GAS GAS QUAD WILD HP 300 RV - 2005 Service Manual
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GAS GAS QUAD WILD HP 300 RV - 2005 Service Manual

GAS GAS QUAD WILD HP 300 RV - 2005 Service Manual

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MANUAL DEL USUARIO
MANUAL DEL USUARIO
SERVICE MANUAL
SERVICE MANUAL
MANUEL D'ENTRETIEN
MANUEL D'ENTRETIEN
LIBRETTO D´USO
LIBRETTO D´USO

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Summary of Contents for GAS GAS QUAD WILD HP 300 RV - 2005

  • 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 USER MANUAL USER MANUAL...

  • Page 5: Presentation

    GAS GAS thank you for the trust you have placed in us. By choosing the new WILD H.P. 300. RV. you have just entered the great GAS GAS family and, as a user of the number one off-road motorbike manufacturer, you deserve the distinguished treatment that we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this manual Our WILD H.P.

  • Page 6: General Warnings

    OTHER PEOPLE. storage and maintenance of the GAS GAS quad you have just acquired. Quad riding is a fantastic sport, and we hope you will enjoy it to the fullest.

  • Page 7: Table Of Contents

    CONTENT - Presentation................3 - Verifications to be made before starting the - General warnings ..............4 machine ...................20 - Contents ..................5 Front and rear brakes ..........20 - Specifications .................7 Fuel ................21 - Information about your safety..........8 Cooling system ............22 - Important information ............10 Chain ................23 Identification number............10 Throttle grip..............23...
  • Page 8 - Tuning ...................32 - Multifunction speedometer............57 Tuning the front suspension ........32 - Trouble shooting table..............58 Tuning the rear suspension .........33 - Electrical diagrams..............64 Tuning the fuel supply..........33 - Warranty manual...............65 - Periodic maintenance and adjustment.......37 Maintenance chart ............37 Clutch lever adjustment ..........38 Adjusting the brake lever and pedal ......38 Checking the brake fluid level........39 Checking the brake front and rear pads ......40...

  • Page 9: Specifications

    SPECIFICATIONS ENGINE Displacement: 294.7 cc Type: Single cylinder, two stroke with crankcase and exhaust valve induction by layers. Cooling system: Liquid cooled Bore x stroke: 72 x 72 mm Carburettor: Keihin PWK 38 mm Ignition: Ducati Energia Reverse System Clutch: Hydraulic controlled multi-disc Gear box: 6 speed...

  • Page 10: Information About Your Safety

    - Always perform the routine checks described in this manual before SAFETY INFORMATION using the QUAD, to make sure it is in perfect operating condition. - Riding a QUAD is not like driving any other vehicle, especially when The QUAD is not a toy: driving it can be dangerous. cornering.
  • Page 11 - This vehicle has been designed to go through water with maximum depth of 35 cm. Do not use the vehicle in fast moving water; carefully read the instructions regarding this type of terrain. Take into account that braking efficiency is diminished when the brakes are wet.

  • Page 12: Important Information

    IMPORTANT INFORMATION The vehicle leaves the factory with some elements not fitted, in order to make transportation easier. The dealer will make sure each element is correctly fitted and you will receive the QUAD ready for use. Thus, this paragraph is purely for your information. A carburettor-adjustment kit is included;...
  • Page 13 NOTE The vehicle's serial number is used to identify your machine. QUALITY APPROVAL PLATE Key identification number The QUAD has two pairs of keys. The first and most important (C) is the ignition key, and the second (D) is used for the fuel tank and seat.

  • Page 14: Location Of Components

    LOCATION OF COMPONENTS GAS GAS WILD H.P. 300. RV. 1- Clutch lever 8- Front brake lever 2- Light switch 9- Throttle control 3- Flash beam 10- Front guard 4- High beam switch 11- Brake pads 5- Emergency stop 12- Fuel tank cap...
  • Page 15 15- Headlight casing 21- Swing arm 16- Fuel cut-off 22- Exhaust pipe 17- Seat 23- Front brake fluid 18- Front shock absorber 24- Kick-starter pedal 19- Spark plug 25- Brake pedal 20- Shift pedal 26- Exhaust...

