Gas gas WILD HP 450 Manual

MANUAL DEL USUARIOIO SERVICEI MANUAL MANUEL D’ENTRETIEN’ I

LIBRETTOI TO USOUSO EE MANUTENZIONEANUTENZIONE

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.

Our WILD H.P. is a sports four-wheel vehicle conceived in and for competition. It will help you appreciate a high degree of technical perfection and reliability, apart from a meticulous design and high performance.

The present manual will offer you a good basic knowledge of the vehicle’s characteristics and handling. It contains important instructions about your safety and information on the necessary skills and techniques required to handle it, as well as the basic maintenance and inspection proceedings.

Thanks for your confidence and welcome to GAS GAS Motos, S.A.

August 2003

WILD HP -68-

COMMON ADVICE

Read this manual thoroughly. It contains all the aspects that must contribute to your and other people's safety, and it also guarantees the correct conservation and maintenance of the GAS GAS vehicle that you have just purchased.

READ THIS MANUAL THOROUGHLY BEFORE USING THE VEHICLE.

Important information on this manual

Not following the advice contained in the manual can lead to grave or even fatal injuries. Specially relevant information is highlighted in the manual with the notations below:

WARNING

Ignoring the WARNING instructions can lead to grave or even fatal injuries for the user, the people nearby or the technicians in charge of its inspection or repairs.

CAUTION

This symbol identifies instructions or procedures which, if not strictly observed, may damage or destroy your vehicle.

NOTE

This symbol indicates points of particular interest for higher efficiency and a more convenient operation of the vehicle.

Inadequate driving may lead to environmental problems and conflict with other people. Riding your vehicle responsibly will ensure that you don't have to face these problems and conflicts.

PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE LEGAL USE OF YOUR VEHICLE, WITH CLEAN CONSCIENCE OF THE ENVIRONMENT AND RESPECTING THE RIGHTS OF THE OTHERS.

QUAD driving is a great sport, and we hope that you can fully enjoy it.

This manual has been designed with the data and specifications available in the moment of its composition. Any difference that may be appreciated with your vehicle will be due to improvements in riding and the product’s quality. GAS GAS Motos SA is constantly improving their vehicles so that you can enjoy higher performance.

WARNING

Hydrogen gas produced by the battery may explode if exposed to open flame or sparks. Keep flames and sparks away from the battery.

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TABLE OF CONTENTS
- Presentation........................................................................		68
- Common advice.......................................................................		69
- Table of contents.....................................................................		70
- Specifications.......................................................................		72
- Safety information	.................................................................	73
- Important information..........................................................		75
Identification numbers.............................................		75
- Loction of components.........................................................		77
- Main parts of Quad............................................................		79
Contact Key........................................................		79
Start the	engine...............................................	79
Lights..............................................................		79
Warning	lights..................................................	80
Throttle grip.....................................................		80
Clutch lever......................................................		80
Front brake lever................................................		81
Rear brake pedal..............................................		81
Emergency stopping...........................................		81
Gear pedal..................................................		82
Stárter..........................................................		82
Seat...................................................................		83
Batery................................................................		83
Front guard..........................................................		83
Rear guard..........................................................		83
Footrest........................................................		84
Foot protection.....................................................		84
- Checkings to be made before riding the vehicle..............		85

Front and rear brakes.......................................	85
Fuel................................................................	85
Cooling system...................................................	87
Chain....................................................................	87
Throttle grip........................................................................	87
Lights...........................................................................	87
Tyres.................................................................	87
- Use of the QUAD.............................................................	89
Engine start.....................................................................	89
Gear box..........................................................................	90
Starting the vehicle...........................................................	91
Stopping the engine..........................................................	91
Engine running-in..............................................................	92
Parking in inclined surfaces.............................................	92
- Driving the QUAD. Practical recommendations...............................	93
Become familiar with your QUAD......................................	93
Drive with care and common sense.................................	93
How to turn with your QUAD............................................	94
Uphill climbing..................................................................	95
Going down slopes...........................................................	95
Going across slopes...........................................................	95
Going across shallow water.................................................	96
Riding in rough terrain....................................................	96
Sliding.............................................................................	96
- Tuning............................................................................................	97
Tuning the front suspension...........................................	97
Tuning the rear suspension...............................................	98

