SHREDDER OWNER’S/OPERATOR’S MANUAL Original Instructions Never allow any child under the age of 16 to operate a DTV Always wear a helmet, it could save your life! Read this manual thoroughly! It contains important safety information.
To the Owner Congratulations on your purchase of the BPG Werks DTV Shredder. This Owner’s/Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable DTV operation. For questions regarding operation and maintenance for this DTV, Please email help@bpgwerks.
To emphasize special important information in the manual, please note the following : This is the alert symbol. The symbol means ATTENTION!, BECOME ALERT!, YOUR SAFETY IS INVOLVED. ! To emphasize important safety information, the word WARNING, with the alert symbol, has special meaning.: ! Indicates a potential hazard that could result in SEVERE INJURY or DEATH to the operator, bystander or person inspecting or repairing the DTV.
TABLE OF CONTENTS WARNING LABEL LOCATIONS................ 1 WARNING LABELS................. 2 SAFETY .............................................. 4 DESCRIPTION AND PART FUNCTIONS.. 5 RIGHT HAND BRAKE LEVER...............5 THUMB THROTTLE LEVER.................. 5 ENGINE KILL SWITCH LANYARD........ 5 HANDLE LOCK RELEASE LEVER......... 5 FUEL TANK CAP.................................5 PULL START CORD............................ 5 CHOKE LEVER.................................. 5 FUEL PETCOCK...................
WARNING LABEL LOCATIONS 2 1 3 4 1
1 fit of the helmet. Securely restrain anything loose that reaches below the deck. Guards are supplementary safety devices. The restraint of hair and clothing is the primary means of avoiding Entanglement, Death or Injury. ! SAFETY WARNINGS UNDER Improper DTV use can result in SEVERE INJURY or DEATH B EE R ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR 16 B EE R Operating the DTV if you are under the age of 16 increases your chance of severe injury or death.
WARNING LABELS 3 2 ! ! WARNING Keep hands, fingers, feet away from sprockets, chains, rollers and track. OPERATION WARNINGS Use caution when applying brakes. Avoid using brakes at high speeds. Sudden braking may result in a rollover and personal injury. Always attempt to decrease speed by gradually letting off 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.
SAFETY Never allow anyone under the age of 16 to operate this DTV. Never take drugs or alcohol before or during operating this DTV. Always wear an approved helmet. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. Never traverse, climb or go down a hill that has over a 30° maximum incline. Avoid hills with loose or slippery terrain.
DESCRIPTION AND PART FUNCTIONS Engine Kill Switch Lanyard Fuel Tank Cap Brake Lever Handle Lock Release Lever: Handle can be adjusted when the Handle Lock Release Lever is pulled toward the hand grip. Fuel Tank Cap: To open the fuel tank cap, turn the cap counter clockwise to remove. To re-install the cap, turn the cap clockwise until snug. Make sure the cap is seated properly .
DESCRIPTION AND PART FUNCTIONS Fuel Petcock Deck “ON” position: 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. Fuel Petcock: The Fuel Petcock has 3 positions: “OFF”, “ON”, “RESERVE” Position Locations: “ON” - 6 oclock “OFF” - 9 oclock “RESERVE” - 12 oclock “OFF” position: Fuel will not flow to the carburetor in this position.
FUEL FUEL AND OIL Fuel Filling Never use leaded gasoline in this product. It could affect the engine’s emissions and damage the engine. This DTV requires clean unleaded regular gasoline. 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). Gasoline/ Ethanol blends A blend of unleaded gasoline with Ethanol, also known as GASOHOL, at or below 10% (E10 ) can be used in your DTV.
Battery Type: 12V Li-Po Operating temperature range: -20C to +55C Storage conditions: -5C to +35C, and less than 75% relative humidity ! WARNING The battery can catch fire, explode or leak if the safety items listed below are not followed: • Do not immerse the battery in water or seawater. Keep the battery in a cool dry environment during storage. • Do not mix the battery with a different type (such as dry battery ) or a battery with different performance characteristics altogether.
