WILD HP 450-07

MANUAL DEL USUARIO USER MANUAL MANUEL DENTRETIEN LIBRETTO DUSO BETRIEBSANLEITUNG

INTRODUCTION

GAS GAS thanks you for the trust you have placed in us. By choosing the new WILD H.P. 450 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. is a sporting quad bike 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 confidence and welcome to GAS GAS motos SA.
GENERAL WARNINGS Read this Manual carefully. It provides all the necessary information for your safety, and that of others, as well as guaranteeing the correct conservation and maintenance of the GAS GAS quadricycle you have just acquired. READ THIS MANUAL COMPLETELY BEFORE USING THE MACHINE. 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.
Inadequate driving skill could cause damage to the environment and conflict with other people. Responsible use of your quadricycle will ensure that these problems and conflicts do not occur 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. Quad riding is a fantastic sport, and we hope you will enjoy it to the fullest.
This manual has been compiled with the data and specifications available at the time of printing. Any difference 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.
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.
WARNING Hydrogen gas produced by the battery may explode if exposed to open flame or sparks. Keep the area ventilated and free from naked flames.
CONTENT - Presentation...3 - General warnings...4 - Contents... 5 - Specifications...7 - Information about your safety... 8 - Important information...10 Identification number..10 - Component location... 12 - The main parts of the QUAD.. 14 Ignition key... 14 Start...14 Lights...14 Emergency lights..15 Throttle grip... 15 Clutch lever... 15 Front brake handle.. 16 Rear brake pedal..16 Steering lock... 16 Shift pedal... 17 Fuel tank cap...17 Seat...17 Battery...17 Front guard...18 Rear guard... 18 Footrest assembly...19 - Checks to make before starting the machine...20 Front and rear brakes...20 Fuel... 21 Cooling system...22 Parking brake... 22 Chain...22 Throttle grip... 23 Lights...23 Tyres... 23 - Using the QUAD... 24 Starting the engine.. 24 Changing gears..25 Starting the vehicle..26 Stopping the engine.. 26 Running in engine... 26 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 Uphill... 30 Downhill...30 Crossing slopes..30 Going across shallow water.. 31 Riding on rough terrain...31 Sliding and skidding.. 31 - Tuning....32 Tuning the front suspension..32 Tuning the rear suspension..33

LIGHTS NOTE The headlights and rear lights will only work when the ignition key is in the ON position.
Low beam Side lights No lights
Switch (C) has three positions, initially in the "OFF" position.
STARTER The quad is fitted with an electrical starter motor and a manual starter by means of the pedal. The control (B) is located to the right of the handle bar. The pedal (C) is located on the right hand side of the quad in an initial rest position, pull until it is in operation position. (C). Light switch. (D). High-low beam switch. (E). Overtaking lights (F). Indicators. (G).Horn. 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 ( ). To turn off the lights push the switch to position ( ).
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). DISTRESS LIGHTS The button is located on the front part of the vehicle (F), in front of the handlebars. This works even when the ignition is off. NOTE Regarding the use of this lights, follow the legal conditions of each country. 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. CLUTCH LEVER 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.
THROTTLE GRIP Before starting the engine, check that the throttle works smoothly (I). Make sure it slides 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.
FRONT BRAKE LEVER The front brake lever (A) is located on the right side of the handlebars. Operate it to apply the front-wheel brakes.
STEERING LOCK As its name suggests, this mechanism allows us to lock the steering. The handlebars should be turned fully to the left, then the key inserted in the lock (A). Turn the key to the left, press it in than turn it to the right and remove it.

WARNING The kick-starter must NEVER be operated when the reverse gear is engaged.
PARKING ON SLOPES WARNING Avoid parking on hills or inclined terrain, as the QUAD may move by itself, with corresponding risk of accident. 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. 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.
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 obstacles, refrain from doing this as the vehicle could be seriously damaged. 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". DRIVE WITH CARE AND COMMON SENSE 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.
WARNING Never carry a passenger. Carrying a passenger could lead to an accident with the consequent injury risk for the driver and/or passenger. The quadricycle is fitted with an emergency-stop system in case the rider falls off, but it has not been designed to cope with passenger falls. THE WILD QUAD IS NOT APPROVED FOR CARRYING A PASSENGER. ONLY THE DRIVER IS PERMITTED TO RIDE THE QUAD. 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 is increased. 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." While riding Always ride with the footrests and protections secured, they will protect you from serious injuries in the legs and feet. Always keep feet on the foot rests while driving and both hands on the handles.

