GAS GAS Pampera 125 2009 User manual

PAMPERA 125 ´09

GAS GAS S.A. is very grateful for the trust you have placed in our company and congratulates
you on your excellent choice.
The Model PAMPERA 125 is the result of long GAS GAS experience developing a highly-relia-
ble, multi-purpose vehicle.
The purpose of this Owners Manual is to indicate how to use and maintain your vehicle, ple-
ase carefully read the information and instructions that it contains.
We would remind you that a vehicle’ s life depends the use and maintenance you provide it
with, keeping it in perfect running order will reduce repair costs.
This manual should be considered as an integral part of the motorbike and as such, should
remain in the basic equipment, including the case of change of ownership.
For any query, please consult a GAS GAS dealer, who will assist you ate all times.
Remember that to guarantee correct operation of your motorbike, original psare parts parts
should always be employed.
1
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 1

CONTENTS
Page
Motorbike description . . . . . . . . . . . . . . .4
Motorbike identification . . . . . . . . . . . . . .5
Main motorbike components . . . . . . . . . .6
- Keys . . . . . . . . . . . . . . . . . . . . . . . . . . .6
- Instruments and indicators . . . . . . . . .6
- Handlebar switches . . . . . . . . . . . . . . .8
- Clutch lever . . . . . . . . . . . . . . . . . . . .10
- Front brake lever . . . . . . . . . . . . . . . .10
- Rear brake lever . . . . . . . . . . . . . . . . .10
- Gear-change pedal . . . . . . . . . . . . . .10
- Battery . . . . . . . . . . . . . . . . . . . . . . . .11
- Fuse . . . . . . . . . . . . . . . . . . . . . . . . . .11
- Petrol tank . . . . . . . . . . . . . . . . . . . . .12
- Choke control . . . . . . . . . . . . . . . . . .12
- Petrol tap . . . . . . . . . . . . . . . . . . . . . .13
Page
Checks before starting-up . . . . . . . . . . .14
Routine checks . . . . . . . . . . . . . . . . . . . .15
- Front brake . . . . . . . . . . . . . . . . . . . .15
- Rear brake . . . . . . . . . . . . . . . . . . . . .16
- Brake pump and pads . . . . . . . . . . . . .16
-Accelerator grip . . . . . . . . . . . . . . . . . .17
- Lights and indicators . . . . . . . . . . . . .17
- Tyres . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine starting and operation . . . . . . . .18
- Starting the engine . . . . . . . . . . . . . . .18
- Running-in . . . . . . . . . . . . . . . . . . . . .19
- Aceleration . . . . . . . . . . . . . . . . . . . . .19
- Braking . . . . . . . . . . . . . . . . . . . . . . . .19
- Stopping . . . . . . . . . . . . . . . . . . . . . . .20
- Carburettor . . . . . . . . . . . . . . . . . . . .20
2
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 2

Page
Front suspension . . . . . . . . . . . . . . . . . .21
Rear suspension . . . . . . . . . . . . . . . . . . .21
Sparkplug checks . . . . . . . . . . . . . . . . . .22
Air filter . . . . . . . . . . . . . . . . . . . . . . . . .23
Transmission chain tensioning and lubrica-
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Lubrication and greasing . . . . . . . . . . . .27
Cleaning and storage . . . . . . . . . . . . . . .28
Maintenance operations . . . . . . . . . . . . .30
Page
Technical specifications and characteristics
31
3
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 3

MOTORBIKE DESCRIPTION
This motorbike incorporates a YAMAHA single-cylinder, 4-stroke, air-cooled, electrical star-
ting engine. Engine size is 123,7 cubic centimetres, with a 54 mm piston diameter and 54 mm
travel.
Ignition uses an AC 120 w magneto generator.
Multiple steel disc in oil bath clutch.
The engine is fixed to a perimeter-type chassis, made of high-strength rectangular section
tubing, with conical steering bearings.
The front suspension consists of a telescopic fork with 36-mm bars. The rear suspension con-
sists of a shock absorber anchored to a (Progressive Racing System), which provides excellent
driving smoothness.
The stainless steel front disc brake has a 260-mm diameter, with radial clip.
The rear brake has a 200-mm diameter.
4
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 4

MOTORBIKE IDENTIFICATION
Your motorbike’ s identification number is engra-
ved on the chassis.
The number engraved on the right-hand section
of the steering pipe will be used by us for all pur-
poses (specifications certificate, insurance and
licence number etc), and should be included in any
suggestion or complaint, and also when ordering
spare parts.
The engine serial number is engraved on the
upper section of the right engine oil sump and this
can be used as a reference when ordering spare
parts from the dealer.
5
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 5