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- 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
Inspection and lubrication of the cables...........................	110
Replacing the lights.......................................................	110
Transmission................................................................	112
- Cleaning, lubrication and storage.................................................	121
Cleaning........................................................................	121
Lubrication........................................................................	122
Storage...........................................................................	123
- Multifunction..................................................................................	118
- Torque Table...........................................................................	119
- Bolt and Nut tightening.......................................................	120
- Troubleshooting...........................................................................	121
- Warranty regulations......................................................................	126

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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.
Transmission:	Primary with gears, secondary with chain.
Start:	Electric starting and aditional kickstarter pedal.
FRAME
Frame:	Multi-tube twin-spar frame, Cr-Mo steel made.
Front suspension:	Wishbone arms with two ÖHLINS multi-adjustable shock absorbers.
Rear suspension:	Aluminium allow swing arm with no welding. Progressive system with multi-
Front brake:	adjustment ÖHLINS shock absorber.
	Two self-ventilated 180mm discs with floating two-piston BREMBO caliper.
Rear brake:	220mm self-ventilated disc with floating twin-piston BREMBO caliper.
Rims:	Aluminium.
Front tyre:	21 x 7,00 – 10”.
Rear tyre:	20 x 11,00 – 9”.
Kick starter:	Forged aluminium.
Engine, disc and chain ring shield:	Forged aluminium.
DIMENSIONS
Wheelbase:	1.280 mm.
Total width:	1.300 mm.
Void weight:	175 Kg.
Fuel capacity:	18 litres.

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SAFETY INFORMATION

WARNING

Not following these instructions may lead to grave injuries or even death.

The QUAD is not a toy: driving it may be dangerous.

The QUAD is driven differently form from other vehicles such as cars and motorbikes. Even during routine manoeuvres like turns, driving on hills or over obstacles, collisions or tumbles can be quickly produced, if precautions are not taken.

-Do not drive the QUAD before reading the sections: "Safety information", "Use of the QUAD", and "Main parts of the vehicle". Even if you are an experienced QUAD driver, not all makes and models are equal and it is necessary to know the machine in depth before starting on your first outing.

-You are not allowed to carry a passenger, and the vehicle is not equipped for that purpose.

-Sit correctly with both hands on the handlebars, your feet on the footrests and your back straight up.

-Always control your speed according to your skills, the weather conditions and the ground characteristics. Pay attention to changes in the ground surface and control your speed when you are not familiar with them.

-Always perform the routine checks described in this manual before using the vehicle, to make sure it is in perfect operating conditions,

-Riding a QUAD is not like driving any other vehicle, and you will notice it specially when cornering. Practise on flat ground with free

of obstacles and with no other vehicles around first. Read the recommendations in the section "Use of the QUAD" of this manual.

-The same applies to steep climbs or descends. Start testing your skills with minimum slopes and raise the difficulty level little by little. Advice on this point is also included in the section mentioned above.

-In case you stall the engine, follow the procedure described in the manual. If the engine stalls and the vehicle starts going backwards, follow the special braking procedure described in the manual. Climb off the vehicle to the higher side of the slope.

-Remember that your safety comes before the machine's, and it is important to keep this priority in mind.

-When going across a slope, move your weight to the higher side, read the manual's advice on that. Avoid very slippery slopes or with loose surface.

-Never try to overcome big obstacles, like rocks or trunks. This vehicle has not been designed for that; it could be damaged and/or you might be injured.

-Do not try to make the vehicle slide sideways if you don't dominate the technique in depth, because it may be dangerous. Like in the cases described above, do some testing on flat, wide and obstaclefree ground beforehand and follow the advice described in this

manual. You must never lose control of the vehicle.

-This vehicle has been designed to go through a maximum depth of 35 cm of water. Do not use the vehicle in fast moving water, read the instructions for this type of terrain carefully. Take into account that brake efficiency is diminished when wet. When coming out of the water, brake several times so that they dry more quickly through friction.

