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MANUAL DEL USUARIO SERVICE MANUAL MANUEL D

1. 55 Fault CI ACIIO M ME 56 Sinai 62 Guarantee manual cece ccccccececececececececececececececececeaeaeavavsnenass 64 Ce KC KT SPECIFICATIONS ENGINE Cylinder size Type Cooling system Bore and stroke Injection system Ignition Clutch Gear box Transmission Starter CHASSIS Chassis Front suspension Rear suspension Front brake Rear brake Rims Front tyres Rear tyres Kick start pedal Engine disc and sprocket guard DIMENSIONS Wheel base Overall width Weight without rider Fuel tank capacity 443 cc Single cylinder 4 stroke with 4 valve cylinder head Liquid 95 x 62 6 mm MAGNETI MARELLI Integrated on injection system Hydraulic multi disc 5 speeds and reverse Primary with gears secondary with chain Electric engine and auxiliary pedal Multi tubular with double shim manufactured in Cr Mo Steel Trapezoidal arms with 2 HLINS multi adjustable shock absorbers Aluminium alloy swing arm weld free Progressive system with multi adjustable HLINS shock absorber 2 180 mm auto ventilated disc brakes with Brembo double piston calliper 2 220 mm auto ventilated disc brakes with Brembo double piston calliper Aluminium 21 x 7 00 10 20 x 11 00 9 Forged aluminium Duralumin plate and carbon fibre guard 1 280 mm 1 200 mm 175 Kg 18 litres GASGA SAFETY INFORMATION THE QUAD is
2. The oil is pumped from the oil reservoir to the engine when this is running The level of oil in the tank rises when the QUAD is not in use The oil reservoir of the engine is located in the front part of the frame To check the oil level follow the instructions below Checking the oil level Look at the two windows on the reservoir When not in use the oil should only cover half of the lower window A Upper window B Lower window CP KC Si 1 Start the engine and leave the QUAD in neutral for 3 minutes Changing the oil and filter NOTE The oil should be changed when the engine is warm this enables When the engine is started pay special attention to the care the oil to go out through the drain in the lowest part of the engine and warnings in the section on starting the engine WARNING The engine oil and the exhaust manifold can get very hot and may Cause burns Wait until the oil and the exhaust manifold are a little cooler 2 Run a cloth across the windows to clean 3 Accelerate progressively e to 2000 rpm and hold this engine speed WARNING 4 Watch how the oil completely covers the lower window and should never reach the upper window If it does allow the engine to cool and then drain the reservoir until the level is at its optimum point Engine oil is a health risk Avoid all contact with the oil as this could cause irritation and in the w
3. P A Nut n 2 bd c 3 Next the rider should attach the emergency stop system see recommendations in the section Principal parts of the bike emergency stop 4 Without using the throttle press the electric start button NOTE If the engine does not start turn the key to the OFF position and wait a few seconds before trying again The attempts should be as short as possible in order to save the battery CHANGING GEAR The quad bike is fitted with a 5 speed gear box The gear box is a return shift type implying that to go from first to third gear you must first go to second that is shift through the gears one by one CP KTP KT CAUTION Always release the accelerator to change speed otherwise the engine and the transmission could be damaged 2 As explained earlier to engage first gear from neutral you should press the clutch step on the shift pedal and release the clutch at the same time accelerating slowly 3 Once the machine has reached the desired speed release the throttle and at the same time quickly operate the clutch lever 4 Change to second gear taking care not to pass through neutral 5 Partially open the throttle and gradually release the clutch lever 6 Follow the same procedure to change to the next gear To engage first gear from neutral press the clutch press the shift pedal and slowly release the clutch The next section describes
4. i USERIVAWUAU GASGA INTRODUCTION GAS GAS thanks you for the trust you have placed in us By choosing the new WILD H P 450 you have just joined the great GAS GAS family and as a user of the number one off road motorbike manufacturer you deserve the special treatment we wish to offer you both in our after sales relations and in the explications offered in this manual Our WILD is a sporting quad bike designed by and for competition With it you can enjoy the high degree of technical perfection and reliability in addition to the careful design and high performance This manual provides you with a good basic knowledge of the features and handling of the machine It also contains important instructions concerning safety and offers information about the special techniques and skills required to drive the machine in addition to the basic maintenance and inspection procedures Thank you for your confidence and welcome to GAS GAS motos SA GASGA GENERAL ADVICE TO PROTECT THE FUTURE OF YOUR SPORT ENSURE YOU USE YOUR BIKE LEGALLY WITH CONCERN FOR THE Read this Manual carefully It explains all the aspects concerning ENVIRONMENT AND RESPECT FOR OTHERS your safety and that of third parties in addition to ensuring the correct care and maintenance of the GAS GAS quad bike which you have just purchased Driving quad bikes is a fantastic sport and we hope you enjoy it to the full PLEASE R
5. CAUTION Only use unleaded petrol The use of leaded petrol may cause serious damage to the internal working of the engine OCTANE RATING METHOD MINIMUM OCTANE RATING Antiknock Index RON MON 2 Research Octane No RON WARNING Petrol is highly inflammable and may be explosive in certain conditions Always stop the engine and do not smoke Ensure that the area is well ventilated and free from naked flames or sparks this includes spot light appliances CP KC THE COOLING SYSTEM Radiator hose Check that the radiator hoses are not cut or worn and that possible connections do not leak Radiator Check the radiator fins for obstruction from insects or mud Clean off any obstructions with a jet of low pressure water CAUTION Using a high pressure water source could damage the radiator fins and render them ineffective Do not block or divert the intake of air to the radiator by fitting unauthorised accessories Interference to the radiator may cause overheating and damage the engine Coolant This absorbs excessive heat from the engine and transfers it to the air through the radiator If the coolant level has dropped to a constant level the engine may overheat resulting in severe damage Check coolant level in tank A while the engine is cold the coolant level varies with the engine temperature The level is acceptable while it falls between the two marks If the level falls below top up
6. Start the engine warm up the engine and then stop it Check the coolant level after the engine cools down AIR FILTER CAUTION The air filter must ALWAYS be cleaned after going out with the Quad Dirt may enter the engine and damage it severely WARNING A blocked air filter allows dirt to enter the carburettor and keeps the throttle open This could cause an accident A blocked air filter restricts the entry of air to the engine increases fuel consumption and reduces engine power and damages the spark plugs NOTE There is a test hose in the lower part of the air filter casing If dust or water enter the hose empty it and clean the air filter element and casing GASGA NOTE Do not twist the element when draining 4 Remove the filter cage 5 Place the filter in a tray with degreaser This will clean the filter without damaging it Clean the filter in a well ventilated area and make sure there are no sparks or naked flames in the vicinity of the work area including spot light appliances Do not use petrol to clean the filter as this could result in an explosion 1 Lift up the seat and in the centre you can see a blue HA sponge 2 If you hold the sponge you will see a bolt E which can be loosened by 6 Next drain it gently and leave to dry a few minutes hand Check the air filter for damage such as scraping hardening shrinkage 7 If
7. The starter motor does not work Battery discharged Low temperature The engine does not rotate Crankshaft locked Cylinder piston crankpin journal seizure Transmission assembly seizure Engine rotates but does not start Fuel supply incorrect Quad bike has been a long time inactive Spark plug soiled or humid Engine flooded The fuse for the starter relay has blown Remove the seat and change the fuse of the starter relay Charge the battery and investigate the causes for discharging visit a specialist workshop Start engine with start pedal Go to a specialist workshop Go to a specialist workshop Go to a specialist workshop Check the fuel pump relay by removing the seat check that the fuel pump filter situated below the fuel tank is not blocked Itis advisable to drain the old fuel from the tank When the fuel tank is refilled with new flammable fuel the engine starts immediately Dry the spark plug out or replace it To unflood the engine full throttle operate the kick start pedal 5 to 10 times or operate the electric starter twice in 5 seconds Then start the engine as described above If the engine does not start undo the spark plug and dry it FAULT CAUSE SOLUTION Engine rotates but does not start The engine starts but does not stop The engine overheats The engine does not run smoothly The engine is under powerful or accelerates
8. and the black terminal is negative FRONT GUARD The front guard juts out from the QUAD assembly In the event of ahead on collision with our vehicle the guard attached directly to the chassis will soften the blow and prevent serious damage to the steering and remainder of the vehicle REAR PROTECTION Similarly the rear guard D also juts out from the quad bike assembly This guard prevents us from overturning backwards given that an accident of this type could result in serious injury NOTE If the slope is very steep the guard will be unable to prevent the vehicle from tipping backwards therefore act with care on slopes and examine the terrain closely FOOT REST ASSEMBLY WARNING The foot protectors and foot rest assembly are a form of protection vital to the safe driving of the QUAD The quad bike has very thick wheels and these could easily drag your leg under them causing serious injury The quad bike is fitted with a pair of foot rests E one on the right and the other on the left Both foot rests have a grille The assembly CP KTP protects feet and legs from the wheels should you lose your balance and your feet slip off the rests The width permits you to move freely 1 i The foot protectors F are located between the rests and the wheels and are a further protection in addition to the foot rest assembly By filling the space we remove any possibility of inju
