manual del usuario service manual manuel d'

MANUAL
MANUAL DEL
DEL USUARIO
USUARIO
SERVICE
SERVICE MANUAL
MANUAL
MANUEL
MANUEL D’ENTRETIEN
D’ENTRETIEN
LIBRETTO
LIBRETTO D´USO
D´USO
ENGLISH
USER
USER MANUAL
MANUAL
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. 300. RV. is a sports quad designed by and for competition. You will appreciate the high level
of technical perfection and reliability as well as a meticulous design and high performance.
This manual will provide you with a solid basic knowledge of the characteristics and machine handling. It also
contains important safety instructions and provides information about the special skills and techniques required
to drive this machine as well as the basic maintenance and inspection processes.
Thank you for your trust in us, and welcome to GAS GAS motorbikes.
-3-
GENERAL WARNINGS
TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE
YOU USE YOUR QUADRICYCLE LEGALLY, WITH CONCERN
FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF
OTHER PEOPLE.
Read this Manual carefully. It provides all the necessary information
for your safety, and that of others, as guaranteeing the correct
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.
READ THIS MANUAL COMPLETELY BEFORE USING THE
MACHINE.
This manual has been compiled with the data and specifications
available at the time of printing. Any differens there may be regarding
your vehicle will be due to improvements in production and in quality.
GAS GAS Motos S.A. are constantly improving their vehicles so that
you may enjoy them more.
Important information about this manual
The information of special importance is signalled in this manual
with the following notation:
WARNING
The WARNING symbol identifies special instructions or procedures
that, if not correctly followed, could result in personal injury, or even
death for the person using the vehicle, those in the proximity and
those technicians responsible for its inspection and maintenance.
CAUTION
This caution symbol identifies special instructions or procedures
that, if not strictly observed, could result in damage to or destruction
of equipment.
NOTE
This symbol indicates points of particular interest for more
efficient and convenient operation.
Inadequate driving skill could cause damage to the environment and
conflict with other people. Responsible use of your quad will ensure
that these problems and conflicts do not occur.
-4-
CONTENT
- Presentation............................................................................3
- General warnings ...................................................................4
- Contents ..................................................................................5
- Specifications .........................................................................7
- Information about your safety...............................................8
- Important information ..........................................................10
Identification number....................................................10
- Verifications to be made before starting the
machine ...................................................................................20
Front and rear brakes ..................................................20
Fuel ..............................................................................21
Cooling system ............................................................22
Chain ...........................................................................23
Throttle grip..................................................................23
Lights ...........................................................................23
Tyres ............................................................................23
- Location of components......................................................12
- The main parts of the QUAD................................................14
Ignition key...................................................................14
Starter pedal. ...............................................................14
Lights ...........................................................................14
Emergency lights .........................................................15
Throttle grip..................................................................15
Clutch lever ..................................................................15
Front brake lever..........................................................16
Rear brake pedal .........................................................16
Emergency stopping ....................................................16
Reverse gear push button............................................17
Shift pedal. ...................................................................17
Starter ..........................................................................17
Fuel tank cap ...............................................................17
Fuel tap ........................................................................18
Seat..............................................................................18
Front guard ..................................................................18
Rear guard ...................................................................19
Footrest assembly........................................................19
Foot protection .............................................................19
- Using the QUAD ...................................................................24
Starting the engine.......................................................24
Changing gears ...........................................................25
Driving the vehicle .......................................................26
Stopping the engine .....................................................26
Running-in the engine..................................................27
Engaging the reverse gear ..........................................27
Parking on slopes ........................................................27
- Driving the QUAD. Practical recommendations ................28
Become familiar with your QUAD ................................28
Drive with care and common sense.............................28
How to turn your QUAD. ..............................................29
Up hills .........................................................................30
Down hills ....................................................................30
Crossing slopes ...........................................................30
Going across shallow water .........................................31
Riding on rough terrain ................................................31
Sliding and skidding .....................................................31
-5-
- Tuning ...................................................................................32
Tuning the front suspension ........................................32
Tuning the rear suspension .........................................33
Tuning the fuel supply..................................................33
- Multifunction speedometer.........................................................57
- Trouble shooting table.................................................................58
- Electrical diagrams......................................................................64
- 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
Changing the wheels ...................................................41
Swing arm shaft ...........................................................41
Adjusting and lubricating the chain guide ....................41
Checking the coolant level...........................................42
The air filter..................................................................44
Spark plug maintenance ..............................................46
Adjusting the idle .........................................................47
Inspecting and lubricating the cables...........................48
Replacing lights ...........................................................48
Tightening torques table ..............................................52
Torque locations diagram ............................................53
- Cleaning, lubrication and storage ......................................54
Cleaning.......................................................................54
Lubrication ...................................................................55
Storage ........................................................................56
-6-
SPECIFICATIONS
ENGINE
Displacement:
Type:
Cooling system:
Bore x stroke:
Carburettor:
Ignition:
Clutch:
Gear box:
Transmission:
Power:
294.7 cc
Single cylinder, two stroke with crankcase and exhaust valve induction
by layers.
Liquid cooled
72 x 72 mm
Keihin PWK 38 mm
Ducati Energia Reverse System
Hydraulic controlled multi-disc
6 speed
Primary by gears, secondary by chain
50.6 HP at 7340 rpm / 5.02 mkg at 6890 rpm
CHASSIS
Chassis:
Front suspension:
Rear suspension:
Front brake:
Rear brake:
Rims:
Front tyres:
Rear tyres:
Kick-starter:
Engine, disc and chain sprocket shield:
Multi-tube twin-cradle frame, made from Cr-Mo steel (Chromolloy).
Wishbone arms with two ÖHLINS multi-adjustable shock absorbers.
Aluminium alloy swing arm with no welding. Progressive system with single
multi-adjustment ÖHLINS shock absorber.
Two self-ventilated 180mm discs with floating two-piston BREMBO calliper.
Self-ventilated 220 mm disc with floating two-piston BREMBO calliper.
Aluminium
21 x 7.00 – 10”
20 x 11.00 -9”
Forged aluminium
Aluminium alloy, fibre
DIMENSIONS
Wheelbase:
Overall width:
Curb weight:
Fuel tank capacity:
1.280 mm
1.200 mm
165 Kg
18 litres
-7-
SAFETY INFORMATION
- Always perform the routine checks described in this manual before
using the QUAD, to make sure it is in perfect operating condition.
The QUAD is not a toy: driving it can be dangerous.
- Riding a QUAD is not like driving any other vehicle, especially when
cornering. Practise on flat, open ground free from obstacles and
other vehicles.
Read the recommendations made by this manual in the section "Use
of the QUAD".
The QUAD is driven differently form other vehicles such as cars and
motorbikes. Even during routine manoeuvres like turns, driving on
slopes or over obstacles, collisions or tumbles can occur if the correct
precautions are not taken.
- The same applies to steep climbs or descents. Start practicing with
minimum slopes and raise the difficulty little by little. Advice about
this is also included in the section mentioned above.
WARNING
- In case the engine stalls, follow the procedure described in this
manual. If the engine stalls and the vehicle starts rolling backwards,
follow the special braking procedure described in this manual. Get
off the vehicle to the higher on the slope than the vehicle. Remember
that your safety comes before that of the machine, and it is important
to keep this priority in mind.
If these instructions are not followed, serious injury or even death
may result.
- Do not drive the QUAD before reading the following sections:
"Safety information", "Use of the QUAD", and "Main parts of the
vehicle". Even if you are an experienced QUAD driver, not all makes
and models are equal and it is necessary to know the machine in
depth before starting on your first outing.
- When traversing a slope, move your weight to the uphill side; read
the manual regarding this. Avoid excessively slippery slopes or loose
surfaces.
- You are not allowed to carry a passenger, and the vehicle is not
equipped for that purpose.
- Never try to overcome big obstacles, like rocks or trunks. This
vehicle has not been designed for this purpose; you may damage
the vehicle and/or cause injury to yourself.
- Sit correctly with both hands on the handlebars, your feet on the
footrests and your back straight up.
- Do not try to make the vehicle slide sideways if you don't master
this technique; this is a particularly dangerous manoeuvre. Like in
the cases described above, do some testing on flat, wide, obstaclefree ground beforehand and follow the advice given in this manual.
You must never lose control of the vehicle.
- Always adapt your speed according to your skills, the weather and
ground conditions.
- Pay attention to surface changes and control your speed when
you are not familiar with these conditions.
-8-
- 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. When coming out of the water, brake several times
so that they dry more quickly by friction.
- Always use the tyre size and type described in this manual.
WARNING
-Always stop the engine before and during 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 is well ventilated and free from any source of
flame or sparks; this includes any appliance with a pilot light.
The fuel might catch fire causing burns. Avoid spilling fuel over the
engine, exhaust or silencer.
- When transporting the QUAD using a trailer, make sure it is upright
and that the fuel tap is in the OFF position (closed). Fuel leaks might
occur in the carburettor or in the fuel tank otherwise.
- Fuel is poisonous. In case of accidental ingestion, abundant vapour
inhalation or contact with eyes, seek medical help immediately. If
fuel comes in contact with your skin, wash it with soap and water.
If fuel is spilled on clothes then change them.
- Always ride your QUAD in well-ventilated areas.
Do not start the engine or keep it running in enclosed areas. The
exhaust vapour is poisonous and may lead to loss of consciousness
or even death in a short time.
-9-
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.
6
A carburettor-adjustment kit is included; the adjustments must be
performed by an expert and only when necessary. The carburettor
is already tuned, so setting changes are not initially required.
