GAS GAS WILD HP 450 Service Manual Download Page 1

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MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

Summary of Contents for WILD HP 450

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Page 3: ...sports four wheel vehicle conceived in and for competition It will help you appreciate a high degree of technical perfection and reliability apart from a meticulous design and high performance The present manual will offer you a good basic knowledge of the vehicle s characteristics and handling It contains important instructions about your safety and information on the necessary skills and techniq...

Page 4: ...TE This symbol indicates points of particular interest for higher efficiency and a more convenient operation of the vehicle Inadequate driving may lead to environmental problems and conflict with other people Riding your vehicle responsibly will ensure that you don t have to face these problems and conflicts PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE LEGAL USE OF YOUR VEHICLE WITH CLEAN CONSC...

Page 5: ...tection 84 Checkings to be made before riding the vehicle 85 WILD HP 70 Front and rear brakes 85 Fuel 85 Cooling system 87 Chain 87 Throttle grip 87 Lights 87 Tyres 87 Use of the QUAD 89 Engine start 89 Gear box 90 Starting the vehicle 91 Stopping the engine 91 Engine running in 92 Parking in inclined surfaces 92 Driving the QUAD Practical recommendations 93 Become familiar with your QUAD 93 Drive...

Page 6: ... change 103 Swing arm axle 103 Adjustment and lubrication of the chain guide 103 Checking the cooling liquid level 104 Air filter 106 Spark plug maintenance 108 Inspection and lubrication of the cables 110 Replacing the lights 110 Transmission 112 Cleaning lubrication and storage 121 Cleaning 121 Lubrication 122 Storage 123 Multifunction 118 Torque Table 119 Bolt and Nut tightening 120 Troubleshoo...

Page 7: ...ETI MARELLI Integrated on EFI Hydraulic multidisc in oil bath 6 gears Primary with gears secondary with chain Electric starting and aditional kickstarter pedal Multi tube twin spar frame Cr Mo steel made Wishbone arms with two ÖHLINS multi adjustable shock absorbers Aluminium allow swing arm with no welding Progressive system with multi adjustment ÖHLINS shock absorber Two self ventilated 180mm di...

Page 8: ...ater read the instructions for this type of terrain carefully Take into account that brake efficiency is diminished when wet When coming out of the water brake several times so that they dry more quickly through friction Always use the tyre size and type described in this manual SAFETY INFORMATION WARNING Not following these instructions may lead to grave injuries or even death The QUAD is not a t...

Page 9: ...sing a trailer make sure it is upright ant that the fuel tap is in the OFF position closed Fuel leaks might take place in the carburettor or in the fuel tank otherwise Fuel is poisonous In case of accidental ingestion abundant vapour inhalation or contact with your eyes go to the doctor at once If fuel gets in contact with your skin wash it with water and soap Should you clothes get wet with fuel ...

Page 10: ...d elements to make transportation easier The dealer will make sure each element is correctly fitted and you will receive the quad ready to use This paragraph is purely for your information You will find enclosed a carburettor adjustment kit The adjustments must be performed by an expert and only when it is necessary The carburettor is already tuned so changes to its settings are initially not requ...

Page 11: ... the picture This number must be mentioned to order a new set of keys in case you lose them WILD HP 76 NOTE The vehicle s serial number is used for your machine s identification C D B A Homologation badge Your quad has its corresponding homologation badge B where its serial number is printed It is also printed at the front and it must coincide with the documents You are recommended to write down t...

Page 12: ...gency stop 6 Contact key 7 Parking brake 8 Starting button and stop engine 11 13 14 15 12 1 2 3 4 7 9 10 6 5 8 9 Front brake lever 10 Throttle grip 11 Front guard 12 Brake pads 13 Fuel tank cap 14 Footrest grids 15 Rear protection LOCATION OF COMPONENTS GAS GAS WILD H P 450 ...

Page 13: ...4 19 22 23 21 25 20 26 16 15 Headlight fairing 16 Full throttle body 17 Seat 18 Front shock absorber 19 Engine 20 Gear pedal 21 Swing arm 22 Exhaust pipe 23 Front brake fluid 24 Kick starter pedal 25 Brake pedal 26 Oil tank ...