9. it is faulty As it is dangerous to drive under these conditions check the brakes immediately CHECKING BRAKE FLUID LEVEL NOTE Regularly check the brake fluid and periodically change it It should also be changed if it is contaminated by water or dirt Fluid level inspection Front To the left of the throttle twist grip there is a small container for the brake fluid If you observe the container carefully you will see a transparent bubble appear on one of the flat sides with which we can control what is happening inside the brake fluid reservoir If you have just bought the QUAD you will not see anything through the bubble because it is full You will see the bubble when the fluid level drops and then you will be able to control the fall in the level When the brake fluid level is very low top up With a Philips screwdriver undo both screws on the container Next top up with fluid Do up the screws and ensure that the container is correctly positioned Rear The rear brake fluid container is under the quad bike seat Take the key which opens the fuel tank and insert in the lock which appears on the right hand side of the QUAD just below the seat Turn the key Insert your hand between the seat and the casing at the back and remove the seat There is a small easily accessible reservoir A on which there are two marks MIN and MAX Ideally the level of the fluid should be near
10. start the engine and run at idle for 15 20 seconds Stop the engine and check the level of the two tanks again probably the level will have dropped because the engine has run out of fluid Refill the containers if necessary Changing coolant The coolant should be changed periodically to ensure long engine life Wait for the engine to cool completely Put the QUAD in a horizontal position Remove the radiator cap Place a bowl under the drain plug and drain the fluid from the radiator and the engine by unscrewing the drain plug which is in the lower part of the water pump cover Immediately wipe or wash off any coolant that spills on the frame engine or wheels A Cover water pump B Cap drain coolant fluid WARNING Coolant on tyres will make them slippery and can cause an accident Inspection of the coolant If white marks are visible in the fluid this means that the aluminium parts of the coolant system are corroded If the fluid is brown the parts made of steel or iron in the system are rusted In both cases clean the system Check the cooling system for damage loose joints or leaks Install the water pump cover drain plug with the specified torque shown in the table Replace seals with new ones GASG A Tighten bolts see table of tightening torques Water pump plug 9 Nm Fill the radiator up to the edge and fit the cap on the radiator Check the cooling system for leaks
11. a replacement Chain lubrication Good maintenance of the chain is essential to ensure the good CP gt lt 54 working of your quad bike Chain lubrication is one of the operations which should be carried out most often When After riding over wet ground When the chain appears dry After cleaning the motorbike If the QUAD has been immobile for a long time A high viscosity oil is preferable to a lighter oil as it will stay on the chain longer and provide better lubrication Apply oil to the side of the chain rollers so that it penetrates better dry off excess oil CHECKING COOLANT LEVEL The coolant absorbs excessive engine heat and transfers it to the air through the radiator If the level of the fluid has fallen to a constant level the engine may overheat and be damaged Check the coolant level each day before riding the QUAD NOTE The level in normal conditions should not fall If you need to add fluid very often check there are no leaks and take the bike to a specialised workshop WARNING To avoid burns do not remove the radiator cap or try to change the fluid while the engine is still hot Wait for it to cool down lt 5 lt A Anti freeze liquid information To protect the aluminium parts of the coolant system engine and radiator from rust and corrosion use chemical rust and corrosion inhibitors in the coolant If corrosion and rust inhibitors are not used in the coolant ov
12. driving at low speeds to allow the friction to dry them After cleaning Remove the plastic bags and clean the air filter intake Lubricate the locations listed in the lubrication section Start the engine and let it heat for 5 minutes CP KC LUBRICATION Lubricate the parts shown with engine oil or grease regularly or when the vehicle has been in wet weather and especially after using high pressure water Before lubricating each part clean rusty spots with rust remover and wipe off any traces of grease oil dirt or grime 1 Clutch lever 2 Front brake 3 Rear brake pedal 4 Rear brake bearing wag 5 Shift lever GASGA Use a spray with pressure tube to lubricate with pressure 6 6 Throttle cable 7 Chain Lubrication of the chain is necessary after driving on wet ground or when the chain appears to be dry A high viscosity oil is preferable to a light oil as it stays on the chain longer providing better lubrication Apply oil to the side of the chain rollers so that it penetrates better dry off excess oil STORAGE When the QUAD is to be stored for any length of time say for over 60 days you should Clean the entire quad bike thoroughly Start the engine for 5 minutes to heat the transmission oil and then drain off see section on transmission Put in fresh transmission oil Empty the fuel tank If fuel is left in
13. for any length of time it will deteriorate Lubricate the drive chain and all the cables Oil all the unpainted metal surfaces to prevent rust avoid using oils on the brakes and rubber parts Wrap the end of the exhaust in a plastic bag to prevent rusting Position the quad bike so that none of the four wheels touch the ground if this is not possible place cardboard under the wheels Put a cover over the quad to keep dust and dirt from collecting on it To get the quad back into use after storage Remove plastic bag from exhaust Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Section Daily Pre ride Inspection General lubrication MULTIFUNCTION The Multifunction has two buttons one to change the display mode and the other to reset certain functions When the battery is connected the clock timer display appears pressing Mode changes the display in the following order 1 Clock timer 2 Speed Km h or Miles hour according to the program 3 Total distance in km or miles This is stored in the memory even if the battery is disconnected 4 Trip distance can be reset Setting the time The time is set from the clock display by holding down the Mode button until the display changes to adjust hour mode where by pressing Reset the hours can be changed Pressing Mode changes to the minute adjustment which are modified as for the hou
14. have described otherwise the risk of serious injury or even loss of life is increased Checks prior to driving For the necessary safety and correct care of the QUAD always carry out the checks before driving These are explained in detail in the section Checks to make before starting the machine While driving Always use the foot rests and protectors they will protect you from serious injury to the lower limbs Always kee feet on the foot rests while driving and both hands on the handlebar WARNING As explained in this manual the use of the foot rests and protectors is vital for protecting your body Modifications Never modify the QUAD by using or fitting unsuitable accessories Parts and accessories added to this vehicle should be originals from GAS GAS or equivalent parts designed for use with this QUAD and they should be fitted and used in accordance with the instructions CP KTP On approaching a bend reduce speed and start to turn the handlebar in the desired direction Lean your body towards the inside of the bend to counteract the inertia produced by the speed Use the throttle to keep a steady speed throughout the manoeuvre This manoeuvre will enable you to take the bend correctly The picture demonstrates how to do so A 1 1 Turning to the right 2 Turning to the left Inappropriate fitting of accessories or the modification of this vehicle may result in changes to the hand
15. inflammable With a Philips screwdriver undo both bolts G and remove the lens To remove the bulb press down turning 1 4 anticlockwise remove and replace with a new one Fit the lens in the same way as you have removed it NOTE Make sure that the lens is correctly fitted Indicators Toremove the bulb press down turning 1 4 anticlockwise remove and replace with a new one Fit the lens in the same way as you have removed it and make sure that the unit is correctly fastened Using a Philips screwdriver undo the screws A located in the rear section and remove the small lens TRANSMISSION To ensure correct working of the transmission and clutch keep the transmission oil at the optimum level and change it regularly A QUAD with insufficient deteriorated or contaminated transmission oil may increase the wear and cause damage to the transmission ENGINE OIL Using a premium 4 stroke engine oil will lengthen the life of your QUAD Use oil classification SF or SG under the API classification The recommended viscosity is SAE 10W 50 if an SAE 10W 50 oil is not possible use an oil in accordance with the alternatives shown in the previous table Checking the oil level and changing the oil regularly are two very important procedures for maintaining the perfect condition of the engine GASGA KT Initially replace the oil after 5 hours of use and subsequently every 60 hours ENGINE OIL
16. it is damaged then replace otherwise dirt will enter the throttle 3 Remove the bolt and the filter Take the air filter unit body out of the casing NOTE The element should be damp but not dripping Once it has stopped dripping place itin a bath of lubricating and greasing fluid If desired you can do without the bath and totally soak the filter with this fluid the result is the same Apply sponge air filter oil to the element If you do not have any sponge air filter oil use engine oil Also clean the cage with a damp cloth as well as the filter casing Make sure that all the cavities are clean before replacing all the components of the air filter casing Grease all of the connections and bolts of the air filter and inlets Place the filter in the cage and cover the filter lip with a thick layer of grease to ensure a seal and to avoid dust penetration Fit the air filter into the QUAD and ensure that it is correctly connected CAUTION Never allow the engine to be used without having fitted the air filter element Otherwise unfiltered air would enter the engine and cause rapid wear and possibly damage In addition if the engine runs without the air filter element this could block the throttle body resulting in reduced engine performance SPARK PLUG The standard spark plug is shown in the table and should be tightened to 11 Nm GASG A The plug should be removed regularly to check
