BPG werks REV060413, Owner'S/Operator'S Manual

Page 1: ...t it could save your life Never allow any child under the age of 16 to operate a DTV Read this manual thoroughly It contains important safety information SHREDDER OWNER S OPERATOR S MANUAL Original Instructions REV060413 ...

Page 2: ...rovide the knowledge needed to have safe and enjoyable DTV operation For questions regarding operation and maintenance for this DTV Please email help bpgwerks com or call 480 718 8066 This DTV is intended for use by operators age 16 or older Never allow a child to operate this DTV who is under age 16 See dealer for instructions and demonstration of proper riding technique THIS DTV IS NOT A TOY AND...

Page 3: ... ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Indicates a potential hazard that could result in SEVERE INJURY or DEATH to the operator bystander or person inspecting or repairing the DTV CAUTION Indicates special precautions that must be taken to avoid damage to the DTV NOTE Indicates key information to make procedures easier or clearer to understand WARNING The first part will identify ...

Page 4: ...ENSION 31 TRACK CLEANING LUBRICATING 31 TRACK REPLACEMENT 32 STEERING ADJUSTMENT 33 STEERING RESISTANCE 33 LUBRICATION POINTS 34 FASTENER TORQUE VALUES 35 STORAGE 36 WASHING THE ATV 37 TRANSPORTING 37 TROUBLE SHOOTING 38 SPECIFICATIONS 39 FRAME AND ENGINE NUMBER LOCATION 40 TABLE OF CONTENTS RIDING ON HILLS 16 CLIMBING A HILL 16 DESCENDING A HILL 17 TRAVERSING A HILL 17 RIDING OVER OBSTACLES 17 SK...

Page 5: ...WARNING LABEL LOCATIONS 1 2 3 4 1 ...

Page 6: ...ld cause loss off control and result in severe injury or death Jumping can also cause damage to the DTV Never perform jumping maneuvers on the DTV or drop it from any height UNDER 16 NEVER OPERATE ALWAYS at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing ...

Page 7: ... the throttle first Sudden release of the throttle may also result in a rollover Smooth throttle control is paramount to maintaining control of the vehicle Never operate this DTV at night or in low light conditions OPERATION WARNINGS WARNING Never touch engine or exhaust after running engine until they have cooled WARNING Keep hands fingers feet away from sprockets chains rollers and track 2 3 4 3...

Page 8: ...ver the ankle boots eye protection gloves long sleeve shirt long pants elbow shin and knee pads while operating this DTV Never allow a passenger on this DTV This DTV is designed for one operator and no passengers Never operate this DTV on paved surfaces and or public roads Pavement may cause the DTV to become unstable Always go slowly and pay attention to unfamiliar terrain Be alert to changing te...

Page 9: ...ion Once engine has warmed up push in the choke lever to the OFF position Pull Start Cord To start the engine Pull the Pull Start Cord Note Make sure the Engine Kill Switch Lanyard is attached before attempting to start the engine Engine will not run without the Engine Kill Switch Lanyard attached Handle Lock Release Lever Handle can be adjusted when the Handle Lock Release Lever is pulled toward ...

Page 10: ...sition This is the normal operating position The ON position allows fuel to flow from the Fuel Petcock to the carburetor Turn the Fuel Petcock to the ON position when ready to start and ride your DTV RESERVE position If engine runs out of fuel when Fuel Petcock is placed in the ON position place fuel Petcock to the RESERVE position Re fuel as soon as possible Once re fueled make sure to place the ...

Page 11: ...ull synthetic oil is necessary for engine life due to the high rotation speeds of the engine Quantity of oil 600 ml 63 qt Overfilling the fuel tank can cause the fuel to expand which can cause overflow due to the heat from the engine or sun Spilled fuel can catch fire Always fill the fuel tank with the handle in the horizontal flat position Never fill the fuel tank above the bottom edge of the fil...

Page 12: ...ry in any way WARNING Do not use or leave the battery at a very high temperature for example in strong direct sunlight or in a vehicle in extremely hot weather Otherwise the battery can overheat catching fire or its performance will degenerate and its service life will be shortened Do not use in a location where static electricity is prevalent otherwise the safety devices may be damaged causing a ...