5
A tool is also enclosed to adjust the chain and to centre the swing
shaft. Do not lose it; it will be extremely useful.
8
7
5. Chain and swing arm
adjustment tool.
6. Idle stop.
7. Full stop.
8. Carburettor needle.
IDENTIFICATION NUMBER
4
Write down your vehicle's identification number (serial number), the
information on the model label and the key identification number in
the spaces provided, to make paperwork easier should any spares
be required or as a reference in case of vehicle loss.
1
2
3
4
Serial number
It is located on the front (A) of the vehicle. Indicates the frame
number with which the vehicle is registered.
1. Chain guard.
2. Swing shaft guard.
3. Footrest assembly.
4. Foot protection.
SERIAL NUMBER
-10-
NOTE
The vehicle's serial number is used to identify your machine.
QUALITY APPROVAL PLATE
Key identification number
(A)
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. The identification number is located precisely where the two
keys join as shown in the image. The identification number is stamped
on the ignition key (C). This number is used to order a new set of
keys in case of loss.
HOMOLOGATION PLATE
(B)
(D)
(C)
Quality approval plate
The QUAD is fitted with its own corresponding quality approval plate
(B) with the serial number, also printed on the front of the vehicle.
The data coincides with that in the documents. We recommend
noting the data in the following space provided.
KEY NUMBER
-11-
10
LOCATION OF COMPONENTS
GAS GAS WILD H.P. 300. RV.
1
2
3 4
5
11
6
7
8
9
12
13
14
1- Clutch lever
2- Light switch
3- Flash beam
4- High beam switch
5- Emergency stop
6- Ignition key
7- Parking brake
8- Front brake lever
9- Throttle control
10- Front guard
11- Brake pads
12- Fuel tank cap
13- Footrest grids
14- Rear protection
-12-
15
16
18
19 20
17
23
21
22
24
15- Headlight casing
16- Fuel cut-off
17- Seat
18- Front shock absorber
19- Spark plug
20- Shift pedal
21- Swing arm
22- Exhaust pipe
23- Front brake fluid
24- Kick-starter pedal
25- Brake pedal
26- Exhaust
-13-
25
26
THE MAIN PARTS OF THE QUAD
LIGHTS
IGNITION KEY
NOTE
The headlight and the rear light can only be switched on when
the engine is on.
The ignition lock (A) is located on the front part of the handlebars.
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"
position.
High beam
Switch (C) has three
positions, initially in the
"OFF" position.
Low beam
No lights
(A)
(E) (C)
(D)
KICK STARTER
The kick-start pedal (B) is located on the right hand side of the
QUAD in an initial rest position, pull until it is in operation position.
Operate the kick in order to start the QUAD.
(C). Light switch.
(D). High-low beam switch.
(E). Overtaking lights
(F). Indicators.
(G). Horn.
(G) (F)
To turn on the low beam lights ( ) push the switch (C) to the position
(
).
To turn on the high beam (
) push the red button (D).
The high beam indicator on the instrument panel will be turned on
(
).
(B)
To turn off the lights push the switch to the position
Once the engine is started, fit the starter pedal fastener.
-14-
.
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).
(I)
DISTRESS LIGHTS
The button is located on the front part of the vehicle (H), in front of
the handlebars. This works even when the ignition is off.
When on, a light inside the button will also flash.
WARNING
If the throttle is not working properly, it may be difficult to accelerate
or decelerate as desired. This could result in an accident. Check the
correct operation of the throttle before starting the engine. If the
throttle does not work smoothly then find the cause. Solve the
problem before using the machine, or go to a specialised workshop.
NOTE
Regarding the use of this lights, follow the legal conditions of
each country.
CLUTCH LEVER
(H)
The clutch lever is located on the left side of the handlebar.
It is used to engage or disengage the clutch (J).
To make the clutch work smoothly, the lever must be pulled quickly
and released slowly.
(H)
(J)
THROTTLE GRIP
Before starting the engine, check that the throttle works smoothly
(I). Make sure it spins smoothly back to idle when the grip is released.
The grip has a return spring that puts the engine to idle and slows
the QUAD down when the control is released.
-15-
FRONT BRAKE LEVER
(D)
The front brake lever (A) is located on the right side of the handlebars.
Operate it to apply the front-wheel brakes.
(A)
(C)
One end (C) is attached to the vehicle and the other end (D) is
secured to the rider.
The cable is elastic. One end is joined to the rider and the other to
the vehicle so that the end of the cable attached to the vehicle is
sensitive to sudden movements and will release.
When released, the engine stops automatically.
REAR BRAKE PEDAL
The rear brake pedal (B) is located on the right hand side of the
lower chassis. Operate it to apply the brake to the rear wheels.
NOTE
Make sure you release the parking brake before operating the
throttle.
(B)
We recommend that the cable is attached to a strong point, so that
it is not accidentally released.
(Ex. The cable may be attached to trousers, jacket, ... to a wrist...
but always to a part where it is secure).
WARNING
The use of this vehicle is prohibited without attaching the emergency
stop system. Disregard for this may result in serious consequences.
(D).
EMERGENCY STOP
The vehicle features an emergency stop system. This prevents the
vehicle from continuing out of control in case the rider should fall off.
-16-
REVERSE GEAR BUTTON
STARTER
The WILD H.P 300 RV. is fitted with a reverse gear. The reverse
gear button (1) is located in the centre of the handlebars.
The starter (F) is a mechanism that aids engine operation in case
it is cold. The engine will reach its optimal temperature, in low time
and without causing damage.
(1)
(F)
To operate, pull up the choke knob without turning the throttle grip,
start the engine. Note that the engine will start after a certain number
of revolutions.
WARNING
-The reverse gear button must NEVER be operated when the QUAD
is moving.
-The kick-starter must NEVER be operated when the reverse gear
system is engaged.
After just a few seconds, the engine will be at a correct operation
temperature. To release the choke just press the button in all the
way.
For more information, see the chapter “Engaging the reverse gear”,
page 27
NOTE
- If the engine is flooded then start with the throttle fully open.
- The QUAD may be started in gear if the clutch is disengaged.
GEAR SHIFT PEDAL
This machine is fitted with a 6 - speed gear box. The gear shift pedal
(E) is located on the left side of the engine and is used in combination
with the clutch when changing gears.
FUEL TANK CAP
To open the fuel tank, turn the key anti-clockwise.
(E)
-17-
FUEL CUT-OFF
Turn the key clockwise, and then insert your hand between the seat
and the chassis at the rear of the seat.
The seat will lift easily.
This tap supplies fuel to the carburettor and is located on the left
hand side under the seat. The cut-off has three positions.
NOTE
When putting the seat back in the normal position, ensure it is
secured.
ON
Open
RES
Reserve
OFF
Closed
(A)
(B)
OFF: With the lever in this position, there is no fuel flow. Always
turn the cut-off to this position when the machine is not in use.
ON: With the lever in this position, fuel flows to the carburettor. The
machine is normally used with the cut-off in this position.
RES: This indicates that the fuel reserve is being used. If the machine
runs out of fuel in the ON position then turn the cut-off to this position.
FRONT GUARD
CAUTION
If the RESERVE must be used then fill the tank as soon as possible!
The front guard (C) projects from the QUAD. In case of a frontal
collision, the protection, attached directly to the frame, will absorb
the impact and protect the steering and the rest of the vehicle from
significant damage.
Following refuelling put the lever of the cut-off back into the position
(A) ON.
SEAT
(C)
To remove the seat, use the same key for the petrol-tank cap (B).
Insert the key into the lock located on the right hand side of the
QUAD.
-18-
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
provided for freedom of movement.
Likewise, the rear guard (D) also protrudes from the vehicle. This
guard prevents the QUAD from falling over backwards, which might
result in serious injuries.
(D)
(E)
NOTE
In case of steep climbs, the rear guard will not prevent the
machine from rolling over backwards, so be prudent in climbs
and examine the terrain carefully.
FOOT GUARDS
(F)
(F)
FOOTREST ASSEMBLY
WARNING
The footrests and foot guards are an essential protection system for
safe driving of the QUAD. The quad has large wheels that could
easily trap a leg causing serious injuries.
The QUAD has two footrests (E), one on the left and one on the
right. Both footrests have a grill.
-19-
The foot guards (F) are
located between the
footrests and the
wheels, they are an
additional protection
system to the
footrests. By filling this
gap, we eliminate any
possibility of injury to
lower limbs by the
wheels.
VERIFICATIONS TO BE MADE BEFORE STARTING THE
VEHICLE
WARNING
2
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.
1
Check that the brake pedal height is correct. If not, have it adjusted
at a specialised workshop.
Check the operation of the lever and pedal. They must move smoothly
and must feel firm when the brakes are applied. Otherwise, have a
specialised workshop inspect the vehicle.
FRONT AND REAR BRAKES
WARNING
Brake liquid level
Always check the brakes before riding. Do not drive the QUAD if
there is any braking problem or if a loss in braking capacity is
possible, or this could result in an accident. If there is any problem
that cannot be solved using the procedures described in this manual,
go to a specialised workshop to have the QUAD checked.
Check the brake liquid level. Add liquid if necessary. (See the
Maintenance section of the manual)
Recommended liquid D.O.T. 3 or D.O.T. 4
Disc and disc pad wear is automatically compensated for and has
no effect on the brake lever or pedal action. So there are no parts
that require adjustment on the brakes except brake lever play and
the brake pedal position and play.
NOTE
The vehicle comes with D.O.T.4. as standard.