  • Page 16: The Main Parts Of The Quad

    THE MAIN PARTS OF THE QUAD LIGHTS IGNITION KEY NOTE The headlight and the rear light can only be switched on when The ignition lock (A) is located on the front part of the handlebars. the engine is on. To turn the ignition ON, turn the key clockwise to the "ON" position. To turn the ignition OFF, turn the key anti-clockwise to the "OFF"...

  • Page 17: Emergency Lights

    Indicators (F) are located in the lower part of the same left hand side grip. Note that pushing the switch to the right turns on the right indicator, and to the left to operate the left indicator. On the same group we will find the horn button (G). DISTRESS LIGHTS The button is located on the front part of the vehicle (H), in front of the handlebars.

  • Page 18: Front Brake Lever

    FRONT BRAKE LEVER The front brake lever (A) is located on the right side of the handlebars. Operate it to apply the front-wheel brakes. One end (C) is attached to the vehicle and the other end (D) is secured to the rider. The cable is elastic.

  • Page 19: Reverse Gear Push Button

    REVERSE GEAR BUTTON STARTER The WILD H.P 300 RV. is fitted with a reverse gear. The reverse The starter (F) is a mechanism that aids engine operation in case gear button (1) is located in the centre of the handlebars. it is cold.

  • Page 20: Fuel Tap

    FUEL CUT-OFF Turn the key clockwise, and then insert your hand between the seat and the chassis at the rear of the seat. This tap supplies fuel to the carburettor and is located on the left The seat will lift easily. hand side under the seat.

  • Page 21: Rear Guard

    REAR GUARD The whole assembly will protect feet and legs from the wheels in case of a loss of balance or if feet slip from the footrests. Width is Likewise, the rear guard (D) also protrudes from the vehicle. This provided for freedom of movement.

  • Page 22: Verifications To Be Made Before Starting The

    VERIFICATIONS TO BE MADE BEFORE STARTING THE VEHICLE WARNING Always inspect the QUAD before use, to ensure it is safe to operate without any danger. Always follow the inspection and maintenance procedures and programs described in this manual. Failure to inspect the machine increases the risk of accident or breakdown.

  • Page 23: Fuel

    If the brakes do not provide adequate braking power, check the brake pads for wear. Recommended fuel FUEL The GAS GAS WILD 300. RV. has a 2-stroke engine that requires CAUTION a mix of petrol and oil. Only use lead-free petrol. The use of leaded petrol will seriously damage internal components of the engine.

  • Page 24: Cooling System

    WARNING THE COOLING SYSTEM Gasoline is extremely flammable and can be explosive under certain Radiator hose conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or Check the radiator hoses for cracks or deterioration, and connections sparks;...

  • Page 25: Chain

    Check the cooling liquid level in the reservoir (A) with the cold engine (the liquid level will vary with engine temperature). The level is correct WARNING when it is between the two marks. If it falls below the lower mark, add antifreeze.

  • Page 26: Using The Quad

    USING THE QUAD If the tyre wears out at the edges, the tyre is a little flat. The tyre WARNING must be worn out equally over its surface. Replace the tyre when the groove depth is below 3mm. Read the User's Manual carefully so as to become familiar with all of the controls.

  • Page 27: Changing Gears

    6.- If the engine is WARNING cold then pull on the choke button (B). - Always use the parking brake before you start the engine. QUAD (B). might start move off unexpectedly if the brake is not on. This could lead to a loss of control or to a collision.

  • Page 28: Driving The Vehicle

    CAUTION To decelerate Do not run with the engine off for a long time, or tow the QUAD for long distances. Even in neutral position the lubrication system for To slow down or stop, release the throttle and apply the brakes the gearbox is only activated when the engine is on.

