BMS Beast 1000 Series Owner'S Manual Download

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TROUBLESHOOTING

101

ENGINE PINGS OR KNOCKS

POSSIBLE CAUSE

SOLUTION

Poor quality or low octane fuel

Replace with recommended fuel

Incorrect spark plug gap or
heat range

Set gap to specs or replace plug

ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES

POSSIBLE CAUSE

SOLUTION

Fouled or defective spark plug

Inspect, clean and/or replace spark plug

Worn or defective spark plug
wires

Your dealer can assist

Incorrect spark plug gap or
heat range

Set gap to specs or replace plug

Loose ignition connections

Check all connections and tighten

Water present in fuel

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

Throttle release switch
malfunction

Your dealer can assist

Other mechanical failure

Your dealer can assist

ENGINE STOPS OR LOSES POWER

POSSIBLE CAUSE

SOLUTION

Out of fuel

Refuel

Water is present in fuel

Replace with new fuel

Fouled or defective spark plug

Inspect, clean and/or replace spark plug

Worn or defective spark plug
wires

Your dealer can assist

Incorrect spark plug gap or
heat range

Set gap to specs or replace plug

Loose ignition connections

Check all connections and tighten

Low battery voltage

Recharge the battery to 12.8 VDC

Summary of Contents for Beast 1000 Series

Page 1: ...1 OWNER S MANUAL The Beast 1000ccZT ...

Page 2: ...California to cause cancer birth defects or other reproductive harm Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING WARNING ...

Page 3: ...1 Owner s Manual Beast 1000 ...

Page 4: ...finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the DW INDUSTRIES Service Manual and can be performed by a factory certified Master Service Dealer Technician Your DW INDUSTRIES de...

Page 5: ...3 Introduction 6 Safety 7 Features and Controls 21 Operation 37 Winch Guide 51 Emission Control Systems 63 Maintenance 65 Specifications 97 Troubleshooting 99 Warranty 103 Maintenance Log 112 ...

Page 6: ...ents NOTICE provides key information by clarifying instructions INTRODUCTION This DW INDUSTRIES vehicle is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar w...

Page 7: ...o sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Never permit a guest to operate this vehicle unless the guest has reviewed the owner s manual and all safety labels and has completed a safety training Always use the cab doors while riding in this vehicle Always keep hands feet and all other body parts inside t...

Page 8: ...6 VEHICLE IDENTIFICATION NUMBERS Vehicle Model Number Frame VIN Engine Serial Number ...

Page 9: ...267 2751 Your DW INDUSTRIES vehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thorough...

Page 10: ...n the rider cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel...

Page 11: ...al number and serial number will also be displayed on the label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Strongly recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept ...

Page 12: ...g is located on the center console Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver slicense Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks canoccur ...

Page 13: ...n ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding acrossslopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason LOCATE AND READ OWNER S MANUA...

Page 14: ...NG IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo CAPTAIN 14 INCH WHEELS MAXIMUM CARGO BOX LOAD 440 lbs 200 Kg TIRE PRESS...

Page 15: ...ering wheel and both feet on the floorboards of the vehicle duringoperation Never permit a guest to operate this vehicle unless the guest has read this manual and all productlabels To reduce rollover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads unless marked for off ro...

Page 16: ... out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual See page 46 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe...

Page 17: ...ould create a substantial safety hazard and increase the risk of bodily injury The DW INDUSTRIES limited warranty on your DW INDUSTRIES vehicle will be terminated if any non DW INDUSTRIES approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may...

Page 18: ...g alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating this vehicle SEAT BELTS Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circums...

Page 19: ...art Key section for details OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities Th...

Page 20: ...xcessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your skills and experience OPERATING ONPAVEMENT This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adver...

Page 21: ...ver Always follow proper procedures for traveling down hills as described in this owner s manual STALLING WHILE CLIMBING A HILL Stalling or rolling backwards while climbing a hill could cause a rollover Maintain a steady speed when climbing ahill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicl...

