GAS GAS WILD HP 300 Service Manual
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GAS GAS WILD HP 300 Service Manual

GAS GAS WILD HP 300 Service Manual

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Summary of Contents for GAS GAS WILD HP 300

  • Page 2: Presentation

    GAS GAS thanks you for your trust By choosing the new WILD H.P. 300 you have just joined the great GAS GAS family and, as a user of the number one off-road manufacturer, you deserve the distinguished treatment that we want to offer to you, both in our after-sales relationship and with the explanations that we will give you in this manual.

  • Page 3: Common Advice

    WARNING be appreciated with your vehicle will be due to improvements in riding and the product’s quality. GAS GAS Motos SA is constantly Ignoring the WARNING instructions can lead to grave or even fatal improving their vehicles so that you can enjoy higher performance.

  • Page 4: Table Of Contents

    TABLE OFCONTENTS Front and rear brakes........87 - Presentation................70 - Common advice................71 Fuel..............88 - Table of contents..............72 Cooling system...........89 - Specefications...............74 Chain................90 - Safety information.............75 Throttle grip................90 - Important information............77 Lights................90 Tyres................90 Identification numbers..........77 - Use of the QUAD..............91 - Location of components............79 Engine start..............91 - Main parts of the QUAD.............81 Gear box................92...
  • Page 5 Carburation tuning............100 - Periodic maintenance and adjustment..........104 Maintenance chart............104 Cluth lever adjustment..........105 Adjustment of the brake lever and pedal.....105 Checking the brake fluid level........106 Checking the brake pads at the front and rear....107 Wheel change..............108 Swing arm axle...............108 Adjustment and lubrication of the chain guide....108 Checking the cooling liquid level.........109 Air filter................111 Spark plug maintenance..........113...

  • Page 6: Specefications

    SPECIFICATIONS ENGINE Cylinder size: 294,7 Type: Two-stroke, single cylinder engine with direct reed intake into lower crankcase and exhaust valve. Cooling system: Liquid Bore x stroke: 72 x 72 mm. Carburettor: Keihin PWK 38 mm. Ignition: Kokusan digital CDI Multispark Clutch: Hydraulically operated multidisc Gearbox:...

  • Page 7: Safety Information

    - Riding a QUAD is not like driving any other vehicle, and you will SAFETY INFORMATION notice it specially when cornering. Practise on flat ground with free of obstacles and with no other vehicles around first. Read the recommendations in the section "Use of the QUAD" of this manual. The QUAD is not a toy: driving it may be dangerous.
  • Page 8 - Always use the tyre size and type described in this manual. WARNING - Always stop the engine before refuelling. - While refuelling, do not smoke, fuel is highly flammable and may explode under certain conditions. Keep the engine off at all times. Make sure the area has good ventilation and free of sparks of flammable sources;...

  • Page 9: Important Information

    IMPORTANT INFORMATION The vehicle leaves the factory with some unassembled elements, to make transportation easier. The dealer will make sure each element is correctly fitted and you will receive the quad ready to use. This paragraph is purely for your information. You will find enclosed a carburettor-adjustment kit.
  • Page 10 NOTE The vehicle's serial number is used for your machine's identification. HOMOLOGATION B. Key identification number The quad has two pairs of keys. The first and most important (C) is the contact key, and the second (D) is used for the fuel tank and seat locks.

  • Page 11: Location Of Components

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

  • Page 13: Main Parts Of The Quad

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

  • Page 14: Luces De Emergencia

    Indicators (D) are located in the lower part of the left grip. Sliding the switch to the right turns on the right indicator, and the same action to the left applies to the left indicator. In the same group we will find the horn button (E). EMERGENCY INDICATORS It is a button on the front part of the vehicle (F), before the handlebars.

  • Page 15: Maneta Freno Delantero

    FRONT BRAKE LEVER The front brake lever (A) is located on the right side of the handlebars. Activate it to apply the front-wheel brakes. One end (C) is attached to the vehicle and the other end (D) is attached to the rider. The cable is elastic, and the two ends are joined to the rider and the vehicle, with the part joined to the vehicle sensitive to sudden REAR BRAKE PEDAL...

  • Page 16: Pedal Cambio

    CHANGE PEDAL To activate it, pull the button and, without turning the throttle, start the engine. You will notice that the engine starts at higher revs than The vehicle features a 6-speed gearbox. in normal operating conditions. The change pedal (E) is located on the left side of the engine and After some seconds, the engine will be in the optimal operating is used in combination with the clutch when changing gears.

