 2)
• KART SAFETY DVD
• ENGINE MANUAL
If any of these items are missing or were not
supplied with your vehicle, please contact
American SportWorks at 800-643-7332 or visit
our website at www.amsportworks.com.
safety section
!
Please thoroughly read and understand the Safety
Section outlined in the Operator Safety Manual supplied
with this Fun Kart along with the Kart Safety DVD. If,
for some reason, you did not receive these items please
contact American Sportworks or visit our website at www.
amsportworks.com.
introduction/safety SECTION 1
1

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
A. Operation controls
Do not attempt to start or operate the engine 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.
Every time, prior to starting the engine, check the throttle assembly to ensure that when the pedal is
pushed all the way forward the assembly is working smoothly and returns to idle when released. Do
not operate this unit if pedal or engine throttle linkage fail to return to the idle position. If unable to
correct the problem through lubrication, adjustment or replacement of worn parts, contact your dealer
for assistance.
WARNING
!
WARNING
!
B. Throttle
The right foot pedal is the throttle and controls the speed of the kart. As the engine speed increases above idle, the driver pulley automatically engages
the drive belt and moves the vehicle forward. To disengage the driver pulley at any time, allow the throttle to return to the idle position.
C. Brake
The brake is controlled by the left foot pedal (See Figure below). Applying pressure to the
pedal draws the brake pads against the brake disc at the rear axle and slows or stops the
kart. The locking lever can be applied to act as a park brake and should remain applied
during starting and engine warming (choke cycle). See I. Park Brake for more instruction.
D. Fuel Valve (see g. D1)
The manual valve is mounted to the bottom of the fuel tank. Refer to the LCT Engines
Operation Manual. NOTE: Turn fuel valve to OFF position during transport
E. Engine Starting (see g. E1)
For parental control and added security, this unit is equipped with a keyed ignition
switch. To start the unit, rst apply the foot brake and ensure the Engine Stop Switch
is in the RUN position. The RUN position may be identied on the switch by the word
“RUN”, the word “ON”, or the symbol “I”. (NOTE: Your Fun-Kart is equipped with (2)
engine stop switches, one located on the dash and one located on the engine. BOTH
switches must be in the “RUN” position for the engine to start). Apply choke by pulling
out and holding the choke cable located under the driver’s seat (See Figure). Turn
ignition key fully clockwise and hold to start the engine. (Caution: Do not let the
engine turn over for more than 5 seconds at a time as this may cause starter
damage). Once the engine starts, allow the key to return to the run position. The engine
will warm up within 5 minutes, allowing the engine to operate at the normal RPM. On a
warm day, this period of time may be reduced to less than 1 minute. The choke may be
closed at this time by releasing the choke cable and allowing it to draw back in. Before
driving this vehicle, test that the ignition switch will turn off the engine. With the engine
running, turn the ignition key counter-clockwise to the “OFF” position to shut down the
engine. A back-up pull rope starter mechanism is provided on the engine. Follow the
same starting instructions except turn the key clockwise only to the “RUN” position and
have a supervisor start the engine by pulling the recoil starter.
F. Engine Stop Switch (see g. F1)
Before driving this vehicle, test each Engine Stop Switch to ensure that it is
operating properly. With the engine running, switch the Engine Stop Switch to
the STOP position to shut down the engine. The STOP position may be identied
on the switch by the word “STOP”, the word “OFF”, or the symbol “O”. Repeat
the process for the other Engine Stop Switch. With the engine running, turn the
ignition key to the “OFF” position to shut down the engine.
KART OPERATION
fuel valve
in “OFF”
position
OFF
ON
g. D1
g. F1
TYPICAL ENGINE
STOP SWITCH
= RUN = STOP
Choke Knob
Brake Pedal
Throttle Pedal
Ignition Keyswitch
Choke Cable
Engine Stopswitch
g. E1
operation
SECTION 2
2

