American Sportworks 36V series Owner's manual

OWNER’S/OPERATOR’S MANUAL – 36V SERIES PART NUMBER 15293

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................... 1
MY VEHICLE IDENTIFICATION NUMBER............................................................................................. 3
AMERICAN SPORTWORKS LIMITED WARRANTY.............................................................. 3
BATTERY CHARGER LIMITED WARRANTY.........................................................................4
BATTERY LIMITED WARRANTY............................................................................................. 5
WARNINGS AND CAUTIONS.................................................................................................... 8
SOME WORDS ABOUT SAFETY............................................................................................. 17
SAFETY LABELS ......................................................................................................................17
QUALIFICATIONS FOR USERS............................................................................................... 19
VEHICLE CONTROLS AND OPERATION.............................................................................. 21
Controls and Features .......................................................................................................... 21
A. Throttle................................................................................................................................. 21
B. Brake....................................................................................................................................22
C. Parking Brake....................................................................................................................... 22
D. Lights...................................................................................................................................22
E. Power Outlet ........................................................................................................................ 22
F. Keyed Ignition Switch ......................................................................................................... 22
G. Rear View Mirror................................................................................................................. 22
H. Seat Adjustment ................................................................................................................... 22
I. Occupant Restraints............................................................................................................. 22
J. Under-seat Storage............................................................................................................... 23
K. Forward / Reverse Switch....................................................................................................23
L. Tool Holders......................................................................................................................... 24
M. Cargo Dump Bed –250lb MAX LOAD........................................................................... 25
N. Charge Gauge....................................................................................................................... 25
O. TAILGATE LATCHAND REMOVAL............................................................................... 25
P. BASIC RADIO OPERATION............................................................................................. 25
VEHICLE FEATURES AND LOCATIONS ............................................................................... 27
ARE YOU READY TO DRIVE? ................................................................................................ 28
Protective Apparel................................................................................................................ 28
Helmet and Eye Protection ..................................................................................................28
Additional Driving Gear ......................................................................................................28

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
Driver Training..................................................................................................................... 28
No Alcohol or Drugs............................................................................................................ 29
IS YOUR VEHICLE READY TO DRIVE?................................................................................30
Battery Charging.................................................................................................................. 30
Pre-Ride Inspection.............................................................................................................. 31
Starting Instructions............................................................................................................. 33
OPERATION - SAFE DRIVING PRECAUTIONS.................................................................... 33
UNIT SERVICE........................................................................................................................... 36
A. Front Wheel Replacement....................................................................................................36
A. Rear Wheel Replacement.....................................................................................................36
B. Front WheelAlignment (Ref Toe Adjustment Diagram)..................................................... 36
C. General Lubrication ............................................................................................................. 36
D. Cleaning Instructions ........................................................................................................... 37
E. Belt Adjustment ................................................................................................................... 37
F. Adjustment of Front and Rear Shock................................................................................... 38
G. Battery Watering .................................................................................................................. 38
H. Storage Instruction............................................................................................................... 40
I. Fuse Replacement................................................................................................................ 40
Fastener Torque Chart.................................................................................................................. 41
ACCESSORIES........................................................................................................................... 42
REPLACEMENT PARTS AND SERVICE................................................................................. 42
SPECIFICATIONS...................................................................................................................... 43
ELECTRICAL SCHEMATICS ................................................................................................... 45

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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 of 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 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 AMANUFACTURER 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.
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: L6KUA00__ __ __ __ __ __ __ __ __ __ Model: __ __36

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
BATTERY CHARGER LIMITED WARRANTY

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
BATTERY LIMITED WARRANTY

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
RESPONSIBLE BATTERY SAFETY AND DISPOSAL
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.

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293

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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 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 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 in 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
Safety DVD.
NOTE: Use of the word “NOTE” will alert you to key information or instructions.
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.
WARNING
Indicates a potential hazard which may result in personal injury or damage to the machine.
CAUTION

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
IMPORTANT SAFETY INFORMATION
Hydrogen gas is generated as a natural part of the lead acid battery charging process. A 4%
concentration of hydrogen gas is explosive and could cause severe injury or death. 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.
WARNING
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.
CAUTION
Always wear a safety shield or approved safety glasses when adding water or charging
batteries.
WARNING
Electrolyte spills should be neutralized with a solution of ¼ cup (60 ml) sodium bicarbonate
(baking soda) dissolved in 1-1/2 gallons (6 liters) of water and then flushed with water.
CAUTION
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.
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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.
CAUTION
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.
WARNING
NEVER adjust, repair, or clean the machine while it is in motion.
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.
WARNING
Vehicle modification or removal of original equipment or safety decals can render the machine
unsafe for operation.
WARNING
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
Safety decals must be replaced if they become unreadable or detached from the vehicle.
-
If decals are unreadable or missing, warning of potential hazards or safety requirements
may be lacking.
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 operated after mature, supervised instruction and sufficient practice
in an un-congested area.
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)
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.
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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 may
be extremely hot.
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.
WARNING
Keep guards in place at all times.
-
Prevent accidental contact by the operator or service personnel while 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.
WARNING
Be sure the passenger restraint system (i.e. Seat Belt) is properly adjusted and fastened at all
times during operation.
-
If 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.
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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.
WARNING
All screws, nuts, and bolts must be properly tightened to make sure the vehicle is in safe
operating condition.
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.
WARNING
Keep the motor free of dirt and debris, especially in the drive belt area.
WARNING
NEVER operate the vehicle without the operator and passengers properly seated and the
restraint system properly adjusted and secured.
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
NEVER power on the unit unless the throttle control is in its initial, fully returned, position.
WARNING
NEVER tamper with, alter, or change the vehicle motor governor settings.
-
The 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.
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.
WARNING
When turning on pavement, loose gravel, or similar surfaces, there is an increased risk in loss of
control. ** ALWAYS SLOW DOWN! **
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.
WARNING

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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.
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 may result in the motor continuing to run and result in loss of control.
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.
WARNING
Read and keep all supplied printed material.
-
Supplements to this Operator’s Manual contain updated information relative to your specific
vehicle model. It is important to keep all of these documents for reference.
WARNING
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.
CAUTION

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
When making repairs or adjustments to the vehicle, the batteries MUST be disconnected to
prevent accidental starting.
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.
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.
WARNING
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.
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.
CAUTION

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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.

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293

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OWNER’S/OPERATOR’S MANUAL – 200 SERIES PART NUMBER 15293
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.
1. 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. Prior to 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. That the throttle cable and linkages operate properly and the throttle cable or other linkages be adjusted properly
for gas engines;
c. That the steering linkage is adjusted and operates smoothly;
d. That the engine stop switch is properly functioning for gas powered models or the keyed ignition switch is
functioning properly for electric models;
e. That all guards originally supplied by the manufacturer are in proper place in serviceable condition;
f. That engine idle speed is below the point of clutch or torque converter engagement for gas models;
g. That the gas tank is in good condition and the proper gas cap is fastened securely for gas models;
h. That the braking system is functioning properly;
i. That all safety labels are in place, legible and understood;
j. 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. That tires are in good condition, inflated properly, and have sufficient tread remaining; and
l. That all fasteners are in place and tightened securely.
4. 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. Long hair, loose clothes, or jewelry can get caught in moving parts below the seat or surrounding environment.
Remove or tie back anything loose that can reach below or behind the seat before riding.
6. 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 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: