Gas gas K2 QUAD 250 2005 User Manual

MANUAL DEL USUARIO

SERVICE MANUAL

MANUEL D’ENTRETIEN

LIBRETTO D´USO

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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