While climbing a slope 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. DESCENTS 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 their with your arms straight.
3 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.
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 negotiate 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 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 begins 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. SHALLOW WATER With the QUAD you can, at slow speed, cross shallow water up to 35 mm 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 make affect the stability of the QUAD or cause it to slip. Drive carefully and slowly. 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 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. SLIDING AND SKIDDING When riding over slippery or loose surface, use caution. An uncorrected unexpected slide 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. 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 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. NOTE Learn to control your slides safely by practising at low speed on flat ground with no inclination.
TUNING TUNING THE FRONT SUSPENSION Formed of two trapezoidal arms with 2 multi-adjustable 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. Also the damping force can be adjusted easily so changing oil viscosity is unnecessary.
To adjust the rebound, turn the knob (B) on the lower part of the shock absorber by hand. There is a possible 22 Clicks (adjustments) in total. The rebound is normally set to 7 Clicks. Turn the knob clockwise until the end, then it is completely closed. Turn the knob anticlockwise 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.
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 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. To adjust the compression, turn the knob (A) on the upper part of the shock absorber by hand. Turning anti-clockwise to the limit will close it completely. There are a possible 38 Clicks (adjustments) in total. The compression is normally set to 20 Clicks. Fully hard compression is at 0 clicks. Fully soft compression is at 38 clicks.

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, which comes with your GAS GAS Quad to adjust the shaft.
- 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 cleaning the motorbike. - 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. 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 The coolant absorbs excessive heat from the engine and transfers it to the air by the radiator. If the level of fluid has diminished constantly, the engine may overheat and become seriously damaged. Check the coolant level each day before riding the QUAD. 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. 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.
NOTE Ensure that the bolts are tightened and that the chain tension is correct. 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. Chain lubrication Good chain maintenance is essential to ensure the correct operation.
Anti-freeze liquid information 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. 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. WARNING Coolant chemicals are harmful to the human body. Follow coolant manufacturer warnings and coolant handing instructions. 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. 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. Coolant Level If a large quantity of liquid has been lost, check

the level of both containers. They are located together on the left side of the quad.
Normally, if the level in the reservoir (C) is below the mark then the radiator must be checked (D). WARNING 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. - 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 idling 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.
Changing the coolant - The coolant should be changed periodically to ensure long engine life. - Wait for the engine to cool 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 (B) at the bottom of the water pump cover. Immediately wipe or wash off any coolant that spills on the frame, engine, or wheels.
the specified torque shown in the table. Replace seals with new ones. 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. AIR FILTER

(A) (B)

(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. -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. - Install the water pump cover drain plug and cylinder drain plug with An obstructed air filter will allow dirt to enter the carburettor and block the throttle open. This could lead to an accident. 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.

NOTE Do not twist the element when drying. (C) 4. Submerge the filter in a container with degreasing liquid for cleaning filters. This liquid should clean the filter without damaging it.
(D) (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) 1. Raise the seat and unlock the metal safety locks Then open the air filter cover. 2. Loosen the metal clamp (E) and remove the air filter from its housing. - Check the air filter for damage such as scraping, hardening, shrinkage If it is damaged then replace, otherwise dirt will enter the throttle body.
5. Then drain it carefully and allow it to dry for a few minutes.
3. Separate the foam and the cage that make up the air filter assembly.
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. 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. SPARK PLUG The standard spark plug is shown in the table and is tightened to 11 Nm.
The plug must be periodically removed to check the gap and the ceramic insulation. Standard spark plug 0.7-0.8 mm The spark plug should be taken out periodically to check the electrode gap. If the plug is oily or has carbon build up on it the clean it with a sand blaster. Following abrasive particle cleaning, the spark plug should be cleaned with a wire brush or similar. Measure the distance between electrodes using a gauge and adjust in case that it is not correct by bending the outer electrode. If the spark plug electrodes are oxidised, damaged or the insulation is broken then replace the plug. NOTE Inspect every 30 hours. Replace every 60 hours. To find the correct heat grade spark plug is being used, 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 coldest plug. If the ceramic is black, the plug should be replaced with the next hottest plug.