17. lever can be adjusted until it feels comfortable Tighten bolt D as shown in the picture This bolt is covered with a piece of rubber Remove the rubber and you will find a groove in which the bolt is inserted and adjusted If you tighten the bolt there will be less play and likewise if it is loosened the lever will have more play lt 5 lt A Itis also possible that air has entered the brake fluid circuit bleed the system proceed as follows Remove the cap from the brake fluid reservoir E in order to check the level Remove the cap F of the bleed screw for the brake in the interior of the wheels and fit a transparent tube onto the end Operate the brake lever several times You will see fluid start to come out of the end where we have attached the tube The transparent tube serves to show whether air is present in the circuit presence of bubbles Once the circuit has been bled top up the tank Rear brake pedal Ensure that the brake responds correctly and does not rub against any part of the QUAD To adjust play in the pedal loosen the locking nut turn the bolt place the lever in the desired position and tighten the locking nut When the brake pedal is in the rest position there should be a play of 10 mm If this is not the case adjust accordingly WARNING If the brake pedal feels spongy when operated it is possible that there may be air in the pump
18. not a toy its use may be dangerous THE QUAD is driven in a different manner to other vehicles such as cars or motorcycles A collision or overturning can happen very fast even during routine manoeuvres such as turning driving on slopes or over obstacles unless the necessary precautions are taken WARNING If these instructions are not heeded you may suffer serious injury or even loss of life Do not drive the QUAD before reading the following sections Information concerning your safety Use of the QUAD and Principal parts of the QUAD Even if you are an experienced quad bike driver not all makes and models are the same and it is imperative to understand the machine well before commencing the first trip It is forbidden to carry passengers nor is the bike adapted for this Sit correctly with both hands holding the handle bar both feet on the foot rests and your back straight Reduce your speed according to your skill experience weather conditions or ground conditions Drive with caution over changing ground and reduce speed when not familiar with the terrain Always carry out routine inspections as described in this manual before going out on the quad bike to ensure that it is in safe working condition Driving a quad bike is unlike driving any other vehicle and you will particularly notice this when turning Practice turning first on flat open ground without any other vehicles in th
19. replace them Recommended lubricant Engine oil REPLACING THE LIGHTS Front headlight 1 Remove the casing covering the headlamp by unscrewing the 5 bolts with a n 4 Allen key WARNING The bulb is hot when it is lit and immediately after having been switched off Wait for the bulb to cool before touching or removing it You could burn yourself or cause a fire if the bulb came into contact with something inflammable CP KTP A Bolts with an 4Allen key NOTE Do not touch the shiny surface B with your fingers or with a cloth as it scratches easily If it is dusty clean with a feather duster 2 Next remove the connector of the headlamp CP KTP Si 3 Undo the bolts holding the headlamp in the interior you will need to bend down to handle them D Cap E Bulb 4 Disconnect the bulb wiring and remove the cap D covering the rear part of the lamp 5 Next you will see some wire clips F holding the bulb F Wire clips holding the bulb 6 Release the bulb E from the clip and remove it through the rear 7 Replace it with a new bulb To fit the bulb follow the same procedure in reverse order Rear lights WARNING The bulb is hot when it is lit and immediately after having been switched off Wait until the bulb cools before touching or removing it You could burn yourself or cause a fire if the bulb came into contact with something
20. the engine while it is running Moving parts could catch clothing or your body and cause injury Electrical components may cause sparks electrical shocks and fire Before carrying out any maintenance work stop the engine unless otherwise indicated If not familiar with the maintenance of your vehicle itis better to take it to a specialised workshop ADJUSTING CLUTCH LEVER Correct clutch lever play is 2 3 mm The play increases with the wear of the clutch plate and thus requires adjustment When there is too much play first try adjusting the level of the clutch lever B Clutch lever A B A Adjustment bolt GASGA Tighten the adjustment bolt to obtain the optimal play If the adjustment of the clutch lever is atits maximum use the clutch cylinder piston rod to adjust play ADJUSTING BRAKE LEVER AND BRAKE PEDAL A worn disc is automatically compensated and does not affect either the brake lever or the brake pedal Therefore the only parts to require adjustment are the play of the front brake lever and the position and play of the rear brake pedal Front brake lever At first the play of the lever is directly related to the wear of the pads that is if you notice play in the lever before adjusting the play it is advisable to check the brake pads carefully in case they need changing g C Brake lever Au C D D Adjustment bolt Once you have checked the pads then the brake
21. to MAX if it is much lower top up with fluid Ce Next check that the fluid container is properly closed replace the seat and turn the key in the opposite direction Also check that the seat has been correctly replaced Recommended liquid Use D O T 3 or D O T 4 CHECKING FRONT AND REAR BRAKE PADS There are 3 brake callipers 2 in the front wheels which brake a wheel each and 1 in the transmission chain which brakes both rear wheels together All work in the same way and should be checked and controlled in the same way As we can see from the picture the brake calliper is made up of various parts The pad is the part which rubs against the disc and therefore it the part which wears down so the thickness of the pad should be checked X C Brake NN 0 Brake disc CP KC Si NOTE Never overuse the brake pads if their wear is not controlled the brake calliper unit could be severely damaged When the thickness of the pad has decreased considerably go to a shop specialising in spares and request a replacement CHANGING THE WHEELS The wheels should be changed when they are worn or when they are punctured Proceed as follows Each wheel has four bolts E which you should undo using a hexagonal wrench size 15 Loosen the bolts and remove the wheel from the shaft To refit the wheel follow the same procedure in reverse order SWING ARM It is important tha
22. with your QUAD nennen 29 Gong Up IONES 30 Going down SIOPES pp 30 CROSSING SIODeS eden nter eon den a gi 30 Crossing shallow Water 31 Driving over rough ground ppp 31 Sliding and skidding pp 31 O oo a A 32 Tuning front Suspension pp 32 Tuning rear suspension eee 33 CP KP Regular maintenance and adjustments 34 Maintenance chart 34 Adjusting clutch 35 Adjusting brake handle and pedal 35 Checking brake fluid 36 Checking front and rear brake 37 Changing wheels eee 38 SWINGING 38 Adjusting and lubricating chain guide 38 Checking coolant 39 A E 41 Spark NGS uti x mean TNES 43 Inspection and lubrication of cables 45 Replacing lightS m anna aaa 45 TE ASEM SIO A AAA 47 o A e o nn 47 Cleaning lubrication and storage 50 e e 50 y PB ll E A 51 vols C En o o E 52 CGO 53 Table of tightening torqueSs pp 54 Diagram of tightening torque
23. EAD ALL THE MANUAL BEFORE USING THE MACHINE This manual has been drawn up using the data and specifications available at the time of writing Any differences you may notice should be attributed to improvements in the production and quality of the product GAS GAS MOTOS S A is constantly improving its vehicles in order for you to better enjoy them Important information about this manual Information of special note is marked in the manual using the following notations WARNING Failure to heed the WARNING instructions may result in serious WARNING injury or loss of life for the user of the machine individuals in the 1 vicinity or the technicians responsible for its inspection or repair Hid c e MA Keep the area ventilated and free from naked flames CAUTION This symbol identifies instructions or procedures which if not strictly observed may result in the damage or destruction of the equipment NOTE This symbol indicates points of particular interest for improved efficiency and more convenient operation Inappropriate use could cause problems to the environment and conflicts with other people Responsible use of your quad bike will ensure that these problems and conflicts do not occur CONTENTS Sd PA Tm 3 General 4 OSI 5 SpecificationsS ASS 7 Information concerning your 8 Important informatiom pp 10 Identificati
24. ace it Remove the spark plug cap U27ESR N If the standard spark plug looks glassyor is white NOTE replace it The spark plug is protected by a cap Keep this clean and dry CAUTION Incorrect installation of the spark plug or use of the incorrect heat grade may cause severe damage to the engine and this damage is not covered by the guarantee Always use spark plugs recommended by GAS GAS Consult your dealer or a qualified mechanic to know which plug is best for your QUAD 7 Remove the plug and clean the carbon deposits on plug using a small bodkin or a wire brush Readjust the gap of the plug between 0 7 0 8 mm 0 028 0 031 in Before removing the carbon deposits check their colour this tells us whether the standard plug is the best for 07 2 10 035 QUT im Removing the spark plug To remove the spark plug follow the following steps 1 Remove the seat 2 Disconnect the fuel pump hoses and cables Caution The hoses contain petrol INSPECTION AND LUBRICATION OF THE CABLES WARNING Inspect the cables often and replace if they are damaged If the outer cover of the control cables is damaged this may cause corrosion The cables may start to peel or be damaged The working of the controls may be limited which could cause an accident or injury Lubricate the inner cables and the ends of the cables If the cables do not run smoothly ask a specialised workshop to
25. antifreeze Change coolant every two years NOTE The coolant fluid should oscillate between the two lines neither above nor below CHAIN Check the general condition and tension of the chain before each trip Lubricate and adjust the chain as necessary See section 12 Maintenance THROTTLE TWIST GRIP Check throttle is working correctly It should accelerate smoothly and return to idle position when released Where necessary check the assembly grease the moving components to ensure correct working LIGHTS Check headlamps and brake lights to ensure they are in perfect working condition If required make the necessary repairs for their correct working TYRES Always use the recommended tyres WARNING The use of unsuitable tyres or driving the vehicle with the tyres inflated to incorrect or uneven pressures may result in loss of control and the consequent risk of accident RAZR RAZR Tyres should be inflated to the recommended pressure Measure 21 x 7 00 10 the tyre pressure using a low pressure gauge 20 x 11 00 9 Front MAXIS Rear MAXIS CAUTION Check and adjust tyre pressures when the tyres are cold Pressure should be equal on both sides a eme 0 400 bar 40 Kpa 0 370 bar 37 Kpa 0 430 bar 43 Kpa 0 450 0 500 bar 45 50 Kpa 0 420 0 470 bar 42 47 0 480 0 530 bar 48 53 Tyre wear limit Examine how the tyres wear If wear is in the cent
