GAS GAS WILD HP 450 - 2005, 2005 WILD HP 450 Service Manual
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
USER MANUAL
USER MANUAL
ENGLISH
INTRODUCTION
GAS GAS thanks you for the trust you have placed in us.
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 motorbike manufacturer, you deserve the special treatment we wish to offer you, both
in our after-sales relations and in the explications offered in this manual.
Our WILD H.P. is a sporting quad bike designed by and for competition. With it you can enjoy the high degree
of technical perfection and reliability, in addition to the careful design and high performance.
This manual provides you with a good basic knowledge of the features and handling of the machine. It also
contains important instructions concerning safety and offers information about the special techniques and skills
required to drive the machine, in addition to the basic maintenance and inspection procedures.
Thank you for your confidence and welcome to GAS GAS motos SA.
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GENERAL ADVICE
Read this Manual carefully. It explains all the aspects concerning
your safety and that of third parties, in addition to ensuring the correct
care and maintenance of the GAS GAS quad bike which you have
just purchased.
PLEASE READ ALL THE MANUAL BEFORE USING THE MACHINE.
Important information about this manual
Information of special note is marked in the manual using the following
notations:
WARNING
Failure to heed the WARNING instructions may result in serious
injury or loss of life for the user of the machine, individuals in the
vicinity or the technicians responsible for its inspection or repair.
CAUTION
This symbol identifies instructions or procedures which, if not strictly
observed, may result in the damage or destruction of the equipment.
NOTE
This symbol indicates points of particular interest for improved
efficiency and more convenient operation.
Inappropriate use could cause problems to the environment and
conflicts with other people. Responsible use of your quad bike will
ensure that these problems and conflicts do not occur.
TO PROTECT THE FUTURE OF YOUR SPORT, ENSURE YOU
USE YOUR BIKE LEGALLY, WITH CONCERN FOR THE
ENVIRONMENT AND RESPECT FOR OTHERS.
Driving quad bikes is a fantastic sport, and we hope you enjoy it to
the full.
This manual has been drawn up using the data and specifications
available at the time of writing. Any differences you may notice should
be attributed to improvements in the production and quality of the
product. GAS GAS MOTOS, S.A. is constantly improving its vehicles
in order for you to better enjoy them.
WARNING
Hydrogen gas produced by the battery may explode if exposed to
flames or sparks.
Keep the area ventilated and free from naked flames.
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CONTENTS
- Introduction.................................................................................. 3
- General advice............................................................................ 4
- Contents...................................................................................... 5
- Specifications.............................................................................. 7
- Information concerning your safety............................................. 8
- Important information................................................................. 10
Identification numbers...................................................... 10
- Component location................................................................... 12
- Principal parts of the QUAD....................................................... 14
Ignition key....................................................................... 14
Starter.............................................................................. 14
Lights............................................................................... 14
Hazard lights..................................................................... 15
Throttle twist-grip.............................................................. 15
Clutch handle.................................................................... 15
Front brake handle............................................................ 16
Rear brake pedal............................................................... 16
Emergency stop................................................................ 16
Reverse gear control ....................................... ..................17
Shift pedal ........................................................................ 17
Fuel cap............................................................................ 17
Seat................................................................................ . 18
Battery............................................................................. 18
Front guard...................................................................... 18
Rear guard....................................................................... 19
Foot rest assembly........................................................... 19
Foot guards...................................................................... 19
- Checks to make before starting the machine............................. 20
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Front and rear brakes................... .................................... 20
Fuel.............................................................. ..................... 21
Coolant system.......................................................... ....... 22
Chain................................................................................22
Throttle twist-grip.............................................................. 22
Lights............................................................................... 22
Tyres................................................................................ 22
- Use of your QUAD...................................................................... 24
Starting the engine.......................................................... 24
Changing gear................................................................. 25
Starting the vehicle ......................................................... 25
Stopping the engine......................................................... 26