Brake lever and pedal
Brake liquid leaks
Ensure that there is no play in the front brake lever (1). If so, check
the condition of the brake pads and consult the “Adjustments and
maintenance” section.
Ensure that there is no play in the rear brake pedal (2).
Check for brake fluid leaks in the brake line joints or fluid reservoirs.
Apply the brakes firmly for about one minute. In case of a leaking,
have a specialised workshop inspect the vehicle.
-20-
(A)
Always make sure there is enough fuel in the fuel tank.
(B)
Fuel tank capacity:
Lead free petrol with an octane
rating of 95-98 with oil
18 litres
Reserve:
1.5 litres
Recommended fuel:
NOTE
It is recommended not to let the fuel level run too low. If there
is dirt at the bottom of the fuel tank, it could enter the engine
and damage it.
(A) and (B). Front and rear brake fluid
reservoirs.
Brake operation
To open the fuel tank cap, pull upwards on the tab and then insert
one of the two red keys. Rotate to the right and pull on the cap with
the key still in place, as shown in the above image.
Test the brakes by riding slowly, to make sure they work to perfection.
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
a mix of petrol and oil.
CAUTION
Only use lead-free petrol. The use of leaded petrol will seriously
damage internal components of the engine.
OCTANE RATING
MEASUREMENT METHOD
Antiknock Index (RON + MON)
2
Research Octane No. (RON)
-21-
MINIMUM OCTANE
NUMBER
90
90
WARNING
THE COOLING SYSTEM
Gasoline is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure
the area is well ventilated and free from any source of flame or
sparks; t h i s includes any appliance with a p i l o t light.
Radiator hose
Check the radiator hoses for cracks or deterioration, and connections
for leaks.
Radiator
Mixing oil in the engine
Check the radiator fins for obstruction by insects or mud. Clean off
any obstructions with a stream of low-pressure water.
The oil must be mixed with petrol in order to lubricate the piston,
cylinder, camshaft, sockets and ball bearings.
CAUTION
Using a high-pressure water source could damage the radiator fins
and render it ineffective. Do not obstruct or deviate the radiator air
intake by installing non-approved accessories. Interfering with the
radiator could cause overheating and result in engine damage.
Recommended oil:
SYNTHETIC 2T
NOTE
If the recommended oil is not found then only use 2-stroke
competition oil.
Coolant
Mix the petrol and oil to the following ratio (petrol 50 parts, engine
oil 1 part).
This absorbs excessive heat from the engine and transfers it to the
air at the radiator. If the coolant level becomes low, the engine
overheats and may suffer severe damage.
CAUTION
Do not mix vegetable and mineral oil. O Too much oil will generate
excess fumes and clog up the spark plugs. O Too little oil will cause
engine damage and premature usage.
To mix the fuel, first put in the oil then half of the petrol into a recipient
and mix them, after add the remainder of the petrol and mix it well.
(A)
NOTE
At low temperatures the oil does not mix easily with the petrol.
Take the time to achieve a correct mixture.
-22-
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
when it is between the two marks. If it falls below the lower mark,
add antifreeze. Change the coolant every two years.
WARNING
The use of inadequate tyres or riding the vehicle with incorrect or
unequal tyre pressures may lead to loss of control, with the subsequent
risk of accident.
NOTE
The liquid must be between the two marks, not above the upper
mark or below the lower.
CHAIN
Front
Rear
Check the overall condition of the chain and its tension before each
run. Lubricate and adjust the chain as necessary (See the section
on Maintenance and periodic adjustments).
Manufacturer
Dimensions
Model
MAXIS
MAXIS
21 x 7.00 - 10"
20 x 11.00 - 9"
RAZR
RAZR
The tyres must be inflated to the recommended pressures. Measure
the tyre pressure with a low pressure gauge.
THROTTLE GRIP
Check the throttle grip for correct operation. It must accelerate
smoothly and return to the idle position when released.
If necessary, service the grip and grease the moving parts so that
it works correctly.
CAUTION
Check and adjust the pressures when the tyres are cold.
Pressures must be the same on both sides.
LIGHTS
Check the headlight and the brake lights to make sure they are in
perfect condition. If necessary, make any reparations required.
Front
Rear
Recommended
Minimum
Max
0.400 bar/ 40 Kpa
0.450 - 0.500 bar/
45 - 50 Kpa
0.370 bar/ 37 Kpa
0.420 - 0.470 bar/
42 - 47 Kpa
0.430 bar/ 43 Kpa
0.480 - 0.530 bar/
48 - 53 Kpa
TYRES
Tyre wear-out limit:
Always use the recommended tyres.
Check the manner in which tyre wear occurs. If the tyre is worn out
at the centre, this means that the tyre pressure is too high.
-23-
USING THE QUAD
If the tyre wears out at the edges, the tyre is a little flat. The tyre
must be worn out equally over 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
of the controls. Loss of control may cause accidents or injuries.
STARTING THE ENGINE
CAUTION
Before starting the engine for the first time, consult the section
“Running in the engine”.
a
WARNING
In cold weather, make sure that all the cables work smoothly before
using the QUAD. If the cables are frozen or do not work smoothly
you may lose control of your QUAD and suffer an accident.
Minimum
stud
difference
(a): 3 mm
1.- To activate the parking brake, pull the brake lever while using
the lock lever.
-24-
6.- If the engine is
cold then pull on the
choke button (B).
WARNING
- Always use the parking brake before you start the engine. QUAD
might start move off unexpectedly if the brake is not on. This could
lead to a loss of control or to a collision.
- Remember to release the parking brake before moving off. The
brake will overheat if the QUAD is used without releasing it. The
brake will loose efficiency and could cause an accident. It would
also wear out prematurely.
(B)
2.- Turn the fuel cut-off to the “ON” position.
3.- Put the machine in neutral.
(A)
(B).
7.- Without using the throttle, use the starter pedal.
NOTE
If the engine does not start, turn the key to the "OFF" position
and wait some seconds before trying again.
4.- Turn the ignition
key (A) clockwise to
the “ON” position.
GEARBOX
This vehicle is fitted with a 6-speed gearbox.
It is a sequential gearbox, which means that in order to reach third
gear from first gear we have to go through second gear, that is, the
gears go up or down one by one.
To engage first gear from neutral, pull in the clutch lever and push
down on the shift pedal then release the pressure on the shift pedal
and gently release the clutch lever.
(In the next section the process of starting the vehicle is described
in more detail).
5.- Then the rider
should be secured to
the emergency stop
system (see the
recommendations in
the section “The
main parts of the
QUAD / emergency
stop”).
CAUTION
When changing gears, press firmly on the shift pedal to ensure
complete, positive shifting. Careless, incomplete shifts can cause
the transmission to jump out of gear and lead to engine damage.
-25-
CAUTION
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
the gearbox is only activated when the engine is on. Insufficient
lubrication may lead to faults.
To decelerate
To slow down or stop, release the throttle and apply the brakes
evenly and gently. As the vehicle slows down, change into a lower
gear. Before reducing a gear, wait for the engine speed to fall to the
adequate level. An incorrect use of the brakes gear shift may cause
the tyres to lose traction, with the subsequent loss of control and
accident risk.
STARTING THE VEHICLE
1.- Activate the throttle.
WARNING
Make sure the engine’s revs are low enough to change into a lower
gear. If the revs are too high when changing into a lower gear, the
wheels may stop spinning rapidly enough. This might lead to loss
of control, with an accident or injury risk. It can also damage the
engine and transmission.
CAUTION
Release the throttle to change gear, otherwise the engine and
transmission may be damaged.
2.- As we have already explained, the clutch must be activated to
engage the first gear from neutral, then press on the shift pedal,
release the clutch slowly and accelerate gradually.
3.- Once the desired speed has been achieved, release the throttle
and, at the same time, activate the clutch lever rapidly.
4.- Change to second gear (be careful not to insert neutral).
5.- Activate the throttle partially and release the clutch lever gradually.
6.- Follow the same procedure to change into higher gears.
STOPPING THE ENGINE
1.- Change into neutral.
(A)
WARNING
2.-Rotate the
ignition key anticlockwise to the
“OFF” position
and the engine
will stop
automatically.
Excessive acceleration or sudden release the clutch lever too quickly
may result in an accident and may cause the vehicle to slide and
turn over. Operate the throttle gradually and release the clutch gently.
-26-
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.
(B)
Simultaneously press the
right hand lever (front
brake) and the push button
located on the centre of the
handlebars (1).
3.-Use the parking
brake (B) to park
the vehicle.
4- The key may be extracted from the ignition.
(1)
RUNNING IN THE ENGINE
The running-in process is a very important element in the life of your
QUAD, and we recommend you to follow the instructions below
carefully.
WARNING
-The reverse gear button must NEVER be operated when the QUAD
is moving.
-The kick-starter must NEVER be operated when the reverse gear
system is engaged.
NOTE
The running-in period is a time (usually the first 20 hours of
use) in which we must take into account several points for the
engine preparation.
DISENGAGING THE REVERSE GEAR
To disengage the reverse gear follow the same process in reverse
order.
During the first 10 hours we recommend not using more than halfthrottle for long periods or in any situation that may cause engine
overheating. On the other hand, short accelerations - for 3-4 seconds
- are beneficial for the engine and will not be a problem. Each
acceleration sequence must be followed by a resting period, so that
the engine can release the heat it has generated.
During this 10-hour period, try not to run at constant speed, vary
the speed from time to time.
During the subsequent 10 hours (10-20), it is advisable not to use
the engine above 3/4 throttle during long periods.