  • Page 17: Seat

    Turn the key clockwise and move your hand to the gap between the seat and the base from behind. Open The seat will open easily. NOTE When putting the seat back in the normal position, make sure it holds well back in place. Reserve Closed OFF: (closed) With the lever in this position, the fuel is closed.

  • Page 18: Rear Guard

    REAR GUARD case of losing balance and taking your feet off the rests. Their width allows for great freedom of movement. Likewise, the rear guard (D) also projects from the vehicle. It will prevent the quad from falling backwards, which might result in serious injuries.

  • Page 19: Vehicle

    CHECKINGS TO BE MADE BEFORE RIDING THE VEHICLE WARNING Always inspect the quad before every use, to make sure it is in safe riding conditions. Always follow the inspection proceedings and programmes described in this manual. Failure to inspect the machine increases the risk of accident or breakdown.

  • Page 20: Fuel

    Make sure the fuel tank cap is tightly closed. FUEL Recomended fuel The GAS GAS WILD 300 c.c. has a 2-stroke engine that requires a gasoline-oil mixture. CAUTION Use only unleaded fuel. The use of leaded fuel would seriously damage the inner parts of the engine.

  • Page 21: Cooling System

    WARNING COOLING SYSTEM Gasoline is extremely flammable and can be explosive under certain Radiator pipe conditions. Always stop teh engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or Check that the radiator pipes do not have cuts or are damaged, and sparks;...

  • Page 22: Chain

    (the liquid level will vary with engine temperature). The level is correct when between the two marks. If it falls below the lower mark, add WARNING anti-freezing liquid. Change the liquid every two years. The use of inadequate tyres or riding the vehicle with incorrect or unequal tyre pressures may lead to loss of control, with the subsequent NOTE risk of accident.

  • Page 23: Use Of The Quad

    If the tyre wears out at the edges, the tyre pressure is too low. USE OF THE QUAD The tyre must be worn out equally on its surface. Replace the tyre when the groove depth is below 3mm. WARNING Read the User's Manual carefully so as to become familiar with all the commands.

  • Page 24: Gearbox

    6.- If the engine is WARNING cold, pull the start button (B). - Always use the parking brake before you start the engine. The QUAD might start unexpectedly if the brake is not on. This could lead to a loss of control or to a crash. - Remember to release the parking brake before starting.

  • Page 25: Starting The Vehicle

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

  • Page 26: Engine Running-In

    Over the next 10 hours (from 10 to 20) try not to use more than ¾ throttle for long periods of time. PARKING IN INCLINED SURFACES WARNING Avoid parking on inclined ground, as the quad may start moving without control, with risk of accident. If it is necessary, insert the first 3.- Use the gear, apply the parking brake and block the front and rear wheels parking brake to...

  • Page 27: Driving The Quad. Practical Recommendations

    DRIVING THE QUAD. Practical recommendations. WARNING Never carry a passenger. The long seat is designed to provide the BECOME FAMILIAR WITH YOUR QUAD driver with the necessary room to slide to the correct riding position. It is not designed for carrying passengers. Carrying a passenger in This quad is destined to expert riders, to be used in recreational this quad reduces the possibility to balance and control the machine activities.

  • Page 28: How To Turn With 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 their use in this 1.- Turn right. quad, and must be fitted and used according to the instructions.

  • Page 29: Uphill Climbing

    If the vehicle starts to incline to the outside of the corner, reduce If you are climbing a slope and you discover that you have not your speed, turn the handlebars or lean even more to the inside. It guessed correctly your ability to reach the top, turn the quad round may also be necessary to reduce your speed gradually and to turn while you still have some traction and if there is enough room for the steering to the outside of the corner to avoid tumbling over.

  • Page 30: Going Across Shallow Water

    balance. While you are crossing the slope, keep your body inclined RIDING IN ROUGH TERRAIN towards the top of the climb. Riding in rough terrain must be performed very carefully. Be always It might be necessary to correct direction by turning the steering alert to any obstacle that may damage the QUAD, make you lose slightly uphill.

  • Page 31: Tuning

    To adjust the rebound, turn the knob (B) in TUNING the lower part of the shock absorber with your hand. TUNING THE FRONT SUSPENSION There are 22 available positions, each one The front suspension is formed by two wishbone arms with 2 multiple- of them reached by turning the knob until adjustment ÖHLINS shock absorbers.