Running in engine............................................................ 26
-Driving your QUAD. Practical advice........................................... 28
Getting to know your QUAD.............................................. 28
Drive carefully using common sense................................. 28
How to turn with your QUAD............................................. 29
Going up slopes................................................................. 30
Going down slopes............................................................ 30
Crossing slopes................................................................. 30
Crossing shallow water...................................................... 31
Driving over rough ground................................................. 31
Sliding and skidding......................................................... 31
- Tuning.......................................................................................... 32
Tuning front suspension...........………………………….... 32
Tuning rear suspension..............………………………….. 33
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- Regular maintenance and adjustments...................................... 34
Maintenance chart....................................................... 34
Adjusting clutch lever................................................... 35
Adjusting brake handle and pedal................................. 35
Checking brake fluid level............................................. 36
Checking front and rear brake pads.............................. 37
Changing wheels........................................................... 38
Swinging arm................................................................. 38
Adjusting and lubricating chain guide........................... 38
Checking coolant level.................................................. 39
Air filter.......................................................................... 41
Spark plugs................................................................... 43
Inspection and lubrication of cables............................. 45
Replacing lights............................................................. 45
Transmission............................................................... 47
Engine oil....................................................................... 47
- Cleaning, lubrication and storage ............................................... 50
Cleaning...................................................................... 50
Lubrication................................................................... 51
Storage........................................................................ 52
- Multi-function.............................................................................. 53
- Table of tightening torques.......................................................... 54
- Diagram of tightening torque locations....................................... 55
- Fault diagnosis............................................................................ 56
- Electrical schemas..................................................................... 62
- Guarantee manual..................................................................... 64
SPECIFICATIONSE
ENGINE
Cylinder size:
Type:
Cooling system:
Bore and stroke:
Injection system:
Ignition:
Clutch:
Gear box:
Transmission:
Starter:
CHASSIS
Chassis:
Front suspension:
Rear suspension:
Front brake:
Rear brake:
Rims:
Front tyres:
Rear tyres:
Kick-start pedal:
Engine, disc and sprocket guard.
DIMENSIONS
Wheel base:
Overall width:
Weight without rider:
Fuel tank capacity:
443 cc
Single-cylinder, 4-stroke with 4-valve cylinder head.
Liquid.
95 x 62.6 mm.
MAGNETI MARELLI.
Integrated on injection system.
Hydraulic multi-disc .
5 speeds and reverse.
Primary with gears, secondary with chain.
Electric engine and auxiliary pedal.
Multi-tubular with double shim, manufactured in Cr-Mo Steel.
Trapezoidal arms with 2 ÖHLINS multi-adjustable shock absorbers.
Aluminium alloy swing arm, weld-free. Progressive system
with multi-adjustable ÖHLINS shock absorber.
2 180 mm auto ventilated disc brakes with Brembo double-piston calliper.
2 220 mm auto ventilated disc brakes with Brembo double-piston calliper.
Aluminium
21 x 7.00 – 10”
20 x 11.00 – 9”
Forged aluminium
Duralumin plate and carbon fibre guard.
1,280 mm
1,200 mm
175 Kg.
18 litres
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- Always carry out routine inspections as described in this manual
before going out on the quad bike, to ensure that it is in safe working
condition.
- Driving a quad bike is unlike driving any other vehicle, and you will
particularly notice this when turning. Practice turning first on flat open
ground without any other vehicles in the area.
Read the advice given in the manual in the section -Use of your
QUAD.
- Similarly for steep hills whether you are going up or coming down.
Start by trying gentle slopes and increase the level of difficulty
gradually. Advice is given concerning this aspect in the same section
as mentioned above.
- Follow the procedures described in this manual if the engine stalls.If
the engine stalls and the vehicle begins to roll backwards, follow the
special braking procedure described in this manual
Get off the quad on the up-side of the slope. Remember that your
safety comes first and then that of the machine, it is important to
clearly understand this.
- To cross a slope move your weight towards the rising section, read
the advice in the manual concerning this. Avoid
slopes which are too slippery or with a loose surface.
- Never try to go over large obstacles such as rocks or tree trunks,
the machine is not prepared to do this and you may damage either
you or the machine.
- Do not deliberately skid if you do not know how to do so correctly,as
it could be dangerous. As for the above, first practice on flat open
terrain, without obstacles and follow the advice given in this manual.
You must never lose control of the machine.
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SAFETY INFORMATION
THE QUAD is not a toy: its use may be dangerous.
THE QUAD is driven in a different manner to other vehicles, such
as cars or motorcycles. A collision or overturning can happen very
fast, even during routine manoeuvres such as turning, driving on
slopes or over obstacles, unless
the necessary precautions are taken.
