Related Manuals for GAS GAS K2 QUAD 250
Summary of Contents for GAS GAS K2 QUAD 250
- Page 1 MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D’ENTRETIEN MANUEL D’ENTRETIEN LIBRETTO D´USO LIBRETTO D´USO...
- Page 3 SERVICE MANUAL SERVICE MANUAL...
- Page 5 Brief introduction 250 EC QUAD embodies the experience and essence of world motorcycle technology. It adopts single-cylinder four-stroke air -cooled engine newly developed by our company, and employs the devices of carburettor carbruetor, wet automatic centrifugal clutch, five- speed shifting, through driving, reverse driving hand pulled recoil starter and eletric- starter in combination, CDI electric ignition, pressure splash lubrication system, etc, which are good in performance.This QUAD is novel and bright in design,having moved, streamlined model and luxury decoration design, and it meet the national standard in...
- Page 6 IMPORTANT INFORMATION FOR OPERATION WARNING Injury or death could be result from failure to follow WARNING instructions when you are operating inspecting or repairing the QUAD. CAUTION A CAUTION indicates special precautions that must be taken to avoiddamage to the QUAD. NOTE A NOTE provides information can make your operation in the QUAD easier or clearer.
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Page 7: Table Of Contents
Content Spring preload adjustment........18 Pre-operation checkes..........19 Safety information.............5 Front and rear brakes ..........19 Description and machine identification .....9 Fuel.................20 Control functions.............11 Engine oil ..............21 Main switch .............11 Lubrication oil of gear case........21 Indicator lights ............11 Throttle lever............21 Handlebar switches ..........11 Fittings and Fasteners ..........21 Start switches ............11 Lights ..............21... - Page 8 Accessories ............28 Front brake lever free play adjustment ....45 Loading ..............28 Rear brake adjustment ...........46 Ride with care ............28 Clutch adjustment ...........47 Speed limit valve ............30 Cable inspection and lubrication......48 Exhaust silencer ............30 Brake and shift pedal/brake lever lubrication Turning ..............31 Steering vertical tube lubrication ......48 Climbing slope ............32 Wheel removal............48...
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Page 9: Safety Information
SAFETY INFORMATION motorcycle helment that fits properly. You should also wear eye protection (goggles or face shield), gloves, This operation manual includes important safty and boots, long-sleeved shirt or jacket.and long pants. maintenance information. When reselling the QUAD - Never consume alcohol or drugs before or while TO THE NEXT BUYER. - Page 10 described in this manual. Check the terrain carefully procedure for braking described in this manual. before starting up any hill. Never climb hills with - Always check for obstacles before operating in a new excessively slippery or loose surfaces. Shift your weight area.Never attempt to operate over large obstacles,such forward.
- Page 11 - Never exceed the stated load capacity for an QUAD. Cargo should be properly distributed and securely attached. - Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. - Improper handing of gasoline can cause fire and can cause injuries and deaths and other serious accident.
- Page 12 Starting or running the engine in a closed area will cause the breakdown. And exhaust fumes are poisonousus and may cause loss of consciousness and death within a short time. Always operate your machine in an area with adequate ventilation.
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Page 13: Description And Machine Identification
DESCRIPTION AND MACHINE IDENTIFICATION 1. Front wheel 2. Headlight 3. Drive select lever 4. Shift pedal 5. Fuel cock 6. Recoil starter 7. Starter(choke) 8. Taillight 9. Rear wheel 10. Rear carrier 11. Spark arrester 12. Seat 13. Fuel tank cap 14. - Page 14 Identification numbers record When ordering spare parts from a our dealer or for reference in case the vehicle is stolen record, vehicle identification number in the spaces provided for assistance. 1. VEHICLE IDENTIFICATION NUMBER: Vehicle identification number The vehicle identification number is stamped on crosstube of pedestal.