PARKING ON SLOPES
WARNING
Avoid parking on hills or inclined terrain, as the QUAD may move
out of control, with a corresponding accident risk. If it is necessary
to park on a hill, engage the first gear, apply the parking brake and
block the front and rear wheels with rocks or other objects.
-27-
1. Use the brakes to stop the vehicle; once it has stopped, engage
the first gear.
2. Without releasing the clutch lever, stop the engine. Now the clutch
lever can be released.
3. With both the front and rear brakes pressed, activate the parking
brake and slowly release the brake pedal.
WARNING
Never carry a passenger. The large seat is designed so that the rider
may alter their position as required while driving. This is not designed
to carry passengers. Transporting a passenger on this QUAD
considerably reduces the possibilities to balance and control the
machine. This could lead to an accident with the consequent injury
risk for the driver and/or passenger. The quad is fitted with an
emergency-stop system in case the rider falls off, but it has not been
designed to cope with passenger falls.
DRIVING THE QUAD. Practical considerations
BECOME FAMILIAR WITH YOUR QUAD
This QUAD is destined for experienced riders, to be used in
recreational activities.
Even if you are an expert with other types of off-road vehicles and
motorbikes, riding the QUAD requires special skills which can only
be achieved through practice.
We recommend that you to familiarize yourself with your vehicle on
flat ground with no obstacles, and without the presence of other
drivers. Do not try difficult manoeuvres until you are totally familiarised
with you QUAD.
A QUAD is not designed to jump over obstacles, refrain from doing
this as the vehicle could be seriously damaged.
Equipment
- Always wear an approved helmet of the correct size.
- You must also wear: eye protection, gloves, boots, long-sleeve
shirt or jacket and long trousers.
WARNING
It is essential to wear the full equipment mentioned above, otherwise
the risk of serious injuries or even death increases.
WARNING
Do not drive the QUAD without first reading this manual. Ensure
that you understand how to use the controls and pay special attention
to the section "safety information".
Verifications before riding
For the due safety and care of the QUAD, always do the verifications
before riding. They are explained in detail in the section "Verifications
to be made before starting the vehicle."
DRIVE WITH CARE AND COMMON SENSE
While riding
As we have already noted, driving your QUAD requires special skills
which can only be achieved through continuous practice over time.
Take your time to learn the basic techniques before attempting more
difficult manoeuvres.
Always ride with the footrests and protections secured, they will
protect you from serious injuries in the legs and feet. Keep your feet
on the footrests at all times while moving and keep both hands on
the handlebars.
-28-
When approaching the corner, slow down and start to turn the
handlebars in the desired direction. Lean your body to the inside of
the corner to compensate the inertia produced by speed. Use the
throttle to keep a uniform speed all through the corner. This manoeuvre
may be used to take the corner correctly. The picture shows the
technique.
WARNING
As we have explained in this manual, the use of the footrests and
guards is essential for your physical integrity.
Modifications
2
1
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,
and must be fitted and used according to the instructions. Fitting
inadequate accessories or modifying the vehicle may provoke
changes in the machine's handling, which, under certain conditions,
might lead to an accident. In case of doubt, consult an authorised
dealer.
1
1.- Turning to the right.
2.- Turning to the left.
2
Exhaust system
The temperature of the QUAD's exhaust system increases with use.
To prevent burns, do not touch it. Park the QUAD in a specially
reserved place or somewhere away from pedestrians or children.
HOW TO TURN WITH YOUR QUAD
At low speeds you will have no problem to turn with the handlebars.
On the other hand, if speed increases the difficulty to turn will also
increase. The back wheels are rigidly mounted on the same axle
and turn at the same speed, so the QUAD will resist turning into
corners unless the inside wheel loses some traction. A technique
is required to turn, and it is important to learn the skill on flat terrain,
with no obstacles and at a moderate speed. The speed may be
increased as your skills increase.
If the technique used is not correct, the QUAD will probably continue in
a straight line. If it does not turn, stop and practise the procedure again.
-29-
If the vehicle starts to turn over towards the outside of the corner,
reduce speed, compensate with the steering or lean even more
to the inside. It could also be necessary to reduce your speed
gradually and to turn the steering to the outside of the corner to
avoid tumbling over.
While climbing a slope if you discover that you have not correctly
calculated your ability to reach the top, turn the QUAD while you still
have some traction (if there is enough room) and descend.
If the vehicle starts rolling backwards, do not use the rear brake or
try to insert a gear, the QUAD might easily tumble over backwards.
Get off the vehicle immediately on the ascending side of the slope.
Remember that your safety comes first.
CLIMBING HILLS
We recommend starting gradually on gradual slopes and increase
the inclination as your skill improves. In any case, avoid loose or
slippery surfaces or obstacles at any time, as we have already
mentioned, the QUAD has not been designed to jump over obstacles
so it is advisable to avoid doing this.
3
DESCENTS
4
It is important to transfer your
weight to the front part of the
QUAD during climbs.
This can be done by leaning
forward and moving the
seating position back and, if
slope is very steep, standing
on the footrests and leaning
forward a little.
When descending a slope
with the QUAD, transfer your
weight to the back, to the
uphill side of the slope.
Move to the back of the seat
and remain seated with your
arms straight.
Select a short gear that allows the engine compression to act as the
main brake. Braking incorrectly may lead to a loss of traction. See
the example in the image.
WARNING
TRAVERSING SLOPES
Do not accelerate or change gear suddenly. The QUAD could tumble
over backwards. In this case the rear guard would not help, as the
inertia would be considerable. Never go over the top of a climb at
full speed. On the other side, there could be an obstacle, a steep
descent, another vehicle or even a person.
To cross a slope with your QUAD you must place your weight correctly
to maintain correct balance. Before attempting to cross a slope make
sure you have learnt the basic skills on flat ground. Avoid slippery
sections and rough terrain that may cause you to lose balance. When
crossing the slope, keep your body inclined uphill. It might be
3
-30-
necessary to correct direction on loose surfaces by turning the
steering slightly uphill. When crossing slopes, do not perform tight
turns up or downhill. If the QUAD starts to turn over, gradually turn
downhill if there is no obstacle in the way. When stability is regained,
turn once more in the required direction.
SLIDING AND SKIDDING
When riding over slippery or loose surface, use caution. An uncorrected
unexpected slide which are not controled could result in a serious
accident. To reduce the tendency of the front wheels to slide on
slippery surfaces, sometimes it is useful to put your body weight
over them.
SHALLOW WATER
If the rear wheels start to slide sideways, control can usually be
regained by turning the handlebars towards the slide, if there is
enough space available. It is not recommended to accelerate or
brake until a skid has been corrected.
With the QUAD you can, at slow speed, cross shallow water up to
35 cm in depth. Before entering the water, choose carefully a path
to cross. Choose a place with no sudden descents and avoid rocks
and other obstacles that may affect the stability of the QUAD or
cause it to slip. Drive carefully and slowly.
With practice, after some time you can dominate the controlledsliding technique. Before attempting to do so you must choose the
ground carefully, as both stability and control are reduced. Note that
it is best to avoid skidding manoeuvres on extremely slippery surfaces
such as ice given that this could result in a total loss of control.
WARNING
Do not cross fast waters or waters deeper than specified in this
manual. Remember that the brakes will get wet and lose braking
efficiency. Check the brakes after leaving the water. If necessary,
operate the brakes a few times in order to dry them by friction.
NOTE
Learn to control your slides safely by practising at low speed
on flat ground with no inclination.
NOTE
After crossing water with the QUAD, eliminate trapped water
by unplugging the retention tube at the bottom of the air filter
housing. Wash this in fresh water if the machine was in salt
water or mud.
RIDING ON ROUGH TERRAIN
Take precautions when riding on rough terrain. Beware of any
obstacle that may damage or destabilise the QUAD or even cause
an accident. Keep your feet firmly placed on the footrests at all times.
Avoid jumping over obstacles with the vehicle as this could lead to
loss of control and damage to the machine.
-31-
To adjust the rebound, turn the knob (B) on
TUNING
(A) the lower part of the shock absorber by hand.
TUNING THE FRONT SUSPENSION
There is a possible 22 “clicks” (adjustments)
in total.
The rebound is normally set to 7 “clicks”.
Turn the knob clockwise to reach the end,
then it is completely closed. Turn the knob
anti-clockwise 7 “clicks”, now it is at the
standard setting. At 0 “clicks” the rebound is
hard, oppositely, at 22 “clicks” the rebound
would be very soft.
The front suspension is formed by two wishbone arms with 2 multipleadjustment ÖHLINS shock absorbers.
To suit various riding conditions, the spring preload of the shock
absorber can be adjusted or the spring can be replaced with an
optional one. The force may be adjusted easily so there is no need
to change the hydraulic oil density.
(B)
WARNING
Always adjust the right and left absorbers to the same level. Unequal
adjustments will cause handling problems and loss of stability, with
the subsequent risk of accident.
Adjusting the compression
Adjusting the rebound
To adjust the compression, turn the knob (A) on the upper part of
the shock absorber by hand. Turning the knob anti-clockwise to the
end closes it completely. 38 “clicks” or adjustments are possible.
The compression is normally set to 20 “clicks”.
Fully hard compression is at 0 “clicks”.
Fully soft compression is at 38 “clicks”.
WARNING
Suspension parts will be hot during operation. Never touch the
compression adjustment, the rebound adjustment nor the oil reservoir
with bare hands nor with any other part of the body until the
compression components have cooled down.
