GAS GAS WILD HP 450 - 2005 Service Manual Download

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MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO

Summary of Contents for WILD HP 450 - 2005

Page 1: ...MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO D USO MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO D USO...

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Page 3: ...USER MANUAL USER MANUAL ENGLISH...

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Page 5: ...a sporting quad bike designed by and for competition With it you can enjoy the high degree of technical perfection and reliability in addition to the careful design and high performance This manual p...

Page 6: ...equipment NOTE This symbol indicates points of particular interest for improved efficiency and more convenient operation Inappropriate use could cause problems to the environment and conflicts with ot...

Page 7: ...rd 19 Foot rest assembly 19 Foot guards 19 Checks to make before starting the machine 20 5 Front and rear brakes 20 Fuel 21 Coolant system 22 Chain 22 Throttle twist grip 22 Lights 22 Tyres 22 Use of...

Page 8: ...arm 38 Adjusting and lubricating chain guide 38 Checking coolant level 39 Air filter 41 Spark plugs 43 Inspection and lubrication of cables 45 Replacing lights 45 Transmission 47 Engine oil 47 Cleani...

Page 9: ...ARELLI Integrated on injection system Hydraulic multi disc 5 speeds and reverse Primary with gears secondary with chain Electric engine and auxiliary pedal Multi tubular with double shim manufactured...

Page 10: ...is not prepared to do this and you may damage either you or the machine Do not deliberately skid if you do not know how to do so correctly as it could be dangerous As for the above first practice on f...

Page 11: ...eep the area ventilated and free from naked flames or sparks this includes spot light appliances The petrol could catch fire and cause burns Take care not to spill petrol on the engine exhaust pipe or...

Page 12: ...not fitted in order to ease transportation The dealer should fit the remaining pieces and you should receive the QUAD ready for use This section is for your information only A kit is included for maki...

Page 13: ...e diagram This number is required to order a new key in the event of loss 11 QUALIFICATION No NOTE The vehicle serial number is used to identify your machine C D B A Qualification approval plate The q...

Page 14: ...Light flash button 4 Full beam button 5 Emergency stop 6 Ignition key 7 Parking brake 8 Start and stop engine control 11 13 14 15 12 1 2 3 4 7 9 10 6 5 8 9 Front brake handle 10 Throttle twist grip 1...

Page 15: ...6 20 27 17 16 Front headlight casing 17 Throttle housing 18 Seat 19 Front shock absorber 20 Engine 21 Shift pedal 24 22 Swing arm 23 Exhaust pipe 24 Front brake fluid tank 25 Kick start pedal 26 Brake...

Page 16: ...ns You will find it in the OFF position Dipped beam Side lights No lights A C B PRINCIPAL PARTS OF THE QUAD IGNITION KEY Key A is located in the front section of the handle bar To switch on the igniti...

Page 17: ...ne check that the throttle spins round smoothly I Ensure that it returns to idle position when the handle is released There is a return spring fitted inside the handle which reduces speed and brings t...

Page 18: ...e never becomes detached E g The cable could be tied to trousers a jacket around the wrist but always to a resistant point WARNING It is forbidden to use the quad bike before attaching the emergency s...

Page 19: ...fitted with a 5 speed gear box The shift pedal E is located on the left hand side of the engine and is used in combination with the clutch when changing gear FUEL TANK CAP To open the fuel tank cap t...

Page 20: ...ly to the chassis will soften the blow and prevent serious damage to the steering and remainder of the vehicle 18 SEAT To remove the seat use the same key as for the fuel tank cap B Put the key in the...

Page 21: ...act with care on slopes and examine the terrain closely FOOT REST ASSEMBLY WARNING The foot protectors and foot rest assembly are a form of protection vital to the safe driving of the QUAD The quad bi...

Page 22: ...re the play of the brake lever and the position and play of the brake pedal Brake lever and pedal Check there is no free play in the front brake lever 1 In the event that there is check the condition...

Page 23: ...se serious damage to the internal working of the engine WARNING Petrol is highly inflammable and may be explosive in certain conditions Always stop the engine and do not smoke Ensure that the area is...

Page 24: ...in severe damage Check coolant level in tank A while the engine is cold the coolant level varies with the engine temperature The level is acceptable while it falls between the two marks If the level...