Page 14: ...ct on turn the key clockwise to the ON position To turn contact off turn the key anti clockwise to the OFF position START THE ENGINE This quadricyle has been fitted with an electric starting mechanism and a pedal operated one Control B is on the right hand side of the handlebars Pedal C is located on the right hand side of the quadricycle You will find it in the rest position Pull this control unt...

Page 15: ...our throttle works smoothly G Make sure it slides back to idle when the grip is released The grip has a spring to return the engine to idle and slow down the vehicle when the hand is taken off the grip CLUTCH LEVER The clutch lever is located on the left side of the handlebar Activate it to engage or disengage the clutch H To make the clutch work smoothly the lever must be pulled quickly and relea...

Page 16: ...ist but always to a part where it will not come off easily WARNING The vehicle must not be used without attaching the emergency stop system Ignoring this order may cause serious consequences WILD HP 81 REAR BRAKE PEDAL The rear brake pedal B is located on the right side of the lower chassis Activate it to apply the brake to the rear wheels EMERGENCY STOP The vehicle features an emergency stop syst...

Page 17: ...ine will reach the optimal operating temperature in a short time and with no need to force it WILD HP 82 For use pull up the choke knob A and without turn the twist grip start the engine Look the engine that starts with high revolutions Waiting few seconds the engine will be a good temperature For pull down the choke button only drive the twist grip NOTE If the engine is choked start with the thro...

Page 18: ...addle and the frame The saddle will lift easily NOTE When putting the seat back in the normal position make sure it holds well back in place BATTERY This battery is maintenance free and checking the fluid level is not required It is recommended to check the charge of the battery periodically The operating instructions for the battery are as follows 1 Check the battery tension while the circuit is ...

Page 19: ...riding The quad has very wide wheels and it would easily drag your leg under the wheels causing serious injuries The QUAD features two footrests E one on each side Both footrests have a grid The package will protect our feet and legs in case of losing balance and taking your feet off the rests Their width allows for great freedom of movement WILD HP 84 The foot protections F are located between th...

Page 20: ...free play the pedal position and its free play Brake lever and pedal Check the free play in the front brake lever 1 Should it be noticeable check the state of the brake pads and look in the Adjustments and Maintenance section of this manual Make sure the free play of the brake pedal is not excessive 2 Check the brake pedal position If you do not find it correct have it adjusted at a specialised wo...

Page 21: ...e the inner parts of the engine WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop teh engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light WILD HP 86 A B A and B Front and rear brake fluid reservoirs Brake operation Test the brakes while riding slowly ...

Page 22: ...ng liquid level in its reservoir A with the cold engine the liquid level will vary with engine temperature The level is correct when between the two marks If it falls below the lower mark add anti freezing liquid Change the liquid every two years NOTE The liquid must be right between the two marks not above the top mark or below the bottom one CHAIN Check the overall state of the chain and its ten...

Page 23: ...ides 1 Tyre wear out limit Observe how the tyre wears out If the tyre is worn out at the centre it means that the pressure is too high If the tyre wears out at the edges the tyre pressure is too low The tyre must be worn out equally on its surface Replace the tyre when the groove depth is below 3mm Manufacturer MAXIS MAXIS Size 21 x 7 00 10 20 x 11 00 9 Type RAZR RAZR Front Rear Recommended 0 400 ...

Page 24: ...CAUTION Before starting the engine for the first time consult the section Engine running in WARNING In cold weather make sure that all the cables work smoothly before you go out on your quad If the cables are frozen or do not operate smoothly you could lose control of your QUAD and have an accident 1 To activate the parking brake pull the brake lever while using the lock lever ...

Page 25: ...charge GEARBOX This vehicle features a 6 speed gearbox It is a return type change which means that we must go through second gear to change from first into third that is one gear at a time To insert the first gear from neutral we must first pull the clutch lever step on the change pedal and slowly release the clutch In the next section the process of starting the vehicle is described in more detai...

Page 26: ...ally 6 Follow the same procedure to change into higher gears WARNING Too brisk acceleration or releasing the clutch lever too quickly may result in an accident and may cause the vehicle to slide and tumble The throttle must be gradually turned and the clutch must be smoothly released To slow down To slow down or stop release the throttle and apply the brakes smoothly and uniformly As the vehicle s...

