ILLUSTRATED PARTS LIST

Transcription

1 CW413 / TW413 WITH 390cc HONDA ENGINE amsportworks.com NOTE: Some part numbers vary by serial number. The serial number is located on a brass tag beneath the dump bed on the driver side. 390cc 4 WHEEL DRIVE UTILITY VEHICLE ILLUSTRATED S LIST

2 HEADLIGHT REPLACEMENT BULBS AND ASSEMBLIES FOR ASW UTILITY VEHICLES Bulb: p/n Bulb: p/n Bulb: p/n Bulb: Sealed housing no bulb available Assembly: p/n (5 1/4 oval) Assembly: p/n (4 3/ rectangle) Assembly: p/n 1564 (3 1/4 Round) Assembly: p/n 1476 (4 round) Amber reflector: p/n 1474 (2 1/4 Round) Light assembly: p/n (5 round) Bulb: p/n Light assembly: p/n (driver side) Light assembly: p/n (passenger side) Bulb: p/n Bulb: p/n Plastic insert: p/n Driver Side (inner bezel) (outer bezel) Plastic insert: p/n Passenger Side (inner bezel) (outer bezel) Measurements are taken from left to right of the visible portion of the lens Depending on your year of manufacture, this housing either has a push-in or twist-in bulb Twist-in Bulb: Sylvania 191 or equivalent Push-in Bulb: Sylvania 225 or equivalent 7625 DiSalle Boulevard Fort Wayne IN 4625 Toll Free Commercial Street Roseland, LA 70456

3 illustrated parts list CW413 / TW cc BODY

4 40 illustrated parts list CW413 / TW cc FRAME a a

5 115 For complete transaxle breakdown refer to the DANA manuals in the SERVICE MANUALS / ENGINE MANUALS / USER GUIDES section of the online manuals at amsportworks.com illustrated parts list CW413 / TW cc DRIVETRAIN a OR b

6 CVTECH DRIVER PULLEY I L L U S T R A T E D P A R T S L I S T This pulley is used on 277cc 2WD / 390cc 2WD / 479cc 4WD Ref# Part# Description Qty WASHER SPRING GUIDE SPRING SHIM EXTERNAL BUSHING INTERNAL SNAP RING CENTRIFUGAL MASS THIS IS ONLY AVAILABLE WITH THE ENTIRE ASSEMBLY ENTIRE ASSEMBLY ( )

7 CVTECH DRIVEN PULLEY I L L U S T R A T E D P A R T S L I S T This pulley is used on 277cc 2WD / 390cc 2WD Ref# Part# Description Qty WASHER CAM SHOE SPRING KEY EXTERNAL RETAINING RING DISASSEMBLY TOOL FLANGE SPREADER THIS IS ONLY AVAILABLE WITH THE ENTIRE ASSEMBLY ENTIRE ASSEMBLY ( )

8 REFERENCE DESCRIPTION 1 - Frame, CW413-4x Rear frame stub, CW - black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ Bumper, CW - black Bumper, Trail Wagon with grill guard - Black bolt, 5/16 x nut, 5/16 nylock bent washer 5/ Vinyl Caps 1 3/4 x 1 1/ Brush guard roof, CW - black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ Brush guard seat back, CW - black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ A-arm 4x4, CW black (left or right) suspension bushings 2 ea bolt, 5/ x 9 1/2 1 ea Nut, 5/ nylock 1 ea Spacer/CW A-arm bushing-4x Strut assembly, left Strut assembly, right Nut, 7/16 NF jam Nut, 3/ NF slotted cotter pin 1/ x 1 2 7a Lower ball joint strut bearing bolt, 5/16 x 3/4 NC Nut, 5/16 keps Hub / rotor 4x Wheel stud,1/2-20 X 1 5/ Nut, 5/ NF slotted cotter pin Metal Dust Cap (Front Only) Rubber Dust Cap (Rear Only) Lug nuts, 1/ Shock, Heavy duty, Black/Yellow (Before Serial #52767) Shock, Heavy duty, Black (After Serial #52767) Bolt, 10 mm x 40mm mm x 70mm bolt Nut, 10mm nylock spacer, shock 2 12L Rim/Tire Assembly, UTV 22/9-10 Left 1 12R Rim/Tire Assembly, UTV 22/9-10 Right Wheel rim, 10 x Tire, Pathfinder 22/9-10 QUANTITY REQUIRED