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
To apply the park brake
Parking brake not engaged
Latch Pin
Locking Lever
Brake pedal
Parking brake engaged
Latch Pin
Locking Lever
Brake pedal
Front Driver Side Front Driver Side
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 stopped and
the engine shut off.
Operating this kart without your seat belt could cause you to be thrown from the kart, causing serious
injury or death.
Attempting to use the spoiler as a cargo rack may cause serious injury or death. Do not place items
on, or tie items to the spoiler.
WARNING
!
WARNING
!
WARNING
!
H. Occupant Restraints
This kart is equipped with 3 point retracting seat belts. Insert the metal tongue into the buckle until it is securely attached. Final adjustments should be
made with the plastic tension stop such that the belt is against the shoulder and chest with no excess slack.
I. Rear Spoiler
The spoiler is NOT to be used as a cargo rack. Do not place items on, or tie items to the spoiler.
J. Park Brake (see g. J1)
The park brake should be applied during starting, engine warming (choke cycle), and anytime the vehicle is parked and/or left unattended. The park
brake is set by applying pressure to the brake pedal and latching the locking lever over the latch pin.
G. Seat Adjustment
The unit is equipped with an adjustable driver’s seat. To adjust, lift the lever just in front of the seat bottom and move the seat either forward or
backward. Release the lever at the desired seat location, ensuring that it snaps back into place to lock the seat in position.
g. J1
NEVER use E-15 or E-85 fuel or blends with Ethanol content in excess of 10%. Ethanol blends in excess of 10%
will cause damage to the engine and void manufacturer warranty
a. Use regular unleaded 87 octane gasoline with up to a 10% ethanol blend.
b. This engine supplied with this Fun-Kart is NOT designed for Flex Fuel operation.
CAUTION
!
operation SECTION 2
3

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
Spoiler
Whip Flag Stem
Fuel Tank
Backup Recoil Start
Fuel Valve
Park Brake Latch
Manual Choke
Air Filter
Steering Wheel
Kart Features and Locations
Engine Stopswitch
Fuel Valve
Fuel Tank
Backup Recoil Start
Air Filter
operation
SECTION 2
4

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
REPLACEMENT PARTS AND SERVICE
SERVICE & GENERAL MAINTENANCE
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 American Sportworks by contacting ASW at 1-800-643-7332 or
online at www.amsportworks.com. Orders may be subject to a minimum fee. A listing of authorized service center locations in your area is also available
from our Customer Service department.
Record the Vehicle Identication Number (VIN) in the spaces provided at the front of this manual. The VIN can be found on the crossbar, behind the seat.
A. Engine Service
NOTE: For engine service, maintenance, and general information, please refer to the LCT Engines Operation Manual.
B. Cleaning Instructions
Keep your kart clean by using a clean rag and a mild detergent and water solution. Wipe off all dirt and oil from around the controls. Wipe off any spilled
fuel and oil. Keep the engine clean and clear of foreign objects, especially those around the air intake fan and air inlet ductwork.
C. Chain Lubrication and Adjustment (see g. C1)
For optimum chain life, lubrication with a spray on chain lubricant should be performed on a regular basis. DO NOT USE OTHER OILS.
A new chain will stretch within the rst few hours of use and therefore will require adjustment. The rst chain adjustment should be made after the rst 2
hours of use. If the chain has more than ½” of slack or “ex” then it will require adjustment.
To adjust:
1) Loosen Nut (1).
2) Adjust nut (2) until the proper chain tension is achieved.
3) Re-tighten Nut (1).
3/8” -1/2”
NUT 2
NUT 1
ADJUSTMENT
g. C1
maintenance SECTION 3
5