Page 13: ...ak in process however too much Break in period Allow oil to circulate before riding Allow the DTV engine to warm up before riding This allows the oil to circulate throughout the engine which lubricates the components Observe your initial and most critical maintenance service The initial service break in maintenance is the most important service for your DTV During the break in time frame all of th...

Page 14: ...portant Following the pre ride check list will help insure the you do not have mechanical problems which could result in injury or becoming stranded Make sure the DTV is in good operating condition before each ride WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement Brakes Brake pad wear Proper brake lever play Tracks Check for exposed and frayed reinforcement threads as well as...

Page 15: ...ontrol resulting in severe injury of death to the operator and or the passenger This DTV is designed for one operator and no passengers Never allow a passenger WARNING Riding this DTV on any public road or highway could be hazardous You could collide with another vehicle if you ride on public roads or highways resulting in severe injury or death Never ride on public roads and highways WARNING Oper...

Page 16: ...rs bugs etc Good eye protection as well as a helmet and protective riding gear should be mandatory when riding a DTV Riding a DTV without a helmet eye protection and protective clothing can be hazardous Riding a DTV without a helmet increases the chance of severe head injury or death in the event of an accident Riding a DTV without eye protection such as a face shield or goggles could result in se...

Page 17: ...d 5 Pull the Pull Start Cord 6 Once engine has warmed up for a few minutes place the choke to the OFF position pushed in Starting or running the DTV in an enclosed area such as a garage or shed where there is no ventilation is hazardous Inhaling exhaust fumes from the DTV can cause severe injury or death Never start or run the DTV in an enclosed environment where there is no ventilation Always sta...

Page 18: ...both or one hand from the handlebars and or feet from the Deck could result in loss of control of the DTV resulting in severe injury or death Always ride with both hands on the handlebars and both feet on the Deck while operating the DTV WARNING STARTING OFF 1 Allow the engine to warm up approximately 3 minutes before starting off 2 Release the parking brake 3 Gradually give the DTV throttle Depre...

Page 19: ...f the tracks Use brakes if necessary Decelerating during a turn can easily cause a loss of balance and control so make sure to slow down prior to turning 2 Once slow enough to make the turn move body weight to the inside of the turn 3 Look into the direction of the turn while shifting weight to the inside of the turn 4 Once turned in the proper direction shift body weight back to the center of the...

Page 20: ...e sure the hill is not too steep the terrain is not loose or slippery and that there are no obstacles 2 Approach the hill at a steady speed and maintain speed throughout the climb 3 Shift body weight forward during the climb 4 Adjust the angle of the handle forward using the handle lock release lever page 5 5 When approaching the top of the hill slow down If it is determined that the DTV will not ...

Page 21: ...DTV over This could result in severe injury or death WARNING Traversing a hill RIDING THE DTV Riding over large obstacles could be hazardous Riding over large obstacles could cause loss of control and cause the DTV to turn over which could result in severe injury or death Never attempt to ride over large obstacles such as large rocks or fallen trees Always make sure to follow the instructions in t...

Page 22: ...fast moving and or too deep Make sure the water your are riding through is shallow and is not more than 10cm 4in deep Make sure you are traveling slow as to not allow water to enter the Air Box Scoop Before crossing any water look at the terrain entering and exiting the water the terrain should have a gradual slope with no obstacles The bottom of the river or pool of shallow water should be hard I...

Page 23: ...ing for a ride in cold weather Plan for and dress for the worst weather conditions Plan for breakdowns Riding in cold weather Proper clothing Riding an DTV in cold weather could be hazardous Becoming too cold in cold weather could result in hypothermia Hypothermia is a condition where the body temperature drops low enough to cause injury or death Never operate a DTV in cold weather without proper ...

Page 24: ...ottle linkages Apply the brakes several times making sure that the friction has dried off the brake pads and shoes Cover the DTV with a protective cover so ice and snow cannot accumulate Riding the DTV with wet or frozen brakes could be hazardous Wet or frozen brakes will increase stopping distance which could result in loss of control which could result in severe injury or death Always inspect th...