-32-
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
ÖHLINS multi-adjustment shock absorber. Like the front suspension
it can be adapted to different riding styles.
There is a possible 56 “Clicks” (adjustments) in total.
The compression is normally set to 28 “Clicks”.
Fully hard compression is at 0 “clicks”.
Fully soft compression is at 38 “clicks”.
Adjusting the rebound
To adjust, turn the knob on the lower part of the shock absorber by
hand.
FUEL TUNING
Mix
There is a possible 28 “clicks” (adjustments) in total.
The compression is normally set to 13 “clicks”.
A basic knowledge about the identification and operation of
components is required. Changes depend on the atmospheric
temperature:
Turn the knob clockwise until the end, then it is completely closed.
Turn the knob anti-clockwise 13 “clicks”, now it is at the standard
setting. At 0 “clicks” the rebound is hard, oppositely, at 28 “clicks”
the rebound would be very soft.
(A)
Conditions
mix
setting changes
Cold
Warm air
Dry air
Low altitude
High altitude
lean
rich
lean
standard
rich
rich
lean
rich
standard
lean
NOTE
The main jet should be adjusted 1 to 5 steps until the maximum
engine power is archived.
Main jet
Adjusting the compression
This has the most effect. The number stamped on the lower part of
the jet indicates the petrol calibration opening. A larger number
indicates a larger opening and larger flow of petrol.
To adjust, rotate the knob on the upper part of the shock absorber
-33-
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).
(B)
(C)
(A)
Carburettor needle
The needle and the diffuser of the needle
should have an effect from 1/4 to 3/4
throttle. The needle moves in and out
of the diffuser; when the needle is
thinner, its position determines the
quantity of gasoline.
On the upper part of the needle there
are six grooves where the clip is fitted.
This clip positions the needle in the petrol
valve and determines the position
relative to the diffuser, this enriches the
mixture.
Moving the clip upwards will make the
mixture poorer. Change the position of
the clip step by step. The straight part
of the clip affects the petrol valve
response for small openings.
(B).
(A). Main jet.
Minimum jet
Controls the mixture from the fully closed position (opening is 1/8)
of the petrol valve but has little effect on the total opening of the
petrol valve. To adjust the mixture, the air adjustment screw may be
turned to change the airflow or the jet may be adjusted for more or
less petrol. First turn the air adjustment screw.
Screw inwards to enrich the mixture. The air adjustment screw should
be turned from a determined position. Turn it in 1/2 turn steps. If,
by turning the screw 1 to 2.5 times, the desired result is not obtained,
change the minimum jet by one step (C) and then fine tune the
adjustment using the air adjustment (B).
-34-
Clip position
Plate needle
number
Straight section
Quad testing
Standard settings
- Heat the engine with the fuel supply in the standard position, then
check the spark plug operation conditions.
-Try the QUAD keeping the carburettor valve open.
Component
Accelerator valve
Idle jet
Needle
Full jet
Symptoms of inadequate adjustments
If the QUAD displays any one of the following symptoms then the
adjustments must be changed. Before adjusting, ensure that the
rest of the machine functions correctly.
Check the condition of the spark plug, ensure that the tuning is
correct, clean the air filter, remove carbon from the exhaust pipe.
(for altitude and temperature changes).
1. Find your correction factor to adjust the carburettor.
For example: 1000 meters (3200 ft) altitude with an air temperature
of 35°C, correction factor 0.94.
Spark plug status
Insulation white
Rich
Insulation humid and black
7
38
N1EC
185
Correction factors
Correct Insulation dry and of a light colour
Lean
Specification
2. Using the corresponding correction factor, select the correct
minimum jet and mixture.
Change the mixture to a
higher level
Change the mixture to a lower
level
For example: For a correction factor of 0.94, multiply the jet size by
this number.
Minimum jet: # 50 x 0.94 = 47.
Main jet: # 162 x 0.94 = 158.
- Adjust the mixture until the engine responds satisfactorily with the
carburettor valve open.
- If the mixture is too lean, the engine tends to over heat and could
seize. On the other hand, if the mixture is too rich, the spark plug
becomes humid and may cause faults. The correct mixture will vary
according to atmospheric conditions, note the conditions first then
adjust the fuel mixture.
3. Find your correction factor for the jet needle and air adjustment
screw chart and change the jet needle clip position and airscrew
opening as indicated.
- Adjusting the needle clip: if already on the 3rd groove to the 2nd.
- Opening the air adjustment screw: 1 1/2 + 1 turn = 2 1/2 turns
outwards.
NOTE
Note the components of the carburettor that control the fuel
flow and air flow adjustment screw, ensure they are correctly
adjusted.
-35-
T
E
M
P
E
R
A
T
U
R
E
(ºC)
(ºF)
30
00
40
(104)
20
m
(9
6
00
30
(86)
00
10
m
ft)
(6
4
00
00
m
Se
a
ft)
le
ve
l
(3
2
00
ALTITUDE
ft)
20
(68)
10
(50)
0
(32)
-10
(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
POSITION
LOWER THE CLIP
1 POSITION
EQUAL
EQUAL
EQUAL
LIFT THE CLIP 1
POSITION
AIR SCREW
OPENING
TIGHTEN 1 TURN
TIGHTEN 1/2
TURN
EQUAL
LOOSEN 1/2
TURN
LOOSEN 1 TURN
-36-
BEFORE USING THE
QUAD
AFTER USE
QUAD
EVERY…
Fuel tank level
Front and rear brake fluid levels
Brake lever and pedal play
Brake pads
Coolant Level
Tyre wear
Chain status
Throttle grip
Clutch lever play
Lights
Switches
QUAD
Shift pedal
Brake lever and pedal
Clutch lever
Air filter
Air filter housing
Chain guide
Cables
Radiator and tube connections
Exhaust
Wheel bearings (10 outings)
Check all screws Tightening torque chart (check table)
Brake piston and dust guard (2 years)
Brake cylinder piston and dust guard (2 years)
Brake pipe (2 years)
-37-
If necessary
Tighten
Adjust
Clean
Change
Fill
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.
Check
MAINTENANCE CHART
Lubricate
PERIODIC MAINTENANCE AND ADJUSTMENTS
Regular inspections, adjustments and regular lubrication keep the
machine in the best possible conditions of safety and efficiency.
Safety is an obligation for the owner of the machine. The most
important points related to inspections, adjustments and lubrication
are described in the following pages.
Tighten the adjustment bolt to obtain the optimal play.
If the clutch lever adjustment is at its limit, play must be adjusted by
using the clutch cylinder piston push rod.
ADJUSTMENT OF THE BRAKE LEVER AND PEDAL
Disc and disc pad wear is automatically compensated for and has
no effect on the brake lever or pedal action. So there are no parts
that require adjustment on the brakes except brake lever play and
the brake pedal position and play.
WARNING
Do not perform any maintenance operation with the engine on.
Moving elements might catch clothes or a part of your body and
cause injuries. The electric parts might produce sparks, provoke
electric shocks or even fire. Before performing any maintenance
operation, stop the engine, unless indicated otherwise. If you are
not familiar with the maintenance of the vehicle it is better to go to
a specialised workshop.
Brake lever
The lever free play will initially be directly related to the brake pad
wear, that is, if some play is noticed before the adjustment, it would
be a good idea to check the brake pads to see if they must be
replaced.
CLUTH LEVER ADJUSTMENT
Correct clutch lever play is 2-3 mm. Play increases with the clutch
wear and thus requires adjustment. When there is too much play,
first try to adjust the level of the clutch lever.
(C)
(D)
(C). Brake lever.
(D). Adjustment bolt.
Once this observation has been performed adjust the lever to suit
comfort. Tighten the screw (D) shown in the picture; it is covered by
silicone protection, pull this off to uncover the groove by which a
screwdriver may be inserted. Tightening the screw reduces play and
loosening increases play.
(A). Adjustment bolt.
(B). Clutch lever.
(A) (B)
-38-
It is possible that air has entered the brake system. Purge the system
in the following way:
10 mm
- Remove the brake
fluid reservoir cap (E)
to check the level.
(E)
When the brake pedal
is in rest position,
there should be a play
of 10mm. If not, then
adjust this.
WARNING
If the brake pedal has a spongy feel when activated, it may be due
to air in the pump or to a fault. It is dangerous to ride under these
conditions, check the brakes immediately.
- Remove the brake
calliper cap (F) (wheel
interior) and attach a
transparent tube to
the end.
CHECKING THE BRAKE FLUID LEVEL
(F)
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
(- Operate the brake lever several times. Fluid starts coming out of
the system through the tube. The transparent tube can be used to
see if there is air, i.e. bubbles, in the system.
- Once the system has been bled, refill the reservoir to the top.
Front: A small brake fluid reservoir is located to the left of the throttle
grip. If we look at the reservoir carefully, a small transparent bubble
is located on one of the flat sides that will allow us to check what is
happening inside the brake fluid reservoir. If you have just purchased
your quad, nothing can be seen through the bubble because the
reservoir is full, the level will be seen when it is going down.
Rear brake pedal
Check the brake operation and make sure it does not rub against
any part of the QUAD. To adjust the pedal play, loosen the locknut,
rotate the bolt, fit the lever in the required position and retighten the
locknut.
-39-
When the fluid level is too low, fill up:
- With a cross-tip screwdriver, unscrew the two screws on the
recipient.
- Next, add liquid as required.
- Put the screws back in place and make sure the reservoir is tightly
secured.
- Make sure that the fluid container is well closed, put the seat back
and lock it in place using the key. Ensure that the seat is secured
correctly.