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
13
15 21
16
D. Belt Replacement
Ensure the kart is on a smooth at surface and the engine is OFF. Apply parking brake. Remove the three mounting bolts for the belt cover. Remove
mounting screw located behind the belt cover at the bottom. Using a ½” socket or box wrench, remove the driver (front) pulley mounting bolt and pull
the pulley off the crank shaft. To prevent the engine crank shaft from turning with the pulley mounting bolt, use a strap wrench around the pulley outer
stationary sheave. If the existing belt is still intact, remove it. If not, look for anything that may have caused the belt to fail prematurely. Inspect pulley
and perform clutch lubrication and cleaning (Section E). Install new belt with the tapered edge away from the engine (Arrow pictured on belt will point
TOWARD THE ENGINE). Place belt around the driven (rear) pulley and stretch over the crank shaft and onto the bronze bushing. Replace the driver
pulley and mounting bolt. Tighten bolt to 30 ft*lb
E. Driver Pulley Lubrication and Cleaning (see g. E1)
The driver pulley may perform poorly if not lubricated properly within each 25 hour period. Premature failure of its components may also occur. Before
reaching 25 hours of operation, remove the driver pulley from the engine output shaft paying close attention to how all the components nest with
each other inside the driver pulley. Disassemble the components of the driver pulley. Using brake or carburetor cleaner and a soft brush, clean all
the components of the assembly. Ensure there are no rough surfaces. Apply a dry graphite lube to the entire outer surface of the hub and the inner
surfaces of the outer stationary sheave. Allow the lube to dry completely. Reassemble the driver pulley and install onto the engine output shaft.
F. Storage Instructions
If you plan to store (and not operate) your kart 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:
1) Drain fuel tank and carburetor by allowing the engine to run until the fuel system is dry.
2) Lubricate the engine cylinder by removing the air cleaner and by spraying an engine fogging oil through the carburetor.
3) Do NOT save or store gasoline over the winter. Using old gasoline, which will deteriorate from storage, will make the engine difcult to start and
affect the performance of the engine.
4) To protect the paint, plastics and upholstery, it is a good idea to keep the unit covered when not in use.
G. Front Wheel Replacement (see g. G1)
Remove cotter pin and castle nut. Wheel should be easily removed. After
replacing the wheels, tighten castle nut and replace cotter pin with a new one.
Replace rubber cover
When installing the driver pulley, make certain to align and
engage the flats of the outer stationary sheave and the pulley
hub. The two parts nested for installation are shown here.
Lube entire inner surface of the driver
pulley outer stationary sheave
Lube entire outer surface of the
driver pulley hub
g. E1
g. G1
maintenance
SECTION 3
6

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
Toe Adjustment Diagram
LockNuts
TieRodAdjustingSleeve
RightRotateRightRotate
LeftRotateLeftRotate
B
A
J. Storage Instruction
If you plan to store (and not operate) your kart 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. Drain fuel tank and carburetor by allowing the engine to run completely out of fuel.
b. Lubricate the engine cylinder by using an engine fogging oil, following the instructions provided with the product.
c. Do NOT save or store gasoline over the winter. Using old gasoline, which will deteriorate from storage, will make the engine difcult to start and
affect the performance of the engine.
d. Remove the battery from the unit and apply a periodic trickle charge to maintain the battery at a proper voltage level for the next riding season.
e. To protect the paint, plastics and upholstery, it is a good idea to keep the unit covered when not in use.
Prevailing torque type locknuts must be replaced with new after the old locknuts are removed.
CAUTION
!
g. I1
H. Rear Wheel Replacement (see g. H1)
Remove cotter pin and castle nut. Wheel should be easily removed. After replacing the wheels,
tighten castle nut and replace cotter pin with a new one. Replace rubber cover
I. Front Wheel Alignment (see g. I1)
The front wheels should be set with a “toe-in” from 1/4” to 1/2”. At the centerline of the tires,
measure the Distance A and the Distance B. For proper toe adjustment, Dimension A should
be 1/4” – 1/2” greater than Dimension B. While adjusting, ensure rubber boots are in good
condition.
To make adjustments:
1) Loosen the lock nuts on both sides of Front Tie Rods.
2) Ensure the steering wheel is centered, and adjust Dimension B by equally rotating the
tie rod adjusting sleeve in or out with a 12mm wrench.
3) After adjusting to the desired length, tighten the lock nuts against the Tie Rods.
4) Recheck the dimensions for proper alignment.
4
18 3
21
g. H1
maintenance SECTION 3
7