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Page 15: Control Functions
CONTROL FUNCTIONS This indicator light comes on when the transmission is in reverse.The light is blue in color. Main switch Functions of the respective switch positions are as Neutral indicator light " N " follows: This indicator light comes on when the transmission is in neutral. -
Page 16: Light Switches
If the starter switch is pushed with the main switch " " and the engine stop switch " " , the starter motor will be activated but the engine will not start. To start the engine ,be sure to set the engine stop switch at "... -
Page 17: Throttle Lever
Throttle lever Once the engine is running .movement of the throttle lever will increase the engine speed.Adjust the speed of the machine by changing the throttle position.Because the throttle is spring-loaded,the machine will decelerate.and the engine will return to an idle any time the hand is removed from the throttle lever.Before starting the engine .check the throttle to be sure it is operating smoothly .Make sure it returns to the idle... -
Page 18: Front Brake Lever
Front brake lever The front brake lever is located on the right handlebar.Pull it toward the handlebar to apply the front brake. Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar. -
Page 19: Parking Brake
Parking brake When you have to start the engine or park the machine, especially on a slope, use the parking brake Apply the rear brake lever and push down the lock plate to apply the parking brake,squeeze the rear brake lever to release the parking brake. -
Page 20: Shift Pedal
HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure the parking brake have been released before you begin to ride. Shift pedal This machine is equipped with a constant mesh 5- speed transmission. The shift pedal is located on the left side of the engine. -
Page 21: Fuel Tank Cap
Fuel tank cap RES: Remove the fuel tank cap by turning it counter clockwise. This indicates reserve. If you run out of fuel while riding.turn the lever to this position. After refuelling, Fuel cock return the fuel cock lever to the "ON"position. The fuel cock supplies fuel from the fuel tank to the carburetor. -
Page 22: Storage Box
Rear shock absorber The spring preload can be adjusted to suit the rider's weight and riding conditions. Spring preload adjustment To increase the spring preload turn the adjuster in direction A.To decrease the spring preload,rum the adjuster in direction B. Standard position: B Storage box A-Minimum(Soft) -
Page 23: Pre-Operation Checkes
PRE-OPERATION CHECKS Before using this machine.check the following points: ITEM ROUTINE PAGE Check operation,condition and free play Brakes Adjust if necessary Check oil level Engine oil Fill with oil if necessery Check fuel level Fuel tank Fill with fuel if necessary Gear oil Check for leakaqe Throttle... -
Page 24: Fuel
move smoothly and there shoud be a firm feeling when the brake is applied. If not, have the machine inspected by a our dealer. Test the brakes at slow speed after starting out to make sure they are working properly. lf the brakes do not provide proper braking performance, inspect the brakes for wear. -
Page 25: Engine Oil
Enegine oil when released.Repair as necessary for proper Make sure the engine oil is at the specified level. Add operation. oil as necessary.(See pape) Recommended oil Fittings and Fastenerns SAE20W40 Always check the tightness of chassis fittings and SAE10W30 fasteners before a ride.Refer to the Service . Manual SAE5W30 for correct tightening torque. -
Page 26: Tires
capacity of battery for 5 to 10 hours,or quickly charge warning the battery with 2A to 3A for 2 hours. Use of improper tires on this QUAD, or operation of this QUAD with improper tire pressure may increase Tire your risk of accident. The size and type (in low pressure condition) of hollow Use of improper tires on this QUAD, or operation of tire used for 250 QUAD are listed below. -
Page 27: Tire Wear Limit
Caution: Recommended Minimum Maiximum The low-pressure tire gauge is included as standard pressure equipment, conduct two measurements if the tire 23Kpa 20Kpa 17Kpa Front pressure and use the second reading. Dust or dirt in (0.23kgf/cm2) (0.20kgf/cm2) (0.17kgf/cm2) the gauge would cause the First reading to be incorrect. 22Kpa 25Kpa 23Kpa... -
Page 28: Operation
OPERATION NOTE If the engine fails to start release the start switch, then WARNING push the start switch again, pause a several secords Never operate QUAD until you are familiar with all before the next attempt. Each cranking should be as controls. -
Page 29: Drive Select Lever Operation And Reverse Driving
Drive select lever operation and reverse driving. move the Handle Bar and softly to make sure the spring CAUTION of the lock-button is released and the Handle Bar is Before shifting, stop the machine and return the throttle locked. lever to its closed position. Otherwise the transmission 5. -
Page 30: Shifting
Shifting: CAUTION This machine has a 5-speed forward and 1-speed Always close the throttle while shifting gears. Otherwise, reverse transmission with centrifugal automatic clutch. the engine and drive train may be damaged. To shift into neutral when driving, return the throttle 2. -
Page 31: Engine Breakrin
Engine break-in Parking There is never a more important period in the left of When parking, stop the engine and shift into neutral. your machine than the period between zero and 20 Turn the fuel to "OFF" and apply the parking brake. hours. -
Page 32: Accessories
Accecsories: accessories):165kg Pay attention to the following points. Front luggage carrier:30kg Choose only accessories designed for you QUAD. Our Rear luggage carrier:60kg dealer has a variety of genuine accessories . Choose Tool kit: 2kg a genuine accessory. Pulling load (total weight of trailer and cargo): 330kg Vertical weight on trailer hook: 15kg WARNING Do not exceed the maximum pulling weight. - Page 33 stability and operation of the QUAD. This machine could be used to carry cargo and passengers is prohibited. OPERATION 1. Get training if you are unexperienced. Beginners should be trained at the guide of professional person. Drive with this QUAD with low speeds first to familiar with its performance even if you are an experienced rider do not attemp to operate at maximum performace until you are totally familiar with QUAD´'abs...
