American Sportworks CW-413 Operator's Manual
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American Sportworks CW-413 Operator's Manual

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Utility Vehicle Operators Manual
6/2008

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March 14, 2025

Where can I find a front drive shaft for my 650cc trail wagon???

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Summary of Contents for American Sportworks CW-413

  • Page 1 Utility Vehicle Operators Manual 6/2008...
  • Page 2 INDEX Introduction pages 3-4 Serial Number Plate Location page 4 Safety pages 5-10 Pre-Delivery Steps page 9 Dealer Inspection Checklist page 10 Assembly Instructions pages 11-13 Seat Back, Brush guard, Bumper page 12 Steering wheel page 12 Cargo Bed page 13 Seat Base page 13 Operating Instructions...

  • Page 3: Safety First

    Terminology Safety First Right-hand and left-hand as used in this manual are American SportWorks is fully aware of the need for safe determined by facing the direction the vehicle will travel operating procedures around all of our equipment. We while in use unless otherwise stated.
  • Page 4 This Your American SportWorks dealer wants you to be information is necessary to provide you with quality satisfied with your new vehicle. If you do not understand customer service.
  • Page 5 Read These Important Rules for Safe Operation Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained within this owners/operators manual before operating utility vehicle. Failure to follow these instructions could endanger the personal safety of the Operator, Passenger and any Bystanders. Close adult supervision is required at all times! Pay close attention to all Caution and Warning labels Located on the Utility Vehicle...
  • Page 6 Safety It is very important to read, understand, and follow all instructions and warnings located on the decals on your Utility Vehicle. Rear Seat Weight Limit is 300lbs...

  • Page 7: Safe Operating Procedures

    * Some conditions may warrant extra safety gear to be Safety worn such as safety helmets and/or goggles. Safe Operating Procedures * Keep hands, arms, feet and all bodily appendages safely inside the confines of the vehicle. The safe operation of any machinery is a big concern to all consumers.
  • Page 8 * Do not exceed 400 lbs. in cargo bed area (NOTE: * Avoid changing direction or making sharp steering 300lbs with rear seat kit installed), or 900 lbs. total on corrections on slopes or rollover may occur. this vehicle. * If this vehicle begins to tip when crossing a slope, turn * Do not mount a receiver hitch type carrier platform to the front wheels downhill to regain stability and control.

  • Page 9: Vehicle Information

    Warranty Registration does not go to the floor. that is to be submitted to American SportWorks upon Retail Sale. The Pre-Delivery Certificate and Warranty __ Make sure seats and seat belts are properly fastened Registration must be submitted to American SportWorks to the frame.

  • Page 10: Important Notice

    __ Engine Manual has been delivered to and reviewed by the customer. __Warranty Policy limits and requirements have been explained to the customer. American SportWorks LLC Toll Free PH: 1-866-646-5278 __ Location and functions of vehicle controls have been explained.

  • Page 11: Assembly Instructions

    Assembly Instructions Utility Vehicle Assembly Instructions Your new Utility Vehicle Utility vehicle should include the following items to be assembled: Item Item #8 black screw (steering cap) 5/8” x 4” Hex bolt ¼” x 1 ¾” Hex head bolts 5/8” nylock nuts ¼”...
  • Page 12 2) Unpack all vehicle and assembly parts. Make sure you have everything listed on the previous page. 3) If you have any questions or problems with your American SportWorks LLC product please call us, toll free 1-866-646-5278. Bumper Installation 1) Align the holes in the front bumper with the mounting holes in the front frame tubes.
  • Page 13 Cargo Bed Installation Locate rear frame stubs at the rear of frame. The bed pivot tube on the stub should be at the top. Insert 5/16” x 2” socket head bolt. Loosely install 5/16” center lock nut (do not tighten until after cargo bed is installed) Fenders installation (if Equipped, no fenders on TW265) Tilt the cargo bed up.
  • Page 14 Operating Instructions Pre-Start Check List Check tire pressure as indicated. __ Make sure wheel lug bolts/nuts are tightened to 65ft. General Operation lbs. Start your Utility Vehicle by following the starting __ All nuts, bolts, screws, and fasteners should be procedures as noted below.