WARNING
If these instructions are not heeded, you may suffer serious injury
or even loss of life.
- Do not drive the QUAD before reading the following sections:
"Information concerning your safety", "Use of the QUAD"
and “Principal parts of the QUAD”. Even if you are an experienced
quad bike driver, not all makes and models are the same and it is
imperative to understand the machine well before commencing the
first trip.
- It is forbidden to carry passengers, nor is the bike adapted for this.
- Sit correctly with both hands holding the handle bar, both feet on
the foot rests and your back straight.
- Reduce your speed according to your skill, experience, weather
conditions, or ground conditions.
- Drive with caution over changing ground and reduce speed when
not familiar with the terrain.
- This quad bike is designed to be driven in water with a maximum
depth of 35 cm. Do not use the machine in rapids, read the instructions
about this type of terrain carefully. Remember that when the brakes
get wet, they lose braking capacity. On exiting the water, pump the
brakes several times to dry them more quickly.
- Always use tyres of the size and type described in this manual.
WARNING
- Always switch off the engine when refuelling.
- Do not smoke while refuelling, petrol is highly inflammable and
may be explosive in certain conditions. Always switch off the engine.
Keep the area ventilated and free from naked flames or sparks; this
includes spot light appliances. The petrol could catch fire and cause
burns. Take care not to spill petrol on the engine, exhaust pipe or
silencer.
- When transporting the quad with a trailer, make sure that the quad
is kept in an upright position.
- Petrol is toxic. In the event that petrol is swallowed, excess fumes
are inhaled, or should fuel splash in eyes, seek medical attention
immediately. If petrol spills onto the skin, wash off with soap and
water. If petrol spills onto clothes, change your clothes.
- Always drive the machine in a well ventilated area. Do not start or
run the engine in a closed space. The exhaust fumes are toxic and
can cause loss of consciousness or even death in a very short time.
-9-
IDENTIFICATION NUMBERS
Make a note of the vehicle identification number (serial nº), information
about the model and the key identification number in the spaces
provided, to facilitate proceedings when ordering spares, or as a
reference in the event of robbery.
Serial number
(B) is located printed on the front. This indicates the chassis number
with which the vehicle is registered.
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SERIAL No.
IMPORTANT INFORMATION
The quad bike leaves the factory with some components not fitted,
in order to ease transportation. The dealer should fit the remaining
pieces and you should receive the QUAD ready for use. This section
is for your information only.
A kit is included for making adjustments to the carburettor, these
adjustments should only be made by a qualified mechanic, and only
when necessary. On delivery, the carburettor has been calibrated
correctly, therefore no adjustments are necessary.
A wrench is also included for adjusting the chain and for aligning
the swing arm. Do not lose it, it will be of great use.
1
2
3
1. Chain guard.
2. Swing arm guard.
5. Wrench for chain and
swing arm adjustment.
5
4
3. Foot rest assembly.
4. Foot protectors.
4
Key identification number
The quad bike has two pairs of keys. The first (C) and most important
is the ignition key, and the second (D) is for opening the fuel tank
and seat. The identification number appears just below the join of
the keys as can be seen from the diagram. This number is required
to order a new key in the event of loss.
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QUALIFICATION No.
NOTE
The vehicle serial number is used to identify your machine.
(C)
(D)
(B)
(A)
Qualification approval plate
The quad bike bears the relevant qualification approval plate (A),
which has the serial number also printed on the front.
This number should match that which appears in the accompanying
documents. We recommend you write the information in the following
table.
KEY ID.
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LOCATION OF COMPONENTS
GAS GAS WILD HP 450
1- Clutch handle
2- Light switch
3- Light flash button
4- Full beam button
5- Emergency stop
6- Ignition key
7- Parking brake
8- Start and stop engine control
11
13
14
15
12
1 2 3 4 7 9 1065 8
9- Front brake handle
10- Throttle twist-grip
11- Front guard
12- Brake pads
13- Fuel tank cap
14- Foot rest grille
15- Rear guard
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1816
19 2522
23
21 2620 27
17
16- Front headlight casing
17- Throttle housing
18- Seat
19- Front shock absorber
20- Engine
21- Shift pedal
24
22- Swing arm
23- Exhaust pipe
24- Front brake fluid tank
25- Kick-start pedal
26- Brake pedal
27- Engine oil tank
To switch on the dipped beam ( ) slide switch (C) into position
( ). To switch on the full beam ( ) press the red switch (D). The
instrument panel will display the full beam lamp ( ). To switch off
the lights slide the switch to position ( ).
