ILLUSTRATED PARTS LIST

Transcription

1 TW400 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 2 WHEEL DRIVE UTILITY VEHICLE ILLUSTRATED S LIST

2 illustrated parts list TW cc BODY b

3 illustrated parts list TW cc FRAME

4 illustrated parts list TW cc DRIVETRAIN 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 a

5 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 ( )

6 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 ( )

7 REFERENCE 1 Frame, CW Rear frame stub, CW - black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ Trail Wagon Wrap Around Front Bumper bolt, 5/16 x nut, 5/16 nylock bent washer 5/ Round Tubing Plug Brush Guard roof, CW black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ brshgrd seat back, CW black /16 x 2-1/4 USS Socket Head bolt nut, 5/16 nylock bent washer 5/ A-arm upper, CW black (left or right) suspension bushings 4 ea bolt, 3/ x.5 1 ea Bolt, 3/ x 3.25 bolt 1 ea DOM 3/ ID x ea Nylock Nut 3/ ea Bolt, 3/ x 2 ea Spacer, 3/ ID ea A-arm Lower, CW black (left or right) suspension bushings 4 ea bolt, 3/ x.5 1 ea Bolt, 3/ x 3.25 bolt 1 ea DOM 3/ ID x ea Nylock Nut 3/ ea Bolt, 3/ x 2 ea Spacer, 3/ ID ea spindle mount, CW black 2 9a Spindle, cw left black 1 9b Spindle, cw right black suspension bushings 2 ea DOM 3/ ID x ea Hub, 4 bolt high speed 1 Complete with Bearings & Seals Wheel stud,1/2-20 X 1 5/ bearing, 1 tapered seal DESCRIPTION castle nut, cotter pin Metal Dust Cap (Front Only) Rubber Dust Cap (Rear Only) Lug nuts, ½ Shock, Heavy duty, Black/Yellow (Before Serial #52767) Shock, Heavy duty, Black (After Serial #52767) QUANTITY REQUIRED

8 REFERENCE DESCRIPTION Bolt, 10 mm x 40mm Nut, 10mm nylock 12 15L Rim/Tire Assembly, Black, UTV 25/11-12 Left 1 15R Rim/Tire Assembly, Black, UTV 25/11-12 Right 1 17L Rim/Tire Assembly, Black, UTV 25/11-12 Left 1 17R Rim/Tire Assembly, Black, UTV 25/11-12 Right Rack & pinion with rod ends Rack & Pinion Boots 2 - N/A Rack & Pinion Rod Not available sold as assembly only ( ) Bolt, 5/16 x 3 ¾ USS Nut, 5/16 keps Nut, ½ SAE nylock Rod end (use before serial #27213) Rod end (use after serial #27214) Nut, ½ SAE jam Steering Shaft u-joints Bolt, 10mm x 30mm Nut, 10mm Tri Lock Jam Bolt, mm x 30mm Lock washer, mm Steering Stub Shaft Double Splined Steering support, LM 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 Washer, 5/16 x 1 ¼ Fender QUANTITY REQUIRED bolt, 5/16 x Lockwasher, 5/ Pivot Pedal Asm, Black Pedal cover, rubber bolt, 5/16 x bolt, ¼ x 1 ¾ bolt, 5/16 x 1 ½ Nut, 5/16 keps Washer, 5/16 flat Brake Rod, with clevis bolt, 3/ x 1 ¼ nut, 3/ nylock cotter pin 1/ x parking brake bar, CW black Clevis, 5/16 rod end Bolt, 5/16-24 X 4 SAE Nut, 5/16 Hex SAE bolt, ¼ x nut, ¼ nylock 1

9 REFERENCE DESCRIPTION Parking Brake Bolt, ¼ x 1 ¼ nut, ¼ nylock bolt, 5/16 x ¾ NC Nut, 5/16 keps Washer, 5/16 flat Brake equalizer, CW (2 ½ ) black bolt, 3/ x 1 ¼ nut, 3/ ny-lock Shifter control assembly, black (used on units built after ) Shifter Cable and Shifter Control (used on units built before ) Cable, shifter (used on units built after ) Knob, Shifter imprinted nut, #10-24 Keps nut screw, #10-24 X ¾ Pan Head Phillips Washer, #10 flat Differential Control assembly with cable and knob Knob, Differential imprinted Cable, Differential lock nut, #10-24 Keps nut screw, #10-24 X ¾ Pan Head phillips Washer, #10 flat Choke Cable Wire Harness Battery, U1L-HDJ7-UTV - 360CCA Battery Cable, Red Battery Cable, Black (24 ) Battery Terminal Cover bolt, ¼ x nut, ¼ keps Battery strap, CW ( ¾ ) black bolt, ¼ x 7 ½ nut, ¼ wing Headlight Switch Key Switch (keys not included) USED ON VEHICLES MANUFACTURED BEFORE SERIAL Key Key Switch (keys included) USED ON VEHICLES MANUFACTURED AFTER SERIAL Key set (includes 2 keys) USED ON VEHICLES MANUFACTURED AFTER SERIAL 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 LAST PAGE FOR HEADLIGHT INFORMATION QUANTITY REQUIRED Hood TW, Red 1 50b 1597 UTV Dash LM Black Push Pin Black Plastic ¼ x 2 Phillip Head Machine Screw nut, ¼ nylock Clamp-Tube-vinyl coated 1-1/4 2