26. ated with arms straight Select a low gear which allows the engine compression to act as the main brake Incorrect braking may lead to loss of traction See example in the picture CROSSING SLOPES To transversally cross a sloping surface with your QUAD you need to place your weight in such a way as to maintain the correct balance Before trying to cross a slope make sure you have learnt the basic skills on flat ground Avoid slopes with slippery surfaces and rough terrains where you might lose your balance While crossing the slope lean your body to the up side of the slope It may be necessary to correct the steering on going over loose surfaces by turning the front wheels slightly upwards When driving on slopes do not make closed turns in either an upwards or downwards direction If the QUAD starts to overturn turn the steering gradually in a downwards direction provided there are no obstacles in the way On regaining balance again turn the steering in the direction in Which you wish to travel CROSSING SHALLOW WATER With the QUAD itis possible to slowly cross water of up to 35 cm in depth Before entering the water choose your path carefully Enter the water where there are no sharp drops and avoid stones or other obstacles which may cause the QUAD to skid or lose stability Drive slowly and carefully WARNING Do not drive through rapids or water deeper than that specified in this manual Remember that if the brakes
27. badly High oil consumption The ECU pin connector generator or coil oxidised or in poor condition Petrol air mixture incorrect Trim Epprom Air supply incorrect Fuel insufficient Insufficient coolant in the circuit The radiator is soiled or partially obstructed Injection system maladjustment Trim Epprom Valve adjustment incorrect Fuel supply faulty Air filter obstruction Exhaust deteriorated with leaks Valve set too small Decompression maladjusted Piston cylinder ring diameter tolerance excessive Engine oil level is too high Remove the seat and the fuel tank clean the ECU pin connector and treat with a contact spray Clean the petrol tank ventilation Adjust the throttle body by pass Adjust the conduit of the air filter Clean the petrol tank ventilation Adjust the injector mounting Check the injector connection Check air filter conduit Fill the fuel tank with fuel Add coolant check the seal of the cooling system Clean the radiator fins or change Adjust the injection system Visit a specialist workshop Adjust the valve play Visit a specialist workshop Clean and check fuel system Clean or change the air filter Check if the exhaust system is deteriorated renew the glass fibre in the silencer if necessary Adjust the valve play Visit a specialist workshop Verify the operation of the system Adjust the
28. de of the quad bike You will find it in the rest position pull it down until it is in the operating position 14 The headlight and tail lights can only switched after the engine has been started __ 0 Dipped beam Switch slides into three positions You will find it the OFF position DE Side lights 7 1915 C Light switch D Full dipped beam switch E Main beam flash F Indicators G F G Horn To switch on the dipped beam 20 slide switch C into position O To switch on the full beam D press the red switch D The instrument panel will display the full beam lamp D To switch off the lights slide the switch to position 0 The indicators F are located in the lower part of the left hand handle By sliding the switch to the right the right hand indicator comes on and similarly the left hand indicator comes on when the switch is moved to the left The button for the horn is located in the same area G HAZARD LIGHTS Button located in the front section of the quad bike H in front of the handlebar This also works when the ignition is switched off When the ignition is switched on a lamp lights up on the button itself NOTE Be sure to heed the laws of each country with respect to the use of these lights THROTTLE TWIST GRIP Before starting the engine check that the throttle spin
29. e area Read the advice given in the manual in the section Use of your QUAD Similarly for steep hills whether you are going up or coming down Start by trying gentle slopes and increase the level of difficulty gradually Advice is given concerning this aspect in the same section as mentioned above Follow the procedures described in this manual if the engine stalls If the engine stalls and the vehicle begins to roll backwards follow the special braking procedure described in this manual Get off the quad on the up side of the slope Remember that your safety comes first and then that of the machine it is important to clearly understand this To cross a slope move your weight towards the rising section read the advice in the manual concerning this Avoid slopes which are too slippery or with a loose surface Never try to go over large obstacles such as rocks or tree trunks the machine is not prepared to do this and you may damage either you or the machine Do not deliberately skid if you do not know how to do so correctly as it could be dangerous As for the above first practice on flat open terrain without obstacles and follow the advice given in this manual You must never lose control of the machine This quad bike is designed to be driven in water with a maximum depth of 35 cm Do not use the machine in rapids read the instructions about this type of terrain carefully Remember that when the brakes get wet they
30. e pedal They should move smoothly and there should be a sensation of firmness on applying the brakes If this is not the case ask a specialised workshop to inspect the vehicle Brake fluid level Check level of brake fluid Top up with fluid if necessary See section Maintenance Recommended fluid D O T 3 or D O T 4 NOTE The fluid issued at the manufacturers is D O T 4 Brake fluid leaks Check for leaks of brake fluid around the seals of the brake fluid pipes and tank Apply brakes hard for one minute In the event of a leak ask a specialised workshop to inspect the machine A and B Fluid tanks for front and rear tanks The working of the brakes On starting the engine check the brakes while travelling at low speeds to ensure that they work correctly If they do not provide sufficient braking inspect the brake pads for wear FUEL The GAS GAS WILD 450 c c has a 4 stroke engine and takes 98 octane unleaded petrol CP KC Ensure that there is sufficient petrol in the tank NOTE We recommend the tank is not allowed to run dry If there is dirt in the bottom of the fuel tank on draining the tank the dirt might enter the engine and cause damage To open the petrol tank cap pull the clip upwards and insert one of the two red keys given to you on purchasing a GAS GAS quad bike Turn key to the right and pull cap off with the key still inserted as shown in the previous picture Recommended fuel
31. ear locked in transmission Goto a specialist workshop Shift lever damaged Change the gear lever Selector position spring broken or loose Go to a specialist workshop Down selector mechanism spring broken Go to a specialist workshop FAULT CAUSE SOLUTION Gears don t engage Broken spring of down selector Go to a specialist workshop Cylinder change if broken Go to a specialist workshop Gear ratchet spring broken Go to a specialist workshop Gear change fork damaged in the gears Change gear fork Go to a specialist workshop Gear teeth worn Change Go to a specialist workshop Gear nipple damaged Change Go to a specialist workshop Groove gear drum worn Change Go to a specialist workshop Gear change fork pivot worn Change shaft Go to a specialist workshop Drum position selector spring broken Replace spring Go to a specialist workshop Gears broken Go to a specialist workshop Clutch slipping No play in the clutch handle Go to a specialist workshop Clutch plate worn Replace the clutch plate Visit a specialist workshop Clutch housing worn Replace the clutch hub Visit a specialist workshop Clutch spring broken or weak Go to a specialist workshop Clutch plates worn Change the clutch disks Visit a specialist workshop The quad bike is unstable Steering rod nut loose Adjust the steering rod nut making sure that there is a pin be
32. er part of the chassis Use the pedal to apply the rear wheel brakes NOTE Make sure that the parking brake has been released before using the throttle B D w f We recommend attaching the cable to a resistant point as it is 2 important that this part of the cable never becomes detached E E g The cable could be tied to trousers a jacket around the P wrist but always to a resistant point Se ii AN gt WARNING Itis forbidden to use the quad bike before attaching the emergency P zF d i stop system The non observance of this warning could have serious consequences EMERGENCY STOP The quad bike is fitted with an emergency stop system This is a mechanism which prevents the quad bike from continuing to go in the event the rider falls off 16 SHIFT PEDAL The machine is fitted with a 5 speed gear box The shift pedal E is located on the left hand side of the engine and is used in combination with the clutch when changing gear FUEL TANK CAP To open the fuel tank cap turn the key anticlockwise 17 CP gt lt KT GASGA SEAT To remove the seat use the same key as for the fuel tank cap B Put the key in the lock which is located on the right hand side of the QUAD Turn the key clockwise and then insert your hand between the seat and the upper part of the casing The seat should lift easily NOTE When replacing the seat ensu
33. er time the radiator will rust This will block the cooling hoses CAUTION The use of unsuitable fluids may cause damage to the engine and the cooling system Use coolant with corrosion and rust inhibitors designed for aluminium engines and radiators in accordance with the manufacturer s instructions WARNING Coolant chemicals are harmful to the human body Follow the manufacturer s instructions Distilled water must be used with the inhibitor chemicals and the antifreeze in the coolant system If the outside temperature falls below the freezing point of water protect the coolant system with antifreeze Use a permanent type of antifreeze distilled water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminium engines and radiators in the coolant system For a coolant mixture ratio under extreme weather conditions choose the mixture ratio suited to low temperatures Coolant Level If a large quantity of liquid has been lost check the level of both containers They are located side by side on the left hand side of the quad bike Normally when the fluid in container C is below the level radiator D should be checked WARNING Only carry out these operations when the engine is cold the fluids may be hot may come out under pressure and may cause burns Remove the radiator cap and top up fluid Remove the container cap and fill up until level is between the two marks Next
