200 series lutv illustrated parts manual - American Sportworksamsportworks.com/pdfs/LUTV/14855R3.pdf · 7/18/13 illustrated parts manual - 200 series lutv part number 14855r3 200

200 SERIES LUTV ILLUSTRATED PARTS MANUAL14855R3

7/18/13 ILLUSTRATED PARTS MANUAL - 200 Series LUTV PART NUMBER 14855R3

200 SERIES LUTV SECTION 1 CYLINDER HEAD ASSEMBLY

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Ref# Part# Description Qty1 14254 HEAD,CYLINDER-150CC 12 50304 SPARKPLUG(CR7HSA) 13 14255 GASKET,CYLHEAD-150CC 14 14256 GASKET,CARBINSULATOR-150CC 15 14257 INSULATOR,CARB-150CC 16 14258 MANIFOLD,INTAKE-150CC 17 14259 CLAMP,CARBHOSE-150CC 18 14260 GASKET,VALVECOVER-150CC 19 14261 O-RING,M27X2RUBBER-150CC 110 14262 TUBE,BREATHER-150CC 111 14263 STUD,M6X1.25X18 212 14264 STUD,M6X1.25X50 2

Ref# Part# Description Qty13 50003 BOLT,M6x1.00x25HHF 414 50024 NUT,M6x1.00HEXFLANGE 215 14265 COVER,VALVE-150CC 116 14266 PIN,M10X16DOWEL 217 50087 BOLTFLANGESH6X100 218 14267 VALVE,INTAKE-150CC 119 14268 SEAL,VALVESTEM-150CC 220 14269 SEAT,VALVESPRINGOUTER-150CC 221 14270 SPRING,OUTERANDINNERVALVE-150CC 222 14271 RETAINER,VALVESPRING-150CC 223 14272 KEEPER,VALVESPRING-150CC 424 14273 VALVE,EXHAUST-150CC 1


Ref # Part # Description Qty1 14317 CYLINDER-150CC 12 14582 GASKET,CYLINDERBASE-150CC 13 50032 BOLTFLANGESH6X22 24 14266 PIN,M10X16DOWEL 25 14276 TENSIONER,CAMCHAIN-150CC 16 14275 GASKET,CAMCHAINTENSIONER-150CC 17 14274 ASM,CAMCHAINTENSIONER-150CC 1

200 SERIES LUTV SECTION 2 CYLINDER


200 SERIES LUTV SECTION 3 ENGINE CRANKCASE

Ref# Part# Description Qty1 14277 HOUSING,CRANKCASERH-150CC 12 14278 BUSHING,ENGINEHANGER-150CC 23 14279 GASKET,CRANKCASE-150CC 14 14280 HOUSING,CRANKCASELH-150CC 15 14558 GROMMET 16 14281 BOLT,M10X1.25X15FHCSZN 17 14282 WASHER,M10.2X18X1.3FLAT 18 14283 COVER,SMALLLEFT-150CC 19 14284 O-RING,M108X2 110 14559 PIN 111 14285 O-RING,M6X1.8 212 50104 OILSEAL19.8X30X5 113 14286 BOLT,M6X1.00X18FHCSZN 4

Ref# Part# Description Qty14 14287 PIN,M10X14DOWEL 215 14288 BOLT,M12X1.5SPECIAL-150CC 116 14690 WASHER,M12DAC 217 14290 SEAL,M20X32X6 218 14883 GUIDE,CAMCHAIN-150CC 119 50016 PINDOWELSPECIAL8X14 220 14291 STUD,M8X1.25X195.5 221 14292 STUD,M8X1.25X187.5 222 14293 WASHER,M8FLATZN 423 14294 NUT,M8X1.25FLANGEHEAD 424 14295 BOLT,M6X1.00X50FHCSZN 225 14501 SPACER,OIL-150CC 126 14296 BOLT,M6X1.00X12FHCSZN 2


200 SERIES LUTV SECTION 4 TRANSMISSION

Ref# Part# Description Qty1 14297 HOUSING,OUTERTRANSMISSION-150CC 12 14298 GEAR,PRIDRIVE-150CC 13 14299 GEAR,SECDRIVE-150CC 14 14300 ASM,SHIFTGEARCLUSTERD/N/R-150CC 15 14841 GEAR,FINALDRIVESHAFT-150CC 16 14302 ASM,SHIFTSELECTOR-150CC 17 14303 PAWL,SHIFTSELECTOR-150CC 18 14304 ROD,SHIFTPAWL-150CC 19 14305 SHAFT,SHIFTERCAM-150CC 110 14306 GASKET,TRANSMISSIONCASE-150CC 111 14307 TUBE,TRANSMISSIONVENT-150CC 112 14308 NIPPLE,VENTTUBE-150CCLARGE 113 14309 BALL,SHIFTINDENT-150CC 114 14310 SPRING,SHIFTINDENT-150CC 115 14311 GASKET,SHIFTINDENT-150CC 116 14312 BOLT,SHIFTINDENT-150CC 117 14502 NIPPLE,VENTTUBE-150CCSMALL 118 14313 BOLT,DRAIN/FILLPLUG-150CC 219 14314 GASKET,TRANSDRAINPLUG-150CC 2

