Table of Contents
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UTILITY VEHICLE
O P E R A T O R ' S
S A F E T Y
M A N U A L
Gasoline, Gas/Electric Hybrid & Electric Utility Vehicles
Up to date Illustrated
This manual applies the following brands:
Parts Lists are now online at:
LANDmaster UTVs
amsportworks.com
BULLDOG UTVs
Trail Wagon UTVs
Chuck Wagon UTVs
15571R1 Rev. C
pub. 05/03/2016
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Table of Contents
Troubleshooting
Related Manuals for AMERICAN SPORTSWORKS Chuck Wagon
Summarization of Contents
Introduction
Terminology
Defines terms used in the operator's safety manual.
Getting Acquainted with Your Utility Vehicle
Overview of vehicle features, design, and capabilities.
Owner Assistance
Information on obtaining parts, service, and customer support.
Safety
Important Rules for Safe Operation
Key safety guidelines and warnings to read before operating the vehicle.
Assumption of Risk
Outlines operator's responsibility for potential hazards and risks.
Safety Warnings and Pre-Operation
Explains safety alert symbols, general warnings, and pre-operation checks.
Observe Following Instructions
Emphasizes reading the manual and decals for safe use and maintenance.
Safe Operating Procedures
Detailed guidelines for safe driving practices and vehicle operation.
Safe Operating Procedures Continued
Further details on safe driving practices, slopes, and vehicle handling.
Hybrid UTV Specific Warnings & Cautions
Specific safety notes and precautions for Gas/Electric Hybrid UTVs.
Before Initial Use
Precautions and checks required before the vehicle's first operation.
Battery Care and Storage
Guidelines for battery charging, storage, and washing procedures.
Before You Drive Checklist
Essential pre-operation checks covering tires, fuel, restraints, and controls.
While Operating This Vehicle
Critical safety instructions and warnings to follow during vehicle operation.
Assembly
Assembly Instructions
Overview of the vehicle assembly process, including unpacking components.
Uncrating and Unpacking Vehicle
Steps for safely removing the vehicle from its shipping crate.
Pre-Assembly Instructions
Initial steps before major assembly, including reading manuals and unpacking.
Seat and Brushguard Assembly
Instructions for installing the seat assembly and brushguard.
Bumper Installation
Step-by-step guide for attaching the front bumper to the vehicle frame.
Steering Wheel Installation
Procedure for correctly mounting the steering wheel onto the vehicle.
Cargo Bed Installation
Steps for attaching the cargo bed to the vehicle frame and securing it.
Rear Fender Installation
Instructions for mounting the rear fenders onto the vehicle bed.
Seat Installation
Procedure for installing the seat base and underseat storage tray.
Inspection
Pre-Ride Inspection
Importance of pre-drive checks for safety and vehicle readiness.
Vehicle Readiness Checks
Evaluating driver readiness, protective apparel, and training needs.
Driver Readiness and Protective Apparel
Guidance on driver preparedness, helmet, eye protection, and riding gear.
Operation
Responsible Operation and Rider Safety
Fundamental principles for operating the UTV safely and responsibly.
Qualifications for Utility Vehicle Users
Age and capability requirements for UTV operators and passengers.
Consumer Responsibility for Safe Use and Maintenance
Owner's duties regarding vehicle modification, operation, and maintenance.
Off-Road Use Only
Restrictions and guidelines for operating the UTV exclusively off-pavement.
Keep Hands and Feet on Controls
Emphasizes maintaining proper hand and foot placement on controls during operation.
Control Speed
Advice on selecting and maintaining safe operating speeds based on conditions.
Operation on Unfamiliar or Rough Terrain
Precautions for driving in challenging terrain and low visibility conditions.
Do Not Perform Stunts
Warning against dangerous maneuvers like jumps and wheelies.
No Alcohol or Drugs
Strict prohibition of operating the vehicle under the influence of substances.
Replacement Parts, Accessories, and Service
Information on obtaining replacement parts, accessories, and service options.
Periodic Checks & Services
Schedule and guidelines for routine maintenance tasks.
Gasoline Utility Vehicles
Operation specifics for gasoline-powered 2WD and 4WD UTVs.
General Operation
Basic procedures for starting, driving, and braking the vehicle.
4WD Models Operation
Specifics on operating four-wheel drive and differential lock features.