34. es carbon brushes footrest rubbers tyres inner tubes cables and other rubber components b Lubricants for example oil grease etc and working fluids for example battery liquid coolant etc c Inspection adjustments and other maintenance tasks as well as all kinds of cleaning work d Damage to the paint work and consequent corrosion due to external causes such as stones salt industrial fumes and other environmental impact or inadequate cleaning with inappropriate products e Any damages caused as a result of the defects as well as any expenses incurred either directly or indirectly as a consequence of the defects for example communication costs accommodation expenses car hire costs public transport costs breakdown 65 COP IIOP truck fees courier costs etc as well as other financial losses for example those caused by the loss of the use of the vehicle loss of income time lost etc f Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle for example small or hidden imperfections noise or vibrations that are normal in use etc g Phenomena that are the result of the ageing of the vehicle for example discolouring of painted or metallic coated surfaces Various 1 GG shall have the prerogative to decide at its own discretion whether to repair or replace defective parts Where parts are replaced ownership of the parts removed shall pas
35. for making adjustments to the carburettor these adjustments should only be made by a qualified mechanic and only when necessary On delivery the carburettor has been calibrated correctly therefore no adjustments are necessary A wrench is also included for adjusting the chain and for aligning the swing arm Do not lose it it will be of great use 5 Wrench for chain and swing arm adjustment IDENTIFICATION NUMBERS Make a note of the vehicle identification number serial n information about the model and the key identification number in the spaces provided to facilitate proceedings when ordering spares or as a reference in the event of robbery Serial number B is located printed on the front This indicates the chassis number with which the vehicle is registered 095 1 Chain guard 3 Foot rest assembly 2 Swing arm guard 4 Foot protectors GASG A NOTE The vehicle serial number is used to identify your machine Key identification number The quad bike has two pairs of keys The first C and most important is the ignition key and the second D is for opening the fuel tank and seat The identification number appears just below the join of the keys as can be seen from the diagram This number is required to order a new key in the event of loss Qualification approval plate The quad bike bears the relevant qualification approval plate A which has the serial number also printed on the
36. fore trying such manoeuvres choose the terrain carefully as stability and control are reduced while manoeuvring Remember that skids on extremely slippery surfaces such as ice should be avoided as you could lose control completely NOTE Learn to safely control skids by practicing at low speed on smooth flat terrain CP KTP KT TUNING TUNING FRONT SUSPENSION Formed of two trapezoidal arms with 2 OLHINS multi adjustable shock absorbers To adjust to different styles of driving the shock absorber spring can be adjusted or replaced by an optional one The strength can be easily adjusted therefore it is not necessary to change the oil viscosity Extension adjustment WARNING The suspension parts heat up when working Never touch the adjustment control of the shock absorber compressor the adjustment control of the shock absorber extension or the oil reservoir with bare hands or any other part of the body until the compression components have cooled A To adjust the extension turn the control B of the lower part of the shock absorber by hand There is a possibility of 22 clicks in total The standard rebound adjustment measurement is 7 clicks Turn clockwise to the maximum now it is totally closed Turn anticlockwise until 7 clocks have been heard now it is in standard position If it is set at O clicks the extension is too stiff on the other hand if it is set at 22 clicks the extension is too s
37. front This number should match that which appears in the accompanying documents We recommend you write the information in the following table 11 lt 5 lt A KT LOCATION OF COMPONENTS GAS GAS WILD HP 450 1234 1 Clutch handle 2 Light switch 3 Light flash button 4 Full beam button 5 Emergency stop 6 Ignition key 7 Parking brake 8 Start and stop engine control 12 9 Front brake handle 10 Throttle twist grip 11 Front guard 12 Brake pads 13 Fuel tank cap 14 Foot rest grille 15 Rear guard 11 12 13 14 15 19 20 21 22 16 Front headlight casing 17 Throttle housing 18 Seat 19 Front shock absorber 20 Engine 21 Shift pedal JAN 1 a 25 26 22 Swing arm 23 Exhaust pipe 24 Front brake fluid tank 25 Kick start pedal 26 Brake pedal 27 Engine oil tank cms lt 5 lt 54 24 27 Ce2 gt gt PRINCIPAL PARTS OF THE QUAD IGNITION KEY Key A is located in the front section of the handle bar To switch on the ignition turn the key clockwise to position ON Turn the key anticlockwise to switch off the ignition until reaching the position OFF STARTER The quad bike is fitted with an electrical starter motor and a manual kick starter using the pedal The control B is located to the right of the handle bar The pedal C is located on the right hand si
38. get wet the braking capacity may be reduced Check the brakes when you come out of the water If necessary pump the brakes several times to allow the friction to dry them NOTE After driving the QUAD through water do not forget to eliminate trapped water by dismounting the retainer hose located at the bottom of the air filter housing Wash with fresh water if you have been driving through salt water or mud CPi KTP DRIVING ON ROUGH GROUND Driving over rough ground should be carried out carefully In this way any obstacle which may cause damage to the QUAD destabilize it or cause an accident can be seen Keep feet firmly on the foot rests at all times Avoid jumping with the vehicle as this may cause you to lose control and damage the machine SLIDING AND SKIDDING When driving over loose or slippery surfaces take care as the QUAD could skid Unexpected skidding which is not corrected could lead to a serious accident To reduce the tendency of the front wheels to skid on loose or slippery terrain sometimes it is useful to load your body weight onto the wheels If the rear wheels of the QUAD start to slip sideways usually it is possible to regain control by turning the steering if there is sufficient space to do so in the direction of the skid It is not a good idea to accelerate or brake until the skid has been corrected With practice after some time the technique of controlled skidding can be mastered Be
39. ify tyre pressure Adjust the chain Change the chain rear sprocket and secondary transmission pinion Change the rear sprocket Lubricate using a correct chain lubricant Align the rear wheels Replace the brake disk Refit the pads or change them Replace the damaged cylinder Verify and adjust to the correct tightening torques Replace Let down the wheels a little fit the rims correctly reinflate the wheels to the correct pressure Check pressure and correct if necessary Inspect wheels and change if necessary Check convergence and divergence of front wheels Align swing arm Tighten the handlebar bracket and the steering shaft bolt to the correct tightening torques FAULT CAUSE SOLUTION Chassis twisted Steering incorrectly aligned Steering rod bent Rear wheel misaligned Possible hard knock to one of the steering knuckle Quad bike tends to lean to one side The brakes do not function correctly Brake pads worn Loss of brake fluid Brake fluid deteriorated Piston cylinder broken Brakes incorrectly adjusted The lights blow Voltage regulator faulty The lighting system does not work The fuse for the lighting circuit has blown Go to a specialist workshop Adjust the steering Go to a specialist workshop Change steering rod Go to a specialist workshop Check convergence and divergence of front wheels Align
40. ion maintenance or repair has been performed on the vehicle by third parties not recognised or authorised by GG c Any maintenance or repair has been carried out on the vehicle that violates the technical requirements specifications and or instructions indicated by the manufacturer d Spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs to the vehicle or in the event that the vehicle has been used with fuels lubricants or other liquids including amongst others cleaning products that have not been expressly mentioned in the specifications set out in the User s Manual e The vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle f The vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements g The vehicle has been used for special purposes other than ordinary use such as competition races or record breaking attempts h The vehicle has been directly or indirectly damaged as a result of a fall or an accident Warranty exclusions The following items are not covered by this Warranty a Worn parts including without any limitation spark plugs batteries petrol filters oil filter elements secondary chains engine output pinions rear sprockets air filters brake discs brake pads clutch plates and discs bulbs fus
41. ling which in certain situations could lead to accident If doubtful ask an authorised dealer Exhaust system The QUAD exhaust system heats up when the vehicle is in use To prevent burns avoid touching it Park the QUAD in a place reserved foritorin an area away from pedestrians and children HOW TO TURN WITH YOUR QUAD If you are travelling at a low speed you will have no problem turning with the handlebar On the other hand as the speed increases so does the difficulty in turning The two rear wheels are mounted rigidly on the same shaft and turn together at the same speed therefore unless the wheel on the inside of the turn is allowed to skid or lose If poor techniques are used the QUAD may continue in a straight line If the machine does not turn stop and practice the procedure some grip the QUAD will be difficult to turn A special technique is again required to turn therefore it is important to learn the technique on flat ground without obstacles and at a reduced speed The speed can be increased as your skill increases GASGA If the machine starts to overturn towards the outside while taking the bend reduce speed turn the steering or lean further towards the inside of the bend It may also be necessary to reduce speed gradually and turn steering towards the outside of the bend to prevent overturning CLIMBING SLOPES We recommend you start by climbing gentle slopes and increase the steepness as your ski