Ref# Part# Description Qty20 14296 BOLT,M6X1.00X12FHCSZN 221 14315 WASHER,M6FLAT 222 14287 PIN,M10X14DOWEL 223 14316 SPACER,M15INNERGEAR-150CC 124 14149 BEARING,OUTER-6202-Z 125 50102 BEARINGBALLRADIAL6203 126 14146 BEARING,INNER-6204-Z 127 14106 CIRCLIP,M20 128 14503 BEARING,630215X42X13 129 14504 BEARING,RNA490530X42X17 130 14505 BUSHING,SHOCKABSORBING-150CC 231 14318 SEAL,M30X40X6 132 14598 BEARING,SEALED6205-150CC 133 14511 WASHER,M22X31X2.5FLAT 134 14319 CIRCLIP,M25 135 14320 CIRCLIP,M52 136 14321 CLAMP,WIRE-150CC 137 14235 BOLT,M6X1.00X40FHCSZN 1038 14597 OILSEAL,SHIFTERCAM-150CC 1


200 SERIES LUTV SECTION 5 CVT COVER

Ref# Part# Description Qty1 14323 COVER,CVT-150CC 12 14507 BRACKET,EXHAUST-150CC 13 14324 NUT,M12X1.25LOCKINGFLANGEZN 14 14508 BEARING,620010X30X9 25 14325 GASKET,CVTCOVER-150CC 16 14235 BOLT,M6X1.00X40FHCSZN 87 14322 SNORKEL,CVT-150CC 18 14322 SNORKEL,CVT-150CC 19 14509 CLAMP,SNORKEL-150CC 2


200 SERIES LUTV SECTION 6 OUTER CRANKCASE ASSEMBLY

Ref# Part# Description Qty1 14326 COVER,OUTERCRANKCASERH-150CC 12 14327 GASKET,OUTERCRANKCASE-150CC 13 14328 CAP,OILDRAIN-150CC 14 14329 SCREEN,OILFILTER-150CC 15 14330 SPRING,OILFILTERSCREEN-150CC 16 14331 DIPSTICK,OILFILL-150CC 17 14332 CLAMP,ACGENERATOR-150CC 18 14333 SEAL,M19.8X30X5OIL 19 14334 O-RING,M30.8X3 110 14335 O-RING,M18X3 111 50016 PINDOWELSPECIAL8X14 212 14336 BOLT,M6X1.00X28FHCSZN 113 14337 BOLT,M6X1.00X95FHCSZN 414 14338 BOLT,M6X1.00X100FHCSZN 115 14339 BOLT,M6X1.00X110FHCSZN 216 14340 BOLT,M6X1.00X35FHCSZN 117 14341 BOLT,M6X1.00X20FHCSZN 218 14296 BOLT,M6X1.00X12FHCSZN 2


200 SERIES LUTV SECTION 7 PISTON, CRANK AND CONNECTING ROD

Ref# Part# Description Qty1 14342 ASM,CRANK-CONROD-150CC 12 14324 NUT,M12X1.25LOCKINGFLANGEZN 13 14510 NUT,M22X1.00SPANNING-150CC 14 14511 WASHER,M22X31X2.5FLAT 15 14344 GEAR,KICKDRIVE-150CC 16 14690 WASHER,M12DAC 17 14324 NUT,M12X1.25LOCKINGFLANGEZN 18 14512 KEY,WOODRUFFM4X14 19 14345 CLIP,PISTONRETAINING-150CC 210 14346 PIN,PISTONWRIST-150CC 111 14347 PISTON-150CC 112 14348 KIT,PISTONRING-150CC 1


200 SERIES LUTV SECTION 8 CAMSHAFT ASSEMBLY

Ref# Part# Description Qty1 14513 NUT,M5X0.5HEX 22 14349 SCREW,TAPPETADJ-150CC 23 14350 ARM,VALVEROCKER-150CC 24 14351 SHAFT,EXHAUSTROCKERARM-150CC 15 14352 CHAIN,CAMSHAFT-150CC 16 14353 CAMSHAFT-150CC 17 14354 SHAFT,INTAKEROCKERARM-150CC 18 14355 PLATE,STOP-150CC 19 14266 PIN,M10X16DOWEL 210 14356 CAP,CAMSHAFTBRG-150CC 1


200 SERIES LUTV SECTION 9 OIL PUMP ASSEMBLY

Ref# Part# Description Qty1 14357 CHAIN,OILPUMP-150CC 12 14358 NUT,M6X1.00HEXFLANGE 13 14359 SPROCKET,OILPUMP-150CC 14 14360 BOLT,M6X1.00X30FHCSZN 25 14361 ASM,OILPUMP-150CC 1


200 SERIES LUTV SECTION 10 DRIVEN PULLEY & CLUTCH

Ref# Part# Description Qty1 14362 ASM,OUTERCLUTCH-150CC 12 14363 BELT,CVT-150CC 13 14364 ASM,DRIVENPULLEY-150CC 14 15164 NUT,M12X1.25LFTHIN 1


