Related Manuals for GAS GAS WILD HP 450 - 2005
Summary of Contents for GAS GAS WILD HP 450 - 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...
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Page 5: 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. -
Page 6: General Advice
Read this Manual carefully. It explains all the aspects concerning 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 Driving quad bikes is a fantastic sport, and we hope you enjoy it to just purchased. -
Page 7: Table Of Contents
CONTENTS - Introduction.................. 3 Front and rear brakes............20 - General advice................4 Fuel................... 21 - Contents..................5 Coolant system..............22 - Specifications................7 Chain................22 - Information concerning your safety..........8 Throttle twist-grip.............. 22 - Important information..............10 Lights................ - Page 8 - Regular maintenance and adjustments........34 Maintenance chart............34 Adjusting clutch lever........... 35 Adjusting brake handle and pedal......... 35 Checking brake fluid level..........36 Checking front and rear brake pads......37 Changing wheels............38 Swinging arm..............38 Adjusting and lubricating chain guide......38 Checking coolant level..........
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Page 9: Specifications
SPECIFICATIONSE ENGINE 443 cc Cylinder size: Single-cylinder, 4-stroke with 4-valve cylinder head. Type: Liquid. Cooling system: 95 x 62.6 mm. Bore and stroke: MAGNETI MARELLI. Injection system: Integrated on injection system. Ignition: Hydraulic multi-disc . Clutch: 5 speeds and reverse. Gear box: Primary with gears, secondary with chain. -
Page 10: Information Concerning Your Safety
SAFETY INFORMATION - 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. THE QUAD is not a toy: its use may be dangerous. - Driving a quad bike is unlike driving any other vehicle, and you will THE QUAD is driven in a different manner to other vehicles, such particularly notice this when turning. - Page 11 - 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 lose braking capacity. On exiting the water, pump the brakes several times to dry them more quickly.
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Page 12: Important Information
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 for making adjustments to the carburettor, these adjustments should only be made by a qualified mechanic, and only when necessary. - Page 13 NOTE The vehicle serial number is used to identify your machine. QUALIFICATION No. 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.
- Page 14 LOCATION OF COMPONENTS GAS GAS WILD HP 450 1 2 3 4 1- Clutch handle 9- Front brake handle 2- Light switch 10- Throttle twist-grip 3- Light flash button 11- Front guard 4- Full beam button 12- Brake pads 5- Emergency stop...
- Page 15 16- Front headlight casing 22- Swing arm 17- Throttle housing 23- Exhaust pipe 18- Seat 24- Front brake fluid tank 19- Front shock absorber 25- Kick-start pedal 20- Engine 26- Brake pedal 21- Shift pedal 27- Engine oil tank...
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Page 16: Principal Parts Of The Quad
LIGHTS PRINCIPAL PARTS OF THE QUAD NOTE IGNITION KEY The headlight and tail lights can only be switched on after the engine has been started 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”. -
Page 17: Hazard Lights
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). -
Page 18: Rear Brake Pedal
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... -
Page 19: Shift Pedal
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. -
Page 20: Seat
SEAT - Initial charge current = 0.1 – 0.5 Cn - Charge duration = 6 hours minimum / 24 hours maximum. 3.2. Constant power charge mode. To remove the seat, use the same key as for the fuel tank cap (B). - Maximum charge current = 0.1 Cn Put the key in the lock which is located on the right-hand side of the - Recommended charge time = 5 - 8 hours. -
Page 21: Foot Rest Assembly
REAR PROTECTION 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. Similarly, the rear guard (D), also juts out from the quad bike assembly. -
Page 22: Checks To Make Before Starting The Machine
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. -
Page 23: Fuel
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. -
Page 24: Chain
THE COOLING SYSTEM Check coolant level in tank (A) while the engine is cold (the coolant level varies with the engine temperature). The level is acceptable Radiator hose while it falls between the two marks. If the level falls below, top up antifreeze. - Page 25 WARNING If wear is at the sides this indicates that the tyre is not sufficiently inflated. The use of unsuitable tyres or driving the vehicle with the tyres Therefore, wear should be spread uniformly over the surface of the inflated to incorrect or uneven pressures, may result in loss of control, tyre.