42. ll increases In all events avoid slopes with loose or slippery surfaces or with obstacles given that as we have already mentioned the quad bike is not designed for jumping over obstacles therefore refrain from doing so On climbing a slope it is important to move your weight to the front part of the QUAD 2 You can achieve this by leaning forwards and moving your Sitting position further On very steep slopes stand up on the rests and Do not accelerate sharply or change gear suddenly The QUAD may flip over backwards In this case the rear guard will not protect you as you have considerable inertia speed Never top the peak of a slope at full soeed There may be an obstacle on the other side a sharp drop another vehicle or person If you are climbing a slope and find that you have not estimated your ability to reach the top correctly turn round with the QUAD while you still have forward traction and space to do so and start to descend If the machine starts to roll backwards do not use the back brake to stop and do not try to engage a gear the quad bike could easily flip over backwards Get off the vehicle immediately on the up side of the slope Always remember that your safety comes first COMING DOWN SLOPES When coming down a slope with the QUAD move your weight back as far as possible towards the up side of the slope Move your body backwards along the seat and remain se
43. lose braking capacity On exiting the water pump the brakes several times to dry them more quickly Always use tyres of the size and type described in this manual WARNING Always switch off the engine when refuelling Do not smoke while refuelling petrol is highly inflammable and may be explosive in certain conditions Always switch off the engine Keep the area ventilated and free from naked flames or sparks this includes spot light appliances The petrol could catch fire and cause burns Take care not to spill petrol on the engine exhaust pipe or silencer When transporting the quad with a trailer make sure that the quad is keptin an upright position Petrol is toxic In the event that petrol is swallowed excess fumes are inhaled or should fuel splash in eyes seek medical attention immediately If petrol spills onto the skin wash off with soap and water If petrol spills onto clothes change your clothes Always drive the machine in a well ventilated area Do not start or run the engine in a closed space The exhaust fumes are toxic and can cause loss of consciousness or even death in a very short time GASG A CP KP IMPORTANT INFORMATION The quad bike leaves the factory with some components not fitted in order to ease transportation The dealer should fit the remaining pieces and you should receive the QUAD ready for use This section is for your information only A kit is included
44. low the nut which will prevent it from coming totally undone Steering bearings damaged or worn Replace the steering bearing Steering shaft bent Change the steering rod Visit a specialist workshop Shock absorption too hard Decompression maladjusted Turn the control of the upper part of the front and rear shock absorbers to the left Remember to evenly adjust both front shock absorbers For further information see Tuning suspension FAULT CAUSE Shock absorption too hard Excessive tyre pressure SOLUTION Shock absorption too soft Rebound poorly adjusted Low tyre pressure Drive chain incorrectly adjusted Chain worn Rear sprocket worn Chain lubrication insufficient Rear wheels misaligned Brake disk worn Brake pads incorrect position or crystallised Quad bike makes strange noises Cylinder damage Brackets nuts bolts not properly tightened Handlebar vibrates Misshapen tyres swing arm or needle bearings worn Rim off centre Wheels with uneven pressures Wheel off centre or misshapen Wheels misaligned due to fall Handlebar bracket loose steering rod bolt loose Quad bike makes strange noises The hydraulic system must be stopped by turning the control of the lower section of the shock absorbers to the right Remember that as with the compression both from shock absorbers should be adjusted equally See Tuning suspension Ver
45. n accident Cylinder head bolts la 28 s Cylindernut 834 35 3 J JP Engine drain plug 20 20 3 JP Kick pedal bolt 20 20 8 Kick pedalmut 0 25 25 8 X J Shift pedal bolt 410 10 6 J Sparkplug 1 11 10 3 X Water pump cover drain plug 9 09 3 J Engine mounting bolt 35 36 3 Engine cylinder head struts 3 36 3 Calliper mounting bolts 25 26 1 Disc plate mounting screws 10 25 1 Rear brake pedal bot 3 410 1 X Sub frame support bolt 26 27 Rear shock absorber 39 40 7 Rear disc wheel drive bolt 29 30 4 Rockerarmbolt 83 7 Rodbits A 83 3 7 Steeringrod 8D 2 Fronttrapezium EH Fronthbb 1201 Rimbolts Bt Rearaxe 1760 16 7 Rearims S 7 GASG A DIAGRAM OF TIGHTENING TORQUE POSITIONS Below we display the positions of the bolts detailed on the previous page These are grouped by units gt Unit Front wheel Unit Front suspension Unit Engine Unit Transmission Unit Rear wheel Unit Shift pedal Unit Rear suspension Unit Kick start pedal Unit Chassis 0 Unit Rear brake pedal p cm rs SAO FAULT DIAGNOSIS NOTE This is not an exhaustive list itis meant simply as a rough guide to assist troubleshooting for some of the more common difficulties FAULT CAUSE SOLUTION
46. new element may cause engine malfunction The engine oil will not flow if the new element is not fitted correctly NOTE Fit a new O ring when the filter is being replaced GASGA KT 9 Replace the filter cover and put in the bolts attaching the cover but do not tighten too hard do not exceed the torque recommended 10 Replace the drain caps and screw them back on accordingly Pour new oil through the dipstick hole Approximately 1 800 ml or the required amount WARNING The engine could be damaged if the oil is not used correctly or if the GAS GAS specifications are not followed Use the type of oil specified in the section on Petrol and Oil recommendations 11 Start the engine and allow it to run some minutes Check for oil leaking from the filter cover 12 Check the oil level is correct according to the oil level verification process LUBRICATION AND STORAGE CLEANING Frequent cleaning of your vehicle will not only serve to improve its appearance but will also improve its general performance and lengthen the useful life of many components Before washing the QUAD take certain precautions to prevent the water entering certain parts Cover with a plastic bag tied with elastic bands Clutch lever brake grips and starter button Cover with a plastic bag Cover with insulation tape or with a Air filter intake cloth Spark plug cap and all Make sure that they are tightly the filler ca
47. o neutral 2 Turn the key anticlockwise OFF position the engine will automatically stop LS 3 Use the parking brake B to park the vehicle 4 The key may be removed from the ignition RUNNING IN THE ENGINE Running in is a very important part in the life of your quad bike therefore we recommend that you follow the instructions below carefully NOTE The run in is a period normally the first 20 hours during which you should observe various points for priming the engine For the first 10 hours we recommend you do not travel at more than half throttle for any length of time or in any other situation which might cause the engine to overheat On the other hand momentary acceleration 3 or 4 seconds is not a problem for the engine to the contrary it is good for the engine Every acceleration period must be followed by a rest period so that the engine can eliminate all the accumulated heat During the first 10 hours try to avoid always travelling at the same speed vary the speed occasionally In the next 10 hours 10 20 we recommend you do not travel at more than 3 4 throttle for any length of time GASGA DRIVING YOUR QUAD Practical advice WARNING GETTING TO KNOW YOUR QUAD This QUAD is designed for experienced drivers for recreational use Although you may be an expert driving other all terrain vehicles or motorcycles driving the QUAD requires special skills which can only be acquired with p
48. oft Always adjust the left and right shock absorbers to the same measurement Uneven adjustment could give rise to faulty handling and loss of stability with the resulting risk of accident Adjusting the compression To adjust turn control A of the upper section of the shock absorber by hand Turning anticlockwise to the maximum will close it completely There is a possibility of 38 clicks in total The standard compression adjustment is set at 20 clicks Total hard compression takes place at O clicks Total soft compression takes place at 38 clicks TUNING REAR SUSPENSION This is a swing arm manufactured in aluminium alloy and is weld free The progressive system using rods with the OHLINS multi adjustable shock absorber As with the front suspension it can be adapted to different types of driving Extension adjustment To adjust turn control A of the lower section of the shock absorber by hand There is a possibility of 28 clicks in total The standard compression adjustment is set at 13 clicks Turn clockwise to the maximum now it is totally closed Turn anticlockwise until 13 clocks have been heard now it is in standard position If set at 0 clicks the extension will be very hard on the other hand if it is set at 28 clicks the extension will be very soft CP KP Adjusting the compression To adjust turn control B of the upper section of the shock absorber using a flat headed sc
49. on numbers 4 10 Component locatiom pp 12 Principal parts of the 14 ROW AEE E Ts 14 lcu MR 14 Hl e 14 Hazard Ao O o 15 THEOLUS sara iaa 15 Clutch handle 15 Front brake 16 Rear brake 16 Emergency stop pp 16 Reverse gear control 17 Sh pedal A 17 A A A 17 A 18 A Po PO E 18 OU 18 Fe Al CO An aa A 19 Foot rest 52 Virada Aa Kai 19 aan aan akan aah 19 Checks to make before starting the machine 20 GASG A Front and rear brakes 20 EU 21 Coolant SY SCI ax hndi AAA A as 22 22 Throttle IST Perrone 22 ES 22 Was 22 Use of your QUAD ici 24 Starting the engiNe 24 Changing 25 Starting the vehicle pp 25 Stopping the 26 Running in 26 Driving your QUAD Practical 28 Getting to know your 28 Drive carefully using common sense 28 How to turn
50. orst case skin cancer Keep new and used oils out of reach of children and animals Clean clothes sleeves and pants Wash yourself with soap if oil has been in contact with your skin MN To change the oil follow the steps below The level of engine oil should be between the lower window and the upper window other wise the engine could be damaged Check the level of oil visually with the QUAD in an upright vertical position every time you are going to use the bike 2 Remove the sump NOTE plug C The plug is Engine oil expands and thus the level increases when it is hot located in the lower part of the QUAD GASGA CAUTION On removing the sump plug to drain the oil you will find a copper washer Replace this washer with a new washer every time you change the oil With the help of a funnel drain the oil from the engine 3 Remove the three screws from the cover of the filter D 4 Remove the cover of the filter pulling the filter element to remove it D and replace with a new one 5 Before replacing the oil filter check that the spring E and the O ring F are in the correct position NOTE Used oil should be put in a suitable container for subsequent recycling WARNING Using a filter with an incorrect design may cause engine malfunction Use the original oil filter design from GAS GAS or an equivalent for your QUAD WARNING Errors in fitting the