LIGHTS
NOTE
The headlight and tail lights can only be switched on after the
engine has been started
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(C) (D)
(F)
(E)
(G)
(C). Light switch.
(D). Full-dipped beam switch.
(E). Main beam flash.
(F). Indicators.
(G). Horn.
Switch (C) slides into three
positions.
You will find it in the “OFF”
position.
Dipped beam
Side lights
No lights
(A)
(C)
(B)
PRINCIPAL PARTS OF THE QUAD
IGNITION KEY
Key (A) is located in the front section of the handle bar. To switch
on the ignition, turn the key clockwise to position “ON”. Turn the key
anticlockwise to switch off the ignition, until reaching the position
“OFF”.
STARTER
The quad bike is fitted with an electrical starter motor and a manual
kick-starter using the pedal.
The control (B) is located to the right of the handle bar.
The pedal (C) is located on the right-hand side of the quad bike.
You will find it in the rest position; pull it down until it is in the
operating position.
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-
The indicators (F) are located in the lower part of the left-hand
handle. By sliding the switch to the right, the right-hand indicator
comes on, and similarly the left-hand indicator comes on when the
switch is moved to the left.
The button for the horn is located in the same area (G).
HAZARD LIGHTS
Button located in the front section of the quad bike (H), in front of
the handlebar. This also works when the ignition is switched off.
When the ignition is switched on, a lamp lights up on the button
itself.
NOTE
Be sure to heed the laws of each country with respect to the
use of these lights.
THROTTLE TWIST-GRIP
Before starting the engine, check that the throttle spins round smoothly
(I). Ensure that it returns to idle position when the handle is released.
There is a return spring fitted inside the handle which reduces speed
and brings the engine back to idle speed when the throttle handle
is released.
WARNING
If the throttle does not work correctly, it may be difficult to increase
or reduce the speed of the vehicle as desired. This could cause
accidents. Check the throttle is working correctly before starting the
engine. If the throttle does not work smoothly, find out why. Solve
the problem before using the machine, or go to a specialist workshop.
CLUTCH LEVER
The clutch lever is located on the left of the handle bar.
Use the lever to engage and release the clutch (J).
For the clutch to work smoothly, the lever should be tightened quickly
and released slowly.
(J)
(H)
(I)
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End (C) is attached to the vehicle and end (D) is securely
attached to the rider.
It consists of an elasticised cable, one end of which is attached to
the vehicle and the other to the rider, in such a way that the end of
the cable which is attached to the vehicle detects any brusque
movement and detaches.
On becoming detached, the engine stops automatically.
NOTE
Make sure that the parking brake has been released before
using the throttle.
We recommend attaching the cable to a resistant point as it is
important that this part of the cable never becomes detached.
(E.g. The cable could be tied to trousers, a jacket, around the
wrist...but always to a resistant point).
WARNING
It is forbidden to use the quad bike before attaching the emergency
stop system. The non-observance of this warning could have serious
consequences.
FRONT BRAKE LEVER
The front brake lever (A) is located on the right of the handle bar.
Use the lever to apply the front wheel brakes.
REAR BRAKE PEDAL
The brake pedal (B) is located on the right-hand side of the lower
part of the chassis. Use the pedal to apply the rear wheel brakes.
EMERGENCY STOP
The quad bike is fitted with an emergency stop system. This is a
mechanism which prevents the quad bike from continuing to go in
the event the rider falls off.
(D)
(A)
(B)
(C)
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SHIFT PEDAL
The machine is fitted with a 5-speed gear box.
The shift pedal (E) is located on the left-hand side of the engine and
is used in combination with the clutch when changing gear.
FUEL TANK CAP
To open the fuel tank cap turn the key anticlockwise.
(E)
(1)
- 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
- Recommended charge time = 5 - 8 hours.