BREAK - IN Break in period The initial 5 hours of operation is most important in the life of your DTV. Proper operation during this break in period will help assure maximum life of your DTV engine. The following guidelines will explain the proper break in procedures. 1. During the first 5 hours of operation, do not apply more than 1/2 throttle. stress could cause damage to the engine components. Be careful not to load the engine too much.
PRE-RIDE INSPECTION Inspecting and checking the condition of the DTV before each ride is important. 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. ! WARNING Failing to inspect and maintain your DTV could be hazardous.
RIDING THE DTV ! WARNING ! WARNING Carrying a passenger on this DTV could be hazardous Riding this DTV on any public road or highway could be hazardous. Carrying a passenger could cause loss of control resulting in severe injury of death to the operator and/or the passenger. You could collide with another vehicle if you ride on public roads or highways resulting in severe injury or death. This DTV is designed for one operator and no passengers. Never allow a passenger.
RIDING THE DTV HELMET, EYE PROTECTION, PROTECTIVE CLOTHING Helmet Wearing a helmet (1) can prevent a severe head injury. Whenever riding a DTV always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
RIDING THE DTV STARTING ENGINE To start the engine 1. Set the parking brake. 2. Make sure the Engine Stop Switch Lanyard is attached before attempting to start 3. Place the Fuel Petcock to the “ON” position 4. If engine is cold, place the choke lever to the “ON” position (pulled out). Note: If the engine is already warm the choke may not be needed. 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).
RIDING THE DTV 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. ! WARNING ! WARNING Operating this DTV at excessive speeds could be hazardous. Riding at excessive speeds increases your chances of losing control of the DTV, which could result in severe injury or death. Always go at a speed that is proper for the terrain, visibility, operating conditions, operator skill, and operator experience.
RIDING THE DTV TURNING DTVs are different than many other types of vehicles in that turning is controlled by the weight of the rider shifting right or left. Steps for proper turning: Practice these steps on a flat, level, obstacle free surface. 1. Let off the throttle to slow down before a turn. The vehicle decelerates very quickly on its own due to the resistance of the tracks. Use brakes if necessary.
RIDING THE DTV RIDING ON HILLS Climbing a hill 1. Stop and evaluate the hill before attempting to climb. Make 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.
RIDING THE DTV Riding over obstacles Descending a hill To operate the DTV down a hill, follow the instructions below. 1. Stop and evaluate the hill before attempting to descend. Make sure the hill is not too steep, the terrain is not loose or slippery and that there are no obstacles. 2. Do not go down the hill on a sharp angle, this could cause the DTV to flip over. Instead, go straight down the hill. 3. Place body weight to the rear of the DTV. 4.
RIDING THE DTV Skidding or Sliding In certain situations you may experience skidding or sliding even though the brakes are not applied. Follow the riding techniques listed below to regain control. Tracks begin to slide or skid: To regain traction, let off the throttle until control of the DTV is achieved Riding through water Riding through water can be hazardous, and can cause damage to the DTV engine if it is fast moving and/or too deep.
RIDING THE DTV Riding in cold weather Proper clothing Riding in cold weather can be hazardous. The body becoming exposed to cold weather for a short period of time can result in hypothermia. When the body temperature drops below normal hypothermia sets in. Symptoms include not being able to perform complex tasks with the hands. The hands become numb along with the other extremities such as arms, legs and feet. Breathing becomes quick and shallow. These are just a few of the symptoms of hypothermia.
RIDING THE DTV Riding in cold weather Pre-ride inspection Brake and throttle linkages: Cold weather requires additional pre-ride inspection of the DTV before riding. Inspect brake and throttle linkages making sure they operate freely and correctly. Ice and snow can cause these items to freeze. If the linkages are frozen, move the DTV to a warm area until these items thaw and work properly.
RIDING THE DTV Riding on snow and ice Be sure to clear the deck and soles of your boots of excess snow and ice before riding. Practice riding the DTV on snow and ice on a flat, obstacle free, familiar area. Learn how the DTV responds in these conditions before attempting to ride on any ice or snow covered trails. Go slow and practice turning and responding to sliding and skidding as explained in this owner’s manual.
RIDING THE DTV Load Guidelines After Market parts Load guidelines including accessories: After market parts and accessories may be available from other manufactures. BPG Werks cannot confirm the quality, safety or suitability of accessories available. When purchasing an accessory, use caution, the handling of the DTV could become affected. Some accessories may make the DTV unsafe to ride. If you have a question about a modification or accessory, contact your dealer or call BPG Werks.
MAINTENANCE For maintenance, your DTV may be maintained by an authorized BPG Werks service dealer or a repair shop of your choosing. Following the proper maintenance procedures and time table for maintenance listed in this manual is important for the safety of the rider and the life span of the DTV. When riding in harsh conditions, such as water, mud and dust, the maintenance procedures should be performed more often.
MAINTENANCE CHART First 5 hours of operation First 20 hours of operation or 1 month Every 50 hours or 3 months Exhaust pipe nuts and muffler bolts T T T Air cleaner element I I I ITEM Valve Clearance** I Spark Plug I I Fuel Line I I Idle speed I I Throttle cable play I I Every 100 hours or 6 months I R Engine oil R Oil should be checked after every 5 hours of use and topped up if necessary. It should be replaced every 20 hours.
MAINTENANCE Air Filter The Air Filter needs to be cleaned or replaced periodically (see maintenance chart for cleaning/replacement intervals). The Air Filter element will need to be cleaned more often if DTV is ridden in muddy, wet, or dusty conditions. A clean Air Filter will help the DTV run at peak performance allowing better gas mileage, more power and will protect the engine from the damaging effects of dirt entering the engine. 5.
Spark Plug This DTV comes equipped with an NGK BPR5ES spark plug. To inspect the spark plug, remove the plug cap then remove the spark plug from the engine. Inspect the plug for carbon deposits and clean if necessary. If plug shows excessive carbon, replace the plug. MAINTENANCE Use a thickness feeler to inspect the 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.
MAINTENANCE Engine Oil Changing the engine oil The proper amount and grade of engine oil will have a great impact on the life of the engine. Check the oil daily. Changing the engine oil as listed in the maintenance schedule is the most important maintenance procedure there is for the engine. Engine Oil fill plug and Dipstick 5. Install the drain plug and fill with the appropriate type of oil as listed in this manual. This DTV takes 600 ml (.63 qt) of 5w-30 full synthetic engine oil. 6.
MAINTENANCE Idle speed adjustment Throttle Cable adjustment The idle speed should be set at 2000 ± 200 RPMs The thumb throttle (2) should have 2.0 4.0mm (0.08 - 0.16) of free play. To adjust the idle speed: Throttle cable adjustment: 1. Remove throttle lever housing top cover (3 screws). 1. locate the idle adjustment (silver finger knob) located on the Right hand side of the vehicle just under the deck. 2. Allow the engine to warm up approximately 10 minutes 3.
MAINTENANCE Fuel Hose Brakes This DTV is equiped with hydraulic disk brakes. Brake Fluid The brakes are hydraulic and require special tools to fill the lines. If brake pressure needs to be increased see dealership for service. Fuel Hose Inspection Inspect the fuel hose for any cracks or leaks and make sure all clamps are in place. Replace the fuel hose if any defects are found.
MAINTENANCE Chain and Sprocket 5 - 15mm (0.2 - 0.6in) Sprocket Wear Diagram Chain and sprocket inspection Inspect the drive chain for wear, rust, bound links, proper lubrication and proper tension. Chain Tension Check the tension of the chain , The Chain slack should be 5 - 15mm (0.2 - 0.6in) If the drive chain has a problem correct or replace. Contact a service center for chain replacement. Chain tension (slack) adjustment A worn drive chain could also mean the sprockets may be worn. 1.
MAINTENANCE Tracks 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 automotive “tire shine” spray-on product. Track Inspection Track Inspect Tracks before each ride for cracks or frayed threads. ! WARNING Operating this DTV with excessive cracks or frayed threads in the tracks could be hazardous. Operating this DTV with worn tracks will reduce traction which could result in an accident.
Track Replacement Track replacement If a track derails while riding use the following procedure to replace it: 1. Remove the two front outside bogie wheels (remember to pull straight on the wheel so the bearing doesn’t jam on the shaft) 2. shut the fuel off at the petcock and tip the machine on its side. 3. Place track back in position ensuring it is fully engaged in the drive sprocket and in the correct position around the upper and lower bogie wheels. Then push the track over the front bogie wheels.
MAINTENANCE Steering Adjustment Steering Resistance If the DTV pulls to the left or the right when attempting to ride a straight line, adjust the steering connecting rod length to bring it back to centre (first ensure it’s not because the deck is being tilted inadvertently while riding). Turn the rod clockwise to shorten it and bias the steering to the left. Turn the rod counterclockwise to lengthen it and bias the steering to the right.
MAINTENANCE Lubrication Points Locate the Grease points on the DTV. Lubricate points 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.
MAINTENANCE Fastener Torque Values FASTNER TYPE 5mm hex bolt and nut 6mm hex bolt and nut 8mm hex bolt and nut 10mm hex bolt and nut 12mm hex bolt and nut 5mm screw 6mm screw 8mm screw TORQUE VALUE (N-m, kgf-m, lb-ft) 6 Nm, .62 kgf-m , 4.5 lb-ft 10 Nm, 1.04 kgf-m, 7.5 lb-ft 25 Nm, 2.49 kgf-m, 18 lb-ft 50 Nm, 5.12 kgf-m, 37 lb-ft 85 Nm, 8.71 kgf-m, 63 lb-ft 6 Nm, .62 kgf-m , 4.5 lb-ft 10 Nm, 1.04 kgf-m, 7.5 lb-ft 25 Nm, 2.49 kgf-m, 18 lb-ft Fig .
MAINTENANCE Storage If the DTV is left unused for an extended period of time proper storage maintenance is required. 4. Remove spark plug and pour 1 tablespoon of motor oil in the spark plug hole. Re-install spark plug. 1. Wash DTV thoroughly, then wax plastics and painted parts with a non abrasive auto wax. Coat rubber parts with a vinyl/ rubber protectant. Note: Keep water away from air intake and muffler outlet while washing to avoid water from entering the engine and/or components. 5.
MAINTENANCE Fuel Petcock Washing the DTV CAUTION Never wash DTV with a power washer. High pressure will penetrate bearing and o-ring chain seals which will cause damaged to the DTV. 1. Wash mud and dirt off DTV with low pressure water from a hose. 2. Wash DTV using a mild detergent or car soap using a sponge, soft rag or brush. Do not use any cleaning materials that could scratch the DTV.
TROUBLESHOOTING Engine is hard to start or will not start 1. Ensure the fuel tank petcock is in the “ON” position. 2. Ensure the engine kill switch is in the “ON” position. 3. Ensure the emergency engine kill lanyard is securely in place. 4. Ensure the deck is level. 5. Pull the choke forward if starting the engine from cold. Let engine idle for about 2 minutes while it warms up, then push in choke before riding. 6.
SPECIFICATIONS Engine Displacement 196cc Starting Manual/Electric (if equipped) Spark Plug Type NGK BPR5ES Cooling Air cooled Engine Oil Capacity 600 ml (.63qt.
VIN AND ENGINE NUMBER LOCATION VIN # The Vehicle identification number and the engine number are needed when calling for parts, service center help 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 Engine Number The engine number is located on the front bottom portion of he DTV Engine.
BPG Recreational Inc. 2940 Portland Dr. Oakville ON L6H 5W8 Canada bpgwerks.
