BMS Beast 1000 Series Owner's Manual
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BMS Beast 1000 Series Owner's Manual

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OWNER'S MANUAL
The Beast 1000cc ZT
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Summary of Contents for BMS Beast 1000 Series

  • Page 1 OWNER’S MANUAL The Beast 1000cc ZT...
  • Page 2 WARNING 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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 Owner's Manual Beast 1000...
  • Page 4 WELCOME Thank you for purchasing a DW INDUSTRIES vehicle, and welcome to our world-wide family of DW INDUSTRIES enthusiasts. We believe DW INDUSTRIES sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your DW INDUSTRIES vehicle, making it the finest machine we’ve ever produced.

  • Page 5: Table Of Contents

    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: Introduction

    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 with their meanings before reading the manual.
  • Page 7 INTRODUCTION INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your DW INDUSTRIES vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 8 VEHICLE IDENTIFICATION NUMBERS Vehicle Model Number: ① Frame VIN ② Engine Serial Number...

  • Page 9: Safety

    SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for DW INDUSTRIES. DW INDUSTRIES strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course.
  • Page 10 SAFETY SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over- the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.
  • Page 11 SAFETY HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, 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.
  • Page 12 SAFETY SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
  • Page 13 SAFETY SEAT BELT/DRIVE RESPONSIBLY WARNING WARNING Improper vehicle use can result in SEVERE INJURY or DEATH BE PREPARED • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use cab nets and/or doors. • Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or hand holds.
  • Page 14 SAFETY LOAD/PASSENGER/TIRE PRESSURE WARNING The Load/Passenger/Tire Pressure warning decal is located on the front panel of the rear cargo box ①. WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. •...
  • Page 15 SAFETY FUEL TRANSPORT WARNING The Fuel Transport Warning is located in the cargo box. WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death. OPERATOR SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.
  • Page 16 SAFETY • Always have this vehicle checked by an authorized DW INDUSTRIES dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. •...
  • Page 17 SAFETY EQUIPMENT MODIFICATIONS Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.
  • Page 18 SAFETY OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle.
  • Page 19 SAFETY CAB DOORS Riding in this vehicle without closed and latched cab doors increases 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 while riding in this vehicle. Cab doors are NOT intended to be used as arm rests.
  • Page 20 SAFETY REFUELING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.
  • Page 21 SAFETY OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
  • Page 22 SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

  • Page 23: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS ⑦ Receiver Hitch ① Console ⑧ROPS Cab Frame ② Headlights ③Radiator ⑨ Cargo Box ④Front Bumper/ Brush Guard ⑩ Taillights ⑤Muffler (Spark Arrester) ⑥ CV Boot/Rear Caliper...
  • Page 24 FEATURES AND CONTROLS GEAR SELECTOR Low gear is the primary driving range for your vehicle. High gear is intended for use on hard-packed surfaces with light loads. Using high gear for heavy loads, hilly terrain or in wet, muddy conditions will increase the chance of drive belt burning.
  • Page 25 FEATURES AND CONTROLS SWITCHES IGNITION SWITCH The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. The engine is off.
  • Page 26 FEATURES AND CONTROLS LIGHT SWITCH The ignition switch key must be in the ON/ RUN position to operate the headlights. Press the top of the switch to place the headlights on high beam. Move the switch to the center position to place the headlights on low beam.
  • Page 27 FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL ① Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1.
  • Page 28 FEATURES AND CONTROLS SEATS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 29 FEATURES AND CONTROLS SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2.
  • Page 30 FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position.
  • Page 31 FEATURES AND CONTROLS FUEL CAP NOTICE Never use fuel blends with more than 10% ethanol. Engine damage could occur. The fuel tank filler cap ① is located on the left side of the vehicle near the driver seat. Use only unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane.
  • Page 32 FEATURES AND CONTROLS CAB DOORS This vehicle is equipped with cab doors. Riding in this vehicle without closed and latched cab doors increases 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 this vehicle.
  • Page 33 FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
  • Page 34 FEATURES AND CONTROLS Odometer When selected, the odometer registers total distance traveled in miles while the ignition is on A. To change the display from trip meter to odometer, press and release the Odometer/Trip meter select button. Functions switch: Press the MODE button. The modes of ODO, TRIP A, TRIP B, HRA and HRB will display in the odograph and be switched between.
  • Page 35 FEATURES AND CONTROLS INDICATOR LAMPS LAMP INDICATES CONDITION When standard mode is selected, speed displays in miles per hour. Vehicle Speed When metric mode is selected, speed displays in kilometers per hour. Over This lamp illuminates to indicate an overheated engine. If the Temperature indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.
  • Page 36 FEATURES AND CONTROLS Km/h & mph mode change Press the MODE button; choose either Km/h or mph as needed. Other indicator lights Coolant temperature indicator light “ ” It indicates the temperature of coolant, if the temperature is above 102℃, stop engine immediately.
  • Page 37 FEATURES AND CONTROLS Check engine indicator light “ ” After turning the ignition switch on, the light shall be on, and the light shall be off after starting the engine. If the lamp is on while the engine is on, it indicates that the system has an error.
  • Page 38 FEATURES AND CONTROLS WARNING WARNING WARNING...