MAIN MOTORBIKE COMPONENTS
KEYS
This model is supplied with a set of keys for the ignition contact switch. These keys are joi-
ned to a tab, which is engraved with the corresponding serial number. It is recommended that
this is kept in a safe place so that the number is at hand if the keys are ever lost.
INSTRUMENTS AND INDICATORS
1-. Main switch of ignition key
The main switch of ignition key has three positions: the OFF position, ignition position for
engine start-up, and a third position for switching on the machine’ s lights.
2-. Speedometer
The speedometer includes the milometer (3).
4-. Neutral indicator
This indicator lamp will come on when the gear-change pedal is in neutral.
5-. Main headlight indicator
This indicator comes on when the main headlights are switched on.
6
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 6

7-. Indicator lights
This indicator comes on when
the indicator lights are opera-
ted.
8-. Rev counter
This indicates the number of
engine revolutions per minute.
7
8 2
4
1
7
53
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 7

HANDLEBAR SWITCHES
1-. Indicator switch
This has three positions: In the central
position the indicators are switched off,
when turned to the right the right-hand
indicators are switched on, and when
turned to the left, the left-hand indica-
tors come on. Note that the switch will
automatically return to the central posi-
tion.
Do not forget to switch it off after having
completed the associated turn, by pres-
sing the button in its central rest posi-
tion.
2-. Horn switch
Press the button to sound the horn.
3-. Light switch
This has two positions: The lower position is for dipped headlights and the upper position
switches on the main headlights. To switch on the light system, the ignition switch must be
in the "light" position.
4-. Trip Display
8
3 2
1 4
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 8

5-. Ignition switch
This switch is used to start the engine,
after verifying that the gear-change
pedal is in the neutral position.
9
5
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 9

CLUTCH LEVER
The clutch lever is located on the left-hand side of the handlebar. To engage the clutch, the
lever should be pressed towards the grip or handlebar.
FRONT BRAKE LEVER
The front brake lever is located on the right-hand side of the handlebar. This brake is opera-
ted by pressing the lever towards the handlebar.
REAR BRAKE PEDAL
The rear brake pedal is located on the right side of the motorbike. It is operated by pressing
down with the foot.
GEAR-CHANGE PEDAL
This can be found on the left side of the motorbike, and is
operated with the foot through its full range of travel and let-
ting it return to its rest position before changing gear again.
To engage first gear, the pedal should be pressed down with
the foot. The other gears are engaged by raising the lever with
the toe of the foot.
10
5
4
3
2
1
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 10

BATTERY
Open the seat with the key to reach the battery.
The terminal block should be checked, together with the
actual terminals themselves.
If any oxide is observed on the terminal block or the ends
of the terminals, this should be cleaned off with a metal
bristle brush, sandpaper or similar. Once the cleaning
operation has been completed, the terminals should be
connected again and grease applied to their ends and the
terminal block.
Correct connection must be verified, otherwise the battery
could be damaged.
Special attention should be applied to battery handling,
since this contains sulphuric acid and you may run the risk of burning your skin, eyes and
clothing. It should also be kept away from flames, sparks and cigarettes.
If it should ever become necessary to replace the battery, then the same battery type should
be fitted.
FUSE
The installation has two fuses, to accede to these it is had to clear the saddle and to disas-
semble the lateral plate. The fuse of 7.5 A corresponds to the circuit of illumination and the
one of 15 A is the general fuse of the motorcycle. If the fuse should blow, switch off the engi-
ne and replace it with one of the same amps. Turn the ignition on again and verify electrical
system operation.
11
Fuse
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 11

PETROL TANK
To access the petrol tank, open the filling cap by turning it
in an anticlockwise direction.
Only oil-free petrol should be used.
The fuel tank capacity is 5.5 litres.
REMEMBER: unleaded petrol must always be used.
12
CHOKE CONTROL
The choke control is under the light switch. When the engi-
ne is cold, the lever should be driven and once the engine is
running, it should be to wait for seconds before loosen to its
original position.
Prolonged use of the choke once the engine is running
could lead to poor engine performance.
Choke control
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 12

PETROL TAP
The petrol tap is on the left, under the fuel tank.
It has three positions:
OFF: Fuel supply is cut-off in this position. The control
should be set to this position when the engine is not run-
ning.
ON: Fuel is supplied to the carburettor in this position.
Normal driving is performed with the lever in this posi-
tion.
RES: This is the RESERVE position. If you run out of fuel
with the lever in the ON position, then it should be moved
to this position. The tank should be refilled as soon as
possible, remembering to return this control to the
“ ON” position.
13
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 13

CHECKS TO BE CARRIED OUT BEFORE OPERATING
The following should be checked before using your motorbike:
Items to check Checks
Lights and indicators Check for correct operation
Speedometer cable Check for smooth operation and lubrication
Front and rear brakes Check both free-play and operation
Accelerator grip Check free-play, adjust and lubricate as necessary
Petrol tank Check level and refill as required
Tyres Check pressure, wear and general condition
Indicator lights Check for correct operation
Clutch Check both free-play and operation.
Transmission chain Check tension and condition
Battery Check its operation Charge where necessary
These checks before use should be carried out each time the motorbike is used.
A complete check-out requires no more than a few minutes.
If any problems are detected during the checks, these must be corrected before the motorbi-
ke is used.
14
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 14