9 REFERENCE DESCRIPTION 13L Rim/Tire Assembly, UTV 22/11-10 Left 1 13R Rim/Tire Assembly, UTV 22/11-10 Right Wheel rim, 10 x Tire, Pathfinder 22/ CV half shaft (axle) (Left or Right) 2 14a > CV Boot (P/N fits 2.5 bell / fits 3 bell) QUANTITY REQUIRED Circlip, 24.5 x front differential 4x Hilliard Front Differential Replacement Oil oz bottle Mobile Fluid Bolt, 3/ x washer, 3/ flat washer, 3/ lock drive shaft, front (used before serial #3156) CV Front Drive Shaft (used after serial# 3156) bolt, ¼ x nut, ¼ keps bearing, shaft support (used before serial #3156) x4, Drive shaft bearing-pillow block style (used after serial # 3156) bolt, 5/16 x ¾ NC Nut, 5/16 keps drive shaft, rear telescoping (used before serial #3156) CV Rear Drive Shaft (used after serial# 3156) Screw, 3/ 16 x ½ square head set key, 3/16 x convoluted tubing 17 inch Rack & pinion with rod ends 4x Rack & Pinion Boots Bolt, 5/16 x 3 3/4 USS Nut, 5/16 keps Rod end 4x4 (used before serial # 2772) Rod end 4x4 (used after serial # 2773) Tie rod 4x Rack boot Steering Shaft w/u-joints 4x Bolt, 10mm x 30mm Nut, 10mm Tri Lock Jam Bolt, mm x 30mm Lock washer, mm Steering Stub Shaft Assembly, CW - Black Steering support, CW - black suspension bushings 2 ea bolt, 5/16 x Nut, 5/16 keps Steering Wheel (used for serial number 459 and above) Center cap (used for serial number 459 and above) Center cap (used for serial number 459 and below) Steering Wheel (used for serial number 459 and below) Steering Washer Bolt, 1/4 x ¾ SS Socket Head Nut, 1/4 nylock 6

10 REFERENCE DESCRIPTION QUANTITY REQUIRED Tapered Bolt Pivot Pedal Asm, Black Pedal cover, rubber bolt, 5/16 x bolt, 1/4 x 1 3/ bolt, 5/16 x 1 1/ Nut, 5/16 keps Washer, 5/16 flat master cylinder bolt, 5/16 x Nut, 5/16 keps Clevis, 5/16 rod end Nut, 5/16 Hex SAE brake caliper brake pads (2 pads required per wheel) brake pins brake clips Spacer Lock collar, 3/ bolt, 3/ x 1 1/ nut, 3/ keps caliper bracket Parking Brake Bolt, 1/4 x 1 1/ nut, 1/4 nylock bolt, 5/16 x 3/4 NC Nut, 5/16 keps Washer, 5/16 flat Brake spreader bolt, 5/16 x nut, 5/16 nylock Brake hose, front Brake hose, rear Shifter control assembly, black Knob Cable, shifter nut, #10-24 Keps nut screw, #10-24 X 3/4 Pan Head phillips Washer, #10 flat Differential Control Assy - 4x4 Diff Control w/ cable Knob cable, diff lock nut, #10-24 Keps nut screw, #10-24 X 3/4 Pan Head phillips Washer, #10 flat /4-20 x 1 Hex Hd Bolt /4 Keps Nut /16-1 x 1 1/2 Hex Hd Bolt /16 Keps Nut Choke Cable Wire Harness 1