Page 22: ...firm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could result in an accident or rollover Always remove ...

Page 23: ...URES AND CONTROLS 21 FEATURES ANDCONTROLS COMPONENT LOCATIONS Console Receiver Hitch Headlights ROPS Cab Frame Radiator CargoBox FrontBumper BrushGuard Taillights Muffler SparkArrester CV Boot Rear Caliper ...

Page 24: ...igh Gear L Low Gear N Neutral R Reverse P Park USING LOW RANGE Always shift into low gear for any of the following conditions Operating in rough terrain or overobstacles Loading the vehicle onto atrailer Towing loads Driving frequently at low RPM or at ground speeds below 7 MPH 11 km h TIP Maintaining shift linkage adjustment is important to assure proper transmission function Your DW INDUSTRIES d...

Page 25: ... gauge and terminal block Check engine and steering warning indicators will appear on the gauge in this mode but will turn off when the vehicle is started if no issues are present ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released AWD DIFFERENTIAL LOCKSWITCH The 4WD ...

Page 26: ... of the switch to turn off theheadlights WINCH SWITCH Press the top of the rocker switch to spool line out from the winch Press the bottom of the rocker switch to spool line in to the winch Move the rocker switch to the center position to stop spooling AUXILIARY OUTLET The vehicle is equipped with a 12 volt accessory outlet on the dash Use the outlet to power an auxiliary light or other optional a...

Page 27: ...n the ignition switch to the ON position 2 Apply the brakes The brake light should come on after about 10 mm 0 4 in of pedal travel THROTTLE PEDAL Push the throttle pedal w down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine If the throttle pedal and brake pedal are appli...

Page 28: ...rly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will selftighten 4 To release the seat belt press the square ...

Page 29: ... belt system checked and or replaced by an authorized dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents Rinse the entire length of the belt webbing Use a garden hose to flush out the retractor and latch housings regularly SEAT REMOVAL AND COMPARTMENT ACCESS Pull the rear edge of a seat upward to release the...

Page 30: ...ing wheel upward or downward Release the lever when the steering wheel is at the desired position ROLLOVER PROTECTIVE STRUCTURE The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized DW INDUSTRIES dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the e...

Page 31: ...ccess the radiator pressure cap and coolant overflow bottle The ECU electrical compartment is located under the hood To remove the hood do the following 1 Unlock the hood latches 2 Pull the hood support lever to hold the hood in position Never use fuel blends with more than 10 ethanol Engine damage could occur Escaping steam can cause burns Never remove the pressure cap while the engine is warm or...

Page 32: ...ases the risk of serious injury or death in the event of an accident or rollover Always make sure all cab doors are closed and latched when riding in thisvehicle Always inspect doors and latches for wear and damage before each use of the vehicle Promptly replace any worn or damaged parts with new parts available from your authorized dealer ...

Page 33: ...rden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster NOTICE ...

Page 34: ...ill display in the odograph and be switched between The figure of speed will display and update synchronous while switching between KM H and MPH in unit of pedometer By pressing Time Set the user can set the hour and minute Adjust hours or minutes by ascending or descending by continuing to press button of mode of Set Reset user can clean the record to zero for particular period ofworkingmileagean...

Page 35: ...on key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Check Engine This indicator appears if an Electronic Fuel Injection EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result Your dealer can assist Check Battery This warning usually indicates that the vehicle is operating at an RPM too low...

Page 36: ...ture indicator light It indicates the temperature of coolant if the temperature is above 102 stop engine immediately Check coolant level and add if low See authorized dealer if temperature indicator stays on and overflow tank is full of coolant Oil pressure indicator light Indicates low high oil pressure When illuminated see authorized dealer ...

Page 37: ... off after starting the engine If the lamp is on while the engine is on it indicates that the system has an error When some electric jet parts are reading faulty check engine indicator light will also be ON the vehicle still can be running the driving performance will get worse which reminds the driver to send the vehicle in for repair ...

Page 38: ...FEATURES AND CONTROLS 36 WARNING WARNING WARNING ...

