GAS GAS WILD HP 450 Service Manual
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GAS GAS WILD HP 450 Service Manual

GAS GAS WILD HP 450 Service Manual

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

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  • Page 1 MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D’ENTRETIEN MANUEL D’ENTRETIEN LIBRETTO USO E MANUTENZIONE LIBRETTO USO E MANUTENZIONE...

  • Page 3: Presentation

    GAS GAS thanks you for your trust. By choosing the new WILD H.P. 450 you have just joined the great GAS GAS family and, as a user of the number one off-road manufacturer, you deserve the distinguished treatment that we want to offer to you, both in our after-sales relationship and with the explanations that we will give you in this manual.

  • Page 4: Common Advice

    Specially relevant information is highlighted riding and the product’s quality. GAS GAS Motos SA is constantly in the manual with the notations below: improving their vehicles so that you can enjoy higher performance.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Front and rear brakes........85 - Presentation................68 Fuel..............85 - Common advice...............69 Cooling system...........87 - Table of contents..............70 Chain..............87 - Specifications...............72 Throttle grip................87 - Safety information..............73 Lights................87 - Important information............75 Tyres..............87 Identification numbers..........75 - Use of the QUAD.............89 - Loction of components............77 Engine start..............89 - Main parts of Quad............79 Gear box................90...
  • Page 6 - Periodic maintenance and adjustment..........99 Maintenance chart............99 Cluth lever adjustment..........100 Adjustment of the brake lever and pedal.....100 Checking the brake fluid level........101 Checking the brake pads at the front and rear....102 Wheel 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...

  • Page 7: Specifications

    SPECIFICATIONS ENGINE Cylinder size: 449 c.c. Type: Single cylinder, four stroke with 4 valves cylinder head. Cooling system: Líquid cooled. Bore x Stroke: 95 x 62,6 mm. Injection system: MAGNETI MARELLI. Ignition: Integrated on EFI. Clutch: Hydraulic multidisc in oil bath. Gear box: 6 gears.

  • Page 8: Safety Information

    SAFETY INFORMATION of obstacles and with no other vehicles around first. Read the recommendations in the section "Use of the QUAD" of this manual. WARNING - The same applies to steep climbs or descends. Start testing your Not following these instructions may lead to grave injuries or even skills with minimum slopes and raise the difficulty level little by little.
  • Page 9 WARNING - Always stop the engine before 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 has good ventilation and free of sparks of flammable sources;...

  • Page 10: Important Information

    IMPORTANT INFORMATION The vehicle leaves the factory with some unassembled 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.
  • Page 11 NOTE The vehicle's serial number is used for your machine's identification. HOMOLOGATION B. Key identification number The quad has two pairs of keys. The first and most important (C) is the contact key, and the second (D) is used for the fuel tank and seat locks.

  • Page 12: Loction Of Components

    LOCATION OF COMPONENTS GAS GAS WILD H.P. 450 1 2 3 1- Clutch lever 9- Front brake lever 2- Light switch 10-Throttle grip 3- Flash beam 11-Front guard 4- High beam 12-Brake pads 5- Emergency stop 13-Fuel tank cap 6- Contact key...
  • Page 13 15-Headlight fairing 21-Swing arm 16-Full-throttle body 22-Exhaust pipe 17-Seat 23-Front brake fluid 18-Front shock absorber 24-Kick starter pedal 19-Engine 25-Brake pedal 20-Gear pedal 26-Oil tank WILD HP -...

  • Page 14: Main Parts Of Quad

    MAIN PARTS OF THE QUAD LIGHTS CONTACT KEY NOTE The headlight and the rear light can only be switched on when The key (A) is located on the front part of the handlebars. To turn the engine is on. the contact on, turn the key clockwise to the "ON" position. To turn contact off, turn the key anti-clockwise to the "OFF"...

  • Page 15: Warning Lights

    Indicators (D) are located in the lower part of the left grip. Sliding the switch to the right turns on the right indicator, and the same action to the left applies to the left indicator. In the same group we will find the horn button (E). EMERGENCY INDICATORS It is a button on the front part of the vehicle (F), before the handlebars.

  • Page 16: Front Brake Lever

    FRONT BRAKE LEVER The front brake lever (A) is located on the right side of the handlebars. Activate it to apply the front-wheel brakes. One end (C) is attached to the vehicle and the other end (D) is attached to the rider. The cable is elastic, and the two ends are joined to the rider and the vehicle, with the part joined to the vehicle sensitive to sudden REAR BRAKE PEDAL...