NOTE If the engine output decreases, replace the spark plug to regain performance. Spark plug maintenance COMMENTS If the standard spark plug is wet then replace it. Standard If the standard spark plug appears crystallized, or white, replace it. CAUTION Incorrect fitting of the spark plug or using an incorrect heat grade could causes serious engine damage that is not covered by the guarantee. Always use spark plugs recommended by GAS GAS. Consult the dealers or a qualified mechanic to know which spark plug is better for your bike. Removing the spark plug To remove the spark plug, follow the following steps: 1. Remove the seat. 2. Remove the side panels from the fuel tank. 3. Remove the connector of the fuel pump (A). 4. Remove the three bolts (arrows) and remove the tank to one side without disconnecting the fuel pipe. 5. Remove the cap from the spark plug. WARNING When the injection pump pipes are removed, petrol may be spilled and cause a fire. Stop the engine before removing the tank. Keep naked flames and sparks away from the tank cap. Do not smoke.
NOTE The spark plug is protected by a cap. Keep this clean and dry.
7. Take out the spark plug and clean 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 colour; this colour tells us whether the standard plug is the best for our use.
INSPECTION AND LUBRICATION OF THE CABLES 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. Lubricate the cable interior and the cable ends. If the cables do not slide smoothly, have a specialised workshop replace them.
1. Remove the bolts (A) on both sides of the vehicle. (A)
Recommended lubricant: Engine oil 2. Remove the bolts (arrows) fastening the side panels to the front and the instrument panel. 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.
REPLACING THE LIGHTS Front headlight
3. Pull the front panel gently forwards until you can reach the light fittings (C) and remove the connectors of the bulb in question.
REAR LIGHTS 1. The rear side light uses two LED diodes instead of a bulb. The LED diodes cannot be replaced separately. 2. If the light is damaged it must be completely replaced. 3. To do this, detach the connector and remove the bolts (G).
4. Turn the light fitting in the direction of the arrow and pull outwards. 5. Replace the bulb. To insert it, follow the above operations in reverse order. FRONT SIDE LIGHT 1. The front side light uses two LED diodes instead of a bulb. The LED diodes cannot be replaced separately. 2. If the light is damaged it must be completely replaced.

- 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. - 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. CAUTION Excessive water pressure may penetrate the wheel bearings, brakes, transmission bushings and electric components, with resulting in damage.
Where to be most careful. Avoid applying high-pressure water to: 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. - 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.
LUBRICATION 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). Brake lever.
(1) 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. After washing the QUAD - 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 for 5 minutes.

Operation of the buttons MODE BUTTON 1. Press the MODE button to switch from one function screen to another when the speed sensor detects no signal.
2. Press the MODE button to switch from one partial screen to another when the speed sensor detects a signal.
RESET BUTTON 1. Press the MODE button until you reach the screen, then press the RESET button for two seconds to return to zero the data stored in TRIP 2, MAX and MAX RPM separately. 2. Return the data in TRIP 1, AVG and RT at the same time. The data of the ODO, CLOCK and TT. cannot be returned to zero. OPERATION OF THE GEAR CHANGE ACCORDING TO RPM 1. Press the MODE button to switch to the RPM screen; accelerate to the rpm which is desired for activating the gear change alert. 2. Press the RESET button to confirm and establish the gear change indicator according to the rpm. 3. The tachometer with bar graph and a LED will flash to indicate the need to change gear. 4. Use the steps 1 and 2 to readjust the gear change according to RPM
Multifunction and wheel circumference adjustment The configuration operations include the 112/24 hour clock, the gear change according to rpm indicator, the number of engine revolutions by signal, the wheel circumference and the units of measurement The configuration must be carried out step by step. The computer will return automatically to the main screen if no button is pressed in any adjustment screen for 75 seconds. 1. Press the MODE and RESET buttons to switch to the adjustment screen. In the adjustment screen, press the RESET button to increase the value of the flashing digits or to convert units, press the MODE button to confirm the configuration and move on to the next digit or the next adjustment screen to be configured. Press the MODE button for 2 seconds in any of the adjustment screens to end configuration and return to the main screen. 2. The screen shows 12 or 24 h, and the symbols XX XX-XX, and AM/PM if the 12h option has been selected. 3. When the RESET button is pressed the 12/24h system changes, and when MODE is pressed, the configuration concludes and the configuration of the clock digits opens. 4. Press the RESET button to increase the value of the flashing digit one by one; press the MODE button to confirm the configuration and pass on to the following digit. 5. Press the MODE button to switch to the adjustment screen of the gear change according to rpm, once the clock has been configured. 6. The screen will show RPM rXXX00. Press the RESET button to increase the value of the digit one by one; press the MODE button to confirm the configuration and pass on to the following digit. 7. Press the MODE button to switch to the adjustment screen for the engine revolution by signal, once the gear change according to rpm configuration is completed. 8. The screen will show SPC-X.X RPM, with 1.0 as the default value There are 4 options 1.0, 2.0, 3.0 and 0.5. They correspond to the number of revolutions for each signal. For example, a value of 2.0 means that the motor turns over twice to produce a signal. 9. Press the RESET button to move between the four values. Press the MODE button to confirm the configuration and to move on to the wheel circumference adjustment screen