Page 39: ...om to familiarize yourself with vehicle operation andhandling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist During the break in period change both the oil and the filter at 25 hours 6 Check fluid levels of transmission and all gearcases after the first 25 hours of operation ...

Page 40: ...le pedal while starting the engine 5 Turn the ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 6 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts STOPPING THE ENGINE 1 Release the throttle pedal completely and brake to ...

Page 41: ...g Ensure free operation page 80 Tires Inspect condition and pressure page 86 Wheels Fasteners Inspect ensure fastener tightness page 86 Frame Nuts Bolts Fasteners Inspect ensure tightness Fuel and oil Ensure proper levels page 73 Coolant Level Ensure proper level page 76 Coolant Hoses Inspect for leaks Throttle Pedal Ensure proper operation Indicator Lights Switches Ensure proper operation page 23...

Page 42: ... LOCK This vehicle is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and conditions NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest ...

Page 43: ...d loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELYARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extrem...

Page 44: ...o not operate the vehicle faster than 10 MPH 16 km h when towing Towing a trailer increases brakingdistance 4 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the Specifications section for towing values 5 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location which could result in loss of control of the v...

Page 45: ... parking on a slope 2 Set the gear select level in the NEUTRAL position 3 Engage the park brake 4 Lower the tailgate 5 With the engine running push down on the top side of the cargo bed dump switch to tilt the cargo bed to the dump position 6 To return the cargo bed to the transport position push down on the down side of the switch until the cylinder stops moving 7 Make sure the cargo bed is in th...

Page 46: ...nspection section for details 3 Sit in the driver s seat and fasten the seat belt 4 Always make sure all cab doors are closed and latched when riding in this vehicle 5 Place the transmission inPARK 6 Start the engine 7 Apply the service brakes and shift the transmission into gear 8 Check your surroundings and determine your path of travel 9 Release the parking brake ifequipped 10 Keeping both hand...

Page 47: ...nditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 9 Vehicle handling may change with a passenger and or cargo on board Allow more time and distance forbraking 10 Always follow all operating guidelines as outlined on safety labels and in this manual DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles 1 Always check for o...

Page 48: ...ions 1 Avoid excessively steep hills 2 ADC Models Always operate in low gear and engage ADC 4X4 before ascending or descending ahill 3 Always travel straight uphill 4 Keep both feet on thefloor 5 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loosesurfaces 6 Proceed at a steady rate of speed and throttle opening Never open the throttle s...

Page 49: ... DRIVING DOWNHILL When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Always check the terrain carefully before descending a hill Never drive on hills with excessively slippery or loose surfaces 3 Slow down Never travel down a hill at high speed 4 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission inneutral 5 Avoid tr...

Page 50: ...OPERATION 48 ...

Page 51: ... Stop the vehicle on a level surface When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 2 Place the transmission inPARK 3 Turn the engine off 4 Engage the parking brake ifequipped 5 Slowly release the brake pedal and make sure the transmission is i...

Page 52: ...it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission inPARK 3 Engage the parking brake ifequipped 4 Turn the engine off 5 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6 Engage the park brake ifequipped 7 Block the rear wheels on the downhill side ...

Page 53: ...h 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 10 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place dur...

Page 54: ... under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Your dealer can provide service on your winch if thisoccurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the ...

Page 55: ... or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Improper winch use can result in SEVERE INJURYor DEATH Always follow all winch instructions and warnings in this manual Each winching situation isunique Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush duringwinching Always pay attention to ...

Page 56: ...h A recovery strap is designed to stretch Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure TIP Never put your fingers into the hook This could lead to SEVERE INJURY Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Sho...

Page 57: ...k or latch Always replace damaged parts before using the winch Yes No 5 Never remove the hook strap from the hook 6 Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cabl...

Page 58: ...ay the damper on top of the mid point of the winch cable length that is spooled out c On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper d Avoid being directly in line with the winch cable whenever possible Also never permit others to stand n...