200 SERIES LUTV SECTION 11 ENGINE ELECTRICAL

Ref# Part# Description Qty1 14365 MAGNETO-150CC 1*1a 15120 MAGNETO,150CCHO 12 14366 FLYWHEEL-150CC 13 14367 FAN,COOLING-150CC 14 14368 BOLT,M6X1.00X15FHCSZN 4

* 2011 and newer models


200 SERIES LUTV SECTION 12 ELECTRIC START

Ref# Part# Description Qty1 14369 ASM,STARTERCLUTCH-150CC 12 14370 SHAFT,STARTERRED-150CC 13 14371 GEAR,STARTERRED-150CC 14 14372 BOLT,M6X1.00X16FHCSZN 25 14373 ASM,STARTERMOTOR-150CC 1


200 SERIES LUTV SECTION 13 DRIVER PULLEY

Ref# Part# Description Qty1 14374 ASM,DRIVERPULLEY-150CC 12 14375 WEIGHT,DRIVERPULLEY-150CC 6


200 SERIES LUTV SECTION 14 OIL COOLER

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10

Ref# Part# Description Qty1 14376 MANIFOLD,OILCOOLER-150CC,W/FILTER 1 (Forunitswithplacementjustbehindseat)2 14514 FILTER,OIL-150CC(SEALINCLUDED) 13 14537 BOLT,M12X28BANJO 44 14538 WASHER,OILLINE-150CC 85 14599 HOSE,OILCOOLING-150CC(540MM) 16 14747 BOLT,M8X1.25X75 27 14088 NUT,M8X1.25LOCKINGFLANGEZN 28 14748 WASHER,M8SPLITLOCK 29 14293 WASHER,M8FLATZN 210 14515 HOSE,OILCOOLING-150CC(400MM) 1


200 SERIES LUTV SECTION 15 FAN COVER & SHROUD ASSEMBLY

Ref# Part# Description Qty1 14540 COVER,FANCOMP-150CC 12 14541 COVER,DUST-150CC 13 14542 DUCT,CARBURETORCOOLING-150CC 14 14543 SHROUD,LOWER-150CC 15 14544 SEAL,LOWERSHROUD-150CC 16 14545 SHROUD,UPPER-150CC 17 14546 CLIP,CORD-150CC 18 14547 SEAL,UPPERSHROUD-150CC 19 50065 SCREWTAPPING 610 50069 BOLTFLANGESH6X18 311 14539 SCREW,3.5X13STFH 3


200 SERIES LUTV SECTION 16 CARBURETOR

Ref# Part# Description Qty1 14925 ASM,CARBURETOR150CC 12 14563 KIT,CARBCHOKE-150CC-DENI/KFCARBS* 13 15347 FITTING,VACUUM“Y”-150CC(NOTSHOWN) 14 15458 ASM,MANUALENRICHER/CHOKE** 15 15460 O-RING,SPECIAL:CARBENRICHER 16 15430 CABLE,CHOKE3050MMLONG** 1

2

1

4

5

6

* For vehicles assembled prior to October 29, 2012.** For vehicles assembled after October 29, 2012.Provide Your American Sportworks Customer Service Representative with the VIN to determine the vehicle’s assembly date.


54

21

67

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8

91315

5554

14

5316

17

1819

20 21

2861

2625

2423

22

22

3052

3132

3329

34

3536

3738 40,4

1

39

42, 4

3

46 47

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44, 4

551

50

4948

6511

11 12

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10

10

1065

6464

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5a

10

200 SERIES LUTV SECTION 17 FRAME GROUP

REFERENCE LISTON NEXT PAGE


200 SERIES LUTV SECTION 17 FRAME GROUP

Ref# Part# Description Qty1 14858 FRAME,200SERIES-CHARCOAL 12 14843 CAP,RUBBERBUMPER-200S 23 14436 BOLT,M8X1.25X25FHCSZN 44 14088 NUT,M8X1.25LOCKINGFLANGEZN 45 14859 BUMPER,200S-CHARCOAL 15a 15112 BUMPER,WINCHMNT-200-CHAR 16 14804-37 HOOD,200SERIES-RED 16a 14804-38 HOOD,200SERIES-BLUE 16b 14804-41 HOOD,200SERIES-DKGREEN 16c 14804-53 HOOD,200SERIES-MENARDGRN 16d 14804-48 HOOD,200SERIES-CHAR 17 14892 NUT,M6TINNERMANPLATED 78 14820 BOLT,M6X1.00X14FHSS 79 14842 CUPHOLDER-200S 210 14697 BOLT,M8X1.25X65FHCSDAC 1311 14837 WASHER,CONCAVECLAMP-200S 1912 14088 NUT,M8X1.25LOCKINGFLANGEZN 613 14860 FRAME,SEATTUBCOVER-200S-CHARCOAL 114 14861 COVER,SEATTUB-200S 115 14893 RIVET,3mmALUMINUM N/A16 14084 ENDCAP,BAR-1.00BLACKPLASTIC 317 14862 BAR,APILLAR-200S-CHARCOAL 218 14863 BAR,CENTERCROSS-200S-CHARCOAL 119 14425 BOLT,M5X.75X25PHMSZN 120 14098 WASHER,MIRRORMOUNT-7150 121 14494 WASHER,M5SPLITLOCKZN 322 14864 BAR,BPILLARRH/LH-200S-CHARCOAL 223 14865 ENDCAP,BAR-1.5BLACKPLASTIC 424 14866 BAR,CPILLAR-200S-CHARCOAL 125 14956 KIT,CARGOLIGHT-200S 126 15045 CIRCLIPM1212ID13.75OD1L 227 14867 CAP,TOOLHOLDER-200S 228 14868 SPRING,TORSIONTOOLHOLDER-200S 229 14869 LOOP,TOOLHOLDER-200S 230 14870 CAP,FUELW/REMOTEVALVE 131 14161 FUELTANK-CHARCOAL-6150/7150 132 14086 BOLT,M8X1.25X55FHCSZN 4