Rear: The rear brake fluid reservoir is located underneath the seat.
Use D.O.T 3 or D.O.T 4
Recommended liquid
- Insert the fuel tank key into the lock on the right side of the QUAD
just below the seat.
CHECKING THE FRONT AND REAR BRAKE PADS
There are 3 brake callipers: One on the each of the front wheels (2);
and 1 on the drive chain which brakes the rear wheels together. All
operate in the same way and are checked in the same way.
- Turn the key.
- Put your hand
between the rear of
the seat and the
chassis and pull the
seat up.
As we can see in the picture, the brake calliper is formed by different
parts. The pad is the part that rubs on the disk, thus, it is this element
that wears down and must be checked.
(A) (C)
(D)
(A)
(C)
(B)
(C)
- The easy-to-access reservoir is located here (A). There are two
marks: “MIN” and “MAX”. The fluid level should be closer to the
"MAX" mark. If it is much below it, add fluid.
(B). Pad
(C). Calliper
-40-
(C). Calliper
(D). Brake disk
NOTE
Never overuse the brake pads, if the thickness is not checked
they could cause damage to the brake calliper.
(F)
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. The process is as follows:
(E)
(C)
ADJUSTMENT AND LUBRICATION OF THE CHAIN GUIDE
The drive chain must be checked, adjusted, and lubricated in
accordance with the Periodic Maintenance table in order to prevent
excessive wear. If the chain is worn or badly adjusted (too tight or
loose) then it may jump off the sprockets or break.
- Each wheel has four
nuts (E) which we will
remove with a no.15
wrench.
- Unscrew the nuts and
remove the wheel from
the axle.
- To put them back in
place, follow the same
procedure in reverse
order.
WARNING
A chain that breaks or jumps off the sprockets could snag on the
engine or the rear wheel, severely damaging the QUAD and causing
it to go out of control.
Checking tension
(F)
SWING ARM SHAFT
It is very important that the rear wheel axle is well centred, otherwise,
or if there is play, the bearing could be damaged.
- To adjust the axle nut, we will go to the rear end of the QUAD. The nut is located at the right of the swing arm.
- Use the (F) spanner, provided when purchasing the vehicle, to
adjust the axle.
-41-
The gap between the
chain and the swing
arm at the chain guide
must be about a finger
width, if it is more or
less, adjust to the
correct measurement.
Follow the procedure
as explained below:
- Go to the rear of the
QUAD. There are four
bolts (A) on the swing
arm.
- Unscrew the 4
screws.
Chain lubrication is one of the operations that must be performed
frequently.
How often do you need to lubricate the chain?
- After riding on wet ground.
- When it has a dry appearance.
- After washing the QUAD.
- If the QUAD has not been used for a long time.
A high viscosity oil rather than low viscosity oil is better because it
will stay on the chain longer providing lubrication.
(A)
Put oil on the sides of the chain pins so that it penetrates into these;
remove excess oil.
- With the spanner (B),
that comes with your
QUAD, adjust the
chain correctly and
then retighten the four
bolts.
CHECKING THE COOLANT LEVEL
(B)
The coolant absorbs excessive heat from the engine and transfers
it to the air by the radiator. If the coolant level is low, the engine
overheats and may suffer severe damage. Check the coolant level
each day before riding the QUAD.
NOTE
Ensure that the bolts are tightened and that the chain tension
is correct.
NOTE
The level should not go down in normal conditions.
If liquid must be added often, revise the circuit for leaks and
take the QUAD to a specialist.
Inspection of the chain
Inspect the chain for damaged links, lost pins, unequal sprocket
teeth or damaged teeth.
If the drive chain is damaged, go to a specialised workshop and
have it replaced.
WARNING
To avoid burns, do not remove the radiator cap or try to change the
coolant when the engine is still hot. Wait for it to cool down.
Chain lubrication
Good chain maintenance is essential to ensure the correct operation.
-42-
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.
This will block the cooling hoses.
(D)
CAUTION
Use of incorrect coolant solutions will cause severe engine and
cooling system damage. Use coolant containing corrosion inhibitors
made specifically for aluminium engines and radiators in accordance
with the instructions of the manufacturer.
(C)
WARNING
Normally, if the level in the reservoir (D) is below the mark then the
radiator must be checked (C).
Coolant chemicals are harmful to the human body. Follow coolant
manufacturer warnings and coolant handing instructions.
WARNING
Soft or distilled water must be used with the inhibitor chemicals and
the antifreeze in the cooling system.
If the lowest ambient temperature encountered falls below the
freezing point of water, protect the cooling system against freezing.
Always perform these operations when the engine is cold, the liquids
may be hot, and be ejected from the system under pressure, causing
serious burns.
Use a permanent type of anti-freeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminium engines
and radiators) in the cooling system.
For the coolant mixture ratio under extreme conditions, choose the
mixture ratio listed on the container for the lowest ambient temperature.
- Remove the cap and fill the radiator to the top.
- Remove the reservoir cap and fill it until the level is between the
two marks.
- Start the engine and leave it at idle for 15-20 seconds.
- Stop the engine and check the levels in the two containers, most
likely it will have gone down because the engine has run out of liquid.
- Refill the containers if necessary.
Coolant Level
In case of a liquid loss we must check the level in two containers.
-43-
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
ones.
The coolant should be changed periodically to ensure long engine life.
- Wait for the engine to cool down completely.
- Place the QUAD in a horizontal position.
- Remove the radiator cap.
- Place a container under the coolant drain plug, and drain the coolant
from the radiator and engine by removing the drain plug at the bottom
of the water pump cover. Immediately wipe or wash off any coolant
that spills on the frame, engine, or wheels.
Bolt torque (see tightening torque table)
Water pump plug: 9 Nm.
- Fill the radiator up to the edge and install the radiator cap.
- Check the cooling system for leaks.
- Start the engine, warm up the engine, and then stop it.
- Check the coolant level after the engine cools down.
(B)(A)
AIR FILTER
(A). Water
pump cap.
(B). Coolant
drain plug
CAUTION
The air filter must ALWAYS be cleaned after using the QUAD.
Otherwise, dirt may penetrate the engine and damage it seriously.
WARNING
WARNING
Coolant on tires will make them slippery and can cause an accident
and injury.
An obstructed air filter will allow dirt to enter the carburettor and
block the throttle open. This could lead to an accident.
-Inspection of the coolant. If white cotton-like patches appear in the
liquid then this means that the aluminium elements of the cooling
system are corroded. If the liquid is brown then this means that the
steel or iron parts of the system are oxidized. In either case clean
out the system.
- Check the cooling system for damage, loose joints, or leaks.
An obstructed air filter restricts the air intake of the engine, increasing
the petrol consumption and reducing the engine power as well as
causing the destruction of the spark plug.
NOTE
There is an examination hose on the lower part of the air filter
box. If dust or water have accumulated in this hose, empty it
and clean the air filter element and the air filter housing.
-44-
NOTE
Do not twist the element when drying.
4.- Extract the filter
cage.
(C)
(D)
5.- Put the filter in a
container with some
de-greasing liquid.
This liquid should
clean the filter
without damaging it.
(C). Air filter housing.
(D). Inspection hose.
Cleaning process
WARNING
Clean the filter in a well-ventilated zone and ensure that there are
no sources of naked flame or sparks near the work area (including
the focus of a powerful light).
Do not use petrol to clean the filter as this could result in an explosion.
(E)
6.- Wring the filter
gently and allow it to
dry for some time.
1.- Remove the seat
to expose a blue
foam in the centre.
2.- Lift the foam will
expose a bolt (E) that
we may loosen by
hand.
- Check the air filter for damage such as scraping, hardening,
shrinkage… If it is damaged then replace it, otherwise dirt will enter
the carburettor.
3.- Remove the bolt and filter. Remove the filter assembly from the
housing.
-45-
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.
If there is no air filter oil available then use engine oil.
- Also clean the cage with a humid cloth as well as the filter housing.
- Make sure all the corners are clean before putting all the parts
back in the filter housing.
- Grease all of the connections and bolts of the air filter and inlets.
- Place the filter into the cage and cover the filter lip with a thick layer
of grease to ensure the correct seal and to prevent dirt from entering
the carburettor.
- Re-install the air filter in the QUAD and make sure it is correctly
secured.
The plug must be
periodically removed
to check the gap and
the ceramic
insulation.
- It is located on the cylinder head. Extract the spark plug hood (A)
and loosen the plug (B) a little anti-clockwise.
(A)
(B)
CAUTION
Never allow the engine to run without the filter element installed.
Otherwise non-filtered air would enter the engine and it may result
in wear and possibly breakdown. On the other hand, using the engine
without the filter element may cause blockage in the carburettor
conduits decreasing the engine performance and probably causing
the engine to overheat.
SPARK PLUG MAINTENANCE
The spark plug is an important part of the engine and it is easy to
inspect. The state of the plug may indicate the condition of the engine.
- Once the spark plug is loosened then finish removing it by hand.
Standard spark plug: NGKBR8EG or QN86 (0.7 – 0.8 mm)
-46-
- Remove the spark plug to see if it is full of carbon and dirt.
- Use a wire brush to clean off the carbon then use a little petrol to
finish cleaning.
- Finish the adjustment of the spark plug using the spark plug wrench
but without tightening excessively.
NOTE
The spark plug is not a bolt, it should not be tightened excessively
otherwise its operation will be affected.
If the spark plug electrodes are oxidised, damaged or the insulation
is broken then replace the plug.