11 REFERENCE DESCRIPTION Battery, U1L-HDJ7-UTV - 360CCA Battery Cable, Red Battery Cable, Black (27 ) Battery Terminal Cover bolt, 1/4 x nut, 1/4 keps nut, 1/4 keps Battery strap, CW ( 3/4 ) - black bolt, 1/4 x 7 1/ nut, 1/4 wing Light Switch / 4x4 switch Key Switch (keys not included) USED ON VEHICLES MANUFACTURED BEFORE SERIAL Key Accessory Plug Accessory Plug cap Terminal Block Cover - plastic screw, #10-24 X 1 Pan Head phillips nut, #10-24 Keps nut 2 47 SEE PAGE 2 FOR HEADLIGHT INFORMATION QUANTITY REQUIRED Switch Headlights Relay w/harness, 4x Hood, plastic - 4x4 (green) Hood, plastic - 4x4 (camo) Hood, plastic - 4x4 (red) /4 X 1 1/4 Pan phillips Machine screw /4 X 2 Pan phillips Machine screw /4 SAE Flat washer nut, 1/4 nylock Clamp-Tube-vinyl coated 1-1/ Glove Box Screw, #10 x 3/4 hex - black Steering Cover Screw, #10 x 3/4 hex - black Steering Cover Bottom Center Console 4x Screw, #10 x 3/4 hex - black Access Cover, Center Console Screw, #10 x 3/4 hex - black Plastic, Seat Bottom wrap 4x Screw, #10 x 3/4 hex - black Underseat storage box Rear Fender, Universal Reflectors /4-20 X 3/4 Carriage bolt /4 SAE Flat washer Fuel Tank, Flambeau (used on units AFTER serial number 590) Fuel Tank, QMI (used on units BEFORE serial number 590) Clamp, 3/ Spring Tube UTV, Fuel Line 3/16 black Elbow Fuel Inlet with #200 Mesh Screen 1

12 REFERENCE DESCRIPTION QUANTITY REQUIRED Fuel Fitting Grommet Fuel Tank Cap (used with Flambeau fuel tank) Fuel Tank Cap (used on units AFTER serial number 590 with QMI opaque fuel tank) Fuel Tank Straps Nut, 3/ Nylock Washer, 3/ Flat bolt, 5/16 x 3/4 NC Washer, 5/16 fender Washer, 5/16 lock Shaft guard bolt, 5/16 x 3/4 NC Nut, 5/16 keps Bolt, 5/16 x 3 3/4 USS tube, 1 14ga Seat back BLACK & GREY Seat back BLACK #14 X 1-3/4 Pan head-tapping screw Headrest BLACK & GREY Headrest BLACK bolt, 1/4 x 1 1/ Seat bottom BLACK & GREY Seat bottom BLACK seat bar, CW (17 1/2 ) - black #14 x 3/4 pan head tapping Seat Belt, 2pt /16 Nylock 4 70a Cargo Bed, Green Cargo Bed, Red Cargo Bed, Black Camo Bed Panel Left Camo Bed Panel Right Camo Bed Panel Tail Gate 1 70b Dump Bed UTV Plastic / x 4 bolt Zinc plate / nylock Bed latch bolt, 3/ x 2 1/ nut, 3/ keps washer, 3/ flat 2 75a Tail gate, green Tail gate, Red Tail gate, Black 1 75b Dump Bed Tailgate UTV Plastic bolt, 5/16 x washer, 5/16 sae nut, 5/16 nylock rubber bump stops Bed Bumper 3/ Rubber /4 Lynch Pin - tailgate latch Roof, green Roof, Red 1