51. ps fitted If the engine casing is excessively greasy apply a degreaser using a brush Do not apply this product to the chain the sprockets or the wheel shafts Remove dirt and degreaser washing the machine with a garden hose Use only the pressure of water necessary for the job CAUTION Excess water pressure may cause water to penetrate in the wheel bearings brakes transmission seals and electrical devices resulting in deterioration Where to be careful Avoid spraying water with any great force near the Brake pump master cylinder and callipers below the petrol tank if water gets into the ignition coil or the spark plug cap the QUAD will not start and the affected parts will have to be dried Front and rear wheel hubs suspension swing arm bearings Wash all the surfaces with warm water and a neutral detergent soap Rinse the machine with clean water and dry all the surfaces with a soft and absorbent cloth Clean the seat with a vinyl upholstery cleaner to keep it soft and shiny You can apply a car wax to all the chrome and painted surfaces Avoid using certain waxes combined with cleaning materials Many of these contain abrasives which migh damage the paintwork or protective finish When finished start the engine and leave it idling for a few minutes WARNING Damp brakes may be less efficient resulting in an increased risk of accident Test the brakes after washing and pump several times
52. ractice We recommend you start by getting to know your quad bike on flat ground with no obstacles and no other drivers around Do not attempt difficult manoeuvres until you are totally familiar with the QUAD A quad bike is not a vehicle for jumping over obstacles refrain from doing so otherwise you could cause serious damage to the vehicle WARNING Do not start driving the QUAD before reading this manual carefully Ensure that you understand the working of the controls and pay special attention to the section Information concerning your safety DRIVE CAREFULLY AND USE COMMON SENSE As we have already mentioned driving your QUAD requires special skills which can only be acquired through continual practice over a certain length of time Take as much time as necessary to learn the basic techniques before attempting more difficult manoeuvres Never carry passengers Carrying a passenger could lead to an accident resulting in injury to the driver and or passenger The quad bike has an emergency stopping system should the rider fall off the bike but it is not prepared for the fall of a second passenger THE WILD QUAD IS NOT APPROVED TO CARRY PASSENGERS ONLY THE DRIVER IS PERMITTED TO RIDE THE QUAD Equipment Always wear an approved helmet of your size In addition you should wear goggles gloves boots long sleeved shirt or jacket and long trousers WARNING It is important to wear all the equipment we
53. re of the tyre this implies pressure is too high GASG A If wear is at the sides this indicates that the tyre is not sufficiently inflated Therefore wear should be spread uniformly over the surface of the tyre Replace the tyre when the depth of tread has worn to 3 mm amp Minimum tread 3mm GASGA KT USE OF YOUR QUAD WARNING The User Manual should be read carefully to familiarise yourself with all the controls Loss of control could cause an accident or injury STARTING THE ENGINE CAUTION Before starting the engine for the first time read the section Running in the engine WARNING In cold weather always make sure that all the control cables operate smoothly before driving the vehicle If the cables are frozen or do not operate smoothly you may lose control of the QUAD and cause an accident 1 Tighten the brake lever while operating the locking lever to apply the parking brake WARNING Always apply the parking brake before starting the engine The QUAD could move unexpectedly if the brake is not applied This could give rise to loss of control or a collision Make sure that the parking brake has been released before starting to drive The brake could overheat if the QUAD is used without releasing the brake The brake could lose efficiency and cause an accident It would also suffer from premature wear 2 Turn the key A clockwise position ON
54. re that it is securely fixed BATTERY This battery is maintenance free and checking the fluid level is not required It is advisable to check the charge of the battery periodically The operating instructions for the battery are as follows 1 Check the battery voltage in open circuit status disconnected 2 Inthe event that the battery voltage is below 12 60V or has been stored for over 6 months the battery should be recharged according to the procedure described in section 3 2 In the event that the voltage is above 12 60V the battery can be fitted in the vehicle without requiring recharging 3 1 Constant voltage charge mode Constant voltage 14 40 14 70V Initial charge current 0 1 0 5 Cn Charge duration 6 hours minimum 24 hours maximum 3 2 Constant power charge mode Maximum charge current 0 1 Cn Recommended charge time 5 8 hours The result charge current x charge time should fall into the range 0 5 0 8 Cn Note In the event that charging procedures are used different to the above never exceed the maximum permissible charging currents or charging time of 24 hours CAUTION Exceeding the standard manner of charging may seriously shorten the life of the battery Never exceed the standard charge CAUTION Inverting the polarity of the battery terminals may cause problems when charging the battery and damage the battery system The red terminal is positive
55. rewdriver Turning anticlockwise to the maximum will close it completely There is a possibility of 56 clicks in total The standard compression adjustment is set at 28 clicks Total hard compression takes place at 0 clicks Total soft compression takes place at 38 clicks CP KC REGULAR MAINTENANCE AND ADJUSTMENTS MAINTENANCE CHART The first service by a specialised workshop is at 500 km or two tanks of fuel Successive services should be made every 2 000 km or every three months BEFORE GOING OUT ON Petrol tank level THE QUAD Brake fluid reservoir levels front and back Play of brake lever and pedal Brake pads Coolant Level Wear to tyres General condition of chain Throttle grip Play of clutch lever Lights Indicators Quad bike Shift pedal Brake pedal and lever Clutch lever Air filter Air filter casing Chain guide Cables Radiator hose and connections Exhaust EVERY Wheel bearings 10 trips Bolts see table for tightening torques Brake piston and dust guard 2 years Brake piston pump and dust guard 2 years Brake attachment 2 years ON RETURN Inspections adjustments and regular lubrications keep the machine in optimum safety and working conditions Safety is the responsibility of the owner of the machine In the following pages the most important points concerning inspections adjustments and lubrication are explained WARNING Do not carry out any maintenance work to
56. rs using the Reset button After modifying the minutes press Mode for the clock to start from the second zero of the selected GASGA minute making coordination with a selected time easy e g in competition Chronometer To measure a time chronometer hold down the Reset button until the Zero point Counting begins immediately The Trip distance in Km or Miles can be reset by pressing the Reset button Trip distance in Km To program the trip distance in Km or Miles Once the battery is connected the display indicates that the programme is active Metric or Imperial To change connect the battery while holding any of the buttons down the change will appear on the display This function will remain in the memory permanently even if the battery is not connected Clock precision The clock precision can be adjusted if itis fast or slow consult Wheel design The design of the wheel may change 10 This affects the precision of the speed and distance measurements Backlight The backlight is an independent circuit which accepts from 8 to 18 volts in AC typical 2T or DC typical 4T red positive black negative The circuit is protected Clock timer Total distance Trip distance The Mode button is used to change screens 53 GASGA TIGHTENING TORQUE TABLE Tighten all of the bolts and nuts using the correct spanners If not correctly tightened this could damage the quad or lead to a
57. ry to the lower limbs from the wheels COP IICT CHECKS TO MAKE BEFORE STARTING THE MACHINE WARNING Always inspect the QUAD each time it is going to be used to ensure that it is in safe working condition Always follow the inspection and maintenance programmes and procedures described in this manual If the machine is not inspected there is an increased risk of accident or breakdown FRONT AND REAR BRAKES WARNING Before driving always check the brakes Do not drive the QUAD if any problems are detected in the brakes or if it is possible that braking capacity has been lost as this may cause an accident If there are any problems which can not be solved following the adjustment procedures described in this manual ask a specialised workshop to inspect the QUAD A worn disc is automatically compensated and does not affect either the brake lever or the brake pedal Therefore the only parts to require adjustment are the play of the brake lever and the position and play of the brake pedal Brake lever and pedal Check there is no free play in the front brake lever 1 In the event that there is check the condition of the brake pads and see section Adjustments and Maintenance Check there is no free play in the front brake lever 2 Check that the height of the brake pedal is correct If the height of the pedal is incorrect ask a specialised workshop to adjust it Check the working of the lever and th
58. s round smoothly 1 Ensure that it returns to idle position when the handle is released There is a return spring fitted inside the handle which reduces speed and brings the engine back to idle speed when the throttle handle is released 15 CP KTP WARNING If the throttle does not work correctly it may be difficult to increase or reduce the speed of the vehicle as desired This could cause accidents Check the throttle is working correctly before starting the engine If the throttle does not work smoothly find out why Solve the problem before using the machine or go to a specialist workshop CLUTCH LEVER The clutch lever is located on the left of the handle bar Use the lever to engage and release the clutch J For the clutch to work smoothly the lever should be tightened quickly and released slowly GASG A FRONT BRAKE LEVER The front brake lever A is located on the right of the handle bar Use the lever to apply the front wheel brakes End C is attached to the vehicle and end D is securely attached to the rider It consists of an elasticised cable one end of which is attached to the vehicle and the other to the rider in such a way that the end of the cable which is attached to the vehicle detects any brusque REAR BRAKE PEDAL movement and detaches On becoming detached the engine stops automatically The brake pedal B is located on the right hand side of the low