Page 27: ...t speed vary your speed now and then Durante las siguientes 10 horas 10 20 se recomienda no rodar a más de de gas durante un largo período Over the next 10 hours from 10 to 20 try not to use more than throttle for long periods of time PARKING IN INCLINED SURFACES WARNING Avoid parking on inclined ground as the quad may start moving without control with risk of accident If it is necessary insert th...

Page 28: ...riod of time Take your time to learn the basic techniques before attempting more difficult challenges WILD HP 93 WARNING Never carry a passenger Carrying a passenger may result in an accident and the subsequent risk of bodily harm to the rider and or the passenger The quadricycle features an emergency stop system in case of rider fall but it has not been designed to cope with passenger falls THE Q...

Page 29: ...nd if speed increases the difficulty to turn will 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 special skill is required to turn and it is important to learn the skill on flat land with no obstacles and at moderate speed When approaching the corner slow down and st...

Page 30: ...d go down If the vehicle starts going backwards do not use the rear brake or try to insert a gear the quad might easily tumble backwards Get off the vehicle immediately over the high side of the climb Always keep your safety in mind as a priority GOING DOWN SLOPES Select a short gear that allows the engine compression to act as the main brake Braking incorrectly may lead to losing traction The pic...

Page 31: ...on tube at the bottom of the filter box Wash it in fresh water if you have driven across salt water or mud RIDING IN ROUGH TERRAIN Riding in rough terrain must be performed very carefully Be always alert to any obstacle that may damage the QUAD make you lose balance or cause an accident Keep your feet firmly placed on the footrests at all times Avoid jumping over obstacles with the vehicle It migh...

Page 32: ...hed by turning the knob until you feel a click The shock absorber comes regulated to 7 clicks as standard Turn the knob clockwise until the end now it is totally closed Turn the knob anti clockwise 7 clicks and it is in the standard setting Leaving it in the 0 click position makes it very hard while position 22 makes it very soft WARNING Always adjust the right and left absorbers with the same mea...

Page 33: ...tting is 13 clicks Turn the knob clockwise to its end now it is totally closed Turn 13 clicks anti clockwise and now the setting is the standard one With 0 clicks the rebound would be very hard and with 28 clicks would be very soft Adjusting compression To adjust the compression settings turn the knob on the top end of the shock absorber with a flat tip screwdriver Turn it anti clockwise to the en...

Page 34: ...box Chain guide Cables Radiator pipes and connections Exhaust Wheel bearings 10 outings Check all screws Tightening force chart check chart Brake piston and cover dust guard 2 years Brake pump piston and cover dust guard 2 years Brake pipe 2 years Prove Fill Change Lubricate Clean Adjust Tighten If it is necessary MAINTENANCE CHART The first revision must be performed by a specialised workshop at ...

Page 35: ...e adjustment screw to obtain the optimal free play If the clutch lever adjustment is at its limit it must be adjusted by using the clutch pump piston push rod ADJUSTMENT OF THE BRAKE LEVER AND PEDAL The disc wear out is automatically compensated and has not effects on the brake lever or pedal The only adjustment required is therefore the free play of the front brake lever and the position and free...

Page 36: ...descends then you will be able to control the level decrease WILD HP 101 Air might also have entered the brake system The process to bleed the system is as follows Activate the brake several times You will see that fluid starts exiting the system through the tube The transparent tube will help us see if there is air i e bubbles in the system Once the system has been bled refill the reservoir to th...

Page 37: ...rubs on the disc and as a consequence is the part that suffers more wear out and requires more control of its thickness When the fluid level is too low add more With a cross tip screwdriver unscrew the two screws on the reservoir Next add the necessary fluid Put the screws back in place and make sure the reservoir is tightly held in place Rear Below the seat of the vehicle we will find the rear br...

Page 38: ...s with your GAS GAS Quad to tighten the axle ADJUSTMENT AND LUBRICATION OF THE CHAIN GUIDE It must be checked adjusted and lubricated according to the regular maintenance to prevent excessive wear out If the chain is too worn out or badly adjusted too tight or with too much slack it might go free or even break WARNING A freed or broken chain might catch in the engine or the rear wheel and damage t...