To find out the working temperature for the spark plug, take it out
and examine the insulation around the electrode. If the ceramic is
light brown, the spark plug is correctly matched to engine temperature.
If the ceramic is white, the plug should be replaced with the next
colder plug. If the ceramic insulation is black then replace the spark
plug with one of a higher heat grade.
- Finally, fit the spark plug tube on to the end.
ADJUSTING THE ENGINE IDLE
This is done using the air adjustment screw and the idle adjustment
screw (C).
NOTE
These kind of diagnostics should ideally be done by a specialized
workshop.
- Rotate the air adjustment screw (D) until it is loose and then tighten
1 and half turns.
CAUTION
The spark plug should be examined regularly, because the heat and
carbon accumulation gradually erode and eventually rupture the
plug. If the spark plug wear is excessive or if there is excess build
up of carbon or other accumulations, replace the spark plug by one
of different specifications.
(C)
(D)
- Once the spark plug has been verified, put it back in place by hand
as far as possible.
CAUTION
Always screw the spark plug by hand, thus it is possible to ensure
it is correctly inserted, otherwise, the screw thread could be damaged
causing the spark to be incorrectly adjusted and eventually leading
to engine damage.
- If the engine seems like it is about to stall, rotate the idle adjustment
screw clockwise. Otherwise, if the motor speed seems high, rotate
the screw anti-clockwise.
- Accelerate and decelerate a couple of times to ensure that the idle
doesn’t change. Re-adjust if necessary.
-47-
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.
(A)
Lubricate the cable interior and the cable ends. If the cables do not
slide smoothly, have a specialised workshop replace them.
NOTE
Do not touch the reflective surface (B) with your fingers, not
even with a cloth, as it will easily be scratched. If there is dust
on it, clean it with a duster.
Recommended lubricant: Engine oil
REPLACING THE LIGHTS
Front headlight
1.- Remove the headlight casing, by removing the 4 Allen screws.
WARNING
(B)
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.
(A).
(B).
(C)
-48-
2.- Next, disconnect
the speedometer
from the cable (C).
3.- Unscrew the 3 bolts that hold the light from below, they must be
engaged to operate them.
Rear lights
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.
(E)
(D)
- With a cross-tip screwdriver unscrew the two screws (G) and
remove the lens.
(D). Cap.
(E). Bulb.
4.- Unplug the bulb cable and remove the rear cover of the light.
5.- A piece of wire spring holds the bulb in place (D).
(F)
(E)
(G)
- To remove the bulb, press it against the spring, turn it 1/4 anticlockwise, extract and replace it with a new one.
(F). Wire spring
bulb
attachment.
- Put the lens back in place.
6.- Free the bulb (E) from the wire part and remove it from the rear.
7.- Replace the bulb by a new one. To insert it, follow the above
operations in reverse order.
NOTE
Make sure the lens is well secured.
-49-
Indicators
- To remove the bulb, press it against the spring, turn it 1/4 anticlockwise, extract and replace it with a new one.
- Put the lens back in place and make sure the assembly is well
secured.
(A)
(B)
- Using a crosstipped screwdriver,
unscrew the screws
(A), located on the
rear, then extract the
small lens.
(B). Oil level
cap.
- If the oil level is low, add the required quantity of oil by opening the
cap (C). Use the same type and brand of oil already in the engine.
Transmission oil
TRANSMISSION
(A)B)
So that the transmission and clutch operate properly, maintain the
proper oil level and change it periodically. A QUAD with an insufficient,
deteriorated or contaminated oil level will suffer premature wear and
transmission damage.
Viscosity: SAE 10W30
Capacity: 1000 cc
Oil level
Put the QUAD on a flat slope-free surface.
(C)
Checking the oil level
- Remove the fill
cap (C) and
empty 900 cc of
new oil into the
transmission.
- If the QUAD has been used, then wait some minutes.
- Check the oil level by the oil level indicator on the lower right hand
side of the engine.
- The oil level should be between the maximum and the minimum.
-50-
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.
- Stop the engine and place a recipient under the engine.
- Remove the oil drain plug (see the photograph below) and put the
QUAD in a horizontal position to allow the oil to drain out.
- Clean the drain plug magnet of any metal.
- Screw in the oil drain plug along with its seal ring to 20 Nm.
- Check the oil level, after using the kick-starter 3 to 4 times.
- Screw the oil filler cap.
(D)
- If there is too
much oil,
remove excess
by the oil drain
plug (D).
-51-
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.
Part name
E
N
G
I
N
E
C
H
A
S
S
I
S
Crankshaft bolts
Cylinder nut
Engine drain plug
Kick pedal bolt
Kick pedal nut
Shift pedal bolt
Spark plug
Water pump cover drain plug
Engine bracket bolt
Cylinder head brace
Calliper mounting bolts
Disc plate mounting screws
Rear brake pedal bolt
Subframe support bolt
Rear shock absorber bolt
Rear disc wheel drive bolt
Rocker arm bolt
Piston bolt
Steering stem
Front trapezium
Front socket
Wheel bolts
Rear axle
Rear sockets
N-m
Kg-m
Assembly
number
25
34
20
20
25
10
27
9
35
35
25
10
36
26
39
29
81
81
80
25
120
15
160
165
2,5
3,5
2,0
2,0
2,5
1,0
2,8
0,9
3,6
3,6
2,6
2,5
1,0
2,7
4,0
3,0
8,3
8,3
8,0
2,6
12,0
1,6
16,0
16,6
3
3
3
8
8
6
3
3
3
3
1
1
10
9
7
4
7
7
2
2
1
1
5
5
-52-
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
2
3
4
5
7
6
9
1. Ass. Front wheel
2. Ass. Front suspension
3. Ass. Engine
4. Ass. Transmission
5. Ass. Rear wheel
6. Ass. Shift pedal
7. Ass. Rear suspension
8. Ass. Kick-starter
9. Ass. Chassis
10. Ass. Rear brake pedal
-53-
8
10
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
start and the wet parts must be dried out); front and rear hubs;
suspension system; swing arm bearings.
Frequently cleaning your vehicle will not serve only to improve its
aspect, but also to improve its overall performance and to preserve
the duration of components.
- Wash all surfaces with hot water and neutral soap.
- Rinse the machine with clean water and dry all the surfaces with
a soft and absorbing cloth.
- Clean the seat with a vinyl-lining cleaner so as to keep it soft and
shiny.
- Apply automotive wax to all chromed and painted surfaces. Avoid
using wax combined with cleaning products. Most of these products
contain abrasive elements that might make the paint matt or destroy
the finish. When finished, start the engine and leave it idling for some
minutes.
Before washing the quad some precautions need to be taken to
prevent water from entering some parts:
Exhaust
- Cover with a plastic bag secured with
rubber bands.
Clutch and brake levers,
handgrips, engine stop button.
- Cover with a plastic bag.
Air filter intake.
- Close up the opening with tape or stuff
a cloth in it.
Spark plug cap and all filler
caps.
- Ensure they are correctly secured.
WARNING
Wet brakes may lose efficiency, and represent an accident risk.
Check the brakes after washing the quad and apply them several
times at low speed, so that friction dries them out.
- If the outside of the engine has too much grease on it, apply a
degreaser with a brush. Do not apply this product to the chain,
sprockets or wheel axles.
After washing the QUAD
- Eliminate all dirt and the degreaser by washing them off with a
garden hose. Reduce the water pressure to the minimum required
for the job.
- 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 up for 5 minutes.
CAUTION
Excessive water pressure may penetrate the wheel bearings, brakes,
transmission bushings and electric components, with resulting in
damage.
-54-
LUBRICATION
Use a spray
with a tube to
lubricate
under
pressure:
Lubricate the points shown here, with either motor oil or regular
grease, periodically or whenever the vehicle has been exposed to wet
conditions, and especially after using a high-pressure spray washer.
Before lubricating each part, clean off any rusty spots with rust
remover and wipe off any grease, oil, dirt, or grime.
(1). Clutch
lever
(2). Front
brake lever.
(6)
(2)
(1)
(6). Throttle
cable.
(4)
(3). Rear brake
pedal.
(4). Rear brake
socket.
(3)
(7). Chain.
(7)
Lubricate the chain after driving on terrain or when the chain looks
dry. A high viscosity oil rather than low viscosity oil is better because
it will stay on the chain longer providing lubrication.
(5)
Put oil on the sides of the chain pins so that it penetrates into these;
remove excess oil.
(5). Shift
pedal.
-55-
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).
- Put in fresh transmission oil.
- Empty the fuel from the fuel tank, and empty the carburettor float
bowl. (If left in for a long time, the fuel will deteriorate).
- Lubricate the drive chain and all the cables.
- Spray oil on all unpainted metal surfaces to prevent rusting. Avoid
getting oil on rubber parts or in the brakes.
- Tie a plastic bag over the exhaust pipe to prevent moisture from
entering.
- Set the QUAD on a box or stand so that both wheels are raised
off the ground. (If this cannot be done, put boards under the front
and rear wheels to keep dampness away from the tire rubber).
- Put a cover over the QUAD to keep dust and dirt from collecting
on it.
To put 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 “Daily Pre-ride Inspection Section”.
- General lubrication.
-56-
THE MULTIFUNCTION INSTRUMENT PANEL
Chronometer
The multi-function display has two buttons, a mode button to change
display and a reset button for certain functions.
To use the chronometer, press Reset to put it to zero. Counting
begins immediately.
The partial distance in Km or Miles can be reset by pressing the
Reset button.