10. When cXXXX appears on screen, the c stands for circumference and is followed by four digits by default; the flashing digit is the one to be changed. 11. Press the RESET button to increase the value of the flashing digit one by one; press the MODE button for 2 seconds to confirm the digit change and pass on to the following digit.
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

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

160 165

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

Assembly number

E N G I N E C H A S S I S
TIGHTENING TORQUE SCHEMA The following is a diagram of the locations of the bolts numbered on the previous page. They are grouped by assembly. 5 7

1. 2. 3. 4. 5.

Ass. Front wheel Ass. Front suspension Ass. Engine Ass. Transmission Ass. Rear wheel
6. Ass. Shift pedal 7. Ass. Rear suspension 8. Ass. Chassis 9. Ass. Rear brake pedal
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.

SOLUTION

- Remove the seat and change the fuse of the starter relay. - Recharge the battery and investigate the causes for discharging, visit a qualified workshop. - Start engine with start pedal. - Go to a specialist workshop. - Go to a specialist workshop. - Go to a specialist workshop. - Check fuel pump relay by removing the seat; check fuel pump filter, located in the fuel tank, isn't blocked. - It is advisable to drain the old fuel from the tank. When the fuel tank is filled with new flammable fuel the engine starts immediately. - Dry the spark plug out or replace it. - To unflood the engine, full throttle, then operate the kick-start 5 to 10 times or operate the electric starter 2 times in 5 seconds. Then start the engine as described below. If the engine fails to start, unscrew the spark plug and dry it.
The starter motor does not work - The fuse for the starter relay is blown. - Battery discharged. - Low temperature.
The engine does not rotate

The brakes do not function - Brake pads worn. correctly - Loss of brake fluid. - Brake fluid deteriorated. - Piston cylinder broken. - Brakes incorrectly adjusted.

The lights blow

- Voltage regulator faulty.
The lighting system does not - The fuse for the lighting circuit has blown work
Warranty Manual (According to law 23/2003 of the 10 of July, regarding Consumer Goods Sales Guarantees.)
Manufacturers guarantee regulations for GAS GAS Motos S.A. The Company GAS GAS Motos S.A. (hereafter referred to as GG) hereby guarantees the final purchaser of a vehicle manufactured by GG that both materials and workmanship are free from defects according to the maximum quality standards. Consequently, GG hereby warrants to the final purchaser (hereinafter referred to as the purchaser), subject to the conditions stated below, to remove any defects in material or production detected in a new motorcycle free of charge within the agreed period of warranty without any limitation whatsoever in terms of the number of kilometres travelled or the number of operating hours. Period of warranty The period of warranty shall commence on the day of delivery of the vehicle by a licensed GG dealer to the purchaser, or in the case of demonstration models, on the date on which the vehicle is put into operation for the first time. The vendor will respond to any conformity faults that appear within the period established by the Law 23/2003 of the 10th of July regarding Consumer Goods Sales Guarantees from the delivery of goods and in accord with the directive 1999/44/CE for the remainder of the European Community Member States. For those countries outside of the European Community the guarantee will be regulated by the relevant current legislation. However, if the conformity fault appears during the first six months following delivery of the motorcycle, it will be assumed that this fault existed when the motorcycle was delivered; from the sixth month, the purchaser must show that the fault existed at the moment the goods were delivered. During the six months following the delivery of the repaired goods, the vendor will respond to the faults requiring repairs. Any defect detected in the product must be brought to the attention of the authorized GG dealer within the period of the guarantee. If the last day of the warranty period is a Sunday or public holiday, the warranty period shall be extended in such a way that the last day of the warranty period is the next working day following the respective Sunday or public holiday. Warranty claims shall be excluded for any defects not brought to the attention of a licensed GG dealer by the end of the warranty period.