American Sportworks Trail Wagon TW400 Owner's Manual page 23

troubleshooting
American SportWorks Utility Vehicle
Shifter Trouble Shooting
Notice: Always check transmission oil level . Dip a clean
screwdriver straight down in the fill hole to the bottom of
the gear case . There should be about 2 ½ inches of oil
on the screw diver . If oil needs to be added, use SAE 30
motor oil . See Page 19 for Instructions
• Engine will not turn over when key is turned to start .
– This vehicle is equipped with a safety switch that only
allows starting in neutral .
Go to Neutral switch diagnostic procedure.
• Gears grind when going into a gear or vehicle stays in
gear when shifted to neutral . – Cables need to be
lubricated or adjusted .
Go to Cable adjustment procedure.
Neutral switch diagnostic procedure
If starter does not engage when shift lever is in neutral:
1 . Apply the parking brake .
2 . Turn and hold the key to start . – "Jiggle" the shift lever
in the neutral slot . If the starter engages, release the
key and call American SportWorks Customer service to
order a neutral switch shim kit .
3 . If the starter did not engage in step 2, turn and hold the
key to start – slowly move the shift lever from neutral to
reverse – if the starter engages, release the key .
Repeat, moving the shift lever from neutral to forward .
• If the starter did engage, go to Cable
adjustment procedure section .
• If the starter did not engage call Customer
Service at 1-866-646-5278 .
Cable adjustment procedure
Stiff or sticking cables can cause the vehicle to not shift
properly and it may affect starting since the vehicle must
go to neutral to start . Before attempting to adjust the
cables there are several steps that can be taken to insure
the cables are operating properly .
• Lubricate the cables . Behind the dash board there are
two cables attached to the gear selector lever . Slide the
rubber dust caps up the cable . Drip or spray penetrating
oil into the cable housing while working the lever . Do
this several times as the oil soaks into the housing . Test
the vehicle . If this did not help move to the next step .
• Remove the center console (with cup holders) . Find the
shifter cables and cut the plastic ties that fasten them to
the frame tube . Over tight cable ties can cause the
SECTION 6
cable to bind . Replace cable ties but leave them loose
so that the cable can move in them . Test the vehicle . If
it is still not performing correctly, move to the adjustment
procedures that follow .
Vehicles with serial number less than 17063.
(See brass tag near top of left rear shock absorber)
1 . Loosen the cable adjusters behind the dash board .
(figure 6 .3)
2 . Place the selector lever on the dashboard in forward .
3 . Make sure the transmission is fully engaged in forward .
The top of the shift lever on the transmission should be
toward the passenger side . You may have to roll the
rear wheels a little until it clicks in .
4 . Pull the slack out of the forward most cable under the
dash (but do not stretch the spring) and tighten the
adjuster nuts or you can also use the adjuster nuts on
the cable bracket located on the transmission .
5 . Place the selector lever on the dashboard in reverse .
6 . Make sure the transmission is fully engaged in reverse .
The top of the shift lever on the transmission should be
toward the passenger side . You may have to roll the
rear wheels a little until it clicks in .
7 . Pull the slack out of the rear most cable under the dash
(but do not stretch the spring) and tighten the adjuster
nuts or you can also use the adjuster nuts on the cable
bracket located on the transmission .
If you have tried all of this and it is still not operating
correctly, you may need new cables and a shifter update
kit . Please call American SportWorks Customer Service at
1-866-646-5278 . Have your Model and Serial number
handy when you call .
figure 6 .3
20