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Page 34: Speed Limit Valve
Never modify this QUAD through improper installation or use of accessories. All parts and accessories added to this vehicle should be genunie our or equivalent components designed for using on this QUAD and should be installed and used according to instructions our dealer. -
Page 35: Turning
Know the terrain where you ride When slowing down or stopping, release the throttle Ride carefully in complicated terrain, stay alert for and brake gradually. As you brake, shift to lower gear. holes, rocks or roots or roots in the terrain otherwise Ensure that the engine has sufficiently slowed Improper may cause the machine to tip over. -
Page 36: Climbing Slope
move your weight forward. WARNING Once you have learn this technique you can turn your There may be other vehicles and persons on the other QUAD at higher speed. side of slope. The sudden acceleration, brake incorrect body position If your QUAD can not climb the slope turn round your and too high speed will cause the QUAD to slip. -
Page 37: Riding Downhill
Riding downhill CAUTION Move your gravity center backward, when riding QUAD Practise the braking skill when decending the hill look downhill your and grisp steering bar and drive at low over the terrain carefully before decending speed. and transfer your body gravity center backward. Ride Note: The brake performance is very important. -
Page 38: Riding Over Rough Terrain
before crossing and avoid of ride where there is sharp drop off. Drive slowly and carefully. Pay attention that wet brakes may reduce brake ability. Check your brakes after leaving water. lf necesary, apply them to let friction dry out the linings several times. -
Page 39: Periodic Maintenance And Adjustment
PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment, and lubrication will keep your machine in the safety and most efficient condition. The points of machine inspectionadjustment and lubrication are detailed in following. NOTE Turn off the engine when maintaining unless specified. Have a our dealer perform service if you are not familiar with maintenance. -
Page 40: Periodic Maintenance/Lubrication
PERIODIC MAINTENANCE/LUBRICATION INITAL EVERY ROUTINE ITEM 1 month 3months 6months 6months 1Year Valves Check valve clearance. Adjust if necessary. Check condition. Adjust gap and clean. Replace if necessary. Spark plug Clean. Replace if necessary. Air filter Every 20-40 hours(more often in wet or dusty areas) Carburetor Check idle speed/Starter operation. - Page 41 PERIODIC MAINTENANCE/LUBRICATION INITAL EVERY ROUTINE ITEM 1 month 3months 6months 6months 1Year Brakes Check operation. Adjust if necessary. Check operation. Adjust if necessary. Clutch Check balance/damage/run out. Replace if necessary. Wheels Wheel bearings Check balance assembly for looseness/damage. Replace if damaged. Front and rear Check operation.
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Page 42: Engine Oil
Engine oil 1. Engine oil level measurement a. Place the machine on a flat surface wram up the engine for several minutes and turn off it. Wait more than 10 minutes for the oil to drain back into the crankcase before checking the oil level. 1. - Page 43 2. Engine oil replacement and oil fitter element cleaning CAUTION a. Place the machine in a flat suface. Warm up the If oil leakage is found, turn off the engine promptly and engine for several minutes and turn off place a container check for the cause.
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Page 44: Lubrication Oil Of Gear Case
b. Slightly loosen the oil gallery bolt in the cylinder Hole. If the level is too low add oil to raise it to the head. proper level. c. Start the engine and keep it at idle speed unil begins b. lnstall the oil filler bolt and tighten to the specified to seep fron the oil gallery bolt.lf no oil comes out after torque: 23Nm(2.3.kg,17ft.lb) one minute.stop the engine to find cause. -
Page 45: Spark Plug Inspection
Recommended oil: Spark plug inspection SAE 80API"GL-4" Hypoid gear oil You should periodically remove and check the spark Oil quality plug because heat and deposits will cause slow damage Periodic oil change: and erosion of the spark plug if electrode erosion is 0.25L(0.21lmpqt,) excessive, you should replace the spark plug with one Total amount:... -
Page 46: Air Filter Cleaning
Air fillter cleaning There is a check hose at the bottom of the air fillter case.if there are dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 1. Check hose 1. -
Page 47: Carburetor Adjustment
7. Squeeze the excess water or solvent out of the foam Idle speed adjustment cover and let it dry. Do not twist the foam 1. Start the engine and warm it up for a few minutes cover when squeezing it. at approximately 1,000 to 2,000 r/min, increase the 8. -
Page 48: Valve Clearance Adjustment