Ref# Part# Description Qty33 14871 COVER,REARDECK-200S 134 14872 BACKSPLASH,SEATTUB-200S 135 14873 SURROUND,SEATTUB-200S 136 14088 NUT,M8X1.25LOCKINGFLANGEZN 437 14293 WASHER,M8FLATZN 438 14163 BUSHING,FUELTANKMOUNT-150CC 439 14162 SPACER,FUELTANK-150CC 440 14874 WHEELWELL,INNERRH-200S 141 14875 WHEELWELL,INNERLH-200S 142 14876 QUARTERPANEL,UPPERRH-200S 143 14877 QUARTERPANEL,UPPERLH-200S 144 14878 FENDERFLARE,RH-200S 145 14879 FENDERFLARE,LH-200S 146 14827 SCREW,M6X1.0X15PHMSNYL-BLK 647 14784 REFLECTOR,54.9MM-AMBER 248 14832 SCREW,M5X20PANST-BLK 1849 14880 SHIELD,CABLEHOUSING-200S 150 14426 BOLT,M6X1.00X14FHCSZN 1051 14358 NUT,M6X1.00HEXFLANGE 1052 14090 ASM,REARVIEWMIRROR-7150 153 14438 BOLT,M8X1.25X35HHCSZN 254 14293 WASHER,M8FLATZN 255 14088 NUT,M8X1.25LOCKINGFLANGEZN 256 50210 AUTOCOCKASSEMBLY* 1 15454 VALVE,MANUALON/OFF/RESW/O-RING** 157 14164 LINE,FUEL#1-6150/7150 158 14165 LINE,VACUUM#1-6150/7150 159 14166 LINE,FUEL#2-6150/7150 160 14167 FILTER,FUEL-6150/7150 161 15046 CAP,TOOLHOLDERD-200S 262 15047 BUSHING,NYLONM1212ID20.5OD11.25L 463 14941 SEAL,BARCONNECTION-1.5IN 664 14945 COVER,BOLTCAP-1.5IN 1865 14944 WASHER,BARCONNECTION 1866 15201 CAP,RUBBERBUMPER-WINCH200 267 15255 BUSHING,STEPPEDTOOLHOLDER-200 2

* For vehicles assembled prior to October 29, 2012.** For vehicles assembled after October 29, 2012.Provide Your American Sportworks Customer Service Representative with the VIN to determine the vehicle’s assembly date.


200 SERIES LUTV SECTION 17 FRAME GROUP (contined)

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Ref# Part# Description Qty1 2-70133 LIGHT,UTV-RECTANGULAR(#0541172) 22 14341 BOLT,M6X1.00X20FHCSZN 43 14358 NUT,M6X1.00HEXFLANGE 44 2-70129 LIGHT,ASMOVAL-SINGLE(725T/862-12V) 25 14768 LIGHT,4.5ROUND35W 26 14802 GRILL-HORW/RNDLIGHT-200SERIES 17 14784 REFLECTOR,54.9MM-AMBER 28 14801 GRILL-VERTW/OVALLIGHT-200SERIES 19 14807 HARNESS,ADAPTORFOROVAL&RECTLT 210 14844 SEAT,BENCH-200S 110a 15121 ASM,SEAT-XLT 111 14171 SLIDE,SEAT(PR)-6150/7150 112 14440 BOLT,M8X1.25X40HHCSZN 4

Ref# Part# Description Qty13 14243 NUT,M10X1.25LOCKINGFLANGEDAC 414 14289 SPACER,M10STEPPEDSEATBELTDAC 415 14451 BOLT,M10X1.25X25FHCSDAC 416 8778 HARNESSLAPSHOULDERREST 217 14936 SCREW,M5X0.80X15PH-BLK 818 14491 NUT,M5X.8NYLOCZN 819 14803 GRILL-HORW/RECLIGHT-200SERIES 120 14451 BOLT,M10X1.25X25FHCSDAC 221 14243 NUT,M10X1.25LOCKINGFLANGEDAC 222* 2-70127 HEADLIGHT862BULB-REPLACEMENT#4831180 223 14994 COVER,SEATSLIDEHANDLE(BLK) 224 15256 CAP,SEATBELTSHOULDER 2