  • Page 17: Gear Pedal

    CHANGE PEDAL 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. The vehicle features a 6-speed gearbox. Waiting few seconds, the engine will be a good temperature. The change pedal (E) is located on the left side of the engine and For pull down the choke button, only drive the twist grip.

  • Page 18: Seat

    SEAT - Charge duration = 6 hours minimum / 24 hours maximum. 3.2. Charge mode with constant power. - Maximum charge power = 0.1 Cn. To remove the saddle, use the same key that was used to open the - Recommended charging time = 5 - 8 hours. petrol-tank cap (B).

  • Page 19: Rear Guard

    REAR GUARD Likewise, the rear guard (D) also projects from the vehicle. It will prevent the quad from falling backwards, which might result in serious injuries. NOTE FOOT PROTECTIONS In case of steep climbs, the rear guard will not prevent a backward tumble, so be prudent in climbs and examine the The foot protections (F) ground carefully.

  • Page 20: Checkings To Be Made Before Riding The Vehicle

    CHECKINGS TO BE MADE BEFORE RIDING THE VEHICLE WARNING Always inspect the quad before every use, to make sure it is in safe riding conditions. Always follow the inspection proceedings and programmes described in this manual. Failure to inspect the machine increases the risk of accident or breakdown.

  • Page 21: Fuel

    Use only unleaded fuel. The use of leaded fuel would seriously brake pad wear-out. damage the inner parts of the engine. FUEL The GAS GAS WILD H.P. 450 c.c. has a 4-stroke engine that requires OCTANE RATING METHOD MINIUM RATING a 98 gasoline.

  • Page 22: Cooling System

    COOLING SYSTEM Check the cooling liquid level in its reservoir (A) with the cold engine (the liquid level will vary with engine temperature). The level is correct Radiator pipe when between the two marks. If it falls below the lower mark, add anti-freezing liquid.
  • Page 23 WARNING Tyre wear-out limit: The use of inadequate tyres or riding the vehicle with incorrect or Observe how the tyre wears out. If the tyre is worn out at the centre, unequal tyre pressures may lead to loss of control, with the subsequent it means that the pressure is too high.

  • Page 24: Use Of The Quad

    USE OF THE QUAD WARNING Read the User's Manual carefully so as to become familiar with all the commands. Loss of control may cause an accident or injuries. ENGINE START CAUTION Before starting the engine for the first time, consult the section "Engine running-in".

  • Page 25: Gearbox

    4.- If the engine is WARNING cold, pull the start button (B). - Always use the parking brake before you start the engine. The QUAD might start unexpectedly if the brake is not on. This could lead to a loss of control or to a crash. - Remember to release the parking brake before starting.

  • Page 26: Starting The Vehicle

    CAUTION To slow down Do not run with the engine off for a long time, or tow the machine during long routes. Even in the neutral position, the gearbox lubrication To slow down or stop, release the throttle and apply the brakes is only activated when the engine is on.

  • Page 27: Engine Running-In

    ENGINE RUNNING-IN The running-in process is a very important part in the life of your quad, and we recommend you to follow the instructions below carefully. 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 tuning.

  • Page 28: Driving The Quad. Practical Recommendations

    DRIVING THE QUAD. Practical recommendations. WARNING Never carry a passenger. Carrying a passenger may result in an BECOME FAMILIAR WITH YOUR QUAD accident and the subsequent risk of bodily harm to the rider and/or the passenger. The quadricycle features an emergency-stop system This quad is destined to expert riders, to be used in recreational in case of rider fall, but it has not been designed to cope with activities.

  • Page 29: How To Turn With Your Quad

    The parts and accessories added to this vehicle must be original 2.- Turn left. GAS GAS parts or equivalent parts designed for their use in 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, in certain conditions, might lead to an accident.

  • Page 30: Uphill Climbing

    UPHILL CLIMBING If you are climbing a slope and you discover that you have not guessed correctly your ability to reach the top, turn the quad round You are recommended to start gradually in slopes with little inclination while you still have some traction and if there is enough room for and increase the inclination as your practice improves.

  • Page 31: Going Across Shallow Water

    slippery sections and rough terrain that may cause you to lose RIDING IN ROUGH TERRAIN balance. While you are crossing the slope, keep your body inclined towards the top of the climb. Riding in rough terrain must be performed very carefully. Be always alert to any obstacle that may damage the QUAD, make you lose It might be necessary to correct direction by turning the steering balance or cause an accident.