10 REFERENCE DESCRIPTION QUANTITY REQUIRED Glove Box Screw, #10 x ¾ hex black Center Console Screw, #10 x ¾ hex black Access Cover, Center Console Screw, #10 x ¾ hex black Plastic, Seat Bottom wrap Screw, #10 x ¾ hex black Under seat storage box Rear Fender, Universal nut, ¼ nylock ¼ -20 X ¾ Carriage bolt ¼ SAE Flat washer Reflectors Fuel Tank, Flambeau (used on units BEFORE serial number 590) Fuel Tank, QMI (used on units AFTER serial number 590) Clamp, 3/ Spring Tube UTV, Fuel Line 3/16 black Elbow Fuel Inlet with #200 Mesh Screen 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 Seat back BLACK & GREY 43 ½ x 17 ½ Seat back BLACK 43 ½ x 17 ½ #14 X 1-3/4 Pan head-tapping screw Headrest BLACK & GREY 9 x 6 ½ Headrest BLACK 9 x 6 ½ bolt, ¼ x 1 ½ Seat bottom BLACK & GREY 43 ½ x 17 ½ Seat bottom BLACK 43 ½ x 17 ½ seat bar, CW (17 ½ ) black #14 x ¾ Pan Head Screw Seatbelt, retractable without sleeve Seatbelt plastic sleeve - 7 length /16 Nylock Dump Bed UTV Plastic / x 4 bolt Zinc plate / nylock Bed Rubber Plug Bed Bumper 3/ Rubber Bed latch bolt, 3/ x 2 1/ nut, 3/ keps washer, 3/ flat Dump Bed Tailgate UTV Plastic 1

11 REFERENCE DESCRIPTION rubber bump stops Roof, Black Textured Roof, Hardware bolt kit Clamp-Tube-vinyl coated 1-3/ bolt, 1/4 x Washer, ¼ rubber domed nut, 1/4 nylock Windshield - clear Fastener kit, windshield Front receiver hitch kit Engine, Honda 390cc /-16 x 1 3/4 Hex Hd Bolt / Flat washer, USS Dana Transaxle Neutral Safety Switch Shims Neutral Safety Switch QUANTITY REQUIRED Swing arm, CW - Black 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 CVTECH (used after Serial Number # 2565) (parts list on page 5) TC, Driven CVTECH (used after Serial Number # 2565) (parts list on page 6) Brake Shoes - Rear UTV Dana (kit includes 4 shoes to cover both rear wheels) Brake Drum Replacement #012WA /16 x 1/4 x 1-1/2 Keystock (for use with CV Tech driver pulley) Belt, CV TECH (used after Serial Number # 2565) /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) 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 / Flatwasher USS Rod End Sphcl-UTV (461-MPM-12) /4 Jam nut SAE Panhard bar, CW - black bolt, 3/ x / Nylock Nut / Flatwasher, USS /4 Spacer Washer /4 x 2.5 SAE bolt /4 SAE nylock 3

12 REFERENCE DESCRIPTION QUANTITY REQUIRED shifter lever, CW - black /4-20 x 3/4 Hex Hd Bolt /4 Keps Nut shifter cable mount, CW - black (used after Serial Number #15245) /4 Keps Nut /4 Flatwasher, USS Brake Cables /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 Differential Cable All 2WD models (before serial #2217) Differential Control Assembly with cable (all models after serial # 2217) Differential Control Cable Only (used on all models after serial # 2217) /4-20 x 1 Hex Hd Bolt /4 Keps Nut /16-1 x 1 1/2 Hex Hd Bolt /16 Keps Nut Knob, Differential Imprinted nut, #10-24 Keps nut screw, #10-24 X 3/4 Pan Head phillips Washer, #10 flat Spring #0704 Black painted Shifter Cable and Shifter Control - used before Serial Number # Cable, shifter - used after Serial Number # 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 Flat washer Choke Bracket Honda Engine 1 * 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.

13 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 Commercial Street Roseland, LA Toll Free Fax