* Use in models with rectangle and oval lights only


200 SERIES LUTV SECTION 18 STEERING & BRAKES

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Ref# Part# Description Qty1 14894 BOLT,M6X1.0X14SHCS-ZN 62 14846 CAP,STEERINGWHEEL-200S 13 14845 STEERINGWHEEL-200S 14 14847 SHAFT,STEERING-200S 15 14104 BUSHING,FLANGEDSLEEVE20X28X24.1 26 14895 WASHER,M20FLATZN 17 14106 CIRCLIP,M20 18 14437 BOLT,M8X1.25X25HHCSZN 29 14495 WASHER,M8SPLITLOCKZN 210 14412 BOOT,STEERINGSHAFTBLACKRUBBER-7150 211 14896 SHAFT,STEERINGU-JOINT-200SERIES 112 14738 DUSTSHEILD,R&PBLACKRUBBER-7150 113 14848 ASM,RACKANDPINION-200S 114 14436 BOLT,M8X1.25X25FHCSZN 415 14112 BRACKET,RACKANDPINIONMNT 216 14088 NUT,M8X1.25LOCKINGFLANGEZN 817 14109 BOOT,R&PBLACKRUBBER-7150 218 14897 ASM,TIERODEND-200SERIES 219 14240 WASHER,M10FLATZN 220 14241 WASHER,M10SPLITLOCKZN 221 14242 NUT,M10X1.25CASTLE 222 14110 PIN,M2X15COTTER 223 14426 BOLT,M6X1.00X14FHCSZN 524 14900 COVER,FLOORBRAKEACCESS-200S 125 14236 NUT,M6X1.00NYLOCZN 526 14426 BOLT,M6X1.00X14FHCSZN 227 14236 NUT,M6X1.00NYLOCZN 228 14849 HANDLE,PARKBRAKE-200S 129 14850 CABLE,PARKBRAKE-200S 1

Ref# Part# Description Qty30 14851 CABLE,THROTTLE-200S 131 14852 SPRING,THROTTLEPEDAL-200S 132 14442 BOLT,M8X1.25X145HHCSZN 133 14113 SPRING,THROTTLEPEDAL-7150 134 14119 BUSHING,SLEEVE12X21X12 435 14088 NUT,M8X1.25LOCKINGFLANGEZN 836 14853-48 PEDAL,THROTTLE-200S-CHAR 137 14439 BOLT,M8X1.25X40FHCSZN 238 14610 NUT,M8X1.25 439 14854-48 PEDAL,BRAKE-200S-CHAR 140 2-70261 PAD,RUBBER-BRAKE 241 14116 PIN,M6X24BRAKEBLOCK-6150/7150 142 14101 TBLOCK,BRAKE-7150 143 14489 PIN,M2X12COTTER 144 14117 PUSHROD,BRAKEADJUST-7150 245 14438 BOLT,M8X1.25X35HHCSZN 246 14088 NUT,M8X1.25LOCKINGFLANGEZN 247 14118 SWITCH,BRAKELIGHT-7150 148 14454 SCREW,M3X.5X6PHMSZN 249 14131 CAP,BRAKEMASTERCYL-7150 150 15466 HOSE,HYDBRAKE-26” 151 14129 HOSE,HYDBRAKE-43” 152 14130 HOSE,HYDBRAKE-75” 153 14460 BOLT,M10X24BRAKEBANJO 354 14127 WASHER,BRASSBRAKELINE 655 14121 ASM,MASTERCYLINDER-7150 156 14610 NUT,M8X1.25DAC 257 15316 BOOT,TIEROD150CC 258 14120 SPRING,BRAKEPEDAL 1


200 SERIES LUTV SECTION 19 FRONT SUSPENSION

Ref# Part# Description Qty1 13979 NUT,M10X1.25WFZN 82 14151 CAP,HUBNOSE-BLACKRUBBER 23 14809 ASM,TIRE/WHRH-20X7-8 14 14810 ASM,TIRE/WHLH-20X7-8 15 14813 TIRE,FRONT20X7-8-FAREAST 26 14756 WHEEL,8X7.54-110MM,SILVER 27 14150 PIN,M2X20COTTER 28 14727 NUT,M14X1.25CASTLE 29 14149 BEARING,OUTER-6202-Z* 2 15339 BEARING,OUTER-3202-2RS** 210 14147 STUD,M10X1.25X31WHEEL 811 14148 HUB,FRONTWHEEL-6150/7150 212 14144 DISC,FRONTBRAKE-7150 213 14237 BOLT,M6X1.00X12HHCSDAC 1214 14146 BEARING,INNER-6204-Z 215 14145 SEAL,M47X25X7DUST 216 14490 PIN,M1.8X20COTTER 217 14244 NUT,M12X1.25CASTLE 218 14245 WASHER,M12SPLITLOCKZN 219 14137 SEAL,BALLJOINT-6150/7150 420 14138 SPACER,BALLJOINTHEAD-6150/7150 421 14246 BOLT,M10X1.25X40FHCSZN 422 14157-48 AARM,LOWER-CHARW/ZERK 223 14808 SHOCK,325MMFRONT-CHRM/BLK 224 14447 BOLT,M10X1.25X80FHCSZN 4