  • Page 32: Tuning

    TUNING To adjust the rebound, turn the knob (B) in the lower part of the shock absorber TUNING THE FRONT SUSPENSION with your hand. The front suspension is formed by two wishbone arms with 2 multiple- There are 22 available positions, each adjustment ÖHLINS shock absorbers.

  • Page 33: Tuning The Rear Suspension

    TUNING REAR SUSPENSION There are 56 positions available in total. It is an unwelded aluminium alloy swing arm. The progressive strut The standard setting is 28 "clicks". system features an ÖHLINS multi-adjustment shock absorber. Like Totally hard compression is 0 "clicks". the front suspension, it can be adapted to different riding styles.

  • Page 34: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT MAINTENANCE CHART The first revision must be performed by a specialised workshop at 500 km or after two fuel tanks. The following revisions must be passed every 2,000 km or three months. BEFORE EVERY OUTING Fuel tank level WITH THE QUAD Brake fluid level (front and rear) Brake lever and pedal Free play...

  • Page 35: Cluth Lever Adjustment

    Regular inspections, adjustments and regular lubrication keep the Tighten the adjustment screw to obtain the optimal free play. machine in the best possible safety and efficiency conditions. Safety If the clutch lever adjustment is at its limit, it must be adjusted by using the clutch pump piston push rod.

  • Page 36: Checking The Brake Fluid Level

    Air might also have entered the brake system. The process to bleed When the brake pedal the system is as follows: is in resting position it must have 10-mm free play. Otherwise it will 10 mm - Remove the brake be necessary to adjust fluid reservoir lid (E) to control the level.

  • Page 37: Checking The Brake Pads At The Front And Rear

    When the fluid level is too low, add more: - Make sure that the fluid container is well closed, put the seat back - With a cross-tip screwdriver, unscrew the two screws on the in place and turn the key back to remove it. Ensure also that the reservoir.

  • Page 38: Wheel Change

    . - The nut is located at the right of the swing arm. Follow the proceedings - Use the (F) spanner, which comes with your GAS GAS Quad, to explained below: tighten the axle.

  • Page 39: Checking The Cooling Liquid Level

    - Go behind the quad. of the vehicle. Chain lubrication is one of the actions that you will You will see four perform very often. screws on the swing arm (A). ¿When must you lubricate the chain? - Unscrew the 4 screws - After riding on damp ground.
  • Page 40 Information on anti-freezing liquid To protect the aluminium parts of the cooling system (engine and radiator) from oxidisation and corrosion, use chemical inhibitors in the essence of the cooling liquid. Without an anti-corrosion liquid, in time, the radiator would oxidise. This would block the cooling ducts inside it.

  • Page 41: Air Filter

    Coolant Change with a new one, if it damaged. The coolant should be changed periodically to ensure long engine Drain plug tightening torque (look maintenance table) life. Water pump cover plug: 9 Nm. - Wait for the engine to cool completely. - Situate the QUAD so that it is perpendicular to the ground.
  • Page 42 NOTE Do not twist the element when you dry it. 4.- Remove the filter cage. 5.- Put the filter in a container with some de-greasing liquid. The liquid will clean (C). Checking hose. the filter without (D). Air filter box. damaging it.

  • Page 43: Spark Plug Maintenance

    NOTE The element must be damp but not dripping. - When the element does not drip anymore 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.
  • Page 44 WARNING DENSO COMMENTS When the injection pump pipes are removed, gasoline may be spilled CR7E U22ESR-N If the standard plug looks and cause a fire. wet or has a dark color, Stop the engine before removing the tank. Keep flames and sparks replace.

  • Page 45: Inspection And Lubrication Of The Cables

    INSPECTION AND LUBRICATION OF THE CABLES (A). 4 Allen screws. WARNING Inspect the cables periodically and replace them if damaged. When the outside hose is damaged, corrosion may enter the cable. The cables may also be worn out or damaged. The control operation could be restricted, which may result in accidents and injuries.
  • Page 46 3.- Unscrew the 3 screws that hold the light from below. Rear lights WARNING The bulb is hot when lit or immediately after turning it off. Wait for it to cool down before touching or removing it. You may get burnt, or fire may catch if the hot bulb touched something.