  • Page 29: Running-In The Engine

    ENGAGING THE REVERSE GEAR The WILD H.P 300 RV. is fitted with a reverse gear. To engage the reverse gear, the following conditions must be fulfilled: 1- The QUAD must be stopped and the engine running. 2- The gears must be in neutral. Simultaneously press the 3.-Use the parking right hand lever (front...

  • Page 30: Driving The Quad. Practical Recommendations

    1. Use the brakes to stop the vehicle; once it has stopped, engage WARNING the first gear. 2. Without releasing the clutch lever, stop the engine. Now the clutch Never carry a passenger. The large seat is designed so that the rider lever can be released.

  • Page 31: How To Turn Your Quad

    Do not modify this QUAD by fitting or using inadequate accessories. The parts and accessories added to this vehicle must be original GAS GAS parts or equivalent parts designed for use on this QUAD, 1.- Turning to the right. and must be fitted and used according to the instructions. Fitting 2.- Turning to the left.

  • Page 32: Up Hills

    If the vehicle starts to turn over towards the outside of the corner, While climbing a slope if you discover that you have not correctly reduce speed, compensate with the steering or lean even more calculated your ability to reach the top, turn the QUAD while you still to the inside.

  • Page 33: Going Across Shallow Water

    necessary to correct direction on loose surfaces by turning the SLIDING AND SKIDDING steering slightly uphill. When crossing slopes, do not perform tight turns up or downhill. If the QUAD starts to turn over, gradually turn When riding over slippery or loose surface, use caution. An uncorrected downhill if there is no obstacle in the way.

  • Page 34: Tuning

    To adjust the rebound, turn the knob (B) on TUNING the lower part of the shock absorber by hand. TUNING THE FRONT SUSPENSION There is a possible 22 “clicks” (adjustments) in total. The front suspension is formed by two wishbone arms with 2 multiple- The rebound is normally set to 7 “clicks”.

  • Page 35: Tuning The Rear Suspension

    TUNING THE REAR SUSPENSION using a flat blade screwdriver. Turning anti-clockwise to the limit will close it completely. The rear suspension is composed of an aluminium alloy swing arm with no welding. The progressive strut system is fitted with an There is a possible 56 “Clicks”...
  • Page 36 WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Ensure that the area is ventilated and that there are no sources of sparks or flames nearby (including a spot lamp). Carburettor needle The needle and the diffuser of the needle should have an effect from 1/4 to 3/4...
  • Page 37 Quad testing Standard settings - Heat the engine with the fuel supply in the standard position, then Component Specification check the spark plug operation conditions. -Try the QUAD keeping the carburettor valve open. Accelerator valve Idle jet Needle N1EC Symptoms of inadequate adjustments Full jet If the QUAD displays any one of the following symptoms then the adjustments must be changed.
  • Page 38 ALTITUDE (104) (86) (68) (ºC) (50) (ºF) (32) (14) 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06 CORRECTION FACTOR NEEDLE POSITION / AIR ADJUSTMENT SCREW CORRECTION FACTOR 1.06 or More 1.06 - 1.02 1.02 - 0.98 0.98 - 0.94 0.94 or Lower NEEDLE LOWER THE CLIP...

  • Page 39: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENTS MAINTENANCE CHART The first revision must be performed by a specialised workshop at 500 km or after two fuel tanks. The following revisions must be made every 2000 km or three months. BEFORE USING THE Fuel tank level QUAD Front and rear brake fluid levels Brake lever and pedal play...

  • Page 40: Clutch Lever Adjustment

    Regular inspections, adjustments and regular lubrication keep the Tighten the adjustment bolt to obtain the optimal play. machine in the best possible conditions of safety and efficiency. If the clutch lever adjustment is at its limit, play must be adjusted by Safety is an obligation for the owner of the machine.

  • Page 41: Checking The Brake Fluid Level

    It is possible that air has entered the brake system. Purge the system in the following way: 10 mm - Remove the brake When the brake pedal fluid reservoir cap (E) is in rest position, to check the level. there should be a play of 10mm.