  • Page 15: Engine Maintenance

    Maintenance Fuel Type Engine Fuel Valve Lever The fuel tank is located under seat. Refer to Figure 5-1 TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. The engine fuel valve opens and closes the passage between the fuel tank and carburetor. Leave fuel valve CW-265 &...
  • Page 16 Before installing the filter elements to make sure they have not been damaged during cleaning. Never run an engine without the filters installed. Maintenance Engine Oil A general description for engine oil maintenance, recommendations, and capacities is provided below. See Engine Operator’s Manual for a detailed description. Note: Running engine low on oil can cause engine damage and void engine warranty.
  • Page 17 4. Fill to edge of oil fill hole with recommended oil when oil levels are low. 5. Replace filler cap/dipstick and tighten securely. Engine Oil Change Maintenance Warms oil drains quickly and completely. Therefore, drain used engine oil while engine is still warm as follows: Transaxle Oil 1.
  • Page 18 3. “Walk” the belt off of the rear pulley as shown in Figure 5-6. Transaxle Oil Change Warm oil drains quickly and completely. Therefore, drain used transaxle oil while transaxle housing is still warm as follows: 1. Park vehicle on a level surface, set park brake, turn off ignition switch, and remove switch key.
  • Page 19 Fuel in the Cylinder Cavity In the event that the fuel valve is left open while transporting or towing this Utility Vehicle it is possible that fuel has leaked down into the cylinder cavity. If this has occurred the engine will not start. With the cylinder cavity full of fuel the engine will feel like it has “locked up”.
  • Page 20 Supplement: 4x4 Utility Vehicles CW-413, TW-413 Because the power transfer is automatic, you may This supplement covers the additional features, operate the vehicle in 4WD mode continuously without operation and maintenance of the 4x4 Utility Vehicles affecting steering effort or tire wear.
  • Page 21 6. Add 150 ml. (5 oz.) of Mobil fluid 424 4. Remove the oil fill plug using a ¼” hex key American SportWorks part # 20848 (note: do wrench. not use any other type of oil in this system 5.
  • Page 22 48 Volt Utility Vehicle OWNERS MANUAL Supplement Do NOT let metal objects fall from the seat onto the top of your batteries. This may cause a serious power short and possibly a fire.
  • Page 24 Battery Prolonged Storage All batteries will self-discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below - 75°...
  • Page 25 It is acceptable to wash your electric utility vehicle, though a pressure washer should not be used, and common sense should be exercised. Remember that some of the electronics in the controller and charging system are sensitive to water and corrosion. The charger should be protected during washing by placing a plastic bag or other protection over the top of the charger before washing.

  • Page 26: Battery Charging

    Battery Charging • Your charger is equipped with a flooded / gel charge mode switch, set switch to FLOODED mode. • Plug the AC cord into a grounded outlet. If an extension cord is used, a heavy duty cord of no more than 25 feet must be used.
  • Page 27 BATTERY WATERING Flooded batteries need water. More importantly, watering must be done at the right time and in the right amount or else the battery's performance and longevity suffers. Water should always be added after fully charging the battery. Prior to charging, there should be enough water to cover the plates.
  • Page 28 Mode Switch Your 48V UTV is equipped with a mode switch. These two modes allow for parental control of the speed of the vehicle. The switch is located on the left side of the vehicle, under the bed. The fast mode will allow speeds up to 18 mph. The slower mode will allow speeds up to 10 mph.
  • Page 29 SAE 30W oil is used in the transaxle.. Oil should be changed after one year of normal use, and every other year after. To change the oil, a vacuum device may be used to remove the old fluid. To fill, fresh oil should be added up to the level of the plug.
  • Page 30 Fuses Your 48V Vehicle has fused protection for the main motor circuit, along with the low amperage 48 volt circuit, and the 12 volt circuit. Pictured below is the 500 amp main fuse. This fuse will blow in the event of a short across the battery posts, or a catasatrophic failure in the motor or controller.
  • Page 31 In addition to the main fuse, there are three smaller fuses to protect the 12volt and 48 volt circuits. These fuses are illustrated below. Should these fuses blow and need replacement, a replacement fuse of the same rating must be used. Under Hood Under Bed Left Side...
  • Page 32 Forward / Reverse Switch Located on the dash, the forward/reverse switch selects the direction of the vehicle. The operator must select the proper switch position before applying the throttle.
  • Page 33 Before depressing the accelerator pedal, operator must be certain of the position of the forward / reverse switch. Unexpected movement will result if the switch is inadvertently in the incorrect position. Wiring Diagram next page. Please note that not all circuits illustrated are included on all models. Please disregard circuits that do not apply to your application.