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
maintenance
SECTION 3
5210 SPECIFICATIONS
5210 ELECTRICAL SCHEMATIC
ENGINE GENERATOR
ENGINE MAGNETO
KEY SWITCH
STARTER
BATTERY
VOLTAGE REGULATOR
ENGINE STOP SWITCH
ENGINE STOP SWITCH
(MOUNTED ON ENGINE)
12V SWITCHED POWER
(NOT USED)
_+
G
G
G
G
G G
G
B
R
R
R
R
Y
Y
Y/R
Y/R
B/W
B/W
B/W
B/W
B/W
Y/R
WIRE COLOR CHART
G
B
B/W
B/W
Black B
Green G
Red R
White W
Yellow Y
ENGINE
Type Single Cylinder, 208cc, Air Cooled, 4 cycle
Power (BHP @ RPM)
≈ 6.45 @ 3573
Torque (Ft-lbs @ RPM)
≈ 9.48 @ 3073
Starting System Electric Start with Recoil Backup plus Manual Choke
Air Filtration Dual Element
Exhaust System Muffler with Heat Shield
Fuel Capacity .67 gal
Oil Capacity 16 oz.
Spark Plug F6RTC
TRANSMISSION
Type: Dual Wheel Drive CVT
CHAIN SIZE #420 1/2” Pitch
TIRES & WHEELS
Front / Rear 16 x 6 - 8 / 18 x 9.5 - 8
ADVANCED GEOMETRY SUSPENSION
Front Double A-Arm with Damped Shocks
Rear Swing Arm with Damped Shocks
STEERING
Type: Rack and Pinion
FRAME
Type - Heavy Gauge - Jig Welded 1.125” Main Frame
Rear Axle 7/8” Hardened Alloy Steel
Finish Baked Powder Coat
BRAKES
Type: Rear Single Hydraulic Disc
PERFORMANCE
Max Speed Approx. Up to 24 mph
Fuel Consumption 30 - 50 mpg
SPECIAL FEATURES
Seat Adjustable Driver, Fixed Passenger Buckets
Restraint System
3-Point Shoulder / Lap Belts w/Retractor
Engine Stop Switch/Dual On Engine, In Dash and Key Switch
Custom Bars 1.125” Full Brush Bars
Safety
Whip flag/Pedal Latch Style Parking Brake
DIMENSIONS
Curb Weight 335 lbs.
Weight (Driver, Passenger & Gear) 400 lbs.
Seat To Pedals 39” - 41”
Wheelbase 54.7”
Vehicle - Overall 82”L x 48”W x 52.7”H
8

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
5210 SECTION 1 FRAME GROUP WARNING LABELS
illustrated parts lists SECTION 4
9

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
illustrated parts lists
SECTION 4
Ref # Part # Description Qty
1 15470 BAR, REAR C PILLAR - 5210 1
2 15471 BAR, OH CROSS - 5210 1
3 15472 BAR, LH B PILLAR - 5210 1
4 15473 BAR, RH B PILLAR - 5210 1
5 14465 BOLT, M12 X 1.75 X 30 FLAG MOUNT 1
6 14492 NUT, M12 X 1.25 HEX ZN 1
7 14087 WASHER, CONCAVE CLAMP DAC 20
8 14696 BOLT, M8 X 1.25 X 50 FHCS DAC 8
9 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 6
10 14466 NUT,1.75 THREAD DECORATIVE PLSTC FLG MNT 1
11 15474 BAR, OH FRONT - 5210 2
12 15475 ENDCAP, BAR - 1.125” BLACK PLASTIC 8
13 14464 FLAG, SAFETY 1
14 (This item is intentionally left blank.)
Ref # Part # Description Qty
15 15476 CABLE, THROTTLE 1
16 15477 CABLE, CHOKE 1
17 (This item is intentionally left blank.)
18 N/A FRAME, 5210 (Not Available) 1
19 14612 PAD, RUBBER FOOT 2
20 15478 HOOD, 5210 1
20a 15565 SCREW, M6 X 1.0 X 16 BUTTON HEAD SOCKET SS 4
20b 15567 WASHER, M6 FENDER 4
21 15479 SPOILER, 5210 1
22 15480 HARNESS, MAIN WIRING - 5210 1
23 15113 COVER, BOLT CAP 20
24 15546 SEAL, BAR CONNECTION - 1.125” 6
25 15114 WASHER, BAR CONNECTION M8 X 24 X 1.25 20
26 14086 BOLT, M8 X 1.25 X 55 FHCS DAC 6
5210 SECTION 2 FRAME GROUP
10