  • Page 42: Checking The Brake Front And Rear Pads

    When the fluid level is too low, fill up: - Make sure that the fluid container is well closed, put the seat back - With a cross-tip screwdriver, unscrew the two screws on the and lock it in place using the key. Ensure that the seat is secured recipient.

  • Page 43: Changing The Wheels

    NOTE Never overuse the brake pads, if the thickness is not checked they could cause damage to the brake calliper. When the thickness of the pads is considerably reduced, visit a specialized shop and have the pads changed. WHEEL CHANGES We must change the wheels when they are worn out or after a puncture.

  • Page 44: Checking The Coolant Level

    - Go to the rear of the Chain lubrication is one of the operations that must be performed QUAD. There are four frequently. bolts (A) on the swing arm. How often do you need to lubricate the chain? - Unscrew the 4 screws.
  • Page 45 Anti-freeze liquid information They are located together on the left side of the quad. To protect the cooling system aluminium parts (engine and radiator) from rust and corrosion, the use of corrosion and rust inhibitor chemicals in the coolant is essential. If coolant containing corrosion and rust inhibitor chemicals is not used, over a period of time, the radiator will rust.

  • Page 46: The Air Filter

    Changing the coolant - Install the water pump cover drain plug and cylinder drain plug with the specified torque shown in the table. Always replace seals with new The coolant should be changed periodically to ensure long engine life. ones. - Wait for the engine to cool down completely.
  • Page 47 NOTE Do not twist the element when drying. 4.- Extract the filter cage. 5.- Put the filter in a container with some de-greasing liquid. (C). Air filter housing. This liquid should (D). Inspection hose. clean the filter without damaging it. Cleaning process WARNING Clean the filter in a well-ventilated zone and ensure that there are...

  • Page 48: Spark Plug Maintenance

    NOTE The element must be damp but not dripping. - When the element does not drip anymore, put it in a bath of lubricant and grease. We may avoid the use of a bath and soak the filter in the same liquid, the result is the same. Apply special air filter oil to the element foam.

  • Page 49: Adjusting The Idle

    - Remove the spark plug to see if it is full of carbon and dirt. - Finish the adjustment of the spark plug using the spark plug wrench - Use a wire brush to clean off the carbon then use a little petrol to but without tightening excessively.

  • Page 50: Inspecting And Lubricating The Cables

    INSPECTION AND LUBRICATION OF THE CABLES (A). Allen bolts 4 WARNING Inspect the cables regularly and replace them if damaged. When the outside protection is damaged, corrosion may occur. The cables may also be worn out or damaged. Control operation could be restricted, which may result in accidents and injuries.
  • Page 51 3.- Unscrew the 3 bolts that hold the light from below, they must be Rear lights engaged to operate them. WARNING The bulb is hot when lit and immediately after turning off the lights. Wait for it to cool down before touching or removing it. It can burn or could cause a fire if it comes in contact with flammable material.
  • Page 52 Indicators - To remove the bulb, press it against the spring, turn it 1/4 anti- clockwise, extract and replace it with a new one. - Put the lens back in place and make sure the assembly is well secured. - Using a cross- tipped screwdriver, unscrew the screws (A), located on the...
  • Page 53 Oil changes The transmission oil should be changed regularly to ensure a long engine life. Heat the engine for 5 minutes so that the oil picks up any sediment in the engine. NOTE In order to reach the correct engine oil temperature for measurement of the level, the engine must be allowed to completely cool, then heat it once more during some minutes to the normal operation temperature.

  • Page 54: Tightening Torques Table

    TIGHTENING TORQUE TABLE Tighten all of the bolts and nuts using the correct spanners. If not correctly tightened then this could result in machine damage or even an accident. Assembly Part name Kg-m number Crankshaft bolts Cylinder nut Engine drain plug Kick pedal bolt Kick pedal nut Shift pedal bolt...