Ref# Part# Description Qty25 14154 CAP,DUST-LWRSUSPARM-7150 826 14140 SPANNER,AARMLOWER-7150 427 14155 BUSHING,FLANGEDSLEEVE15X21X16 828 14156 O-RING,M21.2X2.65 829 14243 NUT,M10X1.25LOCKINGFLANGEZN 830 14594 GREASEZERK-7150 631 14133 BOLT,M8X1.25X105FHCSZN 232 14126 BUSHING,FLANGEDSLEEVE12X16X12 433 14134 SPANNER,AARMUPPER-7150 234 14136-48 AARM,UPPER-CHARW/ZERK 235 14088 NUT,M8X1.25LOCKINGFLANGEZN 236 14490 PIN,M1.8X20COTTER 237 14245 WASHER,M12SPLITLOCKZN 238 14244 NUT,M12X1.25CASTLE 239 14139 ASM,STRUT/SPINDLELH-CHAR-7150* 1 15340 ASM,STRUT/SPINDLELH-CHAR-200** 140 14132 ASM,STRUT/SPINDLERH-CHAR-7150* 1 15341 ASM,STRUT/SPINDLERH-CHAR-200** 141 14152 ASM,BRAKECALIPER-RF-7150 142 14143 ASM,BRAKECALIPER-LF-7150 143 14142 KIT,BRAKEPADFRONT-7150 244 14834 CAP,NUTCOVERRUBBER-BLK 245 14455 BOLT,M8X1.25X14SHCSPL 446 14748 WASHER,M8SPLITLOCK 4

* Use pior to VIN L6KUA0075EKB04807** Use on VIN L6KUA0075EKB04807 and after


200 SERIES LUTV SECTION 20 BED & TAILGATE

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6

7 8

10 9

11

12

10

17

16

19, 20

Ref# Part# Description Qty1 14901 BED,CARGO-200S-CHARCOAL 12 14902 TAILGATE,200S-CHARCOAL 13 14903 LATCH,TAILGATE-200S-ZN 24 14904 BUSHING,TAILGATE-200S 25 14293 WASHER,M8FLATZN 26 14088 NUT,M8X1.25LOCKINGFLANGEZN 27 14696 BOLT,M8X1.25X50FHCSZN 28 14905 KNOB,BEDLATCH-200S-BLK 29 14088 NUT,M8X1.25LOCKINGFLANGEZN 210 14126 BUSHING,FLANGEDSLEEVE12X16X12 4

Ref# Part# Description Qty11 14134 SPANNER,AARMUPPER-7150 212 14133 BOLT,M8X1.25X105FHCSZN 213 14906 PIN,LATCH-200S 314 14907 NUT,LATCHADJUST-200S 315 14908 BRACKET,LATCHADJUST-200S 316 14461 BULB,TAILLIGHT-12V10/5W-7150 117 14462 ASM,TAILLIGHTW/BULB-7150 118 15088 SCREW,BEDADJUSTW/BUMPER 219 15081 HANDLE,BEDLATCHRH-200 120 15082 HANDLE,BEDLATCHLH-200 1


200 SERIES LUTV SECTION 21 UPPER SWINGARM ASSEMBLY

21

27

3

54

6

8

1

17

23

24

12

14 15

16

22

19

20

21

9

2526

27

91011

18

13

11330-NS

28

29

WARNING ADVERTENCIAEXHAUST GAS HARMFUL GASES DE ESCAPE NOCIVOS

Engine exhaust from this product containschemicals, known in certain quantities to causecancer, birth defects, or other reproductive harm.

Gases de motor de este producto contienen productos químicos,conocidos que en determinadas cantidades pueden causar cáncer,defectos de nacimiento u otros daños reproductivos.

11330-NS

Ref# Part# Description Qty1 14324 NUT,M12X1.25LOCKINGFLANGEZN 32 14710 WASHER-CHAINADJUSTER 23 14467 BUSHING,ENGINEADJISOLATOR-150CC 14 14468 SPACER,ENGINEADJCUP-150CC 15 14469 SPACER,ENGINEADJALIGNMENT-150CC 16 14479 DISC,SHIFTCONTROL-150CC 17 14492 NUT,M12X1.25HEXZN 18 14470 LINK,CHAINTENSIONING-150CC 19 14243 NUT,M10X1.25LOCKINGFLANGEZN 110 14446 BOLT,M10X1.25X45FHCSZN 111 14471 SPACER,ENGINEMOUNTINGLINK-150CC 112 14748 WASHER,SPLITLOCK 413 14473 BRACKET,SHIFTCABLE-150CC 114 14431 BOLT,M6X1.00X60PHMSDAC 215 15323 COVER,ELECTRICALBOX-BOXNOSTOPSWIT 1