Page 25: ...wear limit Examine how the tyres wear If wear is in the centre of the tyre this implies pressure is too high 23 Recommended 0 400 bar 40 Kpa 0 450 0 500 bar 45 50 Kpa Minimum 0 370 bar 37 Kpa 0 420 0...

Page 26: ...n ON 3 Next the rider should attach the emergency stop system see recommendations in the section Principal parts of the bike emergency stop A USE OF YOUR QUAD WARNING The User Manual should be read ca...

Page 27: ...STARTING THE VEHICLE 1 Operate the throttle twist grip CAUTION Always release the accelerator to change speed otherwise the engine and the transmission could be damaged 2 As explained earlier to enga...

Page 28: ...roblem for the engine to the contrary it is good for the engine Every acceleration period must be followed by a rest period so that the engine can eliminate all the accumulated heat During the first 1...

Page 29: ...r a certain length of time Take as much time as necessary to learn the basic techniques before attempting more difficult manoeuvres 28 WARNING Never carry passengers Carrying a passenger could lead to...

Page 30: ...have no problem turning with the handlebar On the other hand as the speed increases so does the difficulty in turning The two rear wheels are mounted rigidly on the same shaft and turn together at th...

Page 31: ...op correctly turn round with the QUAD while you still have forward traction and space to do so and start to descend If the machine starts to roll backwards do not use the back brake to stop and do not...

Page 32: ...pped water by dismounting the retainer hose located at the bottom of the air filter housing Wash with fresh water if you have been driving through salt water or mud DRIVING ON ROUGH GROUND Driving ove...

Page 33: ...justment could give rise to faulty handling and loss of stability with the resulting risk of accident Adjusting the compression To adjust turn control A of the upper section of the shock absorber by h...

Page 34: ...n clockwise to the maximum now it is totally closed Turn anticlockwise until 13 clocks have been heard now it is in standard position If set at 0 clicks the extension will be very hard on the other ha...

Page 35: ...Air filter casing Chain guide Cables Radiator hose and connections Exhaust Wheel bearings 10 trips Bolts see table for tightening torques Brake piston and dust guard 2 years Brake piston pump and dus...

Page 36: ...adjustment bolt to obtain the optimal play If the adjustment of the clutch lever is at its maximum use the clutch cylinder piston rod to adjust play ADJUSTING BRAKE LEVER AND BRAKE PEDAL A worn disc...

Page 37: ...drops and then you will be able to control the fall in the level 36 It is also possible that air has entered the brake fluid circuit To bleed the system proceed as follows Operate the brake lever seve...

Page 38: ...it the part which wears down so the thickness of the pad should be checked When the brake fluid level is very low top up With a Philips screwdriver undo both screws on the container Next top up with f...

Page 39: ...F provided with the vehicle adjust the shaft ADJUSTING AND LUBRICATING THE CHAIN The chain should be checked adjusted and lubricated as part of the regular maintenance to prevent excessive wear If th...

Page 40: ...y on the chain longer and provide better lubrication Apply oil to the side of the chain rollers so that it penetrates better dry off excess oil CHECKING COOLANT LEVEL The coolant absorbs excessive eng...

Page 41: ...corrosion and rust inhibitors are not used in the coolant over time the radiator will rust This will block the cooling hoses CAUTION The use of unsuitable fluids may cause damage to the engine and th...

Page 42: ...nts or leaks Install the water pump cover drain plug with the specified torque shown in the table Replace seals with new ones Tighten bolts see table of tightening torques Water pump plug 9 Nm Fill th...

Page 43: ...ng D C Air filter casing D Test hose 1 Lift up the seat and in the centre you can see a blue sponge 2 If you hold the sponge you will see a bolt E which can be loosened by hand C E NOTE Do not twist t...

Page 44: ...e element should be damp but not dripping Once it has stopped dripping place it in a bath of lubricating and greasing fluid If desired you can do without the bath and totally soak the filter with this...

Page 45: ...emoving the hose from the injection pump and cause a fire Stop the engine before removing the tank Keep naked flames and sparks away from the fuel cap Do not smoke 3 Remove the rubber attachment on th...