59. s to GG without any other consideration The GG authorised dealer to whom the making good of the defects has been entrusted is not authorised to make any declarations that are binding on GG 2 In case of doubt regarding the existence of a defect or a visual or material inspection is required GG reserves the right to demand the return of the parts which are the object of a claim under Warranty or to arrange an inspection of the defect by an expert from GG Any additional obligations arising out of guarantees on parts replaced free of charge or any other service rendered free of charge are excluded from the effects of this present warranty The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned 3 Should it prove to be the case that a defect can not be repaired the purchaser guaranteed shall have the right to the cancellation of the contract payment of compensation or a partial refund of the purchase price discount instead of repairing the motorcycle 4 Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised dealer shall not be affected by the terms of this present Warranty Neither will this present Warranty affect those additional contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer However such additional rights may only be exercised thro
60. st six months after the delivery of the motorcycle it will be presumed that the said fault existed at the time of delivery from the end of the sixth month onwards the purchaser must demonstrate that the unwarranted fault existed at the moment of delivery During the first six months subsequent to the delivery of the repaired vehicle the seller will be responsible for any unwarranted faults arising out of the repair Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period If the last day of this period is a Sunday or an official holiday the Warranty period will be extended such that the last day of the period covered will be the first working day after the Sunday or official holiday Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of the Warranty Period will be excluded COP IIP Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that a The purchaser has failed to submit the vehicle to any of the inspections and or maintenance work required in the Users Manual or has exceeded the date set for such inspections or maintenance work Also excluded from guarantee are those faults that appeared prior to the dates established for an inspection or maintenance work where the latter was not carried out or was carried out later than the date established b An inspect
61. swing arm Go to a specialist workshop Check the condition of the brake pads and replace if necessary Check the brake circuits Change those which are damaged or broken and replace Drain brake fluid and replace with new fluid recommended by manufacturer See how to bleed the brake fluid circuit in the section Regular maintenance and adjustments Replace the piston cylinder Adjust the brakes Remove the seat and the fuel tank inspect the connections check the voltage regulator and the fuses in the fuse box Remove the seat and check installation GASGA ELECTRICAL SCHEMAS B Black eo Br Brown TES G Green y E gh Great Lamp hinh fren d Blue wot Orange Sb Light blue Violet eper PH Yellow Bui Aor lt s lt H E m m 11 ma Conrad amc LB High ua DR HO cn LE in ranas t LHE Tid ue i i5 ira d air m 00 ER a Ium peu m la ru e 62 B Br Gr o lt lt 9 Black Brown Green Grey Blue Orange Red Light blue Violet White Yellow 63 GASGA x7 Ce KTP WARRANTY TERMS AND CONDITIONS According to Law decree 23 2003 on the 10th of July covering Warranties on Consumer Item Sales Warranty terms of the man
62. t the shaft supporting the two rear wheels is correctly aligned otherwise either the shaft has too much play or the bearings might be damaged To adjust the shaft bolt go to the rear of the QUAD The bolt is to the right of the swing arm Using the wrench F provided with the vehicle adjust the shaft ADJUSTING AND LUBRICATING THE CHAIN The chain should be checked adjusted and lubricated as part of the regular maintenance to prevent excessive wear If the chain is worn or incorrectly adjusted too tight or loose it may come off or even break WARNING A chain which comes off or breaks can get caught in the engine or in the rear wheel damaging the bike and causing it to lose control Checking chain tension The tension between the chain and the swing arm at the height of the chain slide should be one finger if it is more orless adjust accordingly Follow the procedure explained 4 below Stand to the rear of the QUAD Near the swing arm there are 4 screws A Undo the 4 screws With wrench B provided with the QUAD adjust the chain accordingly and then do up the 4 screws NOTE Make sure that the screws are tightened and that the chain is correctly tensioned Inspecting the condition of the chain Inspect the chain for damaged links lost pins unevenly worn or damaged teeth If the transmission chain is very damaged visit a specialised shop to request
63. the opening and the ceramic insulation Standard spark plug CR8 or DENSO U24ESR N 0 7 0 8 The spark plug should be taken out periodically to check the electrode gap If the plug contains oil or carbon deposits clean with a blast of sand After cleaning the abrasive particles the plug should always be cleaned with a wire brush or similar Measure the electrode gap using a gauge and adjust where necessary by bending the outer electrode If the electrodes of the plug are rusty damaged or if the insulation is broken change the plug NOTE Inspect every 30 hours Replace every 60 hours To find the correct working temperature for the spark plug remove and examine the insulation around the electrode If the insulation is light brown the temperature of the plug is correctly matched to the engine temperature If the ceramic is white the plug should be replaced by a cold plug Ifitis black replace it with a hotter plug lt 5 lt A WARNING If the performance of the engine falls replace the plug to recover performance Petrol may be spilt on removing the hose from the injection pump and cause a fire Stop the engine before removing the tank Keep naked flames and Spark plug maintenance sparks away from the fuel cap Do not smoke DENSO COMMENTS 3 Remove the rubber attachment on the tank 4 Remove the reservoir securing bolt If the standard spark plug E ea the tank is wet repl
64. the process of starting the machine in more detail CAUTION When changing gear press the shift pedal firmly to ensure a positive shift An incomplete shift may cause the transmission to jump to another gear and could damage the engine WARNING Sudden acceleration or releasing the clutch lever too fast could Cause an accident and cause the machine to skid and overturn Open the throttle gradually and release the clutch gently To decelerate To decelerate or stop release the throttle and apply the brakes gently and evenly As the vehicle loses speed change to a ower gear Before shifting down to a lower gear wait for the engine speed to fall sufficiently Incorrect use of the brakes or gear shift could cause the tyres to lose grip resulting in a loss of control and risk of Do not drive under inertia with the engine switched off for long periods nor tow the machine for long journeys Even in neutral the gearbox is only lubricated when the engine is running Insufficient lubrication could cause damage accident STARTING THE VEHICLE 1 Operate the throttle twist grip WARNING Ensure that the engine speed has fallen sufficiently before changing to a lower gear If you shift to a lower gear while the engine speed is too high the wheels may stop spinning This may result in loss of control and risk of accident and injury The engine and transmission could also be damaged STOPPING THE ENGINE 1 Change gear t
65. tolerance by changing the piston rings Correct the level of engine oil Drain oil as necessary from the engine FAULT CAUSE SOLUTION Engine consumes too much The quality or viscosity of the oil is Empty the engine oil and fill with oil of the recommended oil insufficient viscosity Abnormal engine noise Ignition problems Goto a specialist workshop Valve adjustment play Adjust the valve play Visit a specialist workshop Over heating See chapter 5 Detonations in the exhaust Carbon in combustion chamber Clean the combustion chamber Injection system maladjustment Goto a specialist workshop Epprom Fuel of poor quality or octane rating Drain the petrol and fill with fresh or higher octane petrol incorrect Spark plug in poor condition or Change spark plug for a new one or recommended one specifications incorrect Exhaust system joints deteriorated Check if the exhaust system is deteriorated The seals should be in perfect condition if not they must be changed for new ones White fumes from the exhaust Cylinder head gasket leak water leaking Change the cylinder head gasket Visit a specialist into cylinder workshop Brown fumes from the exhaust Air filter obstruction Clean or change the air filter Visit a specialist workshop Gears don t engage Clutch does not release Goto a specialist workshop Shift fork worn or locked Change the gear fork G
66. ufacturer GASGAS Motos S A The company GAS GAS MOTOS S A hereafter referred to as GG with this present document guarantees the consumer the purchaser of a vehicle manufactured by GG that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality Consequently GG with this document guarantees the consumer hereafter referred to as the in accordance with the conditions set out below the repair free of charge of any defect in materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by this Warranty and with no limit on the number of kilometres covered or hours of use Warranty Period The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer or in the case of demonstration models on the date in which the vehicle is used for the first time The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23 2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999 44 EC for other members of the European Community For countries outside the European Community the Warranty Period will be determined by the existing regulations in those countries Nevertheless should the fault appear during the fir
67. ugh claims against the authorised dealer 5 Should the purchaser resell the product within the Warranty Period the duration and conditions of the present Warranty will remain unaltered in such a way as that the rights to make claims under the present Warranty in accordance with the terms and conditions set out in this present document shall be transferred to the new owner of the motorcycle 6 In the case of used motorcycles sold by Gas Gas the Warranty Period will be one year from date of delivery of the goods And in no case shall the consumer request replacement of the goods Notes Ce ce RECOMIENDA EL USO DE ACEITE RECOMMENDS THE USE OF OIL RECOMMANDE L USAGE DE L HUILE CONSIGLIA L USO D OLIO C UNICEF n 17 Poligon Industrial Torremirona 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es

MANUAL DEL USUARIO SERVICE MANUAL MANUEL D

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