-Always use the tyre size and type described in this manual.

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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; this includes lamps. The fuel might catch fire and cause serious burns. Avoid spilling fuel over the engine, exhaust or muffler.

-When transporting the quad using a trailer, make sure it is upright ant that the fuel tap is in the OFF position (closed). Fuel leaks might take place in the carburettor or in the fuel tank otherwise.

-Fuel is poisonous. In case of accidental ingestion, abundant vapour inhalation or contact with your eyes, go to the doctor at once. If fuel gets in contact with your skin, wash it with water and soap. Should you clothes get wet with fuel, change them.

-Always ride your quad in well-ventilated areas. Do not start the engine or keep it running in closed facilities. The exhaust vapours are poisonous and may lead to loss of consciousness or even death in a short time.

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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. The adjustments must be performed by an expert and only when it is necessary. The carburettor is already tuned, so changes to its settings are initially not required.

A spanner for chain tensioning is also enclosed to adjust the chain tension and centre the swing arm axle. Do not lose it; you will make good use of it.

4

1

2

3	4

1.	Chain guard.	3.	Footrests.
2.	Swing arm guard.	4.	Foot protectors.

5

5. Chain and swing arm axle adjustment spanner.

IDENTIFICATION NUMBERS

Write down your vehicle's identification number (serial number), the information in the model label and the key identification number in the gaps, to make paperwork easier should any spares be required or as a reference in case of robbery of the vehicle.

Serial numbers

It is located at the front (A). It indicates the frame number the vehicle is registered with.

SERIAL NUM.

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NOTE

The vehicle's serial number is used for your machine's identification.

	(B)		(A)

Homologation badge

Your quad has its corresponding homologation badge (B), where its serial number is printed. It is also printed at the front, and it must coincide with the documents. You are recommended to write down the data in the chart below.

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. The identification number is located right where the two keys are linked, as shown in the picture. This number must be mentioned to order a new set of keys in case you lose them.

(D)

(C)

KEY ID. N.

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LOCATION OF COMPONENTS
GAS GAS WILD H.P. 450										11
										12
1	2 3	4	5 6	7	8	9	10

13

14

15

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	14-Footrest grids
7- Parking brake	15-Rear protection
8- Starting button and stop engine

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15

16

17

23

18

19 20

21

22

24

25

26

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

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MAIN PARTS OF THE QUAD

CONTACT KEY

The key (A) is located on the front part of the handlebars. To turn the contact on, turn the key clockwise to the "ON" position. To turn contact off, turn the key anti-clockwise to the "OFF" position.

(A)

START THE ENGINE

This quadricyle has been fitted with an electric starting mechanism and a pedal-operated one.

Control (B) is on the right-hand side of the handlebars.

Pedal (C) is located on the right-hand side of the quadricycle. You will find it in the rest position. Pull this control until it reaches its work position.

(B)	(C)

LIGHTS

NOTE

The headlight and the rear light can only be switched on when the engine is on.

Short beam

Low beam

Whithout lights

Switch (A) slides into three positions, we will find it in the "OFF" position.

(A) (C) (B)

(A). Light indicator.

(B). High beam.

(C). Blow of high beam.

(D). Indicators. (E) (D)

(E). Horn button.

Press the red button (B), located to the right of the switch above, to switch to high beam (Position: ). The high beam can only be turned on when the short beam is on.

Slide switch (A) down to the OFF position to turn off the headlight and the rear light.

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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. It also works with the contact off. When on, a light inside the button will flash.

NOTE

Regarding the use of this lights, follow the legal conditions of each country.

(F)

THROTTLE GRIP

Before starting the engine, check that your throttle works smoothly

(G). Make sure it slides back to idle when the grip is released.

The grip has a spring to return the engine to idle and slow down the vehicle when the hand is taken off the grip.

(G)

WARNING

If the throttle is not working properly, it may be difficult to accelerate or slow down as you wish. This may cause accidents. Check the correct operation of the throttle before starting the engine. If the throttle does not work smoothly, check for 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. Activate it to engage or disengage the clutch (H).