Page 46: ...o replace them Recommended lubricant Engine oil REPLACING THE LIGHTS Front headlight 1 Remove the casing covering the headlamp by unscrewing the 5 bolts with a n 4 Allen key WARNING The bulb is hot wh...

Page 47: ...remove and replace with a new one Fit the lens in the same way as you have removed it NOTE Make sure that the lens is correctly fitted F E 3 Undo the bolts holding the headlamp in the interior you wil...

Page 48: ...RANSMISSION To ensure correct working of the transmission and clutch keep the transmission oil at the optimum level and change it regularly A QUAD with insufficient deteriorated or contaminated transm...

Page 49: ...lug C The plug is located in the lower part of the QUAD 1 Start the engine and leave the QUAD in neutral for 3 minutes NOTE When the engine is started pay special attention to the care and warnings in...

Page 50: ...itting the new element may cause engine malfunction The engine oil will not flow if the new element is not fitted correctly NOTE Fit a new O ring when the filter is being replaced 49 D E F D CAUTION O...

Page 51: ...on Exhaust Clutch lever brake grips and starter button Air filter intake Spark plug cap and all the filler caps Cover with a plastic bag tied with elastic bands Cover with a plastic bag Cover with ins...

Page 52: ...ain abrasives which migh damage the paintwork or protective finish When finished start the engine and leave it idling for a few minutes WARNING Damp brakes may be less efficient resulting in an increa...

Page 53: ...tion on transmission Put in fresh transmission oil Empty the fuel tank If fuel is left in for any length of time it will deteriorate Lubricate the drive chain and all the cables Oil all the unpainted...

Page 54: ...circuit which accepts from 8 to 18 volts in AC typical 2T or DC typical 4T red positive black negative The circuit is protected 00 00 Reset Mode The Mode button is used to change screens 0 Speed 00 0...

Page 55: ...inder head struts Calliper mounting bolts Disc plate mounting screws Rear brake pedal bolt Sub frame support bolt Rear shock absorber bolt Rear disc wheel drive bolt Rocker arm bolt Rod bolts Steering...

Page 56: ...Unit Chassis 10 Unit Rear brake pedal 1 Unit Front wheel 2 Unit Front suspension 3 Unit Engine 4 Unit Transmission 5 Unit Rear wheel 1 7 3 4 8 DIAGRAM OF TIGHTENING TORQUE POSITIONS Below we display t...

Page 57: ...change the fuse of the starter relay Charge the battery and investigate the causes for discharging visit a specialist workshop Start engine with start pedal Go to a specialist workshop Go to a special...

Page 58: ...il level is too high Remove the seat and the fuel tank clean the ECU pin connector and treat with a contact spray Clean the petrol tank ventilation Adjust the throttle body by pass Adjust the conduit...

Page 59: ...Selector position spring broken or loose Down selector mechanism spring broken Empty the engine oil and fill with oil of the recommended viscosity Go to a specialist workshop Adjust the valve play Vis...

Page 60: ...ge Go to a specialist workshop Change shaft Go to a specialist workshop Replace spring Go to a specialist workshop Go to a specialist workshop Go to a specialist workshop Replace the clutch plate Visi...

Page 61: ...absorbers should be adjusted equally See Tuning suspension Verify tyre pressure Adjust the chain Change the chain rear sprocket and secondary transmission pinion Change the rear sprocket Lubricate us...

Page 62: ...cialist workshop Change steering rod Go to a specialist workshop Check convergence and divergence of front wheels Align swing arm Go to a specialist workshop Check the condition of the brake pads and...

Page 63: ...62 ELECTRICAL SCHEMAS B Black Br Brown G Green Gr Grey L Blue O Orange R Red Sb Light blue V Violet W White Y Yellow...

Page 64: ...63 B Black Br Brown G Green Gr Grey L Blue O Orange R Red Sb Light blue V Violet W White Y Yellow...

Page 65: ...s 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 Direc...

Page 66: ...nents 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 r...

Page 67: ...e 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...

Page 68: ...Notes Notes...

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Page 71: ...a 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es FEBRERO FEBRUARY FEBRER 2005 RECOMIENDA EL USO DE ACEITE RECOMMENDS THE USE OF O...

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GAS GAS WILD HP 450 - 2005, Service Manual

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Summary of Contents for WILD HP 450 - 2005

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