Page 25: ...e harmful rays of the sun This will also will help you see better Riding on terrain that is covered with snow could be hazardous Terrain covered with snow can hide obstacles such as holes large rocks logs etc Running into one of these obstacles could result in loss of control which could result in severe injury or death Always go slow when riding over snow covered terrain be alert to changing terr...

Page 26: ...go that is not bulky or too heavy Make sure all cargo is held securely in place loose cargo can become a hazard While carrying cargo go slow Cargo can adversely affect handling at higher speeds Allow plenty of distance to stop while carrying cargo The more weight on the DTV the longer distance it will take to stop Load Guidelines Riding this DTV with modifications or adding accessories could be ha...

Page 27: ...will need to be performed more often if ridden in wet muddy or dusty conditions CAUTION Failing to use compatible parts with the original replacement parts could damage DTV Using parts that are of low quality could result in DTV breakdowns and reduce the useful life of the DTV Never use parts that are not compatible with the original parts CAUTION MAINTENANCE For maintenance your DTV may be mainta...

Page 28: ... It should be replaced every 20 hours Drive Tracks Inspect drive Tracks before each ride to ensure they re free of cracks tears or debris Brakes I I I Brake hose I I I Brake fluid If brake lever feels spongy add DOT4 fluid Brake lever free play I I I Chain I I I Steering I I I Suspension system I I I Chassis nuts and bolts T T T Valve cover and air box drain tubes Check and empty if req d the valv...

Page 29: ...ning frequently can plug up the air filter which can cause poor gas mileage low power and damage to the engine CAUTION Air Filter MAINTENANCE Air filter removal inspection and cleaning instructions 1 The Air Filter is located behind the front Skid Plate To access the Air Filter housing remove front Skid Plate 2 Remove Air Filter access cover 3 Remove Air Filter 4 Inspect Air Filter If damaged repl...

Page 30: ...spark plug gap 2 The spark plug gap should be 0 6 0 7mm 0 024 0 028 in Re install the inspected plug or new plug until finger tight Finish tightening plug with a wrench If the plug is a new plug tighten approximately 1 2 turn more with the wrench If plug is an old plug tighten approximately 1 8 turn more with a wrench 0 6 0 7 mm 0 024 0 028 in NGK BPR5ES 2 Dirt can damage the engine if it enters t...

Page 31: ... To avoid damage to the engine do not over or under fill with oil Changing the engine oil 1 Start engine and run for a short period of time to allow the engine oil to warm up A warm engine will help oil drain quicker 2 Remove front skid plate to gain access to the oil drain plug 3 Remove Oil Drain Plug 4 Allow the oil to drain in an appropriate container Note Dispose of oil at an oil recycle cente...

Page 32: ...eved Note A service center can perform this adjustment A diagnostic tachometer is required for this adjustment Throttle Cable adjustment The thumb throttle 2 should have 2 0 4 0mm 0 08 0 16 of free play Throttle cable adjustment 1 Remove throttle lever housing top cover 3 screws 2 Loosen cable clamp screw not shown 3 Use pliers to pull cable tight and simultaneously tighten cable clamp screw 4 Che...

Page 33: ...edures WARNING This DTV is equiped with hydraulic disk brakes Brake Fluid MAINTENANCE Fuel Hose Valve Clearance Adjusting the valves should be done by an authorized service center or comparable servicing dealer Proper valve gap will help DTV to run at peak performance Follow the valve gap adjustment intervals listed in the maintenance chart Proper Valve Clearance Intake 0 002 in 0 05mm Exhaust 0 0...

Page 34: ...ket Instructions for cleaning and chain lubrication 1 Clean chain with a chain cleaner 2 Lubricate chain with chain lube before each ride Chain lubrication MAINTENANCE Rear Axle Bolt Chain Tension Nut Chain and sprocket inspection Inspect the drive chain for wear rust bound links proper lubrication and proper tension If the drive chain has a problem correct or replace Contact a service center for ...