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Page 26: Use Of Your Quad
USE OF YOUR QUAD. WARNING WARNING - Always apply the parking brake before starting the engine. The QUAD could move unexpectedly if the brake is not applied. This The User Manual should be read carefully to familiarise yourself could give rise to loss of control or a collision. with all the controls. -
Page 27: Changing Gear
NOTE CAUTION If the engine does not start, turn the key to the OFF position Always release the accelerator to change speed, otherwise the and wait a few seconds before trying again. The attempts engine and the transmission could be damaged. should be as short as possible, in order to save the battery. -
Page 28: Stopping The Engine
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. -
Page 29: Driving Your Quad. Practical Advice
DRIVING YOUR QUAD. Practical advice. WARNING GETTING TO KNOW YOUR QUAD Never carry passengers. Carrying a passenger could lead to an accident, resulting in injury to the driver and/or passenger. The quad This QUAD is designed for experienced drivers, for recreational use. bike has an emergency stopping system should the rider fall off the Although you may be an expert driving other all-terrain vehicles or bike, but it is not prepared for the fall of a second passenger. -
Page 30: How To Turn With Your Quad
Parts and accessories added to this vehicle should be originals from 1.- Turning to the right. GAS GAS or equivalent parts designed for use with this QUAD, and 2.- Turning to the left. they should be fitted and used in accordance with the instructions. -
Page 31: Crossing Slopes
If the machine starts to overturn towards the outside while taking If you are climbing a slope and find that you have not estimated your the bend, reduce speed, turn the steering or lean further towards ability to reach the top correctly, turn round with the QUAD while you the inside of the bend. -
Page 32: Crossing Shallow Water
skills on flat ground. Avoid slopes with slippery surfaces and rough DRIVING ON ROUGH GROUND terrains where you might lose your balance. While crossing the slope, lean your body to the up side of the slope. Driving over rough ground should be carried out carefully. In this It may be necessary to correct the steering on going over loose way any obstacle which may cause damage to the QUAD, destabilize surfaces, by turning the front wheels slightly upwards. -
Page 33: Tuning
TUNING To adjust the extension, turn the control (B) of the lower part of the shock absorber by TUNING FRONT SUSPENSION hand. Formed of two trapezoidal arms with 2 ÖLHINS multi-adjustable There is a possibility of 22 clicks in total. shock absorbers. -
Page 34: Tuning Rear Suspension
TUNING REAR SUSPENSION Adjusting the compression This is a swing arm manufactured in aluminium alloy, and is weld- To adjust, turn control (B) of the upper section of the shock absorber free. The progressive system using rods, with the “OHLINS” multi- using a flat headed screwdriver. -
Page 35: Regular Maintenance And Adjustments
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... -
Page 36: Adjusting Clutch Lever
Inspections, adjustments and regular lubrications keep the machine Tighten the adjustment bolt to obtain the optimal play. in optimum safety and working conditions. If the adjustment of the clutch lever is at its maximum, use the clutch Safety is the responsibility of the owner of the machine. In the cylinder piston rod to adjust play. -
Page 37: Checking Brake Fluid Level
It is also possible that air has entered the brake fluid circuit. To bleed the system proceed as follows: When the brake pedal is in the rest position there - Remove the cap should be a play of from the brake fluid 10 mm. -
Page 38: Checking Front And Rear Brake Pads
When the brake fluid level is very low, top up: - Next check that the fluid container is properly closed, replace the - With a Philips screwdriver, undo both screws on the container. seat and turn the key in the opposite direction. Also check that the - Next, top up with fluid. -
Page 39: Changing Wheels
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. -
Page 40: Checking Coolant Level
- Stand to the rear of working of your quad bike. Chain lubrication is one of the operations the QUAD. Near the which should be carried out most often. swing arm there are 4 screws (A). When? - Undo the 4 screws. - After riding over wet ground. - Page 41 Anti-freeze liquid information containers. They are located side by side on the left hand side of the quad bike. 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.
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Page 42: Air Filter
Changing coolant Tighten bolts (see table of tightening torques) Water pump plug: 9 Nm. The coolant should be changed periodically to ensure long engine life. - Wait for the engine to cool completely. - Fill the radiator up to the edge and fit the cap on the radiator. - Put the QUAD in a horizontal position. - Page 43 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. (C). Air filter casing. (D). Test hose. Cleaning process WARNING 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).