Page 39: ... on the chain longer and lubricate it better Lubricate on the pin side of the chain so that it filters into them dry out the oil excess CHECKING THE COOLING LIQUID LEVEL The cooling liquid absorbs the engine s excess heat and transfers it to the air through the radiator If the liquid level decreases the engine overheats and may be severely damaged Check the liquid level everyday before riding the ...

Page 40: ...t an anti corrosion liquid in time the radiator would oxidise This would block the cooling ducts inside it CAUTION The use of inadequate liquids may damage the engine and the cooling system Use cooling liquid with specific anti corrosion agents for aluminium engines and radiators according to the manufacturer s instructions WARNING Chemicals are toxic for the human body Follow the manufacturer s i...

Page 41: ... in the table Always replace the gasket with a new one if it damaged Drain plug tightening torque look maintenance table Water pump cover plug 9 Nm Fill the radiator up to the bottom of the radiator filler neck with coolant and install the radiator cap Check the cooling system for leaks Start the engine warm up the engine throughly then stop the engine Check the coolant level after the engine cool...

Page 42: ...en you dry it Inspect the filter for damage such as scratches hardened parts contracted parts In case of damage replace it or you will allow dirt to enter the throttle valve C Checking hose D Air filter box 1 Remove the seat and you will see a blue foam right in the centre 2 Hold the foam and you will see a screw E that can be turned with your fingers 4 Remove the filter cage 5 Put the filter in a...

Page 43: ...re we must put it in a lubricant and greasing bath We can also wet the filter completely and not dip it in a liquid bath the effect will be the same Apply special air filter oil to the element foam If you have no air filter oil use engine oil Also clean the filter cage and the filter box with a damp cloth Make sure all the corners are clean before putting all the parts back in place Grease all the...

Page 44: ...gasoline WILD HP 109 NOTE for the correct use of the plug it is protected by a cap Keep the cap clean and dry 7 Extract de plug and remove the carbon deposits from the spark plug with a small tip or a metallic brush Readjust the gap in the plug between 0 7 and 0 8 mm 0 028 0 031 in Before removing the carbon deposits check its color this color tells us whether the standard plug is the best for our...

Page 45: ... have a specialised workshop replace them Recommended lubricant Engine oil REPLACING THE LIGHTS Front headlight 1 Remove the headlight fairing removing the 4 Allen screws A 4 Allen screws A NOTE Do not touch the shining surface B with your fingers not even with a cloth as it will easily be scratched If any dust has settled on it we recommend you to clean it with a duster B WARNING The bulb is hot ...

Page 46: ...nst the spring turn it anti clockwise and replace it with a new one Put the lens back in place NOTE Make sure the lens is well tightened F E 6 After freeing the bulb E from the wire part we can remove it from the rear 7 Replace the bulb by a new one To put it in place we will follow the inverse process 3 Unscrew the 3 screws that hold the light from below 4 Unplug the bulb cable and remove the cov...

Page 47: ... clockwise and replace it with a new one TRANSMISSION For the transmission and clutch to function properly maintain the oil level at the proper level Change the oil periodically Oil at an insufficient level deteriorates and contaminates rapidly This accelerates wear and promotes premature failures Oil level The use of premium grade four stroke engine oil will prolong the service life of your motor...

Page 48: ... To change the oil and the oil filter follow these instructions 2 Remove the connection screw C 1 Run the engine with the motorcycle in neutral gear for 3 minutesRun the engine with the motorcycle in neutral gear for 3 minutes NOTE When starting the engine closely follow care and warnings from the start the engine section 2 Wipe both sight glasses clean 3 Gradually increase the power to 2000 rpm a...

Page 49: ...nction Use the oil filter with the genuine GAS GAS design or equivalent for your motorcycle WARNING A mistake in the placement of the new element may cause engine malfunction The motor oil will not flow if the new element is placed incorrectly NOTE Put a new o ring at the same time the filter is replaced 9 Replace the filter cover and put the screws that secure the cover but without tightening the...

Page 50: ...ngs brakes transmission bushings and electric components with the subsequent damage 10 Replace the drain caps and screw them back on Pour new oil through the dipstick hole Approximately 1800 ml or else the required amount WARNING The engine can be damaged if the oil is not used properly or the specifications recommended by GAS GAS MOTOS are not followed Use the type of oil in the section of recomm...