  • Page 35: Owners Manual

    650cc Utility Vehicle OWNERS MANUAL Supplement This vehicle is capable of reaching speeds in excess of 25mph. Use caution when turning to avoid vehicle rollover. Improper operation of this vehicle may cause serious injury or death. Maintaining safe performance depends to a large extent on the operator.
  • Page 36 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.
  • Page 37 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.
  • Page 38 5. Pull the slack out of both cables (but do not stretch the springs) and tighten the adjuster nuts. If you have tried all of this and it is still not operating correctly, you may need new cables. Please call American SportWorks Customer Service at 1-866-646-5278. Have your serial number handy when you call.
  • Page 39 Troubleshooting...

  • Page 40: Trouble Shooting

    Trouble Shooting Steering feels funny/pulling to one side/hard to steer (Call normally for 4wd) Probable Cause: • One side may still be engaged in 4wd with the switch off. Possible Remedy: • Put unit in reverse and back up straight a few feet to get the axle to release. •...
  • Page 41 Gas in oil Probable Cause • Unit may have been transported with fuel valve on. Every time a unit is transported on a trailer or in a truck the fuel must be shut off using the shut off valve on the side of the engine. Leaving this valve open during transport could allow fuel to be deposited into the crank case locking the engine up.
  • Page 42 Wiring Diagram HONDA Engine Models...
  • Page 43 Wiring Diagram SUBARU Engine Models...
  • Page 44 Terminal Block Wiring...
  • Page 45 2 Wheel Drive Dana Transaxle Parts Breakdown...
  • Page 46 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 47 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 49 265cc CW265 & TW265 Utility Vehicle Parts Breakdown...
  • Page 50 Body 265cc Models...
  • Page 51 Frame 265cc Models...
  • Page 52 Drive Train 265cc Models...
  • Page 53 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 45419 Frame, CW11 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 54 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 30623 dust cap 30622 castle nut, 1” 30621 cotter pin 50060 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30142 Rim/Tire Assembly, UTV 22/11-8”...
  • Page 55 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake bar, CW – black 50806 Clevis, 5/16 rod end 50170...
  • Page 56 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 18500 Terminal Block Cover – plastic 50625 screw, #10-24 X 1” Pan Head Phillips 50053 nut, #10-24 Keps nut 70129 Headlights CW265 – oval 70133 Headlights TW265 – rectangular 70055 Switch Headlights 18302...
  • Page 57 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 45420 Cargo Bed, Red CW265 45434 Flat Cargo Bed, Black - TW265 50255 5/8 x 4” bolt Zinc plate 50015 5/8 nylock 18402 Bed Rubber Plug 50208 Bed latch bolt, 3/8 x 2 1/2" 50013 nut, 3/8 keps 50740...
  • Page 58 Reference Part Quantity Part Description - 265cc 2WD Models Number Number Required 50021 3/4 Jam nut SAE 45403 Panhard bar, CW - black 50206 bolt, 3/8 x 1 50010 3/8" Nylock Nut 50740 3/8" Flatwasher, USS 50730 3/4' Spacer Washer 50280 3/4 x 2.5 SAE bolt 50020...
  • Page 59 340cc CW11, TW11, &TW11R Utility Vehicle Parts Breakdown...
  • Page 60 Body 340cc Models...
  • Page 61 Frame 340cc Models...
  • Page 62 Drive Train 340cc Models...
  • Page 63 Reference Part Quantity Part Description - 2WD Models Number Number Required 45419 Frame, CW11 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 64 Reference Part Quantity Part Description – 2WD Models Number Number Required 50060 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30122 Rim/Tire Assembly, UTV 22/9-10” Left 30123 Rim/Tire Assembly, UTV 22/9-10” Right 30480 Wheel rim, 10”...