To make the clutch work smoothly, the lever must be pulled quickly and released slowly.

(H)

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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.

(A)

REAR BRAKE PEDAL

The rear brake pedal (B) is located on the right side of the lower chassis. Activate it to apply the brake to the rear wheels.

(B)

EMERGENCY STOP

The vehicle features an emergency stop system. This mechanism prevents the vehicle from running on in case the rider should fall.

(D)

(C)

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 movements and easily released in such cases. When released, it automatically stops the engine.

NOTE

Make sure you release the parking brake before operating the throttle.

You are recommended to attach the cable to a strong point, as it is important that the cable is not accidentally released in any case. (For example, the cable may be attached to your trousers, jacket, to your wrist... but always to a part where it will not come off easily).

WARNING

The vehicle must not be used without attaching the emergency stop system. Ignoring this order may cause serious consequences.

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CHANGE PEDAL

The vehicle features a 6-speed gearbox.

The change pedal (E) is located on the left side of the engine and is used in combination with the clutch when changing gears.

(E)

STARTER

The starter (F) is a mechanism that opens the throttle to a certain degree, without having to move the throttle grip, so as to favour the engine when cold. The engine will reach the optimal operating temperature in a short time and with no need to force it.

(F)

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. Waiting few seconds, the engine will be a good temperature.

For pull down the choke button, only drive the twist grip.

NOTE

-If the engine is choked, start with the throttle fully open.

-You can use the clutch to start the motorbike with a gear in.

FUEL TANK CAP

To open the fuel tank, turn the key anti-clockwise.

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SEAT

To remove the saddle, use the same key that was used to open the petrol-tank cap (B). Insert the key into the lock located on the righthand side of the QUAD. Turn the key clockwise, and then insert your hand through the rear, between the saddle and the frame. The saddle will lift easily.

NOTE

When putting the seat back in the normal position, make sure it holds well back in place.

(B)

BATTERY

This battery is maintenance free and checking the fluid level is not required. It is recommended to check the charge of the battery

periodically.

The operating instructions for the battery are as follows:

1.Check the battery tension while the circuit is open.

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. In case the tension is above 12.60 V, the battery can be installed on the vehicle without having to recharge it.

3.1.Charge mode with constant tension.

-Constant tension = 14.40 - 14.70V

-Initial charging power = 0.1 - 0.5 Cn

-Charge duration = 6 hours minimum / 24 hours maximum.

3.2.Charge mode with constant power.

-Maximum charge power = 0.1 Cn.

-Recommended charging time = 5 - 8 hours.

-The product of (charging power) x (charging time) has to stay within the range:0,5 - 0,8 Cn.

NOTE

In case charging modes different than the established ones are used, by no means, may the maximum allowed power or the charging time of 24 hours be surpassed.

CAUTION

Exceeding charge standards may reduce the life cycle of the battery. Never surpass charge standards.

CAUTION

Inverting the polarity of the battery terminals may cause battery charge problems and cause damage to it.

The red terminal is the positive (+) and the black terminal is the negative (-).

FRONT GUARD

The front guard projects from the quad. In case of a front crash, the protection, attached directly to the frame, will absorb the crash and prevent the steering and the rest of the vehicle from suffering significant damage.

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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.

(D)

NOTE

In case of steep climbs, the rear guard will not prevent a backward tumble, so be prudent in climbs and examine the ground carefully.

FOOTRESTS

WARNING

The footrests and protectors are an essential protection system for the quad's safe riding. The quad has very wide wheels and it would easily drag your leg under the wheels, causing serious injuries.

The QUAD features two footrests (E), one on each side. Both footrests have a grid. The package will protect our feet and legs in case of losing balance and taking your feet off the rests. Their width allows for great freedom of movement.

(E)

FOOT PROTECTIONS

(F)

The foot protections (F) are located between the footrests and the wheels, and they are a n a d d i t i o n a l protection system to the footrests. By filling

the gap, we	have
e l i m i n a t e d	t h e

possibility to damage our lower limbs with the wheels.

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