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
illustrated parts lists SECTION 4
Ref # Part # Description Qty
1 15271 SWITCH, ENGINE STOP ROCKER 1
2 15482 IGNITION SWITCH W/KEY - 5210 1
2a 14588 KEY SET (not shown) 1
3 15371 HEADREST - 5210 BLACK 2
4 15369 ASM, SEAT W/SLIDES - DRIVER 5210 1
4 15370 ASM, SEAT W/ NO SLIDES - PASS 5210 1
5 14440 BOLT, M8 X 1.25 X 40 HHCS DAC 2
6 15483 BOLT, M8 X 1.25 X 40 “T” STYLE DAC 2
7 14088 NUT, M8 X 1.25 LOCKING FLANGE DAC 2
8 14243 NUT, M10 X 1.25 LOCKING FLANGE DAC 4
9 14289 SPACER, M10 STEPPED SEAT BELT DAC 4
10 14451 BOLT, M10 X 1.25 X 25 FHCS DAC 2
11 8778 SEATBELT, RETRACTABLE W/ SLEEVE 2
12 14324 NUT, M12 X 1.25 LOCKING FLANGE DAC 3
Ref # Part # Description Qty
13 15485 BOLT, M12 X 1.25 X 25 FHCS DAC 3
14 14451 BOLT, M10 X 1.25 X 25 FHCS DAC 2
5210 SECTION 3 INTERIOR
11

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
illustrated parts lists
SECTION 4
Ref # Part # Description Qty
1 14615 BOLT, M8 X 1.25 X 95 FLANGE 2
2 14126 BUSHING, FLANGED SLEEVE 12 X 16 X 12 8
3 14617 UPPER SUSPENSION ARM COLLAR, 75MM 2
4 14618-2 UPPER SUSPENSION ARM - BLACK 2
5 14243 NUT, M10 X 1.25 LOCKING FLANGE ZN 4
6 14246 BOLT, M10 X 1.25 X 40 FHCS ZN 4
7 14619 SHOCK, FRONT - RED 2
8 14620 BOLT, M8 X 1.25 X 105 2
9 14621 LOWER SUSPENSION ARM COLLAR, 85MM 2
10 14622-2 LOWER SUSPENSION ARM ASSY - BLACK 2
11 14623-2 SPINDLE AND STRUT SUPPORT, R - BLK 1
12 14624 BEARING 6003Z 2
13 15367 ASM, TIRE/WH RH 16X6-8 1
13 15368 ASM, TIRE/WH LH 16X6-8 (not shown) 1
Ref # Part # Description Qty
13a 15486 TIRE, 16 X 6 - 8 FAR EAST “V” TREAD (not shown) 2
14 14626 BEARING 6201 2
15 14244 NUT, M12 X 1.25 CASTLE ZN 2
16 14627 HUB COVER, FRONT 36MM ID 2
17 14242 NUT, M10 X 1.25 CASTLE 4
18 15542 PIN, M2.5 X 25 COTTER 4
19 14629-2 SPINDLE AND STRUT SUPPORT, L - BLK 1
20 14241 WASHER, M10 SPLIT LOCK ZN 4
21 15542 PIN, M2.5 X 25 COTTER 2
22 (This item is intentionally left blank.)
23 14923 CAP, NUT COVER RUB - BLK 2
24 14857 SEAL, BALL JOINT 4
25 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 4
5210 SECTION 4 FRONT SUSPENSION
12

