GAS GAS 2005 WILD HP 450 Service Manual Download

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

Summary of Contents for 2005 WILD HP 450

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Page 3: ...ports 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 pres...

Page 4: ...E 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...

Page 5: ...ection 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 8...

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...

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 m...

Page 8: ...ter 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 quick...

Page 9: ...ing 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 acci...

Page 10: ...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 fin...

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 ba...

Page 12: ...ency 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 Foot...

Page 13: ...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 B...

Page 14: ...t 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...

Page 15: ...ur 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...

Page 16: ...st 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...

Page 17: ...ne 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 engin...

Page 18: ...ddle 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 fl...

Page 19: ...iding 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 packag...

Page 20: ...ree 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...

Page 21: ...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 f...

Page 22: ...g 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 free...

Page 23: ...des 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 Th...

Page 24: ...AUTION 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 cab...

Page 25: ...harge 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 th...

Page 26: ...lly 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 tu...

Page 27: ...speed vary your speed now and then Durante las siguientes 10 horas 10 20 se recomienda no rodar a m s de de gas durante un largo per odo Over the next 10 hours from 10 to 20 try not to use more than...

Page 28: ...iod 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 s...

Page 29: ...d 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...

Page 30: ...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...

Page 31: ...n 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 ale...

Page 32: ...ed 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 c...

Page 33: ...ing 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...

Page 34: ...ox 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 a...

Page 35: ...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 Th...

Page 36: ...escends 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...

Page 37: ...ubs 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...

Page 38: ...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...

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...

Page 40: ...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...

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 fi...

Page 42: ...n 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 filte...

Page 43: ...e 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...

Page 44: ...asoline 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...

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...

Page 46: ...st 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...

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...

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 n...

Page 49: ...ction 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 flo...

Page 50: ...gs 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...

Page 51: ...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...

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...

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...

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...

Page 55: ...al 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 bolt...

Page 56: ...or 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 investigat...

Page 57: ...ark 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 C...

Page 58: ...cknut 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 s...

Page 59: ...ed 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 a...

Page 60: ...e 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 Maintenan...

Page 61: ...nd 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 in...

Page 62: ...e 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 examin...

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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GAS GAS 2005 WILD HP 450, Service Manual

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