GasGas Pampera450 2007 Owner's manual
PAMPERA 450-07
Foreword
GAS GAS thanks you for the trust you have placed in us.
By choosing a new PAMPERA 450 2007 you have become part of the great GAS GAS family and, as a user
of the number one manufacturer of off-road motorbikes, you deserve to receive the best treatment we can offer
you both in our post-sales relations and in the explanations we offer in this manual.
Our PAMPERA 450 2007 motorcycle has been designed for your enjoyment. In fact, it is the result of many
years of competition and experience in this highly demanding discipline and of the many excellent results
obtained by the great riders who have supplied the basic data to enable us to develop these excellent motorbikes,
GAS GAS exclusive models with certain key advantages: reliability, high performance and good stability.
Congratulations, because your choice has been, without doubt, the correct one. With skill at the commands
of this motorbike, an adequate preparation and the corresponding essential servicing this GAS GAS will remain
highly reliable and you will be able to enjoy the most comfortable and rewarding motor sport.
Thank you for your confidence and welcome to GAS GAS motos SA.
-3-
IMPORTANT NOTICE
Read this Manual carefully. This manual covers aspects that will
contribute to your security and to that of others, as well as guaranteeing
a correct conservation and maintenance of this GAS GAS motorcycle
you have just acquired.
All of the necessary instructions for the correct driving and handling
of this vehicle are set out below. Each message will be preceded
by a symbol.
Inadequate driving skill could cause problems to the environment
and conflict with other people. Responsible use of your motorcycle
will ensure that these problems and conflicts do not occur.
TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE
YOU USE YOUR BIKE LEGALLY, WITH CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER
PEOPLE.
WARNING
This warning symbol identifies special instructions or procedures
that, if not correctly followed, could result in personal injury, or even
death.
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.
Driving motorbikes is a fantastic sport, and we hope
you enjoy it to the full.
USE OF OIL RECOMMENDED:
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CONTENTS
Foreword......................................................................................... 3
Important notice.............................................................................. 4
Table of contents............................................................................ 5
General information ........................................................................ 6
Component locations...................................................................... 8
Side stand....................................................................................... 10
Petrol .............................................................................................. 10
Serial number and the qualification approval plate......................... 11
Starting and stopping the engine.................................................... 12
Starting when the engine is cold..................................................... 13
Changing gears .............................................................................. 13
Stopping the motorcycle................................................................. 14
Running-in ...................................................................................... 14
Maintenance chart .......................................................................... 15
Battery ............................................................................................ 16
Cooling system ............................................................................... 17
Spark plug....................................................................................... 20
Air filter............................................................................................ 23
Accelerator cable............................................................................ 24
Clutch.............................................................................................. 25
Exhaust system .............................................................................. 25
Chain.............................................................................................. 26
Tension adjustment ........................................................................ 27
Handlebars ..................................................................................... 29
Brakes............................................................................................. 29
Steering .......................................................................................... 31
Steering lock................................................................................... 32
Front fork ........................................................................................ 33
Rear suspension............................................................................. 35
Wheels............................................................................................ 37
Cleaning.......................................................................................... 38
Tightening nuts and bolts................................................................ 39
Table of tightening torques............................................................. 40
Lubrication ...................................................................................... 41
Engine oil........................................................................................ 42
Suspension adjustment .................................................................. 45
In competition ................................................................................. 49
Storage ........................................................................................... 50
Multifunction instructions ................................................................ 51
Fault diagnosis................................................................................ 57
Guarantee manual.......................................................................... 63
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GENERAL INFORMATION
ENGINE
Motor 4 stroke, single-cylinder DOHC 4 valves, liquid cooled
Displacement in cubic centimetres 443 cc
Bore and stroke 95 x 62.5 mm
Spark plug CR8 E o U24ESR-N
Fuel supply Carburetor
Ignition Digital CDI
TRANSMISIÓN
Transmission type 6 speed
Clutch type Oil bath, multi-disk hydraulic action
Secondary transmission By chain
Gear ratio 1st 2.071(29/14)
2nd 1.625(26/16)
3rd 1.333(24/18)
4th 1.100(22/20)
5th 0.913(21/23)
6th 0.791(19/24)
Primary reduction ratio 2.85(57/20)
Final reduction ratio 3.231 (42/13)
Overall drive ratio 7.289(6th gear)
Transmission oil Capacity 1000 cc
Type 10W50 API SF or SG
CHASSIS
Type Manufactured with chromoly tubes.
Swing arm made of aluminium, cast in one piece.
Tyre sizes Front 90/90 x 21
Rear 120/90 x 18
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Suspension Front ø'bf 45mm telescopic fork.
Rear Progressive system with single shock absorber
Suspension stroke Front 202 mm
Rear 220 mm
Front suspension oil SAE 7.5
Front fork oil level 200 mm (compressed, without spring)
BRAKES
Type Front / rear Disk brakes, pump and simple / double callipers.
Effective disk diameter Front 260 mm
Rear 220 mm
DIMENSIONS
Overall height 1,120 mm
Overall length 2,135 mm
Overall width 820 mm
Wheel base 1,450 mm
Minimum ground clearance 300 mm
Fuel tank capacity 7.4 litres
Weight 119 Kg.
(Specifications subject to change without notification, also possibly not applicable in some countries).
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LOCATION OF COMPONENTS
GAS GAS PAMPERA 450
1- Clutch handle
2- Engine start button
3- Fuel tank cap
4- Front brake fluid tank
5- Front brake handle
6- Throttle control
-8-
7- Front suspension
8- Radiator
9- Fuel tank
10- Air filter
11- Seat
12- Front brake disk
13- Front brake callipers
14- Rear brake fluid tank
15- Shift pedal
16- Rear shock absorber
17- Chain guide
18- Chain
19- Silencer
20- Rear shock absorber gas tank
21- Tie rod and rocker suspension
22- Rear brake pedal
23- Engine oil cap
24- Exhaust bend
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SIDE STAND
PETROL
To unfold side stand (A), open to vertical position.
The stand returns to its original position with the aid of the spring (B).
(A)
(B)
(A). Side stand.
(B). Spring.
NOTE
Do not start the engine or ride the motorcycle when the side
stand is down. Always engage the security strap before driving
the motorcycle.
The GAS GAS PAMPERA 450 has a four stroke engine and requires
98 octane, unleaded petrol.
Fuel Tank Capacity
7.4 L
(B)
(A)
(A). Fuel cap.
(B). Fuel vent hose.
To open the fuel cap (A), release the fuel vent hose (B) from the
handlebar and rotate the fuel cap in an anti-clockwise direction.
To close the fuel cap, rotate it in a clockwise direction.
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RECOMMENDED FUEL
SERIAL NUMBER
Use lead-free petrol with an octane rating equal to or higher than
that shown in the table.
OCTANE RATING METHOD MINIMUM
OCTANE RATING
Antiknock Index (RON+MON)/2 95
Research Octane No. (RON) 98
NOTE
If knocking occurs, try a different brand of gasoline or higher
octane grade.
WARNING
Gasoline is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure
the area is well ventilated and free from any source of flame or
sparks; this includes any appliance with a pilot light.
Printed on the steering tube. Indicates the frame number with which
the motorcycle is registered.
Qualification approval plate
The motorcycle is fitted with its own corresponding qualification
approval plate with the serial number, also printed on the steering
tube and whose data also coincides with that in the documents.
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STARTING THE ENGINE
Stopping the engine
- Ensure that the motorcycle is in neutral.
- Rotate the starter key clockwise (“ON” (A) position), in this way
the electric circuits are active and the engine can start.
(A)
(B)
- Without using the throttle, press the electric start button (B).
- Change gear to neutral.
- Then release the throttle completely and rotate the ignition key
anti-clockwise.
(D)
- The key should point left (D), this means that all of the electric
circuits are inactive. The engine cannot start.
- The key may be extracted from the ignition.
NOTE
Starting the engine while the key is being turned to the ON
position may cause a loss in battery power.
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STARTING WHEN THE ENGINE IS COLD
SHIFTING GEARS
The cold start function is responsible for aiding the engine start if it
is cold.
After some minutes, the engine will be at normal operating
temperature. The engine will reach its optimal temperature, in low
time and without causing damage.
NOTE
- If the engine is flooded then start with the throttle fully open.
- The motorcycle may be started in gear if the clutch is
disengaged.
STARTING THE ENGINE
1.-Ensure that the motorcycle is in neutral or press the clutch.
2.-Turn the fuel tap key clockwise to "ON"
3.-If the engine is cold, pull out the choke
4.-Press the starter button to start the motorbike.
5.-Even after the engine has started, leave the choke out.
The transmission is a 6 speed, return shift type meaning that to go
back to first gear from a higher gear, you must shift back through
the gears one by one.
To engage first gear from neutral, pull in the clutch lever and push
down on the shift pedal then release the pressure on the shift pedal
and gently release the clutch lever.
CAUTION
When changing gears, press firmly on the shift pedal to ensure
complete, positive shifting. Careless, incomplete shifts can cause
the transmission to jump out of gear and lead to engine damage.
(B)
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(B). Shift pedal.
STOPPING THE MOTORCYCLE
For maximum deceleration, release the throttle (A) and apply both
front and rear brakes. Disengage the clutch as the motorcycle comes
to a stop. Independent use of the front or rear brake may be
advantageous under certain conditions.
The slow speed necessary during the break-in period may cause
NOTE
dirt to build up on the spark plug. If inspection of the spark plug
shows this to be the case, replace the standard spark plug with
a higher heat grade spark plug for the duration of the break-in
period.
Downshift progressively as speed is reduced to ensure good engine
response when you want to accelerate.
(A)
BREAK-IN
To obtain the proper operating clearances in the engine and
transmission that are necessary for smooth engine performance
and reliability, an initial break-in must be completed. For the first
hour or 100 Km of operation, run the engine at a low and medium
speed.
Break-in following these steps:
1. Start the engine and let it run at idle until the engine is thoroughly
warmed up.
2. Stop and let the engine cool completely
3. Start the engine and ride for 10 minutes at moderate speed.
NEVER ACCELERATE FULLY.
4. Stop and let the engine cool completely. Check and adjust the
chain and spokes and carry out a general inspection.
5. Start the engine and ride for 20 minutes at moderate speed.
NEVER ACCELERATE FULLY.
6. Stop and let the engine cool completely. Check and adjust (4).
7. Fit the inspected parts.
8. Fill the radiator up completely with cooling liquid. Before starting
the engine bleed the air from the cooling system.
9. Start the engine and ride for 30 minutes at moderate speed.
10. Stop and let the engine cool completely. Check and adjust (4).
11. After the run-in procedure has been properly carried out, the
motorcycle is ready to be ridden normally.
CAUTION
In any case, even an imprudent acceleration can cause engine
trouble, take special care and use the proper skills and techniques
required for correct driving of the motorcycle.
NOTE
Following the break-in, fit a new standard spark plug.
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Article
Air filter
*Exhaust connectors and
bolts
*Valve tolerances
Spark plug
Fuel pipes
Engine oil and filter oil
*Engine oil pipes
Coolant
Radiator hoses
Clutch
Chain
*Brakes
Brake lines
Brake liquid
Tyres
*Steering assembly
*Front forks
*Rear suspension
*Chassis bolts and nuts
MAINTENANCE CHART
Period
First 5 hours
Period
Every 30 hours
Period
Every 60 hours
Inspect each time that the motorcycle has run or when necessary
T
I
I
T
I
I
T
I
R
I
*Change every 4 years
R
I
-
R
I
I
R
I
I
Change every 2 years
I
I
I
I
I
I
Clean, lubricate and inspect each time the motorcycle has been ridden
I
I
I
I
I
I
*Revise every 4 years
I
I
I
*Change every 2 years
Inspect tyres for damage and check the tyre pressure every time the motorcycle has run
I
I
I
T
-
-
-
T
I
I
I
T
I NOTE: I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace, T = Tighten, C = Clean
-15-
BATTERY
This battery is maintenance free and checking the fluid level is not
required.
It is advisable to check the charge of the battery periodically
3. Disconnect the terminals ensuring that they do not
enter into contact with metal parts then extract the battery.
WARNING
To remove the battery, follow these steps:
(C)
1. Remove the screws (A) and remove the seat (B).
2. Release the rubber (C).
Hydrogen gas produced by the battery may explode if exposed to
open flame or sparks.
Keep the area ventilated and free from naked flames.
(A)
The operating instructions for the battery are as follows:
(B)
1. Check the battery voltage in open circuit status (disconnected).
2. In case the battery's tension is below 12.60 V, or if the storage
period has exceeded 6 months, the battery has to be recharged
following the instructions in paragraph 3.
If the battery voltage is above 12.60 V, the battery can be
installed on the vehicle without having to recharge it.
3.1. Constant voltage charge mode.
- Constant voltage = 14.40 - 14.70V
- Initial charge current = 0.1 – 0.5 Cn
- Charge duration = 6 hours minimum / 24 hours maximum.
3.2. Constant power charge mode.
- Maximum charge current = 0.1 Cn
-16-
- Recommended charge time = 5 - 8 hours.
- The product (charge current) X (charge duration) must be
within the range:. 0.5 – 0.8 Cn
Note
In case that a different mode of charging is used to those
established here, never exceed the maximum allowed currents
nor the maximum charge duration of 24 hours.
CAUTION
Using a high-pressure water source could damage the radiator fins
and render them ineffective.
Do not obstruct or deviate the radiator air intake by installing nonapproved accessories. Interfering with the radiator could cause
overheating and result in engine damage.
Coolant
CAUTION
Not using the standard manner of charging may seriously shorten
the battery life.
Never exceed the standard charge.
CAUTION
Inverting the polarity of the battery terminals may cause battery
charge problems and cause damage to the battery system.
The red terminal is positive (+) and the black terminal is negative (-).
COOLING SYSTEM
Radiator hose
Check the radiator hoses for cracks or deterioration, and connections
for leaks.
Radiator
Check the radiator fins for obstruction by insects or mud. Clean off
any obstructions with a stream of low-pressure water.
This absorbs excessive heat from the engine and transfers it to the
air at the radiator. If the coolant level becomes low, the engine
overheats and may suffer severe damage. Check the coolant level
each day before riding the motorcycle. Replenish coolant if the level
is low.
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.
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.
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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.
CAUTION
Soft or distilled water must be used with the inhibitor chemicals and
the antifreeze in the cooling system.
If normal water is used in the system, it the cooling system tubes
may become blocked.
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
- Situate the motorcycle so that it is perpendicular to the ground.
- Remove the radiator cap in two stages. First turn the cap anti-clock
wise and wait for a few seconds. Then push and turn it further in the
same direction to remove the cap.
(A)
(A). Radiator Cap.
CAUTION
Permanent types of antifreeze on the market have anticorrosion and
anti-rust properties. When over-diluted, antifreeze loses its antifreeze
and anti-corrosive properties.
It should be diluted in accordance with manufacturer instructions.
-18-
Check the level when the engine is cold.
NOTE
(1). Coolant level.
(2). Filler opening.
If the coolant level is low, add the correct amount of coolant through
the filler opening.
Recommended liquid
Permanent type of antifreeze (distilled water and ethylene glycol)
with corrosion and rust inhibitor chemicals for aluminium engines
and radiators).
Changing the coolant
- The coolant should be changed periodically to ensure long engine life..
- Wait for the engine to cool completely.
- Situate the motorcycle so that it is perpendicular to the ground.
- 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 at the bottom
of the water pump cover. Immediately wipe or wash off any coolant
that spills on the frame, engine, or wheels.
Initially a permanent type of antifreeze is installed in the cooling
NOTE
system by the manufacturer. This is green and contains 50%
ethylene glycol and freezes at a temperature of -35º'bcC.
Total quantity
Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).
(A). Water pump cover
(B). Coolant drain Plug.
WARNING
Coolant on tires will make them slippery and can cause an accident
and injury.
-19-
-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
steal 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
the specified torque shown in the table. Replace seals with new
ones.
Bolt torques:
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. Add coolant
up to the bottom of the radiator filler neck.
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
The standard spark plug is shown in the table and is tightened to
11 Nm.
Standard spark plug
CR8 E or U24ESR-N 0.7-0.8 mm.
The spark plug should be taken out periodically to check the electrode
gap. If the spark plug is oily or has carbon build up on it, clean it
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
Spark plug maintenance
-20-
CR9E
CR8E
CR7E
U22ESR-N
U24ESR-N
U27ESR-N
COMMENTS
If the standard spark plug
appears to be crystallised or
is a white colour, it should be
replaced.
Standard
If the standard spark plug is
wet then replace it.
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