  • Page 39: Operation

    OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
  • Page 40 OPERATION CVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
  • Page 41 OPERATION PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. ITEM REMARKS PAGE Brake System/Pedal Travel...
  • Page 42 OPERATION On–Command four-wheel drive and differential gear lock switches 1. On-Command four-wheel-drive switch “2WD”/“4WD” 2.On-Command differential gear lock switch “4WD”/“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.
  • Page 43 OPERATION HAULING CARGO WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: • Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, non-factory installed accessories, loads in the rack or box and the load on the trailer tongue.
  • Page 44 OPERATION WARNING Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely. TOWING LOADS Towing improperly can alter vehicle handling and may cause loss of control or brake instability.
  • Page 45 OPERATION BELT LIFE To extend belt life, use low gear when hauling or towing heavy cargo. DUMPING THE CARGO BED The cargo bed can be tilted to the dump position at any point. 1. Stop the vehicle on a level surface.Avoid parking on a slope. 2.
  • Page 46 OPERATION TOWING THE GENERAL Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See page 97. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral.
  • Page 47 OPERATION DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.
  • Page 48 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 49 OPERATION 7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. DRIVING ON A SIDEHILL Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover.
  • Page 50 OPERATION...
  • Page 51 OPERATION 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4. Avoid operating through deep or fast-flowing water. WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast- flowing water, which could result in loss of control and lead to serious injury or death.
  • Page 52 OPERATION 6. Remove the ignition key to prevent unauthorized use. PARKING ON AN INCLINE Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Engage the parking brake (if equipped). 4.

  • Page 53: Winch Guide

    WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 54 WINCH GUIDE 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 55 WINCH GUIDE WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to think through the winching you are about to do. •...
  • Page 56 WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
  • Page 57 WINCH GUIDE WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace DW INDUSTRIES winch parts (including the cable) with genuine DW INDUSTRIES replacement parts available at your authorized DW INDUSTRIES dealer.
  • Page 58 WINCH GUIDE 8. Read and adhere to the following information for winch damping to ensure safe winch use. a. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be heavy jacket, tarp, or other soft, dense object.
  • Page 59 WINCH GUIDE 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle.
  • Page 60 WINCH GUIDE 15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task. a. Release the clutch on the winch. b.
  • Page 61 WINCH GUIDE 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged.
  • Page 62 WINCH GUIDE 2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading. 3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds.
  • Page 63 WINCH GUIDE 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 65: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.