  • Page 47: Transmission

    Indicators 20W-50 - With a cross-tip screwdriver remove the screws, located at the rear, and remove the small lens. 15W-40 15W-50 ENGINE OIL - To remove the bulb, press it against the spring (A), turn it ¼ anti- 10W-40 10W-50 clockwise and replace it with a new one.
  • Page 48 1. Run the engine with the motorcycle in neutral gear for 3 minutesRun Cange of oil and filter. the engine with the motorcycle in neutral gear for 3 minutes. The oil should be changed when the engine is hot, since this helps NOTE the oil to go out through the drain located in the lowest part of the When starting the engine, closely follow care and warnings...
  • Page 49 WARNING Use a funnel to drain the Using a filter with an incorrect design may cause engine malfunction. contents of the oil Use the oil filter with the genuine GAS GAS design or equivalent for reservoir. your motorcycle. NOTE Recycle and dispose of used motor oil in an appropriate WARNING container.
  • Page 50 The engine can be damaged if the oil is not used properly or the specifications recommended by GAS GAS MOTOS are not followed. Before washing the quad some precautions need to be taken to Use the type of oil in the section of «recommended gasoline and oil...
  • Page 51 Where you must be most careful: Avoid applying high-pressure LUBRICATION water near: Lubricate these parts with engine oil or grease; do it periodically or Brake caliper and brake pump piston below the fuel tank (if water after riding in rainy conditions, and specially after using high-pressure enters the electric coil or in the spark plug boot, the quad will not water to wash the vehicle.
  • Page 52 Use a spray STORAGE with a tube attached to If you need to keep the QUAD for a long period of time (we consider lubricate with that long is 60+ days) you must: pressure: - Wash the quad thoroughly. - Start the engine for about 5 minutes to warm the transmission oil and then drain it (see transmission section).

  • Page 53: Multifunction

    (when you have set the time the seconds automatically start from MULTIFUNCTION zero ) The top button is the reset button. The bottom button is the mode button. Trip distance: - From time display press mode 3 times. (l- 0) to zero the trip , keep Reset the reset button pressed until it zeros.
  • Page 54 TORQUE TABLE Tighten all bolts and nuts to the proper torque using an accurate torque wrench. A bolt or nut if insufficiently tightened may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. Part name Kg-m NUMBER...

  • Page 55: Bolt And Nut Tightening

    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. 1. Front wheel set 6.

  • Page 56: Troubleshooting

    TROUBLESHOOTING NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. CAUSE REMEDY TROUBLE Starter engine doesn't crank - Blown fuse in the starter relay.
  • Page 57 TROUBLE CAUSE REMEDY Engine start but stops few - Incorrect air supply. - Close the starter. Clean fuel tank air vent. Check the seconds ago. injector mounting. Check the air filter. - There isn't fuel. - Fill up fuel tank. Engine gets to hot - Insufficient cooling liquid.
  • Page 58 TROUBLE CAUSE REMEDY Exhaust pipe get out white - Cylinder head gasket leaking. - Change cylinder head gasket leaking. Go to specialized garage. smoke. - Air filter is bloked. - Clean or change the air filter. Go to specialized garage. Exhaust pipe get out brown smoke.
  • Page 59 TROUBLE CAUSE REMEDY Shock absorption too hard - Tire air pressure too high. - Check tire air pressure. Shock absorption too soft - Rebound damping adjustment incorrect. - Turn right the rebound dampening adjuster on the shock absorber lower end. Front suspension must to be balanced. Look "Suspension tuning", for more details.
  • Page 60 TROUBLE CAUSE REMEDY Pull to one side - Change direction axis. Go to specialized garage. - Steering stem bent. - Check front wheels convergence and divergence. Centre - Wheel misalignment.. swing arm axle. - Go to specialized garage. - Posible knock to one of steering kneecap. Brakes don't hold - Check pad and replace if it is necesary.

  • Page 61: Warranty Regulations

    The Company GAS GAS Motos S.A. hereby warrants to the final appeared before the prescribed date of such inspection or...
  • Page 62 b) Lubricants (e.g. oil, grease, etc.) and operating fluids (e.g. battery 3.- If it turns out that any defect cannot be removed, the warranty fluid, cooling liquid, etc.). shall be entitled to demand termination of the contract (payment of c) Inspection, adjusting and other periodical maintenance work as a compensation) or partial reimbursement for the purchasing price well as all kinds of cleaning work.
  • Page 63 RECOMIENDA EL USO DE ACEITE: AGOSTO / AUGUST 2003 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 · Web: www.gasgasmotos.es...

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