Electric Utility Vehicles
Operation specifics for electric 2WD UTVs, including LSV use.
Multi Function Stalk
Explanation of controls for headlights, turn signals, and horn.
Hybrid Utility Vehicles
Operation details for Gas/Electric Hybrid UTVs in different modes.
Maintenance
Vehicle Maintenance Overview
Introduction to routine maintenance procedures for the utility vehicle.
Differential Gear Box Maintenance
Procedures for changing oil in front, rear, and transfer gear boxes.
Gear Spacing Adjustment
Steps for adjusting the gear spacing on the front gear box.
Hydraulic Brakes
Maintenance and checks for the hydraulic braking system fluid level.
Fuel Type and Filling
Information on fuel capacity and safe practices for filling the fuel tank.
Engine Fuel Valve Lever
Operation and importance of the engine fuel shut-off valve.
Engine Maintenance
General guidance for engine servicing, oil levels, and recommendations.
Engine Oil Level Check
Procedure for checking the engine oil level using the dipstick.
Engine Oil Change
Detailed steps for draining and refilling the engine oil.
Transaxle Oil Maintenance
Procedures for checking and changing transaxle oil, including capacities.
Drive Belt
Information on inspecting, replacing, and maintaining the vehicle's drive belt.
Cable Lubrication
Instructions on lubricating stiff or sticking control cables.
Cleaning the Windshield
Guidelines for safely cleaning the vehicle's windshield.
Electric or Hybrid Vehicles Maintenance
Special care and attention required for electric and hybrid vehicle maintenance.
Battery Charging and Watering
Procedures for charging batteries and adding water to flooded batteries.
Battery Disposal
Proper procedures for safely disposing of and recycling lead-acid batteries.
Transaxle Oil for Electric/Hybrid
Specific transaxle oil type and maintenance for electric/hybrid models.
Mode Switch
Explanation of the mode switch for parental speed control.
Fuses
Location and replacement guidelines for the vehicle's fuses.
Wiring of Tail Lights
Instructions for connecting the tail light wiring harness.
Troubleshooting
Troubleshooting Symptoms and Remedies
Common vehicle issues categorized by symptom with suggested solutions.
Fuel in the Cylinder Cavity
Procedure for safely clearing excess fuel from the engine cylinder.
Cable Adjustment Procedure
Steps for lubricating and adjusting shifter cables for proper operation.
Shifter Trouble Shooting
Diagnostic procedures for gear shifting and neutral switch issues.
Diagrams
Kohler 277cc Wiring Diagram
Electrical wiring schematic for Kohler 277cc engines.
Honda 390cc Wiring Diagram
Electrical wiring schematic for Honda 390cc engines.
Subaru 265cc Wiring Diagram
Electrical wiring schematic for Subaru 265cc engines.
Subaru 653cc Wiring Diagram
Electrical wiring schematic for Subaru 653cc engines.
Vanguard 479cc Wiring Diagram
Electrical wiring schematic for Vanguard 479cc engines.
48 Volt DC Motor Control & Terminal Block Wiring
Detailed wiring diagrams for electric motor control and terminal blocks.
48 Volt 2WD Wiring Harness Diagram
Wiring schematic for the 48V 2WD vehicle wiring harness.
Wiring Diagram Gas / Electric Hybrid
Electrical schematic illustrating the wiring for gas/electric hybrid models.
Wiring Diagram Terminal Blocks
Diagrams showing terminal block connections for various gasoline and electric models.
Warranty
Limited Warranty Overview
General terms, conditions, and duration of the limited warranty.
Warranty Claims and Exclusions
Procedures for claims, responsibilities, and items excluded from warranty.
Implied Warranties and Service
Legal disclaimers on implied warranties and how to obtain service.
Service and Warranty Contact Information
Contact details for dealers and American SportWorks for support.
Utility Vehicle Set-Up / Pre-Delivery Checklist
Comprehensive checklist for vehicle setup and pre-delivery inspections.
Dealer Set-Up Items
Specific inspection points for dealers during vehicle setup.
Pre-Delivery Checks
Key checks to perform on the vehicle before customer delivery.
Customer Checklist
Items for the customer to verify regarding vehicle condition and documentation.
Pre-Drive Inspection Checklist
Detailed checklist for performing daily pre-drive inspections.
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