ROUTINE CHECKS
FRONT BRAKE
The front brake consists of a 260 mm
diameter disc brake, which is operated
by means of a double-piston floating
clip and hydraulic pump.
The braking surface should be free
from both grease and dirt to ensure
perfect operation. The following pro-
cedure should be followed if you find
it necessary to empty and the refill the
brake fluid circuit.
Remove the pump cover and fill
almost completely with brake fluid.
The loosen the bleeding nit and fit a
piece of tubing (for petrol) to this
same nnut.
It is recommended that this tube is inserted into some form of container so that there is no
spilled fluid. With the liquid in the pump and the bleeding nut loose, slowly operate the lever
until the liquid drops and exits the tube without any air bubbles. At this point, close the ble-
eding nut and refill the tank with brake liquid to the halfway mark. Close the cover and ope-
rate until perfect braking is achieved. Check the brake liquid level through the view-port on
the brake pump. Refill if necessary.
15
Brake liquid level
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 15

REAR BRAKE
Check the oil level on a regular basis. It should never be
allowed to drop below the lower mark on the tank which
is located above the brake pump and underneath the
right-hand side number plate. Only hydraulic oil for
brakes should be employed to fill this tank.
When the brake travel is made empty, the system should
be purged at one of our service centres.
BRAKE PUMP AND PADS
Verify the brake fluid level, if it is not correct, the tank
should be refilled to the correct mark. If the hydraulic
clip brake pads are worn, they must be replaced.
The minimum thickness of the Ferodo pads is 2 mm.
16
Please remember that these operations should be carried out by an official GAS GAS ser-
vice centre.
Brake liquid tank
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 16

ACCELERATOR GRIP
Check for correct operation by rotating the
grip and verifying correct free-play.
The grip should firmly return when the acce-
lerator is released.
LIGHTS AND INDICATORS
Check that all headlights, road lights, indica-
tor lights, rear lights and indicator lamps
operate correctly.
TYRES
Tyre pressure has a direct influence on machine stability and comfort with respect to braking,
and above all on user safety, therefore tyre pressure should be regularly checked and maintai-
ned. Check that the rim is centred and also inspect for tyre wear. Do not overload the motor-
bike as this will lead to a loss of stability and excessive tyre wear.
WARNING: If tyre pressure is very
high, they lose their shock-
absorbing capabilities and all the
effects of uneven roads will be
directly transmitted to the chas-
sis, with negative consequences
on both safety and comfort.
Pressure in cold
Until 90 Kg. of load 1,7 Kg/Cm22,0 Kg/Cm2
Front Rear
17
From 90 Kg. of load 1,8 Kg/Cm22,2 Kg/Cm2
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 17

ENGINE STARTING AND OPERATION
It is very important that you have full knowledge of your motorbike and how it works.
WARNING: The engine should never be left running in an enclosed space because the toxic
exhaust fumes could have serious consequences on your health.
STARTING THE ENGINE
Open the petrol tap.
If the engine is cold, use the choke, which is located next the carburettor under the fuel tank.
Turn the ignition key in a clockwise direction, check that the engine is in neutral, fully close
the accelerator grip and press the electrical start push-button.
Remember that the electrical starter motor must not be engaged for more than five seconds
at a time.
A few seconds after the engine starts up the choke should be returned to its original position.
Then press the clutch lever and engage first gear, progressively releasing the clutch lever as
the accelerator is smoothly operated.
Do not fully accelerate or operate the engine at a high rev count until it is sufficiently heated-
up.
WARNING: Before actually moving off, you should always allow sufficient time for the
engine to heat up and should never strongly accelerate with the engine cold. This will
guarantee longer engine life.
18
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 18

RUNNING-IN
The most important part of your motorbike’ s life occurs between 0 and 500 kilometres. For
this reason, we recommend that you carefully read the following instructions.
During the first 500 kilometres, you should not overload your motorbike since the engine is
new and the various component parts have to mutually wear down and polish themselves until
perfect running order is achieved.
During this period of time, prolonged use at high revolutions should be avoided, together with
conditions which could lead to excessive engine heating.
ACCELERATION
Speed is adjusted by opening or closing the accelerator. Rotating it backwards will increase
speed, whereas rotating forwards will reduce speed.
BRAKING
Close the accelerator grip, then progressively operate the front and rear brakes.
WARNING:
Sharp braking can cause skids or bouncing.
19
Manual PAMPERA 125-ING Jul09.qxp:Manual MRX-SMX 125-ING v4 22/07/09 12:31 Página 19