Ref# Part# Description Qty16 14173 ASM,UPPERSWINGARM-CHARCOAL-7150 117 14452 BOLT,M12X1.25X60FHCSZN 218 14456 CABLE,D/N/RSHIFT-150CC 219 14174 LINK,REARSWINGARM-CHARCOAL-7150 220 14175 BUSHING,FLANGEDSLEEVE15X21X10 821 14176 SPACER,SWINGARMLINK-7150 422 14434 BOLT,M8X1.25X16FHCSZN 423 14449 BOLT,M10X1.25X195HHCSZN 124 14177 SPANNER,ENGINEMOUNT-6150/7150 125 14594 GREASEZERK-7150 426 14478 ASM,TRANSSHIFTLEVER-150CC 127 14426 BOLT,M6X1.00X14FHCSZN 228 14341 BOLT,M6X1.00X20FHCSZN 129 15389 CAP,SOCKETCAPSCREW-BLACK 4


200 SERIES LUTV SECTION 22 ENGINE / MUFFLER / AIR CLEANER

Ref# Part# Description Qty1 14192 ASM,AIRCLEANER-150CC 12 14423 SCREW,M5X16PHSMZN 93 14495 WASHER,M8SPLITLOCKZN 14 14194 FILTER,AIR-150CC 15 14201 BRACKET,#2AIRCLEANERMNT-6150/7150 16 14480 BRACKET,REARENGMOUNT-150CC 17 14762 AIRINJECTIONASM,MUFFLER-6150/7150 18 14481 CLAMP,HOSE45MM 39 14196 GASKET,EXPIPE-150CC 110 14925 ASM,CARBURETOR150CC 111 14531 ASM,ENGINE-7150 112 14482 SPRING,EXHAUSTPIPE-150CC 213 50050 NUT(HEX)CAPM6 2

Ref# Part# Description Qty14 14236 NUT,M6X1.00NYLOCFLANGEZN 216 14760 ASM,MUFFLERW/AIRINJMOUNT-6150/7150 117 14433 BOLT,M8X1.25X15FHCSZN 318 14439 BOLT,M8X1.25X40FHCSZN 119 14239 BOLT,M8X1.25X20FHCSZN 320 14200 BRACKET,#1AIRCLEANERMNT-6150/7150 121 14445 BOLT,M10X1.25X10FHCSZN 122 14484 GUARD,CHAIN-150CC 123 14426 BOLT,M6X1.00X14FHCSZN 224 14434 BOLT,M8X1.25X16FHCSZN 125 14497 WASHER,M8X27X2FLATZN 126 14238 WASHER,M6SPLITLOCKDAC 2


200 SERIES LUTV SECTION 23 LOWER REAR SWINGARM ASSEMBLY

Ref# Part# Description Qty1 14246 BOLT,M10X1.25X40FHCSZN 42 14535 SHOCK,REAR-CHR/YELLOW-6150/7150 23 14243 NUT,M10X1.25LOCKINGFLANGEZN 44 14485 SPANNER,M18X37-150CC 25 14182 BUSHING,REARSWINGARMUPPER-7150 46 14909 WDMT,LOWERSWINGARM-200S-CHARCOAL 17 14183 KIT,REARBRAKEPAD-7150 18 14184 ASM,REARCALIPERW/PARK-7150 19 14441 BOLT,M8X1.25X100FHCSZN 110 14432 BOLT,M8X1.25X12HHCSZN 111 14500 WASHER,M8STARZN 1

Ref# Part# Description Qty12 14185 GUARD,LOWERCHAIN-6150/7150 113 14372 BOLT,M6X1.00X16FHCSZN 314 14236 NUT,M6X1.00NYLOCFLANGEZN 315 14324 NUT,M12X1.25LOCKINGFLANGEZN 216 14191 BUSHING,SWINGARMISOLATOR-6150/7150 217 14452 BOLT,M12X1.25X60FHCSZN 218 14187 STRAP,BATTERYHOLDDOWN-6150/7150 119 14188 GASKET,BATTERYCAP-6150/7150 120 14189 BATTERY-GTX9-BS 121 14186 COVER,BATTERY-6150/7150 1

3

2

6 75

1

8

9

10

12

4

11

15

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1719

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21

18

14

13

11330-AS

WARNING ADVERTENCIAHOT SURFACES

11330-AS

Surfaces around the engine and exhaust can be extremely hot. Allow surfaces to cool beforeservicing.

SUPERFICIES CALIENTESLas superficies alrededor del motor y el escape pueden estarextremadamen te calientes. Permita que las superficies se enfríenantes de realizar el mantenimiento.


200 SERIES LUTV SECTION 24 REAR AXLE

Ref# Part# Description Qty1 14435 BOLT,M8X1.25X22FHCSZN 42 14202 DISC,8.75REARBRAKE-6150/7150 13 14088 NUT,M8X1.25LOCKINGFLANGEZN 164 14816 AXLE,TAPEREDEND-200SERIES 15 14831 CHAIN,DBLROW54X50PINCLML 16 14819 SPROCKET,DBLROW40T-200S 17 14436 BOLT,M8X1.25X25FHCSZN 48 14206 SEAL,M50X34X7DUST 29 14207 HOUSING,AXLEBRG-6150/7150 210 14208 BEARING-6206 211 14209 FLANGE,BEARING-6150/7150 212 14439 BOLT,M8X1.25X40FHCSZN 613 14210 SEAL,M42X30X7DUST 214 14147 STUD,M10X1.25X31WHEEL 815 14817 HUB,TAPERED150CC-4-165MM 2

Ref# Part# Description Qty16 14811 ASM,TIRE/WHFARWAYRH-22X10-10 117 14912 MASTERLINK,DR50CHAIN 118 13979 NUT,M10X1.25WFZN 819 14812 ASM,TIRE/WHFARWAYLH-22X10-10 120 14248 SPACER,M16X16X4 221 14249 NUT,M16X2.00CASTLE 222 14213 PIN,M4X30COTTER* 2 15387 PIN,M3.2X32COTTER** 223 14151 CAP,HUBNOSE-BLACKRUBBER 224 14830 SPROCKET,DBLROW50P12T-200S 125 14218 KEEPER,SPROCKET-6150/7150 126 14296 BOLT,M6X1.00X12FHCSZN 227 14814 TIRE,22X10-10-FAREAST 128 14758 WHEEL,10X9.54-165MM,SILVER 229 15384 WASHER,BELLEVILLE,M16** 2

* Use pior to VIN L6KUA0076FBB05241** Use on VIN L6KUA0076FBB05241 and after


200 SERIES LUTV SECTION 25 ELECTRICAL

Ref# Part# Description Qty1 14222 SWITCH,KEYEDIGNITIONW/KEY-6150/7150 12 14588 KEYSET-6150/7150 13 14220 SWITCH,HEADLIGHT-7150 24 14914 PLUG,WEATHER-12VOUTLET 15 14915 OUTLET,12V15A 16 14916 HARNESS,MAINWIRING-200S 16a* 15084 HARNESS,MAINW/FUSE-200 17 14740 HARNESS,SWINGARMWIRING-7150 17a* 15083 HARNESS,SWINGARMHOALT-200 18 14231 FUSE,15AMP-WAYTEK46115 29 14227 COIL,IGNITIONW/CAP-6150/7150 1

Ref# Part# Description Qty10* 82664 FUSE,15AMPATC/ATOBLADEFUSE 211 14486 HARNESS,BATTERY-150CC 112 14425 BOLT,M5X.75X25PHMSZN 113 14491 NUT,M5X.75NYLOCZN 114 14225 RELAY,STARTER-6150/7150 115 14226 CDI-6150/7150 116 14224 REGULATOR,VOLTAGE-6150/7150 116a* 15085 REGULATOR,VOLTAGE-HOALTERNATOR-200 117 14236 NUT,M6X1.00NYLOCFLANGEZN 218 14428 SCREW,M6X1.00X20PHMSDAC 219 15016 RELAY,BRAKEINTERLOCK-200S 1

* 2011 and newer models

2

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45

6

1

7

9

8

13

14

15

16

12

17

18

11


200 SERIES LUTV SECTION 26 WARNING DECALS

11330-WS

11330-YS

11330-US

11330-FS

11330-Q - Driver Side

11330-QS - Pass Side

11330-V - Driver Side

11330-VS - Pass Side

Max Tongue Weight: 75 LbsMax Trailer Weight: 500 Lbs

Peso Máximo de Lengüeta: 34 KgPeso Máximo de Remolque: 226 Kg

Maximum Weight:250 Lbs

Peso Máximo:113 Kg

WARNING ADVERTENCIAALWAYS WEAR SEATBELT

Seatbelt must be properly fastened andadjusted for each occupant prior to operatingthe vehicle; See Owner’s Manual.

SIEMPRE USE CINTURON DE SEGURIDADEl cinturón de seguridad debe ser apropiadamente atado y ajustado para cada ocupante antes de la operación delvehículo; Ver Manual de Dueño.

11330-IS

VEHICLE MAY

EL VEHÍCULO SEPUEDE VOLCAR

ROLLThis vehicle will handledifferently from anyordinary passenger caror truck. Sharp turns orabrupt maneuvers athigh speeds may causethis vehicle to roll overor go out of control.Read and understandOwner’s Manual beforeoperating this vehicle.

11330-YS

Este vehiculo se manejay se maniobra diferentede cualquier otro carro ocamión común depasajeros. Curvascerradas o maniobrasbruscas en altavelocidad puede causaruna volcadura o pérdidadel control. Lea ycomprenda el Manual deDueño antes de operareste vehículo.

ADVERTENCIAWARNING

4404 Engle Ridge DriveFort Wayne IN 46804

62194 Commercial StreetRoseland, LA 70456

Toll Free 800-643-7332Fax 866-329-5278www.amsportworks.com

200 series lutv illustrated parts manual - American Sportworksamsportworks.com/pdfs/LUTV/14855R3.pdf · 7/18/13 illustrated parts manual - 200 series lutv part number 14855r3 200

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