  • Page 65 Reference Part Quantity Part Description – 2WD Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake bar, CW – black 50806 Clevis, 5/16 rod end 50170 Bolt, 5/16”-24 X 4”...
  • Page 66 Reference Part Quantity Part Description – 2WD Models Number Number Required 45414 Battery strap, CW (8 ¾”) – black 50083 bolt, ¼ x 7 ½ 50002 nut, ¼” wing 70055 Light Switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081 Accessory Plug cap...
  • Page 67 Reference Part Quantity Part Description – 2WD Models Number Number Required 55060 Fuel Tank 55063 Elbow Fuel Inlet w/ #200 Mesh Screen 55062 Fuel Fitting Grommet 55061 Cap Fuel Tank 50163 bolt, 5/16 x 3/4" NC 50706 Washer, 5/16 fender 50703 Washer, 5/16 lock 10754...
  • Page 68 Reference Part Quantity Part Description - 2WD Models Number Number Required 18312 Roof, green 18301 Roof, Red 18351 Roof, Camo 18391 Roof, Top Vinyl Trim 18390 Roof, Hardware bolt kit 50847 Clamp-Tube-vinyl coated 1-3/4" 50087 bolt, 1/4" x 1 50718 Washer, ¼”...
  • Page 69 Reference Part Quantity Part Description - 2WD Models Number Number Required 50722 1/2" Lock Washer 50721 1/2" Uss Flat Washer 10186 Key stock – Special Key – 3/16” X 1/4” X 31/2” 45431 Tension Mount Engine, CW - Black 50157 5/16x 3/4"...
  • Page 70 Reference Part Quantity Part Description - 2WD Models Number Number Required 11086 Differential Control Assembly w/ cable all models after serial # 22187 11083 Knob 11091 Differential Control Cable Only used on all models after serial # 22187 50053 nut, #10-24 Keps nut 50616 screw, #10-24 X 3/4"...
  • Page 71 4 Wheel Drive Dana Transaxle Parts Breakdown...
  • Page 72 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 73 Please contact our Customer Service Department (866-646-5278) To special order DANA Transaxle Parts...
  • Page 75 390cc CW413 & TW413 4-wheel drive Utility Vehicle Parts Breakdown...
  • Page 76 Body 390cc Models...
  • Page 77 frame 390cc Models...
  • Page 78 Drive Train 390cc Models...
  • Page 79 Reference Part Quantity Part Description – 4x4models Number Number Required 45501 Frame, CW413 - 4x4 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 Bumper, CW - black 45433 Bumper, Trail Wagon –...
  • Page 80 Reference Part Quantity Part Description – 4x4models Number Number Required 20851 CV half shaft (axle) – (Left or Right) 20868 Boot CV 20839 front differential – 4x4 20848 Hilliard Front Differential Replacement Oil “8oz bottle Mobile Fluid 424” 50206 Bolt, 3/8 x 1 50740 washer, 3/8 flat 50741...
  • Page 81 Reference Part Quantity Part Description – 4x4models Number Number Required 11123 master cylinder 50167 bolt, 5/16 x 2 50005 Nut, 5/16 keps 50806 Clevis, 5/16 rod end 50077 Nut, 5/16" Hex SAE 11124 brake caliper 11167 brake pads (2 pads required per wheel) 11168 brake pins 11169...
  • Page 82 Reference Part Quantity Part Description – 4x4models Number Number Required 45414 Battery strap, CW (8 3/4") - black 50083 bolt, 1/4 x 7 1/2 50002 nut, 1/4" wing 70055 Light Switch / 4x4 switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081...
  • Page 83 Reference Part Quantity Part Description – 4x4models Number Number Required 10754 Seatback 43 1/2 x 17 1/2 50619 #14 X 1-3/4" Pan head-Tapping screw 10803 Headrest - UTV 9 x 6 1/2 50085 bolt, 1/4 x 1 1/2" 10755 Seat bottom 43 1/2 x 17 1/2 45416 seat bar, CW (17 1/2") - black 50609...
  • Page 84 Reference Part Quantity Part Description – 4x4models Number Number Required 45502 Swing arm, CW - Black 4x4 45430 Motor Plate, CW - Black 18023 Throttle Guard Laser 50086 1/4-20 x 1 1/4" Hex Hd Bolt 50082 1/4-20 x 2 1/4" Hex Hd Bolt 50000 1/4"...
