Gas gas K2 QUAD 250 2005 User Manual
MANUAL DEL USUARIO
MANUAL DEL USUARIO
SERVICE MANUAL
SERVICE MANUAL
MANUEL D’ENTRETIEN
MANUEL D’ENTRETIEN
LIBRETTO D´USO
LIBRETTO D´USO
SERVICE MANUAL
SERVICE MANUAL
ENGLISH
Brief introduction
250 EC QUAD embodies the experience and essence of world motorcycle technology.
It adopts single-cylinder four-stroke air -cooled engine newly developed by our company,
and employs the devices of carburettor carbruetor, wet automatic centrifugal clutch, fivespeed shifting, through driving, reverse driving hand pulled recoil starter and eletricstarter in combination, CDI electric ignition, pressure splash lubrication system, etc, which
are good in performance.This QUAD is novel and bright in design,having moved,
streamlined model and luxury decoration design, and it meet the national standard in
noise and dirt drainage, specially it embodies the great power, reliability, endurance,
being an ideal transportation facility for QUAD funs.
The correct operation and maintenance are the prerequisites at your safety riding of the
QUAD, and also can reduce the fault of the QUAD and keep its best performance. So
please read this manual to understand its basic operation,repair and maintenance
methoels The information contained here in all relates to the QUAD of the current design
and is subject to changes by our company according to the demands of market and users
without notice. If you have any questions, please consult with our motorcycle dealer. We
are welcome for you precious advice and suggestions. Our company has established
many service centers (stations,points), with specially-tranined technical personnel in
operation and maintenance, please contact with our motorcycle dealer and service center
(stations, points). Our company consisitantly adheres to the principle of quality first users
upmost, reputation foremost and be ready to provide you with high quality service.
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IMPORTANT INFORMATION FOR OPERATION
WARNING Injury or death could be result from failure to follow WARNING instructions when you are operating
inspecting or repairing the QUAD.
CAUTION A CAUTION indicates special precautions that must be taken to avoiddamage to the QUAD.
NOTE
A NOTE provides information can make your operation in the QUAD easier or clearer.
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Content
Safety information.....................................................5
Description and machine identification.....................9
Control functions.....................................................11
Main switch.............................................................11
Indicator lights ........................................................11
Handlebar switches ................................................11
Start switches .........................................................11
Light switches.........................................................12
Throttle lever...........................................................13
Speed limiter...........................................................13
Front brake lever ....................................................14
Rear brake pedal and lever ....................................14
Parking brake .........................................................15
Shift pedal...............................................................16
Drive select lever....................................................16
Recoil statrer ..........................................................16
Fuel tank cap..........................................................17
Fuel cock ................................................................17
Seat ........................................................................17
Storage box ............................................................18
Front carrier............................................................18
Rear carrier.............................................................18
Rear shock absorber ..............................................18
Spring preload adjustment......................................18
Pre-operation checkes............................................19
Front and rear brakes.............................................19
Fuel.........................................................................20
Engine oil................................................................21
Lubrication oil of gear case.....................................21
Throttle lever...........................................................21
Fittings and Fasteners............................................21
Lights......................................................................21
Switches .................................................................21
Battery ....................................................................21
Tires........................................................................22
How to measure tire pressure ................................22
Tire wear limit .........................................................23
Operation................................................................24
Starting an engine ..................................................24
Starting a cold engine.............................................24
Starting a warm engine...........................................24
Prewarming ............................................................24
Drive select lever operation
and reverse driving.................................................25
Shifting....................................................................26
To start out and accelerate.....................................26
To decelerate..........................................................26
Engine breakrin ......................................................27
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Accessories ............................................................28
Loading...................................................................28
Ride with care.........................................................28
Speed limit valve ....................................................30
Exhaust silencer ....................................................30
Turning ...................................................................31
Climbing slope........................................................32
Riding downhill .......................................................33
Crossing depression...............................................33
Crossing through shallow water .............................33
Riding over rough terrain........................................34
Slipping...................................................................34
Periodic maintenance and adjustment ...................35
Operation manual and tool kit.................................35
Periodic maintenance /Lubrication .........................36
Engine oil................................................................38
Lubrication oil of gear case.....................................40
Replace of lubrication oil of gear case....................40
Spark plug inspection .............................................41
Air filter cleaning.....................................................42
Carburetor adjustment............................................43
Idle speed adjustment ............................................43
Valve clearance adjustment ...................................44
Throttle lever adjustment........................................44
Front and rear brake shoe inspection.....................44
Front brake lever free play adjustment...................45
Rear brake adjustment ...........................................46
Clutch adjustment...................................................47
Cable inspection and lubrication.............................48
Brake and shift pedal/brake lever lubrication
Steering vertical tube lubrication ............................48
Wheel removal........................................................48
Wheel installation ...................................................49
Fuse replacement...................................................50
Replacing the headlight bulb ..................................51
Spark arrester cleaning ..........................................52
Cleaning and storage .............................................52
Cleaning .................................................................52
Storage...................................................................53
Main data and specification....................................54
Maintenance record................................................56
Electric wiring diagram ...........................................57
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SAFETY INFORMATION
This operation manual includes important safty and
maintenance information. When reselling the QUAD
TO THE NEXT BUYER. The operation manual should
be passed on together with it because the next user
also need the manual. Please read the manual carefully
before driving the new. If failed to conform the
requirements described in the manual. It will be easy
to cause injuries and deaths.