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
illustrated parts lists SECTION 4
5210 SECTION 5 STEERING ASSEMBLY
Ref # Part # Description Qty
1 14631 COVER, STEERING WHEEL 1
2 14426 BOLT, M6 X 1.00 X 14 FHCS ZN 3
3 14632 STEERING WHEEL 1
4 14633-2 SHAFT, STEERING - BLACK 1
5 14634 BUSHING, NYLON - 18 X 16 1
6 14635 KEY, 4 X 4 X 11.5 1
7 14341 BOLT, M6 X 1.00 X 20 FHCS ZN 4
8 14636 STEERING BALL JOINT DUST COVER 2
9 14565 SCREW, M5 X 12 PH 2
10 14637 ASM, TIE ROD END - BLACK 2
11 14638 ASM, RACK & PINION 1
12 14639 STEERING GEAR 1
13 14243 NUT, M10 X 1.25 LOCKING FLANGE ZN 1
14 14641 DUST COVER 1
15 14236 NUT, M6 X 1.00 NYLOC FLANGE ZN 4
16 14642-2 STEERING GEAR BRACKET (R.S.B.) - BLACK 2
17 14643 SPRING, THROTTLE PEDAL 1
18 14119 BUSHING, SLEEVE 12 X 21 X 12 4
19 14645-2 PEDAL, THROTTLE BLACK 1
20 14526 CAP, THROTTLE PEDAL - 31X/41X/61X 1
21 14646 CAP, BRAKE MASTER CYLINDER 1
Ref # Part # Description Qty
22 14647 BOLT, M6 X 1.0 X 25 ZN 2
23 14648 BOLT, M8 X 1.25 X 144 HHCS 1
24 14649-2 PEDAL, BRAKE - BLACK 1
25 14650 PAD, BRAKE PEDAL - BLACK 1
26 14651 SPRING, BRAKE PEDAL 1
27 14239 BOLT, M8 X 1.25 X 20 FHCS ZN 1
28 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 3
29 14652 LEVER, PARKING BRAKE 1
30 14628 PIN, M1.6 X 14 COTTER 1
31 14653 STUD, 6 X 16 1
32 14654 KIT, BRAKE PAD 1
33 14236 NUT, M6 X 1.00 NYLOC FLANGE ZN 2
34 14655 ASM, HYDRAULIC BRAKE 1
35 14656 BOOT, BRAKE 1
36 14657 SHAFT, BRAKE MASTER CYLINDER 1
37 14658 ASM, BRAKE CALIPER (includes brake pads) 1
38 14455 BOLT, M8 X 1.25 X 14 SHCS PL 2
39 14744 MASTER CYLINDER, BRAKE (RESERVOIR AND CAP INCLUDED) 1
40 14130 HOSE, HYD BRAKE - 75” 1
41 14495 WASHER, M8 SPLIT LOCK 2
13

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
illustrated parts lists
SECTION 4
5210 SECTION 6 REAR SWING ARM
Ref # Part # Description Qty
1 15271 SWITCH, ENGINE STOP ROCKER 1
2 15424 PLATE, MTG - ENGINE STOP SWITCH 1
3 15490 HARNESS, ENGINE STOP SWITCH 1
4 14246 BOLT, M10 X 1.25 X 40 FHCS ZN 6
5 14796 SHOCK, REAR - RED & BLACK 2
6 14243 NUT, M10 X 1.25 LOCKING FLANGE ZN 6
7 14661 BUSHING, SWINGARM ISOLATOR 2
8 14243 NUT, M10 X 1.25 LOCKING FLANGE ZN 1
9 15489 ASM, REAR SWINGARM - 5210 1
10 14662 BOLT, M10 X 1.25 X 174 HHCS 1
11 14666 SPANNER 1
12 14426 BOLT, M6 X 1.00 X 14 FHCS DAC 2
13 15054 COVER, DRIVE - PLASTIC 1
14 8227 NUT, 1/4-20 CLIP NUT 2
15 14778 SCREW, M4 X 1.75 X 12 PH 1
16 14341 BOLT, M6 X 1.00 X 20 FHCS 1
Ref # Part # Description Qty
16a 14236 NUT, M6 X 1.00 NYLOC (not shown) 1
17 15390 BRKT, BELT COVER 1
17a 14426 BOLT, M6 X 1.00 X 14 FHCS DAC 1
18 14186 COVER, BATTERY 1
19 14187 STRAP, BATTERY HOLD DOWN 1
20 14189 BATTERY - GTX9-BS 1
21 14188 GASKET, BATTERY CAP 1
22 15444 ENGINE, LCT 208CC 49 STATE 1
22 15388 ENGINE, LCT 208CC 50 STATE 1
23 15491 FILTER, AIR - PAPER ELEMENT (SEE SPECS) 1
24 15057 SPARK PLUG, TORCH F6RTC 1
25 15059 PLUG, OIL DRAIN - LCT 136CC / 208CC 1
26 15058 DIPSTICK, OIL - LCT 136CC / 208CC 1
27 15055 CAP, FUEL - LCT 136CC / 208CC 49 STATE 1
27 15495 CAP, FUEL - LCT 208CC 50 STATE 1
14