Valve clearance adjustment Front and rear brake shoe inspection Incorrect valve clearance will result in improper fuel/air A wear indicator is mounted on each brake. The wear supply or engine noise. To prevent this, the valve of brake shoe could be checked under the condition clearance must be adjusted regularly, but the adjustment of disassembling brake. -
Page 49: Front Brake Lever Free Play Adjustment
Front brake lever free play adjustment Inspect the front brake shoes before adjusting the brake. The front brake lever free play should be adjusted to 1. Adjusting nut 5-7mm (0.2-03in) If the free play is incorrect, adjust as (front hub) following steps: 3. -
Page 50: Rear Brake Adjustment
Rear brake adjustment 2. Brake lever 1. Brake pedal a. Loosen the locknut and fully turn in the adjusting nut a. Fully loosen the adjusting nut on the brake cable. on the handlebar. b. Rotate the adjusting nut on the brake rod untill free b.Turn in the adjusting nut on brake cable to get a gap play is 20-30mm. -
Page 51: Clutch Adjustment
After maintaining, pay attention to: Make sure the brakes operate smoothly and the free play is correct. Make sure the brakes do not skid. Replacement of brake components requires professional knowledge. These procedures should be done by our Group dealer. Clutch adjustment 1. -
Page 52: Cable Inspection And Lubrication
NOTE Wheel removal Turn the adjusting bolt counterclockwise to decrease 1. Lift the wheel by placing a suitable support under the clutch free play and turn it clockwise to increase the frames. the free play. 2. Remove the nut on the wheel. 3.Remove te wheel assembly. -
Page 53: Wheel Installation
Wheel installation When installing the wheel reverse the removal procedure. Pay attention to the following points: 1.Tapered nut Wheel nut torque: 1. Arrow mark Front wheel: 55Nm (5.5m.kg) Rear wheel: 55Nm (5.5m.kg) 1. The arrow mark " " on the tire must point to the rotation direction of the wheel. -
Page 54: Fuse Replacement
Use and maintenance 1. Don't remove electrolyte cover after enclosed battery being used. Please obey the operation instruction on 1. Main fuse battery to use the battery. 2.Start relay 2. If QUAD is suspended from use for a month or much longer time, remove the battery and store in a cool and dark place, charge fully before reusing. -
Page 55: Replacing The Headlight Bulb
Replacing the headlight bulb If the headlight bulb burns out, replace the bulb as following steps: 1.Remove the headlight cover. 2.Remove the cover and rotate the bulb holder counterclockwise and remove the defective bulb. 1. Cover (x2) 1.Headlight 1.Bulb holder... -
Page 56: Spark Arrester Cleaning
WARNING CLEANING AND STORAGE Wait for the bulb to cool before removing it. 3. lnstall a new bulb to the bulb holder. CLEANING 4.Reinstalll the cover and headlight cover. Ad-just the General speaking thorough cleaning of your QUAD headlight beam if necessary. Will improve its runing performance and prolong the service life of many components. -
Page 57: Storage
6. Clean the seat with a vinyl upholstery cleaner to film of oil. Do not apply oil to any plastic parts or the keep the cover pliable and glossy. seat cover. 7. Apply automotive type wax to all chrome plated 7. -
Page 58: Main Data And Specification
MAIN DATA AND SPECIFICATIONS Item specification Item specification Engine oil: Dimension: Periodic oil change 1.5L Overall length 1940mm With oil fillter replacement 1.6L Overal width 1050mm Total amount 1.8L Overall height 1160mm Total amout of gear oil 0.27L Seat height 810mm Main fuel tank capacity Wheel base... - Page 59 MAIN DATA AND SPECIFICATIONS Item specification Item specification Gear ratio: Suspension Supporting rod 34/12(2.833) Front Rotary rod 34/19(1.789) Rear 29/22(1.318) Shock absorber: 26/25(1.040) Front Spring/oil damper 23/28(0.281) Rear Spring/oil damper Reverse 73/22 x34/12 X 19/18 X 46/11(41.5) Wheel travel: Frame Front 135mm Frame type...
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Page 60: Maintenance Record
MAINTENANCE RECORD Maintenance times, receipts of purchased componects and assembly will be required to be recorded, which should be done according to the warranty. The chart below only acts as maintenance record, not as maintenance proof: MAINTENACE DATE INTERVAL DRIVING MILEAGE SERVICING DEALER NAME AND ADDERSS REMARKS TIME MAINTENACE... -
Page 61: Electric Wiring Diagram
ELECTRIC WIRING DIAGRAM 1. Headlight switch 12. Meter background light 22. Relay 33. Foot brake clutch switch 2. Position light 13. Position light switch 23. Fan 34. Total switch 3. Headlight 14. Reverse indicator 24. Fan 35. Fuse 4. Fr.R.winker switch 25. - Page 64 RECOMIENDA EL USO DE ACEITE: RECOMMENDS THE USE OF OIL: RECOMMANDE L’USAGE DE L’HUILE: CONSIGLIA L’USO D’OLIO: Mayo / May / Mai / Maggio 2005 C/ UNICEF nº 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...
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