Reset
Mode
00:00
Trip distance in Km
To program the trip distance in Km or Miles. Once the battery is
connected the display indicates that the program is active (metric or
imperial). To make the change connect the battery while holding in
one of the buttons, the change will appear on the screen.
This function remains completely in memory even though the battery
may not be connected.
Clock precision: The clock precision can be adjusted if it is fast or
slow.
The initial display is the clock (time) screen; if you press mode the
display changes 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 has a memory even if battery
disconnected.
4. Trip distance (can be reset).
Wheel design
The design of the wheel may change (10"). This affects the precision
of the speed and distance measurements.
Backlight
The internal display back light has an independent circuit that can
accept 8 to 18 volts AC (Two stroke engines) or DC (4 stroke engines).
The circuit is protected.
Setting the time
To set the time go to the clock screen and hold in the Mode button
until the time set screen appears, Reset can be used to change the
hours, pressing Mode once more will allow the minutes to be set also
using the Reset button. Once the time is set then the button Mode
will begin the clock at zero seconds of the minute chosen, this can
be useful to coordinate times (ex: in competition).
0
00:00
Clock/timer
0000
Speed
Total distance
(The Mode button is used to change screens.)
-57-
0.0
Partial distance
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.
1
FAULT
CAUSE
SOLUTION
The engine does not rotate
- Crankshaft locked.
- Cylinder/ piston/ crankpin journal seizure.
- Transmission assembly seizure.
- The QUAD has been out of operation for a
longer period of time.
- Go to a specialist workshop.
- Go to a specialist workshop.
- Go to a specialist workshop.
- It is advisable to drain the old fuel from the tank. When
the fuel tank is full of fresh fuel, the engine should start
immediately
- Take the spark plug out and replace it.
- To “unflood” the engine, put the throttle to maximum and
operate the start pedal 5 to 10 times. If the engine fails to
start, unscrew the spark plug and dry it.
- Clean the petrol tank ventilation. Adjust the air filter conduit.
- Go to a specialist workshop.
- Spark plug soiled or humid.
- Engine flooded.
- Petrol / gas mixture incorrect.
- Exhaust valve open.
2
The engine starts but does not
stop
- Air supply incorrect.
- Close the starter. Clean the petrol tank ventilation. Adjust
the air filter conduit.
- Fill the fuel tank with fuel.
- Fuel insufficient.
3
The engine overheats
- Insufficient coolant in the circuit.
- The radiator is soiled or partially
obstructed.
-58-
- Add coolant, verify the cooling system seal.
- Clean the radiator fins or change it.
FAULT
4
The engine does not run
smoothly
CAUSE
SOLUTION
- Dirty, broken or wet spark plug.
- Spark plug hood or cable problem.
- Ignition rotor damaged.
- Water in the fuel.
5
The engine is under powerful or
accelerates badly.
- Fuel supply faulty.
- Air filter obstruction.
- Exhaust deteriorated with leaks.
- Check the condition of the spark plug and clean, adjust
or replace it.
- Check the condition of the spark plug hood, if it is
deteriorated, change it.
- Go to a specialist workshop.
- Empty the fuel tank and refill it.
- Carburettor jets dirty.
- Crankshaft bearings damaged or worn.
- Clutch slipping.
- Clean and check fuel system. Go to a specialist workshop.
- Clean and grease, or change if necessary.
- Check if the exhaust system is damaged, change the glass
fibre in the silencer if necessary.
- Go to a specialist workshop.
- Go to a specialist workshop.
- Go to a specialist workshop.
6
Abnormal engine noise
- Ignition problems.
- Over heating.
- Go to a specialist workshop.
- See chapter 3.
7
Detonations in the exhaust
- Carbon in combustion chamber.
- Incorrect or poor gasoline or wrong
octane rating.
- Incorrect or non-specified spark plug.
- Exhaust system joints deteriorated.
- Go to a specialist workshop.
- Drain the petrol and fill with fresh or higher-octane petrol.
- Cylinder head gasket leak (water leaking
into cylinder).
- Go to a specialist workshop.
8
White fumes from the exhaust
-59-
- Change spark plug for a new one or recommended one.
- Check if the exhaust system is deteriorated. The seals
must be in perfect condition, if not then they must be changed
for new ones. - Go to a specialist workshop.
FAULT
CAUSE
SOLUTION
8
White fumes from the exhaust - Petrol valve cable maladjusted.
- Go to a specialist workshop.
9
Brown fumes from the exhaust - Air filter obstruction.
- Main jet too high.
- Clean or change the air filter. Go to a specialist workshop.
- Change the main jet and verify.
10
Gears don’t engage
- Clutch does not release.
- Shift fork worn or locked.
- Gear locked in transmission.
- Shift lever damaged.
- Selector position spring loose or broken.
- Down shift selector mechanism spring
broken.
- The spring of the retro-selector is broken.
- Cylinder change if broken.
- Gear ratchet spring broken.
- Go to a specialist workshop.
- Change the gear fork.
- Go to a specialist workshop.
- Change the gear lever.
- Go to a specialist workshop.
- Go to a specialist workshop.
- Go to a specialist workshop.
- Go to a specialist workshop.
- Go to a specialist workshop.
11
Gears jump
- Gear change fork damaged in the gears.
- Gear teeth worn.
- Gear nipple damaged.
- Groove gear drum worn.
- Gear change fork pivot worn.
- Selector drum position spring broken.
- Broken gears.
- Change gear fork. Go to a specialist workshop.
- Change. Go to a specialist workshop.
- Change. Go to a specialist workshop.
- Change. Go to a specialist workshop.
- Change shaft. Go to a specialist workshop.
- Change the spring. Go to a specialist workshop.
- Go to a specialist workshop.
12
Clutch slipping
- No play in the clutch handle.
- Clutch plate worn.
- Clutch housing worn.
- Clutch spring broken or weak.
- Go to a specialist workshop.
- Replace the clutch plate. Go to a specialist workshop.
- Replace the clutch hub. Go to a specialist workshop.
- Go to a specialist workshop.
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FAULT
CAUSE
SOLUTION
12
Clutch slipping
- Clutch plates worn.
- Change the clutch disks. Go to a specialist workshop.
13
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.
- Replace the steering bearing.
- Change the steering stem. Go to a specialist workshop.
- Steering bearings damaged or worn.
- Steering stem bent.
14
Shock absorption too hard
- Compression maladjusted.
- Excessive tyre pressure.
15
Shock absorption too soft
- Rebound maladjusted.
- We must hold the hydraulics when rotating the control on
the lower part of the shock absorbers to the right.
Ensure that the compression of the front shock absorbers
are adjusted equally. See “Suspension tuning”.
- Verify tyre pressure.
- Low tyre pressure.
16
The QUAD makes unusual
noises
- Rotate the control on the upper part of the front and rear
shock absorbers to the left. Ensure that the balance of the
front shock absorbers is done correctly.
For more details, see “suspension tuning”.
- Verify 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.
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- 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
FAULT
CAUSE
SOLUTION
16
The QUAD makes unusual
noises
- Cylinder damage.
- Brackets, nuts, bolts not properly tightened.
- Replace the damaged cylinder.
- Verify and adjust to the correct tightening torques.
17
The handlebars vibrate
- Tyre deformation, swing arm or needle
bearing worn.
- Rim off-centre.
- Refill.
18
19
The QUAD pulls to one side
The brakes do not function
correctly
- Different tyre pressures.
- Wheel off-centre or deformed.
- Release air from the wheels, fit the rims correctly, and
inflate the tyres to the correct pressure.
- Check tyre pressures and correct if necessary.
- Check the wheels thoroughly and replace if necessary.
- Wheels not aligned, due perhaps to a
fall.
- Handlebar bracket loose, steering shaft
bolt loose.
- Check front wheel convergence and divergence. Centre
the swing arm shaft.
- Tighten the handlebar bracket and the steering shaft bolt
to the correct tightening torques.
- Chassis twisted.
- Steering incorrectly aligned.
- Steering stem bent.
- Rear wheel misaligned.
- Go to a specialist workshop.
- Adjust the steering. Go to a specialist workshop.
- Change steering stem. Go to a specialist workshop.
- Check front wheel convergence and divergence. Centre
the swing arm shaft.
- Possible violent shock to one of the
steering joints.
- Go to a specialist workshop.
- Brake pads worn.
- Loss of brake fluid.
- Brake fluid deteriorated.
- Piston cylinder broken.
- Brakes incorrectly adjusted.
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- Check the condition of the pads and change them if
necessary.
- Check the brake circuits. Change those that are damaged
or broken.
- Drain the brake fluid and put a new product, recommended
by the maker. (See “Maintenance and periodic adjustments”
for information on bleeding the brake fluid circuit).
- Replace the piston cylinder.
- Adjust the brakes.
FAULT
CAUSE
SOLUTION
20
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.
21
The lighting system does not
work
- Bulbs melted or short-circuit in the electric
installation.
- Check the condition of the bulbs and the electrical
installation.
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ELECTRICAL SCHEMAS
B black
Br Brown
G Green
Gr Grey
L Blue
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O Orange
R Red
Sb Sky blue
V Violet
W White
Y Yellow
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 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. Consequently, GG with this document guarantees the consumer (hereafter
referred to as the “purchaser”), 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 first 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.
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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 inspection, 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, fuses, 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
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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
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 pass 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 through 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.
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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
PU010538006
RECOMIENDA EL USO DE ACEITE:
RECOMMENDS THE USE OF OIL:
RECOMMANDE L’USAGE DE L’HUILE:
CONSIGLIA L’USO D’OLIO: