200 SERIES LUTV ILLUSTRATED PARTS MANUAL - …

1 200 SERIES LUTV ILLUSTRATED PARTS MANUAL14855R37/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 1 CYLINDER HEAD ASSEMBLY1 2 3 4 5 6 7 8 9 13 11 12 15 14 14 10 13 24 23 22 21 20 19 19 23 22 21 20 18 16 17 Ref# part # Description Qty1 14254 HEAD, CYLINDER - 150CC 12 50304 SPARK PLUG (CR7 HSA) 13 14255 GASKET, CYL HEAD - 150CC 14 14256 GASKET, CARB INSULATOR - 150CC 15 14257 INSULATOR, CARB - 150CC 16 14258 MANIFOLD, INTAKE - 150CC 17 14259 CLAMP, CARB HOSE - 150CC 18 14260 GASKET, VALVE COVER - 150CC 19 14261 O-RING, M27 X 2 RUBBER - 150CC 110 14262 TUBE, BREATHER - 150CC 111 14263 STUD, M6 X X 18 212 14264 STUD, M6 X X 50 2 Ref# part # Description Qty13 50003 BOLT, M6 x x 25 HHF 414 50024 NUT, M6 x HEX FLANGE 215 14265 COVER, VALVE - 150CC 116 14266 PIN, M10 X 16 DOWEL 217 50087 BOLT FLANGE SH 6 X 100 218 14267 VALVE, INTAKE - 150CC 119 14268 SEAL, VALVE STEM - 150CC 220 14269 SEAT, VALVE SPRING OUTER - 150CC 221 14270 SPRING, OUTER AND INNER VALVE - 150CC 222 14271 RETAINER, VALVE SPRING - 150CC 223 14272 KEEPER, VALVE SPRING - 150CC 424 14273 VALVE.

2 EXHAUST - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3 Ref # part # Description Qty1 14317 CYLINDER - 150CC 12 14582 GASKET, CYLINDER BASE - 150CC 13 50032 BOLT FLANGE SH 6 X 22 24 14266 PIN, M10 X 16 DOWEL 25 14276 TENSIONER, CAM CHAIN - 150CC 16 14275 GASKET, CAM CHAIN TENSIONER - 150CC 17 14274 ASM, CAM CHAIN TENSIONER - 150CC 1200 SERIES LUTV SECTION 2 CYLINDER7/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 3 ENGINE CRANKCASERef# part # Description Qty1 14277 HOUSING, CRANKCASE RH - 150CC 12 14278 BUSHING, ENGINE HANGER - 150CC 23 14279 GASKET, CRANKCASE - 150CC 14 14280 HOUSING, CRANKCASE LH - 150CC 15 14558 GROMMET 16 14281 BOLT, M10 X X 15 FHCS ZN 17 14282 WASHER, X 18 X FLAT 18 14283 COVER, SMALL LEFT - 150CC 19 14284 O-RING, M108 X 2 110 14559 PIN 111 14285 O-RING, M6 X 212 50104 OIL SEAL X 30 X 5 113 14286 BOLT, M6 X X 18 FHCS ZN 4 Ref# part # Description Qty14 14287 PIN, M10 X 14 DOWEL 215 14288 BOLT, M12 X SPECIAL - 150CC 116 14690 WASHER, M12 DAC 217 14290 SEAL, M20 X 32 X 6 218 14883 GUIDE, CAM CHAIN - 150CC 119 50016 PIN DOWEL SPECIAL 8 X 14 220 14291 STUD, M8 X X 221 14292 STUD, M8 X X 222 14293 WASHER, M8 FLAT ZN 423 14294 NUT, M8 X FLANGE HEAD 424 14295 BOLT, M6 X X 50 FHCS ZN 225 14501 SPACER, OIL - 150CC 126 14296 BOLT.

3 M6 X X 12 FHCS ZN 27/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 4 TRANSMISSIONRef# part # Description Qty1 14297 HOUSING, OUTER TRANSMISSION - 150CC 12 14298 GEAR, PRI DRIVE - 150CC 13 14299 GEAR, SEC DRIVE - 150CC 14 14300 ASM, SHIFT GEAR CLUSTER D/N/R - 150CC 15 14841 GEAR, FINAL DRIVE SHAFT - 150CC 16 14302 ASM, SHIFT SELECTOR - 150CC 17 14303 PAWL, SHIFT SELECTOR - 150CC 18 14304 ROD, SHIFT PAWL - 150CC 19 14305 SHAFT, SHIFTER CAM - 150CC 110 14306 GASKET, TRANSMISSION CASE - 150CC 111 14307 TUBE, TRANSMISSION VENT - 150CC 112 14308 NIPPLE, VENT TUBE - 150CC LARGE 113 14309 BALL, SHIFT INDENT - 150CC 114 14310 SPRING, SHIFT INDENT - 150CC 115 14311 GASKET, SHIFT INDENT - 150CC 116 14312 BOLT, SHIFT INDENT - 150CC 117 14502 NIPPLE, VENT TUBE - 150CC SMALL 118 14313 BOLT, DRAIN/FILL PLUG - 150CC 219 14314 GASKET, TRANS DRAIN PLUG - 150CC 2 Ref# part # Description Qty20 14296 BOLT, M6 X X 12 FHCS ZN 221 14315 WASHER, M6 FLAT 222 14287 PIN, M10 X 14 DOWEL 223 14316 SPACER, M15 INNER GEAR - 150CC 124 14149 BEARING, OUTER - 6202-Z 125 50102 BEARING BALL RADIAL 6203 126 14146 BEARING, INNER - 6204-Z 127 14106 CIRCLIP, M20 128 14503 BEARING, 6302 15 X 42 X 13 129 14504 BEARING, RNA4905 30 X 42 X 17 130 14505 BUSHING, SHOCK ABSORBING - 150CC 231 14318 SEAL, M30 X 40 X 6 132 14598 BEARING, SEALED 6205 - 150CC 133 14511 WASHER, M22 X 31 X FLAT 134 14319 CIRCLIP, M25 135 14320 CIRCLIP, M52 136 14321 CLAMP, WIRE - 150CC 137 14235 BOLT, M6 X X 40 FHCS ZN 1038 14597 OIL SEAL.

4 SHIFTER CAM - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 5 CVT COVERRef# part # Description Qty1 14323 COVER, CVT - 150CC 12 14507 BRACKET, EXHAUST - 150CC 13 14324 NUT, M12 X LOCKING FLANGE ZN 14 14508 BEARING, 6200 10 X 30 X 9 25 14325 GASKET, CVT COVER - 150CC 16 14235 BOLT, M6 X X 40 FHCS ZN 87 14322 SNORKEL, CVT - 150CC 18 14322 SNORKEL, CVT - 150CC 19 14509 CLAMP, SNORKEL - 150CC 27/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 6 OUTER CRANKCASE ASSEMBLYRef# part # Description Qty1 14326 COVER, OUTER CRANKCASE RH - 150CC 12 14327 GASKET, OUTER CRANKCASE - 150CC 13 14328 CAP, OIL DRAIN - 150CC 14 14329 SCREEN, OIL FILTER - 150CC 15 14330 SPRING, OIL FILTER SCREEN - 150CC 16 14331 DIPSTICK, OIL FILL - 150CC 17 14332 CLAMP, AC GENERATOR - 150CC 18 14333 SEAL, X 30 X 5 OIL 19 14334 O-RING, X 3 110 14335 O-RING, M18 X 3 111 50016 PIN DOWEL SPECIAL 8 X 14 212 14336 BOLT, M6 X X 28 FHCS ZN 113 14337 BOLT, M6 X X 95 FHCS ZN 414 14338 BOLT, M6 X X 100 FHCS ZN 115 14339 BOLT, M6 X X 110 FHCS ZN 216 14340 BOLT, M6 X X 35 FHCS ZN 117 14341 BOLT, M6 X X 20 FHCS ZN 218 14296 BOLT, M6 X X 12 FHCS ZN 27/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 7 PISTON, CRANK AND CONNECTING RODRef# part # Description Qty1 14342 ASM, CRANK - CON ROD - 150CC 12 14324 NUT, M12 X LOCKING FLANGE ZN 13 14510 NUT, M22 X SPANNING - 150CC 14 14511 WASHER.

5 M22 X 31 X FLAT 15 14344 GEAR, KICK DRIVE - 150CC 16 14690 WASHER, M12 DAC 17 14324 NUT, M12 X LOCKING FLANGE ZN 18 14512 KEY, WOODRUFF M4 X 14 19 14345 CLIP, PISTON RETAINING - 150CC 210 14346 PIN, PISTON WRIST - 150CC 111 14347 PISTON - 150CC 112 14348 KIT, PISTON RING - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 8 CAMSHAFT ASSEMBLYRef# part # Description Qty1 14513 NUT, M5 X HEX 22 14349 SCREW, TAPPET ADJ - 150CC 23 14350 ARM, VALVE ROCKER - 150CC 24 14351 SHAFT, EXHAUST ROCKER ARM - 150CC 15 14352 CHAIN, CAMSHAFT - 150CC 16 14353 CAMSHAFT - 150CC 17 14354 SHAFT, INTAKE ROCKER ARM - 150CC 18 14355 PLATE, STOP - 150CC 19 14266 PIN, M10 X 16 DOWEL 210 14356 CAP, CAMSHAFT BRG - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 9 OIL PUMP ASSEMBLYRef# part # Description Qty1 14357 CHAIN, OIL PUMP - 150CC 12 14358 NUT, M6 X HEX FLANGE 13 14359 SPROCKET, OIL PUMP - 150CC 14 14360 BOLT, M6 X X 30 FHCS ZN 25 14361 ASM, OIL PUMP - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 10 DRIVEN PULLEY & CLUTCHRef# part # Description Qty1 14362 ASM, OUTER CLUTCH - 150CC 12 14363 BELT, CVT - 150CC 13 14364 ASM, DRIVEN PULLEY - 150CC 14 15164 NUT.

6 LF THIN 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 11 ENGINE ELECTRICALRef# part # Description Qty1 14365 MAGNETO - 150CC 1*1a 15120 MAGNETO, 150CC HO 12 14366 FLYWHEEL - 150CC 13 14367 FAN, COOLING - 150CC 14 14368 BOLT, M6 X X 15 FHCS ZN 4* 2011 and newer models7/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 12 ELECTRIC STARTRef# part # Description Qty1 14369 ASM, STARTER CLUTCH - 150CC 12 14370 SHAFT, STARTER RED - 150CC 13 14371 GEAR, STARTER RED - 150CC 14 14372 BOLT, M6 X X 16 FHCS ZN 25 14373 ASM, STARTER MOTOR - 150CC 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 13 DRIVER PULLEYRef# part # Description Qty1 14374 ASM, DRIVER PULLEY - 150CC 12 14375 WEIGHT, DRIVER PULLEY - 150CC 67/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 14 OIL COOLER1 2 3 4 5 6 7 8 9 10 Ref# part # Description Qty1 14376 MANIFOLD, OIL COOLER-150CC, W/ FILTER 1 (For units with placement just behind seat)2 14514 FILTER, OIL - 150CC (SEAL INCLUDED) 13 14537 BOLT, M12 X 28 BANJO 44 14538 WASHER, OIL LINE - 150CC 85 14599 HOSE, OIL COOLING - 150CC (540MM)

7 16 14747 BOLT, M8 X X 75 27 14088 NUT, M8 X LOCKING FLANGE ZN 28 14748 WASHER, M8 SPLIT LOCK 29 14293 WASHER, M8 FLAT ZN 210 14515 HOSE, OIL COOLING - 150CC (400MM) 17/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 15 FAN COVER & SHROUD ASSEMBLYRef# part # Description Qty1 14540 COVER, FAN COMP - 150CC 12 14541 COVER, DUST - 150CC 13 14542 DUCT, CARBURETOR COOLING - 150CC 14 14543 SHROUD, LOWER - 150CC 15 14544 SEAL, LOWER SHROUD - 150CC 16 14545 SHROUD, UPPER - 150CC 17 14546 CLIP, CORD - 150CC 18 14547 SEAL, UPPER SHROUD - 150CC 19 50065 SCREW TAPPING 610 50069 BOLT FLANGE SH 6 X 18 311 14539 SCREW, X 13 STFH 37/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 16 CARBURETORRef# part # Description Qty1 14925 ASM, CARBURETOR 150CC 12 14563 KIT, CARB CHOKE -150CC- DENI/KF CARBS* 13 15347 FITTING.

8 VACUUM Y - 150CC (NOT SHOWN) 14 15458 ASM, MANUAL ENRICHER / CHOKE** 15 15460 O-RING, SPECIAL: CARB ENRICHER 16 15430 CABLE, CHOKE 3050 MM LONG** 12 1 4 5 6* For vehicles assembled prior to October 29, 2012.** For vehicles assembled after October 29, Your American Sportworks Customer Service Representative with the VIN to determine the vehicle s assembly ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3542167389131555541453161718192021 2861262524232222305231323329343536373840 ,413942 , 434647944 , 4551504948651111121010101065646463276256 595857605a10200 SERIES LUTV SECTION 17 FRAME GROUPREFERENCE LISTON NEXT PAGE7/18/13 ILLUSTRATED PARTS MANUAL - 200 SERIES LUTV part NUMBER 14855R3200 SERIES LUTV SECTION 17 FRAME GROUPRef# part # Description Qty1 14858 FRAME, 200 SERIES - CHARCOAL 12 14843 CAP, RUBBER BUMPER - 200S 23 14436 BOLT, M8 X X 25 FHCS ZN 44 14088 NUT, M8 X LOCKING FLANGE ZN 45 14859 BUMPER.

9 200S - CHARCOAL 15a 15112 BUMPER, WINCH MNT - 200 - CHAR 16 14804-37 HOOD, 200 SERIES - RED 16a 14804-38 HOOD, 200 SERIES - BLUE 16b 14804-41 HOOD, 200 SERIES - DK GREEN 16c 14804-53 HOOD, 200 SERIES - MENARD GRN 16d 14804-48 HOOD, 200 SERIES - CHAR 17 14892 NUT, M6 TINNERMAN PLATED 78 14820 BOLT, M6 X X 14 FHSS 79 14842 CUP HOLDER - 200S 210 14697 BOLT, M8 X X 65 FHCS DAC 1311 14837 WASHER, CONCAVE CLAMP - 200S 1912 14088 NUT, M8 X LOCKING FLANGE ZN 613 14860 FRAME, SEAT TUB COVER - 200S - CHARCOAL 114 14861 COVER, SEAT TUB - 200S 115 14893 RIVET, 3mm ALUMINUM N/A16 14084 ENDCAP, BAR - BLACK PLASTIC 317 14862 BAR, A PILLAR - 200S - CHARCOAL 218 14863 BAR, CENTER CROSS - 200S - CHARCOAL 119 14425 BOLT, M5 X .75 X 25 PHMS ZN 120 14098 WASHER, MIRROR MOUNT - 7150 121 14494 WASHER, M5 SPLIT LOCK ZN 322 14864 BAR, B PILLAR RH/LH - 200S - CHARCOAL 223 14865 ENDCAP, BAR - BLACK PLASTIC 424 14866 BAR, C PILLAR - 200S - CHARCOAL 125 14956 KIT, CARGO LIGHT - 200S 126 15045 CIRCLIP M12 12ID OD 1L 227 14867 CAP, TOOL HOLDER - 200S 228 14868 SPRING, TORSION TOOL HOLDER - 200S 229 14869 LOOP, TOOL HOLDER - 200S 230 14870 CAP, FUEL W/REMOTE VALVE 131 14161 FUEL TANK - CHARCOAL - 6150/7150 132 14086 BOLT, M8 X X 55 FHCS ZN 4 Ref# part # Description Qty33 14871 COVER, REAR DECK - 200S 134 14872 BACKSPLASH, SEAT TUB - 200S 135 14873 SURROUND, SEAT TUB - 200S 136 14088 NUT, M8 X LOCKING FLANGE ZN 437 14293 WASHER, M8 FLAT ZN 438 14163 BUSHING, FUEL TANK MOUNT - 150CC 439 14162 SPACER, FUEL TANK - 150CC 440 14874 WHEEL WELL, INNER RH - 200S 141 14875 WHEEL WELL.

10 INNER LH - 200S 142 14876 QUARTER PANEL, UPPER RH - 200S 143 14877 QUARTER PANEL, UPPER LH - 200S 144 14878 FENDER FLARE, RH - 200S 145 14879 FENDER FLARE, LH - 200S 146 14827 SCREW, M6 X X 15 PHMS NYL - BLK 647 14784 REFLECTOR, MM - AMBER 248 14832 SCREW, M5 X 20 PAN ST - BLK 1849 14880 SHIELD, CABLE HOUSING - 200S 150 14426 BOLT, M6 X X 14 FHCS ZN 1051 14358 NUT, M6 X HEX FLANGE 1