- The result ((charge current)x (charge time)) should fall into the range:
0.5 – 0.8 Cn
Note
In the event that charging procedures are used different to the
above, never exceed the maximum permissible charging currents
or charging time of 24 hours.
CAUTION
Exceeding the standard manner of charging may seriously shorten
the life of the battery.
Never exceed the standard charge.
CAUTION
Inverting the polarity of the battery terminals may cause problems
when charging the battery and damage the battery system.
The red terminal is positive (+) and the black terminal is negative
( - ).
FRONT GUARD
The front guard juts out from the QUAD assembly. In the event of
ahead-on collision with our vehicle, the guard attached directly to
the chassis, will soften the blow and prevent serious damage to the
steering and remainder of the vehicle.
-18-
SEAT
To remove the seat, use the same key as for the fuel tank cap (B).
Put the key in the lock which is located on the right-hand side of the
QUAD. Turn the key clockwise and then insert your hand between
the seat and the upper part of the casing. The seat should lift
easily.
NOTE
When replacing the seat, ensure that it is securely fixed.
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
The operating instructions for the battery are as follows:
1. Check the battery voltage in open circuit status (disconnected).
2. In the event that the battery voltage is below 12.60V, or has been stored
for over 6 months, the battery should be recharged according to the
procedure described in section 3.2.
In the event that the voltage is above 12.60V, the battery can be fitted
in the vehicle without requiring recharging.
3.1. Constant voltage charge mode.
- Constant voltage = 14.40 - 14.70V
(B)
protects feet and legs from the wheels should you lose your balance
and your feet slip off the rests. The width permits you to move freely.
FOOT PROTECTORS
REAR PROTECTION
Similarly, the rear guard (D), also juts out from the quad bike
assembly. This guard prevents us from overturning backwards, given
that an accident of this type could result in serious injury.
NOTE
If the slope is very steep, the guard will be unable to prevent
the vehicle from tipping backwards, therefore act with care on
slopes and examine the terrain closely.
FOOT REST ASSEMBLY
WARNING
The foot protectors and foot rest assembly are a form of protection
vital to the safe driving of the QUAD. The quad bike has very thick
wheels and these could easily drag your leg under them, causing
serious injury.
The quad bike is fitted with a pair of foot rests (E), one on the right
and the other on the left. Both foot rests have a grille. The assembly
-19-
The foot protectors (F)
are located between
the rests and the
wheels, and are a
further protection in
addition to the foot rest
assembly. By filling the
space we remove any
possibility of injury to
the lower limbs from
the wheels.
(F)
(D)
(E)
CHECKS TO MAKE BEFORE STARTING THE MACHINE
WARNING
Always inspect the QUAD each time it is going to be used, to ensure
that it is in safe working condition.
Always follow the inspection and maintenance programmes and
procedures described in this manual. If the machine is not inspected,
there is an increased risk of accident or breakdown.
FRONT AND REAR BRAKES
WARNING
Before driving, always check the brakes. Do not drive the QUAD
if any problems are detected in the brakes or if it is possible that
braking capacity has been lost, as this may cause an accident. If
there are any problems which can not be solved following the
adjustment procedures described in this manual, ask a specialised
workshop to inspect the QUAD.
A worn disc is automatically compensated and does not affect either
the brake lever or the brake pedal. Therefore, the only parts to
require adjustment are the play of the brake lever, and the position
and play of the brake pedal.
Brake lever and pedal
Check there is no free play in the front brake lever (1). In the event
that there is, check the condition of the brake pads and see section
"Adjustments and Maintenance".
Check there is no free play in the front brake lever (2).
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1
2
Check that the height of the brake pedal is correct. If the height of
the pedal is incorrect, ask a specialised workshop to adjust it.
Check the working of the lever and the pedal. They should move
smoothly and there should be a sensation of firmness on applying
the brakes. If this is not the case, ask a specialised workshop to
inspect the vehicle.
Brake fluid level
Check level of brake fluid. Top up with fluid if necessary. (See section
"Maintenance")
Recommended fluid D.O.T 3 or D.O.T 4
NOTE
The fluid issued at the manufacturers is D.O.T.4.
Brake fluid leaks
Check for leaks of brake fluid around the seals of the brake fluid
pipes and tank. Apply brakes hard for one minute. In the event of
a leak, ask a specialised workshop to inspect the machine.
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