  • Page 32: Tuning The Rear Suspension

    TUNING REAR SUSPENSION There are 56 positions available in total. It is an unwelded aluminium alloy swing arm. The progressive strut The standard setting is 28 "clicks". system features an ÖHLINS multi-adjustment shock absorber. Like Totally hard compression is 0 "clicks". the front suspension, it can be adapted to different riding styles.
  • Page 33 WARNING Petrol is highly flammable and can explode under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and there are no spark or flame sources nearby (including a lamp). Carburettor needle (A).
  • Page 34 Test with your vehicle Standard measurements - Warm the engine up with the carburettor in the standard settings, PETROL UNLEADED and examine the spark plug condition. - Test the quad keeping the carburettor valve open. Accelerator valve Idle jet Needle N1EC Symptoms of inadequate changes Main jet...
  • Page 35 ALTITUDE (104) (86) (68) (ºC) (50) (ºF) (32) 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06 (14) CORRECTION FACTOR JET NEEDLE / AIR SCREW CHART CORRECTION FACTORS 1,06 or ABOVE 1,06 - 1,02 1,02 - 0,98 0,98 - 0,94 0,94 or BELOW JET NEEDLE LOWER CLIP ONE...

  • Page 36: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT MAINTENANCE CHART The first revision must be performed by a specialised workshop at 500km or after two fuel tanks. The following revisions must be passed every 2,000 km or three months. BEFORE EVERY OUTING Fuel tank level WITH THE QUAD Brake fluid level (front and rear) Brake lever and pedal Free play...

  • Page 37: Cluth Lever Adjustment

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

  • Page 38: Checking The Brake Fluid Level

    Air might also have entered the brake system. The process to bleed the system is as follows: - Remove the brake 10 mm fluid reservoir lid (E) When the brake pedal to control the level. is in resting position it must have 10-mm free play.

  • Page 39: Checking The Brake Pads At The Front And Rear

    When the fluid level is too low, add more: - Make sure that the fluid container is well closed, put the seat back - With a cross-tip screwdriver, unscrew the two screws on the in place and turn the key back to remove it. Ensure also that the reservoir.

  • Page 40: Wheel Change

    - To adjust the axle nut, we will go to the rear end of the quad. Follow the proceedings - The nut is located at the right of the swing arm. explained below: - Use the (F) spanner, which comes with your GAS GAS Quad, to tighten the axle. WILD HP -...

  • Page 41: Checking The Cooling Liquid Level

    - Go behind the quad. of the vehicle. Chain lubrication is one of the actions that you will You will see four perform very often. screws on the swing arm (A). ¿When must you lubricate the chain? - Unscrew the 4 screws - After riding on damp ground.
  • Page 42 Information on anti-freezing liquid They are located together on the left side of the quad. To protect the aluminium parts of the cooling system (engine and radiator) from oxidisation and corrosion, use chemical inhibitors in the essence of the cooling liquid. Without an anti-corrosion liquid, in time, the radiator would oxidise.

  • Page 43: Air Filter

    Coolant Change the specified torques shown in the table. Always replace the gasket with a new one, if it damaged. The coolant should be changed periodically to ensure long engine life. Drain plug tightening torque (look maintenance table) - Wait for the engine to cool completely. Water pump cover plug: 9 Nm.
  • Page 44 NOTE Do not twist the element when you dry it. 4.- Remove the filter cage. 5.- Put the filter in a container with some de-greasing liquid. The liquid will clean (C). Checking hose. the filter without (D). Air filter box. damaging it.

  • Page 45: Spark Plug Maintenance

    NOTE The element must be damp but not dripping. - When the element does not drip anymore we must put it in a lubricant and greasing bath. We can also wet the filter completely and not dip it in a liquid bath, the effect will be the same. Apply special air filter oil to the element foam.

  • Page 46: Idle Adjustment

    - Brush out the cinder with a metal brush and finish the cleaning - Finish tightening the plug with the spark plug spanner, but do not with a little petrol. use excessive force. If the spark plug electrodes are oxidised or damaged, or the insulation NOTE is broken, replace the plug.

  • Page 47: Inspection And Lubrication Of The Cables

    INSPECTION AND LUBRICATION OF THE CABLES (A). 4 Allen screws. WARNING Inspect the cables periodically and replace them if damaged. When the outside hose is damaged, corrosion may enter the cable. The cables may also be worn out or damaged. The control operation could be restricted, which may result in accidents and injuries.
  • Page 48 3.- Unscrew the 3 screws that hold the light from below. Rear lights WARNING The bulb is hot when lit or immediately after turning it off. Wait for it to cool down before touching or removing it. You may get burnt, or fire may catch if the hot bulb touched something.