Page 35: ...l reduce traction which could result in an accident WARNING Track Inspection Track Front swingarm track clamping bolt Track tension adjustment screw 1 Loosen track clamping bolt 2 Adjust track tension with adjustment screw 3 Tighten clamping bolt Track Cleaning Lubrication To reduce the rolling friction of the tracks they should be cleaned and lubricated on the inside after use using a common auto...

Page 36: ...ect position around the upper and lower bogie wheels Then push the track over the front bogie wheels Rotating the track can help the track slide on more easily Replace the two front outer bogie wheels making sure the bolt is tight 4 The track may have come off due to insufficient tension Follow the track tensioning instructions to increase the track tension Ensure the track tension is equal on bot...

Page 37: ...to shorten it and bias the steering to the left Turn the rod counter clockwise to lengthen it and bias the steering to the right Steering Adjustment Adjusting the deck tilting resistance is accomplished through the pivot bolts Turning the bolts clockwise will make deck tilt feel stiffer which is better suited for heavier riders or for more stability at high speeds Turning the bolts counter clock w...

Page 38: ... periodically Lubricate more often if riding in wet sandy or dusty environments When lubricating the rear swingarm disconnect the shock at the bottom and rotate the swingarm up and down while pumping Rear Swing Arm Grease Points Steering Rod Grease Point Front Swing Arm Gease point 34 ...

Page 39: ... 5 lb ft 6mm hex bolt and nut 10 Nm 1 04 kgf m 7 5 lb ft 8mm hex bolt and nut 25 Nm 2 49 kgf m 18 lb ft 10mm hex bolt and nut 50 Nm 5 12 kgf m 37 lb ft 12mm hex bolt and nut 85 Nm 8 71 kgf m 63 lb ft 5mm screw 6 Nm 62 kgf m 4 5 lb ft 6mm screw 10 Nm 1 04 kgf m 7 5 lb ft 8mm screw 25 Nm 2 49 kgf m 18 lb ft Fig 1 35 ...

Page 40: ... stores Returning to service 1 Wash DTV thoroughly Note Keep water away from air intake and muffler outlet while washing to avoid water from entering the engine and or components 2 Remove oily rags from air intake and muffler outlet 3 Drain engine oil and replace with fresh clean oil as listed in this manual 4 Review this owner s manual and follow the pre ride inspection procedures 5 Start engine ...

Page 41: ... Transport Position MAINTENANCE Handle lock release lever Transporting 1 Make sure Fuel Petcock is turned to the OFF position 2 Fold down DTV handle for storage and transportation use handle lock release lever to release handle Never wash DTV with a power washer High pressure will penetrate bearing and o ring chain seals which will cause damaged to the DTV CAUTION Note To reduce the rolling fricti...

Page 42: ...tion If unit is equipped with electric start all of the above applies plus 1 Ensure to keep the deck level while starting 2 If the starter motor does not work check the battery connections are not loose and the battery is charged 3 If the above are ok take your DTV to an authorized service station Engine Lacks Power 1 Ensure all connections in the engine air intake system are tight and the rubber ...

Page 43: ...1321mm 52 in Width 678mm 27 in Height Handle down 584mm 23 in Handle up 1270mm 50 in Vehicle Wt 111kg 245lbs Weight Cap 113kg 250lbs Fuel Gas Tank Capacity 3 78L 1 gal Fuel type Use premium high octane fuel due to the high compression ratio Use 91 on the AKI scale USA or 95 on the RON scale rest of world SPECIFICATIONS Noise The A weighted emission sound pressure level at operating station 82 dB A...

Page 44: ...p or when registering your DTV Locate the numbers and list the numbers below for your reference The VIN is located on top of the trailer hitch receptacle Vehicle Identification Number The engine number is located on the front bottom portion of he DTV Engine VIN Engine Number VIN AND ENGINE NUMBER LOCATION 40 ...

Page 45: ...BPG Recreational Inc 2940 Portland Dr Oakville ON L6H 5W8 Canada bpgwerks com Phone 480 718 8066 ...