WARNING
- Read this manual carefully and follow the operating
procedures and methods described in this manual.
- Never operate an QUAD without proper
training or instruction.
- A child under 16 years old should never operate an
QUAD. Never allow drive of an QUAD by an individal
person if he or she does not have the abilities to operate
it safely.
- Always avoid driving an QUAD on any paved surfaces,
including sidewalks, driveways, parking lots and streets.
- Never operate an QUAD in any public street, road or
highway.even a dirt or gravel one.
- Never drive an QUAD without wearing an approved
motorcycle helment that fits properly. You should also
wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket.and long pants.
- Never consume alcohol or drugs before or while
operating this QUAD.
- Never operate at speeds too fast.always drive at low
speed on dusty surface.
- Always inspect your QUAD each time you use it to
make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and
schedules described in this maunal.
- Always keep both hands on the handlebars and both
feet on the footboards of the QUAD during operation.
- Never operate on excessively rough, slippery or loose
terrain unless you have learned and d practiced the
skills necessary to control the QUAD on such terrain.
Always be especially cautious on these kinds of terrain.
- Always follow proper procedures for turning as
described in this manual. Practice turning at low speeds
before attempting to turn at faster speeds. Do not turn
at excessive speed.
- Never drive the QUAD on hills too steep for the QUAD
or for your abilities. Practice on smaller hills before
attempting larger hills.
- Always follow proper procedures for climbing hills as
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described in this manual. Check the terrain carefully
before starting up any hill. Never climb hills with
excessively slippery or loose surfaces. Shift your weight
forward. Never open the throttle suddenly or make
sudden gear changes. Never go over the top of a hill
at high speed.
- Always follow proper procedures for going down hills
and for braking on hills as described in this manual.
Check the terrain carefully before starting down any
hill. Shift your weight backward.Never go down a hill
at high speed. Avoid going down a hill at an angle that
would cause the vehicle to lean sharply to one side.
Go straight down the hill where possible.
- Always follow proper procedures for crossing the side
of a hill as described in this manual. Avoid hills with
excessively slippery or loose surfaces, shift your weight
to the uphill side of the QUAD. Never attempt to turn
the QUAD around on any hill until you have mastered
the turning technique described in this manual on level
ground .Avoid crossing the side of a steep hill if possible.
- Avoid crossing the steep hills.
- Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling, use
proper gear and maintaina steady speed when climbing
a hill. If you stall or roll backwards. Follow the special
procedure for braking described in this manual.
- Always check for obstacles before operating in a new
area.Never attempt to operate over large obstacles,such
as large rocks or fallen trees. Always follow proper
procedures when operating over obstacles as described
in this manual.
- Always be careful when skidding or sliding. Learn to
safely control skidding or sliding by practicing at low
speeds and on level, smooth terrain. On extremly
slippery surfaces, such as ice. Go slowly and be very
cautious in order to reduce the chance of skidding or
sliding out of control.
- Never operate an QUAD in fast flowing water or in
water deeper than that recommended in this manual.
Remember that wet brakes may have reduced stopping
ability. Test your brakes after wiping water away. If
necessary,apply them several times to let fricting dry
out the linings.
- Always be sure there are no obstacles or people
behind you when operating in reverse. When it is safe
to procceed in reverse, go slowly. Always use the size
and type tires specified in this manual. Always maintain
proper tire procedure as described in this manual.
- Never modify an QUAD through improper
installation or use of accessories.
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- Never exceed the stated load capacity for an QUAD.
Cargo should be properly distributed and securely
attached.
- Reduce speed and follow instructions in this manual
for carrying cargo or pulling a trailer. Allow greater
distance for braking.
- Improper handing of gasoline can cause fire and can
cause injuries and deaths and other serious accident.
So do not refuel right after the engine has been running
and is still every hot. Never refuel while smoking, or
while in the vicinity of sparks, open flames, or other
sources of ignition, when transporting the machine in
another vehicle, be sure it is kept upright and that the
fuel cock is in the "OFF" position, otherwise fuel may
leak out of the carburetor or fuel tank.
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Starting or running the engine in a closed area will cause the breakdown. And exhaust fumes are poisonousus and
may cause loss of consciousness and death within a short time. Always operate your machine in an area with adequate
ventilation.