Page 59: ...g Shift to the lowest gear available on the stuck vehicle h Slowly and carefully apply vehicle throttle and winch together to free the vehicle i Stop winching as soon as the stuck vehicle is able to propel itself without the help of thewinch j Detach the winch cablehook k Rewind the winch cable evenly back onto the winch drum following the instructions in this manual 12 Never attempt to winch anot...

Page 60: ...ble in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum f Doing this reduces the chances of the winch cable wedging itself between lower layers of winchcable WINCH CABLECARE For your safety always replace DW INDUSTRIES winch parts including the cable with genuine DW INDUSTRIES replacement parts available at your auth...

Page 61: ...ion Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition SHOCK LOADING Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take u...

Page 62: ...ed by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading WINCH MAINTENANCE AND SERVICE SAFETY 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware 2 Permit your winch motor to cool down prior to servicing your winch 3 ...

Page 63: ...WINCH GUIDE 61 WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH ...

Page 64: ...62 ...

Page 65: ...losed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaustsystem EXHAUST EMISSION CONTROL SYSTEM Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The em...

Page 66: ...64 ...

Page 67: ...veals the need for replacement parts genuine DW INDUSTRIES parts are available from your DW INDUSTRIES dealer Equivalent parts may be used for emissions related service Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perform these operations Vehicles subjected to heavy or severe use pattern...

Page 68: ...nt Daily Check level XU Power steering unit if equipped Daily Inspect daily clean often Head lamp tail lamp Daily Verify proper operation XU Air filter Weekly Inspect replace as needed XU D Brake pad wear 10 H Monthly 100 160 Inspect periodically Battery 25 H Monthly 200 320 Check terminals clean test Fuel System 25 H Monthly 200 320 Inspect cycle key to pressurize fuel pump check lines and fittin...

Page 69: ...eeded Throttle body air intake ducts flange 50 H 6 M 500 800 Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M 500 800 Inspect adjust replace as needed Cooling system if applicable 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly XU Radiator if applicable 50 H 6 M 500 800 Inspect clean external surfaces XU Oil lines and fasteners 50 H 6 M 1000 1600 Insp...

Page 70: ...utches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24 M 2000 3200 Change every two years Ratcheting cam chain tensioner 200 H 2000 3200 Check adjust as needed Suspension bushings 250 H 24 M 2000 3200 Inspect replace if necessary Spark arrester 300 H 36 M 3000 4800 Clean out D Valve ...

Page 71: ...ase conforming to NLGI No 2 Grease one fitting on each side of the vehicle ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart Always use the recommended engine oil Always change the oil filter whenever changing oil OIL RECOMMENDATIONS DW INDUSTRIES recommends the use of PS 4 5W 50 4 Cycle Oil or a similar oil Refer to the Specifications section f...

Page 72: ...l level 6 Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill 7 Reinstall the dipstick 8 Lower the cargo box and push down securely to latch OIL AND FILTER CHANGE Always change the oil and filters at the intervals outlined in the Periodic Maintenance Chart section Always change the oil filter whenever changing oil The crankcase drain plug is located on the ...

Page 73: ... filter cover screws and oil filter cover 9 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 10 Install the new filter into the cover 11 Reinstall the drain plug Torque the drain plug to 12 ft lbs 16 Nm 12 Install the cover on the engine tighten oil filter cover screws 9 ft lbs 10Nm 13 Start the engine and check for leaks 14 ...

Page 74: ... end of the outlet hose Tighten the clamp 20 Reinstall the fuel line and spark plug wires to the retaining clips on the outlet hose 21 Lower the cargo box and push down securely to latch 22 Dispose of used filter and oilproperly GEARCASES GEARCASE SPECIFICATIONCHART GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG TORQUE Main Gearcase Transmission SAE80 API GL 5 Gearcase Lubricant Transmiss...

Page 75: ...e on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid to the bottom of the fill plug hole Do not overfill 5 Reinstall the fill plug Torque to specification OIL CHANGE The drain plug is located near the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug w 3 Remove the drain plug Allow the fluid to drain completely 4 Clean...

Page 76: ...f the front gearcase 1 Position the vehicle on a level surface 2 Place the transmission inPARK 3 Remove the fill plug Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification OIL CHANGE 1 Support the vehicle securely with a jackstand 2 Remove the fill plug 3 Place a drain pan under the drain plug 4 Remove the drain plug Allow the oil to drain comple...

Page 77: ... Reverse the procedure for spark plug installation Apply anti seize compound to the spark plugthreads 4 Torque to specification NORMAL PLUG The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip ind...

Page 78: ...ecommended by adding coolant to the overflow bottle ADDING OR CHANGING COOLANT DW INDUSTRIES recommends the use of DW INDUSTRIES Antifreeze 50 50 Premix This antifreeze is already premixed and ready to use Do not dilute with water To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 P...

Page 79: ...here may be a leak in the system Your DW INDUSTRIES dealer can inspect the cooling system RADIATOR COOLANT LEVEL Check the radiator coolant level ONLY if the overflow bottle is dry If the overflow bottle contains fluid the radiator level should NOT be inspected 1 Open the hood 2 If the overflow bottle is dry slowly remove the radiator pressure cap 3 View the coolant level through theopening 4 Use ...

Page 80: ...nts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your DW INDUSTRIES dealer or other qualified person for service and repair assistance This CVTsystem is inte...

Page 81: ...overs to fail Switch to low range while operating at slower speeds to extend the life of the CVT components belt cover etc CVT DRYING There may be some instances when water is accidentally ingested into the CVT system Use the following instructions to dry it out before operating 1 Remove the clutch cover drainplug 2 Allow the water to drain Reinstall the drain plug 3 Place the transmission in PARK...

Page 82: ...sible whether you succeed in starting it or not Your DW INDUSTRIES dealer can provide the required service 8 If water has been ingested into the CVT follow the CVT Drying procedure STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart section 1 Position the vehicle on level ground 2 Lightly turn th...

Page 83: ...rated in wet conditions or at high throttle for extended periods 1 Lift the cargo box to access the air box 2 Release the air box cover latches and remove the cover 3 Remove the air filter 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean cloth 5 Install a new filter if needed Do not attempt to clean the air filter CVT INTAKE SCREEN The CVT intake screen is locate...

Page 84: ... pedal Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection andgloves Never run the engin...

Page 85: ...ir in the driver s side wheel well 4 The level should be between the upper MAX and lower MIN level lines 5 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 6 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottl...

Page 86: ...etting at the factory The factory setting is appropriate for nearly all riding conditions If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Always heed the following rules if you make adjustments to this suspension Always return the suspension to the lowest setting after the load is removed from the vehicle The increased suspension height will negat...

Page 87: ...RELOAD SETTINGS Front 6 5 8 168 3 mm Rear 1 5 8 41 3 mm Your DW INDUSTRIES dealer can provide the tool required to make suspension adjustments 1 Elevate the vehicle to allow the suspension to fully extend 2 Loosen the jam nut and back it away from the adjusting ring 3 Turn the adjusting ring to the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease pre...

Page 88: ... Lug Nut Aluminum Wheels Front and Rear 120 ft lbs 163 Nm Lug Nut Tapered Front and Rear 60 ft lbs 81 Nm Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of t...

Page 89: ...n fuse then replace the fuse Raise the front hood cover to access the fuses Spare fuses are provided in the fuse box If you suspect that a fuse or relay may not be working properly please see your DW INDUSTRIES dealer LIGHTS Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out ...

Page 90: ... 2 Place the transmission inPARK 3 Measure the distance from the floor to the center of the headlight and makea mark on the wall at the same height 4 Apply the brakes Start the engine Turn on the headlights 5 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this...

Page 91: ...Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 91 before installing the battery 1 Ensure that the battery is fullycharged 2 Place the fully charged battery in the battery holder Make sure the positive terminal is toward the driver s side of the vehicle 3 ...

Page 92: ...nd fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the batter...

Page 93: ...ean will not only improve its appearance but it can also extend the life of various components The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently Water in the CVTsystem could cause the drive belt to become wet and slip...

Page 94: ...mponents and could remove paint and labels Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring Air intake components If an informational or graphic label becomes illegible or comes off contact your DW INDUSTRIES dealer to purchase a replacement Replacement safety labels are ...

Page 95: ...nd filter See page 69 AIR FILTER AIR BOX Replace the air filter See the Filter Systems section for details Clean the air box INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart section BATTERY MAINTENANCE See page 89 and page 90 for storage and charging procedures FLUID LEVELS Inspect the fluid levels Add or change fluids...

Page 96: ...th a protective film of fresh oil 6 Reinstall the spark plugcaps 7 If DW INDUSTRIES fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline STORAGE AREA COVERS Be sure the storage area is well ventilated Cover the vehicle with a genuine DW INDUSTRIES cover Do not use plastic or coated materials They do not allow enough ventilation to prevent con...

Page 97: ...prevent loss during transporting 4 Secure the fuel cap hood doors if equipped and cargo box Ensure that the seats are attached correctly and are not loose 5 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure ...

Page 98: ...96 ...

Page 99: ... Capacity 2000 lbs 907 kg Hitch Tongue Capacity 150 lbs 68 kg Max Cargo Box Load 440 lbs 200 kg Overall Length 113 in 286 8cm EPS w Winch and Aluminum Wheels Overall Width 66 in 168 cm Overall Height 75 in 190 cm Wheelbase 75 in 191 5 cm Cargo Box Dimensions Inside 32 x55 x 10 in 82 x 141 x 25 cm Ground Clearance 13 in 34cm Min Turning Radius 190 in 483 cm Engine 4 Stroke DOHC Twin Cylinder Displa...

Page 100: ...ange H L N R P Transmission Gear Ratio High 10 88 1 Transmission Gear Ratio Low 21 52 1 Transmission Gear Ratio Reverse 26 32 1 Front Rear Drive Ratio 3 666 1 Tire Size Front 26 x 9 14 27 x 9 14 Tire Size Rear 26 x 11 14 27 x 11 14 Tire Pressure Front 10 psi 69 kPa 12 psi 87 kPa Tire Pressure Rear 18 psi 125 kPa 14 psi 96 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 2...

Page 101: ...d carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Belt slippage fr...

Page 102: ...ark plug Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your authorized dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your authorized dealer can assist ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark p...

Page 103: ...en Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Throttle release switch malfunction Your dealer can assist Other mechanical failure Your dealer can assist ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Water is present in fuel Replace ...

Page 104: ... fresh recommended fuel Clogged air filter Inspect and clean or replace Throttle release switch malfunction Your dealer can assist Other mechanical failure Your dealer can assist Overheated engine Clean radiator screen and core clean engine exterior Your dealer can assist ...

Page 105: ...egistration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH DW INDUSTRIES Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTYCOVERAGEANDEXC...

Page 106: ...ended lubricants or fluids is not covered by thiswarranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT DW INDUSTRIES OPTI...

Page 107: ...S WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW ...

Page 108: ... selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair IF YOU MOVE If you move to another country be sure to contact DW INDUSTRIES Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may...

Page 109: ...u may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect U S A EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the DW INDUSTRIES standard limited warranty for your vehicle DW INDUSTRIES Industries Inc warrants that at the...

Page 110: ...e additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension ...

Page 111: ...ehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Fuel system Ignition system Exhaust gas recirculationsystems The following parts are also considered emission related components for e...

Page 112: ...ECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHAN...

Page 113: ...pair shop or person may maintain replace or repair the emission control devices or systems on your vehicle An authorized DW INDUSTRIES dealer can perform any service that may be necessary for your vehicle DW INDUSTRIES also recommends DW INDUSTRIES parts however equivalent parts may be used for such service It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts...

Page 114: ...WARRANTY 112 MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED I COMMENTS ...

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