13 REFERENCE DESCRIPTION Roof, Camo Roof, Top Vinyl Trim Roof, Hardware bolt kit Clamp-Tube-vinyl coated 1-3/ bolt, 1/4 x /4 SAE Flat washer nut, 1/4 nylock Washer, ¼ Rubber Domed Windshield - clear (for lo-rise hoods) Fastener kit, windshield QUANTITY REQUIRED Front receiver hitch 4x4 kit Bolt, 5/16 x 1-3/ - U Washer, 5/16 Flat Nut, 5/16 Nylock Engine, Honda 13hp /-16 x 1 3/4 Hex Hd Bolt / Flatwasher, USS Dana Transaxle 4x Swing arm, CW - Black 4x Motor Plate, CW - Black Throttle Guard Laser /4-20 x 1 1/4 Hex Hd Bolt /4-20 x 2 1/4 Hex Hd Bolt /4 Keps Nut /4 Flatwasher, USS TC, Driver Comet 500 (used before Serial Number #25663) TC, Driver CVTECH (used after Serial Number #25663) (parts list on page 6) TC, Driven Comet 500 (used before Serial Number #25663) TC, Driven CVTECH (used after Serial Number #25663) (parts list on page 7) Brake Shoes - Rear 4WD UTV Dana (1 set per wheel) 2 109b Brake Drum Replacement #012WA I.D. Spacer Washer Comet only (not used with CV Tech pulley) /16 x 1/4 x 1-1/2 Keystock (for use with CV Tech driver pulley) / I.D. Fender Washer Comet only (not used with CV Tech pulley) / Lock Washer Comet only (not used with CV Tech pulley) /x 3 Bolt Hex Hd NF Comet only (not used with CV Tech pulley) Belt, Comet (used before Serial Number # 25663) Belt, CV TECH (used after Serial Number # 25663) /2 x 2 SAE /2 Lock Washer /2 Uss Flat Washer /16 x 3/16 x 3-1/4 Keystock (for use with CV Tech driven pulley) /16 x 3/16 x 2-3/4 Keystock (for use with Comet driven pulley before serial number #25663) Tension Mount Engine, CW - Black /16x 3/4 Bolt Hex Hd NF /16 Lock Washer /16 Flatwasher Rubber Feet (Isolators)* SEE NOTE ON NEXT PAGE 4 120a Rubber Feet (Isolator)* SEE NOTE ON NEXT PAGE / Nylock Nut 10

14 REFERENCE DESCRIPTION QUANTITY REQUIRED / Flatwasher USS Rod End Sphcl-UTV (461-MPM-12) /4 Jam nut SAE Panhard bar, CW - black 4x bolt, 3/ x / Nylock Nut / Flatwasher, USS /4 Spacer Washer /4 x 2.5 SAE bolt /4 SAE nylock shifter lever, CW - black /4-20 x 3/4 Hex Hd Bolt /4 Keps Nut shifter cable mount, CW - black Parking Brake Cables 4x /16-1 x 1 Hex Hd Bolt /16 Nylock Nut Throttle Cable, UTV /4-20 x 1 Hex Hd Bolt /4 Keps Nut Spring #0704 Black painted Spring #0704 Black painted fuel hose 3/16 dia hose clamps - small Belt Guard Plastic UTV - Front Belt Guard Plastic UTV - Rear Belt Guard Plastic UTV - Bottom #10 x 3/4 Blunt Point Black #10 Speed Nut - for Plastic #10 Flatwasher Choke Bracket Honda Engine right angle gearbox Key, 3/16 x gearbox coupling Gear box bracket torque arm (long) used on units built before Gear box bracket (short) used on units built after rubber washer - used on units built before bolt, 5/16 x 3/4 NC Washer, 5/16 flat Washer, 5/16 lock Nut, 5/16 keps Bolt 7/16 x 1 3/4 - used on units built before Washer, 7/16 flat - used on units built before Nut, 7/16 nylock - used on units built before diff lock mount bolt, 5/16 x 3/4 NC Washer, 5/16 flat Washer, 5/16 lock 2 * On single cylinder models, quantity 5 of was replaced by quantity 4 of and 1 of on 6/1/2012. The 4 of the go under the engine and the 1 of the goes in the vertical mount. We do not recommend replacing only one bushing and that all four bushings should be replaced together.