  • Page 85 Reference Part Quantity Part Description – 4x4models Number Number Required 11804 Spring #80704 Black painted 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18313 Belt Guard Plastic UTV - Front 18314 Belt Guard Plastic UTV - Rear 18315 Belt Guard Plastic UTV - Bottom 50624...
  • Page 89 Models CW-650 & TW-650 Parts List Reference Part Quantity Part Description 650cc Models Number Number Required Pending Frame, - CW650 4x4 45401 Rear frame stub, CW - black 50206 bolt, 3/8 x 1 50013 nut, 3/8 keps 45413 bumper, CW - black 50167 bolt, 5/16 x 2 50007...
  • Page 90 Pending UTV 25/11-12 Tire only 30146 Rim/Tire Assembly, UTV 25/11-12" Left 30147 Rim/Tire Assembly, UTV 25/11-12" Right Pending Wheel rim, 12" Pending UTV 25/11-12 Tire only 20851 CV half shaft (axle) front differential - 4x4 20839 50206 Bolt, 3/8 x 1 50740 washer, 3/8 flat 50741...
  • Page 91 50806 Clevis, 5/16 rod end 50077 Nut, 5/16" Hex SAE 11124 brake caliper 11167 brake pads 11168 brake pins 11169 brake clips Spacer Lock collar, 3/8 50826 50217 bolt, 3/8 x 1 1/2 50013 nut, 3/8 keps 18030 caliper bracket 11127 Parking Brake 50086...
  • Page 92 70080 Accessory Plug 70081 Accessory Plug cap 18500 Terminal Block Cover - plastic 50625 screw, #10-24 X 1" Pan Head phillips 50053 nut, #10-24 Keps nut 70129 Headlights Relay w/harness, 4x4 70019 18380 Hood, plastic - 4x4 (green) 50620 1/4" X 1 1/4" Pan phillips Machine screw 50621 1/4"...
  • Page 93 50152 bolt, 5/16 x 1 50701 washer, 5/16 sae 50007 nut, 5/16 nylock 70230 rubber bump stops 50815 1/4" Lynch Pin - tailgate latch 18312 Roof, green Clamp-Tube-vinyl coated 1-1/4" 50846 50087 bolt, 1/4" x 1 50717 1/4" SAE Flat washer 50001 nut, 1/4"...
  • Page 94 18011 shifter cable mount, CW - black 11104 Parking Brake Cables 4x4 50150 5/16-18 x 1" Hex Hd Bolt 50007 5/16" Nylock Nut 11010 Throttle Cable, UTV 50087 1/4-20 x 1" Hex Hd Bolt 1/4" Keps Nut 50000 11804 Spring #80704 Black painted 11804 Spring #80704 Black painted 65500...
  • Page 98 Reference Part Quantity Part Description – 48V Models Number Number Required XXXXXX Frame, CW48V 45401 Rear frame stub, CW - black 50168 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon –...
  • Page 99 50060 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30148 Rim/Tire Assembly, UTV 22/11-10” Left 30148 Rim/Tire Assembly, UTV 22/11-10” Right XXXXXX Wheel rim, 10” x 6” XXXXXX Tire, Terra Trac 30148 Rim/Tire Assembly, UTV 22/11-10”...
  • Page 100 Reference Part Quantity Part Description – 48V Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake bar, CW – black 50806 Clevis, 5/16 rod end 50170 Bolt, 5/16”-24 X 4”...
  • Page 101 70080 Accessory Plug 70081 Accessory Plug cap 18500 Terminal Block Cover – plastic 50625 screw, #10-24 X 1” Pan Head Phillips 50053 nut, #10-24 Keps nut 70129 Headlights 70055 Switch Headlights 18311 Hood, plastic Green 18302 Hood, plastic Red 18350 Hood, plastic Camo 50620 ¼”...
  • Page 102 50609 #14 x ¾ Pan Head Screw 8778 Seat Belt, 3pt 50025 7/16 Nylock 45426 Cargo Bed, Green 45420 Cargo Bed, Red 45424 Cargo Bed, Black 18352 Camo Bed Panel Left 18353 Camo Bed Panel Right 18354 Camo Bed Panel Tail Gate 50255 5/8 x 4”...
  • Page 103 Reference Part Quantity Part Description – 48V Models Number Number Required 18312 Roof, green 18301 Roof, Red 18351 Roof, Camo 18391 Roof, Top Vinyl Trim 18390 Roof, Hardware bolt kit 50847 Clamp-Tube-vinyl coated 1-3/4" 50087 bolt, 1/4" x 1 50718 Washer, ¼”...
  • Page 104 50087 1/4-20 x 1" Hex Hd Bolt 50000 1/4" Keps Nut...

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