  • Page 55: Torque Locations Diagram

    lTIGHTENING TORQUE SCHEMA The following is a diagram of the locations of the bolts numbered on the previous page. They are grouped by assembly. 1. Ass. Front wheel 6. Ass. Shift pedal 2. Ass. Front suspension 7. Ass. Rear suspension 3.

  • Page 56: Cleaning, Lubrication And Storage

    CLEANING, LUBRICATION AND STORAGE Where to be most careful. Avoid applying high-pressure water to: CLEANING Brake calliper and brake pump piston below the fuel tank (if water enters the electric coil or in the spark plug hood, the quad will not Frequently cleaning your vehicle will not serve only to improve its start and the wet parts must be dried out);...

  • Page 57: Lubrication

    LUBRICATION Use a spray with a tube to Lubricate the points shown here, with either motor oil or regular lubricate grease, periodically or whenever the vehicle has been exposed to wet under conditions, and especially after using a high-pressure spray washer. pressure: Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.

  • Page 58: Storage

    STORAGE If you need to keep the QUAD for a long period of time (we consider that long is 60+ days) you must: - Clean the entire vehicle thoroughly. - Run the engine for about five minutes to warm the oil, shut it off and drain the transmission oil (See the section on transmission).

  • Page 59: Multifunction Speedometer

    Chronometer THE MULTIFUNCTION INSTRUMENT PANEL To use the chronometer, press Reset to put it to zero. Counting The multi-function display has two buttons, a mode button to change begins immediately. display and a reset button for certain functions. The partial distance in Km or Miles can be reset by pressing the Reset button.

  • Page 60: Trouble Shooting Table

    TROUBLE SHOOTING NOTE: This is not an exhaustive list, it is meant simply as a rough guide to assist troubleshooting for some of the more common difficulties. CAUSE SOLUTION FAULT The engine does not rotate - Crankshaft locked. - Go to a specialist workshop. - Cylinder/ piston/ crankpin journal seizure.
  • Page 61 FAULT CAUSE SOLUTION The engine does not run - Dirty, broken or wet spark plug. - Check the condition of the spark plug and clean, adjust smoothly or replace it. - Spark plug hood or cable problem. - Check the condition of the spark plug hood, if it is deteriorated, change it.
  • Page 62 FAULT CAUSE SOLUTION White fumes from the exhaust - Petrol valve cable maladjusted. - Go to a specialist workshop. - Air filter obstruction. - Clean or change the air filter. Go to a specialist workshop. Brown fumes from the exhaust - Main jet too high.
  • Page 63 FAULT CAUSE SOLUTION Clutch slipping - Clutch plates worn. - Change the clutch disks. Go to a specialist workshop. The QUAD is unstable. - Steering stem nut loose. - Adjust the steering stem, ensure that there is a pin underneath the bolt preventing it from loosening in any case.
  • Page 64 FAULT CAUSE SOLUTION The QUAD makes unusual - Replace the damaged cylinder. - Cylinder damage. noises - Verify and adjust to the correct tightening torques. - Brackets, nuts, bolts not properly tightened. The handlebars vibrate - Refill. - Tyre deformation, swing arm or needle bearing worn.
  • Page 65 FAULT CAUSE SOLUTION The lights blow - Voltage regulator faulty. - Remove the seat and the fuel tank then check connections, verify the voltage regulator and the fuses in the fuse box. The lighting system does not - Bulbs melted or short-circuit in the electric - Check the condition of the bulbs and the electrical work installation.

  • Page 66: Electrical Diagrams

    ELECTRICAL SCHEMAS B black O Orange Br Brown R Red G Green Sb Sky blue Gr Grey V Violet L Blue W White Y Yellow...

  • Page 67: Warranty Manual

    Warranty terms of the manufacturer 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.
  • Page 68 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.
  • Page 69 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.
  • Page 72 RECOMIENDA EL USO DE ACEITE: RECOMMENDS THE USE OF OIL: RECOMMANDE L’USAGE DE L’HUILE: CONSIGLIA L’USO D’OLIO: FEBRERO / FEBRUARY / FEBRER 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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