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DESCRIPTION AND MACHINE IDENTIFICATION 1. Front wheel
2. Headlight
3. Drive select lever
4. Shift pedal
5. Fuel cock
6. Recoil starter
7. Starter(choke)
8. Taillight
9. Rear wheel
10. Rear carrier
11. Spark arrester
12. Seat
13. Fuel tank cap
14. Brake pedal
15. Front carrier
16. Rear brake lever
17. Parking brake
18. Main switch
19. Throttle lever
20. Front brake lever
21. Handlebar switch
The machine you have purchased may differ slightly
fron those shown in the figures of this manual for
progress or other change.
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Identification numbers record
When ordering spare parts from a our dealer or for reference in case the vehicle is stolen record, vehicle identification
number in the spaces provided for assistance.
1. VEHICLE IDENTIFICATION NUMBER:
Vehicle identification number
The vehicle identification number is stamped on crosstube of pedestal.
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CONTROL FUNCTIONS
Main switch
Functions of the respective switch positions are as
follows:
ON:
Engine can be started only at this position and the
headlight and taillight come on when the light swithc
is on.
This indicator light comes on when the transmission is
in reverse.The light is blue in color.
Neutral indicator light " N "
This indicator light comes on when the transmission is
in neutral.
High beam indicator light " "
This light is yellow in color .It comes on when the head
light and high beam light is on.
OFF:
All electrical circuits are switched off. The key can be
removed in this position.
Indicator lights
Reverse indicator light "R"
Handlebar switches
Engine stop switch
Make sure that the engine stop switch is in the " "
position. The engine stop switch controls ignition and
can be used at all times to stop the engine,especially
in an emergency.
The engine will not start or run when the engine stop
switch is turned to " ".
Start switch
The starter motor cranks the engine when this switch
is pushed.
See starting instructions prior to starting engine (see
page for details).
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If the starter switch is pushed with the main switch
" " and the engine stop switch " " , the starter
motor will be activated but the engine will not start. To
start the engine ,be sure to set the engine stop switch
at " ".
Lights swtich "LIGHTS"
Turn the switch to " " for the low beam and taillight.
for the hight beam
Turn the switch to " " for the hight beam and taillight.
1. Neutral indicator light "N"
2.Reverse indicator light "R"
3.Hight beam indicator light " "
1. Lights switch "LIGHTS"
2. Engine stop switch " " " "
3. Start switch " "
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Throttle lever
Once the engine is running .movement of the throttle
lever will increase the engine speed.Adjust the speed
of the machine by changing the throttle position.Because
the throttle is spring-loaded,the machine will
decelerate.and the engine will return to an idle any
time the hand is removed from the throttle lever.Before
starting the engine .check the throttle to be sure it is
operating smoothly .Make sure it returns to the idle
position as soon as the lever is released.
Check the operation of the throttle lever before starting
the engine.lf it does not work smoothly.check
for the cause. Correct the problem before riding the
QUAD. Consult a our dealer if you can't find or solve
the probem yourself.
1 .Throttle lever
Speed limiter
The speed limiter keeps the throttle from fully opening,
even when the throttle lever is pushed to the maximum.
Screwing in the adjusting screw limits the maximum
engine power available and decreases the maximum
speed of the QUAD.
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1. Locknut
2. Adjusting screw a.12mm (047in)
CAUTION
Do not turn the speed adjusting screw out more than
12mm. Always make sure the throttle lever free play
is adjuted to 3-5mm.
Front brake lever
The front brake lever is located on the right
handlebar.Pull it toward the handlebar to apply the
front brake.
Rear brake pedal and lever
The brake pedal is located on the right side of
the machine and the brake lever is located on the left
handlebar. Pull the lever toward the handlebar or tread
slow the pedal to apply the rear brake.
1. Rear brake pedal
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Parking brake
When you have to start the engine or park the machine,
especially on a slope, use the parking brake
Apply the rear brake lever and push down the lock
plate to apply the parking brake,squeeze the rear brake
lever to release the parking brake.
CAUTION
The QUAD could start moving unexpectedly if the
parking brake is out of function before starting the
engine. This could cause loss of control or a collision.
The barke could overheat if you ride the QUAD without
releasing the parking brake. You could lose braking
performance which could cause an accident. You could
also wear out the brakes prematurely.
1. Rear brake lever
2. Lock plate
1. Lock plate
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HOW TO AVOID THE HAZARD
Always set the parking brake before starting the engine.
Always be sure the parking brake have been released
before you begin to ride.
Shift pedal
This machine is equipped with a constant mesh 5speed transmission. The shift pedal is located on the
left side of the engine. Neutral is at the bottom position.
Drive select lever
The drive select lever is used for driving the machine
either forward or in reverse. Refer to page for drive
select lever operation.
1.Shift pedal N.Neutral
1 .Drive select lever
2. Hand start lever
Recoil starter
Firmly grasp the handle and pull slightly up to
engagement can be felt. Then pull forcefully.being
careful not to pull the rope all the way out.
CAUTION
Don't start the engine in non-neutral or without setting
the parking brake system.
Put the transmission in neutral and set the parking
brake before starting the engine.
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