  • Page 49: Transmission

    Indicators - With a cross-tip screwdriver remove the screws, located at the rear, and remove the small lens. - To remove the bulb, press it against the spring (A), turn it ¼ anti- clockwise and replace it with a new one. (B).
  • Page 50 Oil Change - The transmission oil should be changed periodically to assure long engine life. - Warm the engine (over 5 minutes) to suspend the sediment, liquify the impurities, and faciclitate removal. - Stop the engine, and place an oil pan beneath the engine. - Remove the drain plug and position the vehicle so that it is perpendicular to the ground to allow all the oil to drain out.

  • Page 51: Tightening Force Chart

    TIGHTENING FORCE CHART Tighten all the screws and nuts using the adequate spanners. If the tightening force is not correct, you may damage the quad or even provoke an accident. Part name Kg-m Nº Set Cylinder head bolts 25/ 18 Cylinder bolt 34/ 25 Engine drain plug...
  • Page 52 BOLT AND NUT TIGHTENING Every day before riding, check without fail the tighteness of the bolts and nuts described here. Also, check to see whether or not each cotter pin is in place and in good condition. 1. Set rear wheel 6.

  • Page 53: Cleaning, Lubrication And Storage

    CLEANING, LUBRICATION AND STORAGE Where you must be most careful: Avoid applying high-pressure water near: CLEANING Brake caliper and brake pump piston below the fuel tank (if water Frequently cleaning your vehicle will not serve only to improve its enters the electric coil or in the spark plug boot, the quad will not aspect, but also to improve its overall performance and to make the start and the wet parts must be dried out), Front and rear hubs;...

  • Page 54: Lubrication

    LUBRICATION Use a spray with a tube Lubricate these parts with engine oil or grease; do it periodically or attached to after riding in rainy conditions, and specially after using high-pressure lubricate with water to wash the vehicle. Before lubricating each part, clean the pressure: oxidised parts with anti-oxidiser and remove any trace of grease, oil or dirt.

  • Page 55: Storage

    STORAGE If you need to keep the QUAD for a long period of time (we consider that long is 60+ days) you must: - Wash the quad thoroughly. - Start the engine for about 5 minutes to warm the transmission oil and then drain it (see transmission section).
  • Page 56 MULTIFUNCIÓN Funciones - Work mode. This can be activated (ON) and deactivated (OFF). - Clock. Indicates hour and minutes. - Chronometer. Indicates the time passed since the last activation of the work mode. - Partial distance. Indicates the distance covered since the last activation of the work mode. - Maximum speed obtained since the last activation of the work mode.
  • Page 57 Installation of batteries Fig.2 - To replace the batteries, remove the cover of the battery space by unscrewing the two screws at the back of the multi-function. - Substitute the old batteries with the new ones, maintaining the same polarity which is indicated Fig.3 on the diagram.

  • Page 58: Troubleshooting

    TROUBLESHOOTING NOTE: This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. CAUSE REMEDY TROUBLE Engine doesn't crank - Crankshaft seizure.
  • Page 59 TROUBLE CAUSE REMEDY Engine operate unevenly - Spark plug dirty, or maladjusted. - Check spark plug, clean, adjust or replace. - Spark plug cap or high tension wiring - Check spark plug cap, if it's damaged, change it. trouble. - Wiring shorted or open. - Go to specialized garage.
  • Page 60 TROUBLE CAUSE REMEDY Clutch not disengaging properly - No clutch lever play maladjusted. - Go to specialized garage. - Friction plate worn or warped. - Go to specialized garage. - Steel plate worn or warped. - Go to specialized garage. - Gear lever damaged.
  • Page 61 TROUBLE CAUSE REMEDY Shock absorption too soft - Tire air pressure too high. - Check tire air pressure. Abnormal train noise - Drive chain adjusted improperly. - Adjust drive chain. - Chain worn. - Change chain and rear engine sprocket. Go to specialized garage.
  • Page 62 TROUBLE CAUSE REMEDY Brakes don't hold - Check pad and replace if it is necesary. - Pad or disc worn. - Check and repalce if it is necesary. - Brake fluid leak. - Empty brake fluid and replace with new recomended one. - Brake fluid deteriorated.

  • Page 63: Warranty Regulations

    The Company GAS GAS Motos S.A. hereby warrants to the final appeared before the prescribed date of such inspection or...
  • Page 64 b) Lubricants (e.g. oil, grease, etc.) and operating fluids (e.g. battery 3.- If it turns out that any defect cannot be removed, the warranty fluid, cooling liquid, etc.). shall be entitled to demand termination of the contract (payment of c) Inspection, adjusting and other periodical maintenance work as a compensation) or partial reimbursement for the purchasing price well as all kinds of cleaning work.

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