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Page 44: Spark Plugs
NOTE The element should be damp but not dripping. - Once it has stopped dripping, place it in 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. - Page 45 Always use spark plugs recommended by GAS GAS. Consult your dealer or a qualified mechanic to know which plug is best for your 7.
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Page 46: Inspection And Lubrication Of Cables
INSPECTION AND LUBRICATION OF THE CABLES (A). Bolts with a nº 4 Allen key. 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. - Page 47 3.- Undo the bolts holding the headlamp in the interior, you will need Rear lights to bend down to handle them. 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.
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Page 48: Transmission
Indicators Initially replace the oil after 5 hours of use and subsequently every 60 hours. - To remove the bulb, press down, turning 1/4 anticlockwise, remove and replace with a new one. 20W-50 - Fit the lens in the same way as you have removed it and make sure that the unit is correctly fastened. - Page 49 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.
- Page 50 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. 3. Remove the three screws from the cover of WARNING the filter.
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Page 51: Cleaning
The engine could be damaged if the oil is not used correctly or if the - Cover with a plastic bag Exhaust GAS GAS specifications are not followed. tied with elastic bands. Use the type of oil specified in the section on Petrol and Oil Clutch lever, brake, recommendations. -
Page 52: Lubrication
Where to be careful? Avoid spraying water with any great force LUBRICATION near the: Lubricate the parts shown, with engine oil or grease, regularly or Brake pump master cylinder and callipers, below the petrol tank ( if when the vehicle has been in wet weather and especially after using water gets into the ignition coil or the spark plug cap, the QUAD will high pressure water. -
Page 53: Storage
Use a spray STORAGE with pressure tube to When the QUAD is to be stored for any length of time (say for over lubricate with 60 days) you should: pressure: - 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). -
Page 54: Multifunction
MULTIFUNCTION minute , making coordination with a selected time easy (e.g. in competition). The Multifunction has two buttons, one to change the display (mode) Chronometer and the other to reset certain functions. To measure a time (chronometer), hold down the Reset button until the zero point. - Page 55 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 an accident. Name of part Unit Nº Cylinder head bolts Cylinder nut Engine drain plug Kick pedal bolt Kick pedal nut Shift pedal bolt...
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Page 56: Diagram Of Tightening Torque Locations
DIAGRAM OF TIGHTENING TORQUE POSITIONS Below we display the positions of the bolts detailed on the previous page. These are grouped by units. Unit- Front wheel Unit- Shift pedal. Unit- Front suspension Unit- Rear suspension Unit- Engine Unit- Kick-start pedal Unit- Transmission Unit- Chassis Unit- Rear wheel... -
Page 57: Fault Diagnosis
FAULT DIAGNOSIS 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 starter motor does not work - The fuse for the starter relay has blown. - Remove the seat and change the fuse of the starter relay. - Page 58 FAULT CAUSE SOLUTION - Remove the seat and the fuel tank, clean the ECU pin Engine rotates but does not start - The ECU pin connector, generator or connector and treat with a contact spray. coil oxidised or in poor condition. - Clean the petrol tank ventilation.
- Page 59 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 insufficient. viscosity. - Ignition problems. - Go to a specialist workshop. Abnormal engine noise - Valve adjustment play.
- Page 60 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. Gears jump - Gear change fork damaged in the gears.
- Page 61 FAULT CAUSE SOLUTION Shock absorption too hard. - Verify tyre pressure. - Excessive tyre pressure. Shock absorption too soft - The hydraulic system must be stopped by turning the - Rebound poorly adjusted control of the lower section of the shock absorbers to the right.
- Page 62 FAULT CAUSE SOLUTION Quad bike tends to lean to one - Chassis twisted. - Go to a specialist workshop. side - Steering incorrectly aligned. - Adjust the steering. Go to a specialist workshop. - Steering rod bent. - Change steering rod. Go to a specialist workshop. - Rear wheel misaligned.
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Page 63: Electrical Schemas
ELECTRICAL SCHEMAS Black Brown Green Grey Blue Orange Light blue Violet White Yellow... - Page 64 Black Brown Green Grey Blue Orange Light blue Violet White Yellow...
- Page 65 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 66 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 67 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...
- Page 68 Notes Notes...
- Page 71 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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