Page 51: ...t make the paint matt and destroy the paint finish When you have finished start the engine and leave it idling for some minutes WARNING Wet brakes may lose efficiency and lead to risk of accident Test the brakes after washing the quad and apply them several times at low speed so that friction dries them out After washing the quad Remove the plastic bags and clean the air filter inlet Lubricate the...

Page 52: ... to warm the transmission oil and then drain it see transmission section Put in new transmission oil Empty the fuel tank Fuel deteriorates if left quiet for a long time Lubricate the chain and all the cables Apply oil on all unpainted metal surfaces to prevent dust avoiding oil on brakes and rubber parts Wrap the exhaust pipe in a plastic bag on the outside to prevent rust Leave the quad so that t...

Page 53: ... From time display press mode 3 times l 0 to zero the trip keep the reset button pressed until it zeros To change to kilometers per hour or miles per hour Disconnect the battery the total distance will be saved Re connect the battery whilst holding down either button and it will read either The white plastic block connector on the speedo is for the display backlight The red wire is positve The bla...

Page 54: ... 2 5 3 5 2 0 2 0 2 5 1 0 1 0 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 2 1 7 7 Cylinder head bolts Cylinder bolt Engine drain plug Kickstarter bolt Kickstarter nut Change pedal bolt Spark plug Water pump lid drainage screw Engine mount bolt Cylinder head struts Brake caliper bolt Disc base bolt Rear brake pedal bolt Subframe mou...

Page 55: ...dal set 1 Front wheel set 2 Front suspension set 3 Engine set 4 Transmission set 5 Rear wheel set 1 7 3 4 8 BOLT AND NUT TIGHTENING Every day before riding check without fail the tighteness of the bolts and nuts described here Also check to see whether or not each cotter pin is in place and in good condition ...

Page 56: ...tor or the ignition coil has oxydized Fuel air mixture incorrect 1 2 3 Dismount the right paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate the causes for discharging contact a KTM dealer Start engine with start pedal Go to specialized garage Go to specialized garage Go to specialized garage Check fuel pump relay extract air filter cov...

Page 57: ...park plug Connecting rod exhaust system damage Close the starter Clean fuel tank air vent Check the injector mounting Check the air filter Fill up fuel tank Close the starter Clean fuel tank air vent Check the injector mounting Check the air filter Full up fuel tank Adjust injection system Go to specialized garage Adjust valve gap Go to specialized garage Clean and check fuel system as well as car...

Page 58: ...ocknut too tight Steering stem bent Compression damping adjustment incorrect Change cylinder head gasket leaking Go to specialized garage Clean or change the air filter Go to specialized garage Go to specialized garage Change friction plate Go to specialized garage Change gear lever Check or change clutch spring Check clutch release mechanism Change clutch hub Change it and go to specialized garag...

Page 59: ...ced Look Suspension tuning for more details Check tire air pressure Adjust drive chain Change chain and rear engine sprocket Go to specialized garage Change it Go to specialized garage Lubricate with apropiate chain oil Align rear wheels Change disc brake Replace pad or change Change cylinder damaged Go to specialized garage Look Torque table and tighten all bolts and nuts Replace Deflate wheels p...

Page 60: ...le Go to specialized garage Check pad and replace if it is necesary Check and repalce if it is necesary Empty brake fluid and replace with new recomended one Look how purge the fluid brake in Maintenance and ajustment Replace piston pump Go to specialized garage Adjust brake Extract seat and fuel tank and check connections and verify tension regulator and box fuses fuse Extract seat box fuse cover...

Page 61: ...and to the extent that a The purchaser has failed to subject the vehicle to any of the inspections and or maintenance work prescribed in the operating manual or has exceeded the date stated for such inspections or maintenance work also excluding from the warranty defects that appeared before the prescribed date of such inspection or maintenance work performed not at all or performed only after the...

Page 62: ...he existence of a defect or if a visual inspection or material testing is required GG shall be entitled to demand submission of the parts for which warranty claims are put forward or to order an examination of the defect by a GG expert Any additional warranty obligations for parts replaced free of charge or for any service performed free of charge under the present warranty shall be excluded The w...

Page 63: ...PU010338021 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 partsgg gasgasmotos es Web www gasgasmotos es UGUST 2003 RECOMIENDA EL USO DE ACEITE ...

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