  • Page 67: Maintenance

    MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair 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 for emissions-related service, however equivalent parts can be used.
  • Page 68 MAINTENANCE WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized DW INDUSTRIES dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log.
  • Page 69 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) HOURS CLNDR REMARKS ITEM Demand drive fluid (front gearcase) (if Monthly 25 H Perform a break-in oil level check equipped) Monthly Transmission oil 25 H Perform a break-in oil level check Engine oil change Perform a break-in oil change 25 H (break-in)
  • Page 70 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) ITEM HOURS CLNDR REMARKS 1000 Engine mounts Inspect 100 H 12 M (1600) Exhaust muffler 1000 Inspect 100 H 12 M /pipe (1600) 1000 Remove and grease Drive shafts 100 H 12 M (1600) 1000 Spark plug...
  • Page 71 MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
  • Page 72 MAINTENANCE OIL CHECK Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components.
  • Page 73 MAINTENANCE CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components. Access the oil fill cap, filter under the console cover. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
  • Page 74 MAINTENANCE 16. Reinstall the dipstick completely. Remove the dipstick and check the oil level. 17. Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the dipstick. Do not overfill. 18. Reinstall the fill cap. Reinstall the dipstick. 19.
  • Page 75 MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. OIL CHECK The fluid check/fill plug is located on the rear of the gearcase. Maintain the oil level even with the bottom of the plug hole threads.
  • Page 76 MAINTENANCE FRONT&REAR GEARCASE Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications.
  • Page 77 MAINTENANCE SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use DW INDUSTRIES-recommended spark plugs or their equivalent. SPARK PLUG GAP / TORQUE ELECTRODE GAP PLUG TORQUE...
  • Page 78 MAINTENANCE WET FOULED PLUG The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are: incorrect spark plug type or heat range, excessive engine oil consumption or incorrect throttle body adjustments.
  • Page 79 MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface. 2.
  • Page 80 MAINTENANCE 5. Reinstall the pressure cap securely. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your DW INDUSTRIES dealer can provide the correct replacement part. 6. With the pressure cap securely installed, add coolant to the overflow bottle to the recommended level.
  • Page 81 MAINTENANCE 3. Remove the clutch cover screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the CVT system. Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.
  • Page 82 MAINTENANCE VEHICLE IMMERSION WARNING If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your dealer can provide this service. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below: 1.
  • Page 83 MAINTENANCE POWER STEERING UNIT If your model is equipped with power steering, frequently clean the areas around ① and on the power steering unit to allow proper cooling. Clean these areas thoroughly. FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart.
  • Page 84 MAINTENANCE SPARK ARRESTER WARNING 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.
  • Page 85 MAINTENANCE BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 86 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.
  • Page 87 MAINTENANCE SUSPENSION SETTINGS (EPS) FRONT/REAR SPRING PRELOAD (EPS) The front and rear suspensions are preload adjustable. The suspensions are set on the lowest setting 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.
  • Page 88 MAINTENANCE SETTING COMPRESSION DAMPING Softest Position 1 Factory Position 2 Firmest Position 3 TIRES WARNING 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”...
  • Page 89 MAINTENANCE WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5.
  • Page 90 MAINTENANCE HEADLIGHT REPLACEMENT If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
  • Page 91 MAINTENANCE BATTERY Your vehicle has a sealed battery, which requires little maintenance. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.
  • Page 92 MAINTENANCE BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
  • Page 93 MAINTENANCE STATE OF VOLTAGE ACTION CHARGE TIME* CHARGE *(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY) 100% 12.8-13.0 volts None, check at 3 None required mos. from date of manufacture 75%-100% 12.5-12.8 volts May need slight 3-6 hours charge, if no charge given,...
  • Page 94 MAINTENANCE 3. Dry surfaces with a chamois to prevent water spots. WASHING TIPS • Avoid the use of harsh cleaners, which can scratch the finish. • Do not use a power washer to clean the vehicle. • Do not use medium to heavy duty compounds on the finish. •...
  • Page 95 MAINTENANCE STORAGE TIPS NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. CLEAN THE EXTERIOR Make any necessary repairs and clean the vehicle as recommended. STABILIZE THE FUEL 1.
  • Page 96 MAINTENANCE FOG THE ENGINE 1. Treat the fuel system with Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.
  • Page 97 MAINTENANCE TRANSPORTING THE GENERAL Follow these procedures when transporting the vehicle. 1. Place the transmission in PARK. Stop the engine. 2. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 3. Remove the key to prevent loss during transporting. 4.

  • Page 99: Specifications

    SPECIFICATIONS SPECIFICATIONS BMS THE BEAST 1000 EPS BMS THE BEAST 1000 EPS EPS Maximum Weight Capacity (including operator, 880 lbs. (400 kg) passenger, cargo, non-factory installed accessories) 1606 lbs. (730 kg) (EPS w/Winch and Aluminum Dry Weight Wheels) Fuel Capacity 7.9 gal.
  • Page 100 SPECIFICATIONS BMS THE BEAST 1000 EPS EPS Fuel System Electronic fuel injection Ignition System Electronic Spark Plug / Gap DCPR7E / 0.7-0.8 mm Front Suspension Independent Double A-arm w/12.25 in. (31 cm) of travel Rear Suspension Independent Double A-arm w/13.25 in. (33.7...

  • Page 101: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground Drive at a higher speed or use low range more frequently. speed (3-7 MPH) Warm the engine at least 5 minutes.
  • Page 102 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE...
  • Page 103 TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug...
  • Page 104 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Throttle release switch Your dealer can assist malfunction Other mechanical failure Your dealer can assist Overheated engine Clean radiator screen and core, clean engine exterior. Your dealer can assist.

  • Page 105: Warranty

    WARRANTY WARRANTY LIMITED WARRANTY DW INDUSTRIES Industries Inc. gives a SIX MONTH LIMITED WARRANTY on all components of your DW INDUSTRIES vehicle against defects in material or workmanship. DW INDUSTRIES further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with DW INDUSTRIES recommendations.
  • Page 106 WARRANTY This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: •...
  • Page 107 WARRANTY ABOVE SIX MONTH WARRANTY PERIOD. DW INDUSTRIES DISCLAIMS ALL EXPRESS 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 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a DW INDUSTRIES Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) DW INDUSTRIES suggests that you use your original selling dealer;...
  • Page 109 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from DW INDUSTRIES.
  • Page 110 WARRANTY purchase 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 WARRANTY This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions.
  • Page 112 WARRANTY The following parts are considered emission-related components for evaporative emissions: • Fuel Tank • Vacuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • Purge Valves • Clamps* • Vapor Hoses •...
  • Page 113 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. DW INDUSTRIES may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which DW INDUSTRIES has no responsibility, or by acts of God.

  • Page 114: Maintenance Log

    WARRANTY MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. MILES (KM) DATE TECHNICIAN SERVICE PERFORMED I OR HOURS COMMENTS...

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