15362R1 5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST
illustrated parts lists SECTION 4
5210 SECTION 7 JACKSHAFT
NOTE:
* For vehicles assembled prior to March, 2013
** For vehicles assembled after March, 2013
Provide your American SportWorks Customer Service Representative with
the VIN to determine the vehicle’s assembly date.
Ref# Part# Description Qty
1 15542 PIN, M2.5 X 25 COTTER 1
2 14727 NUT, M14 X 1.25 CASTLE 1
3 14690 WASHER, M12 ZN 1
4 14691 SHAFT, SPROCKET & DRIVEN PULLEY 1
5 14692 KEY 1
6 14693 BEARING 2
7 15494 ENGINE MOUNTING PLATE - 208CC 1
8 14088 NUT, M8 X 1.25 LOCKING FLANGE ZN 4
9 14695 BUSHING 2
10 (This item is intentionally left blank.)
11 14697 BOLT, M8 X 1.25 X 60 FHCS 4
12 14698 SHEAVE, STATIONARY 1
13 14699 BUSHING 1
14 14700 SHEAVE, MOVEABLE 1
15 14701 HUB 1
16 14702 DRUM 1
17 14703 WASHER, M8 1
18 1454 BOLT 5/16-24 X 1.750 HHCS G5 1
19 5959 BELT 1
20 14705 NUT, M16 X 1.25 LOCKING FLANGE 1
21 14706 DRIVEN PULLEY 1
Ref# Part# Description Qty
22 15061 GUARD, REAR CHAIN (black plastic) 1
23 (This item is intentionally left blank.)
24 14446 BOLT, M10 X 1.25 X 45 FHCS ZN 1
25 14243 NUT, M10 X 1.25 LOCKING FLANGE ZN 1
26 14708 CHAIN ADJUSTER 1
27 14709 NUT, M12 2
28 14710 WASHER - CHAIN ADJUSTER 2
29 14469 SPACER, ENGINE ADJ ALIGNMENT 1
30 14467 BUSHING, ENGINE ADJ ISOLATOR 1
31 14468 SPACER, ENGINE ADJ CUP 1
32* 14714 SPROCKET, 10T DRIVEN 1
32** 15564 SPROCKET, 9T DRIVEN 1
33 14423 SCREW, M5 X 16 PHSM ZN 1
34 (This item is intentionally left blank.)
35 14716 DRIVER PULLEY 1
36 15552 PLATE, BACK - 5210 (WITH TABS) 1
36a 9101 BOLT 5/16-24 X .500 HHCS G5 NL Z (not shown) 2
37 14723 CAP, JACKSHAFT 2 IN 1
38* 15464 SPACER, TORQUE CONV. DRIVER 30 SERIES 1
38** 14838 WASHER, FLAT 0.75 X 1.050 X 0.115 HT ZN 1
39 14724 WASHER, 29.5 X 17MM X 3.0 1
15

5210 OWNERS MANUAL / ILLUSTRATED PARTS LIST 15362R1
illustrated parts lists
SECTION 4
5210 SECTION 8 REAR AXLE
Ref # Part # Description Qty
1 14627 CAP, HUB NOSE - BLACK 2
2 15541 COTTER PIN 3.2 X 40 2
3 14249 NUT, M16 X 1.5 CASTLE 2
4 15365 ASM, TIRE/WH RH - 18X9.5-8 1
4 15366 ASM, TIRE/WH LH - 18X9.5-8 1
4a 15487 TIRE, 18 X 9.5 - 8 FAR EAST “V” TREAD (not shown) 2
5 14434 BOLT, M8 X 1.25 X 16 FHCS ZN 10
6 14668 FLANGE BEARING - 150CC 2
7 14593 BEARING 6005Z 2
8 14669 MASTER LINK 1
9 14670 DISK, REAR BRAKE - 150CC 1
10 14671 SPACER, SPROCKET 1
11 14769 SCREW, SET M8 X 1.25 X 14 SHCS PL 1
12 14672 SPROCKET, 60 TOOTH 1
Ref # Part # Description Qty
13 14434 BOLT, M8 X 1.25 X 16 FHCS ZN 4
14 15488 AXLE - 5210 1
15 14724 WASHER, 29.5 X 17MM X 3.0 ZN 2
16 14675 CHAIN (#420 1/2” pitch) 1
17 14676 KEY, 5 X 5 X 75 1
16

4404 Engle Ridge Drive
Fort Wayne IN 46804
62194 Commercial Street
Roseland, LA 70456
Toll Free 800-643-7332
Fax [phone]
www.amsportworks.com