GAS GAS PAMPERA 400 - 2006 User manual

MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D’USO
BETRIEBSANLEITUNG

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Foreword
GAS GAS thanks you for the trust you have placed in us.
By choosing a new PAMPERA 400 2006 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 400 2006 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.

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USE OF OIL RECOMMENDED:
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.
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.
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.
Driving motorbikes is a fantastic sport, and we hope
you enjoy it to the full.

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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 guide .................................................................................... 26
Tension adjustment ........................................................................ 27
Handlebars ..................................................................................... 29
Brakes............................................................................................. 29
Steering .......................................................................................... 31
Steering lock................................................................................... 32
Front fork ........................................................................................ 33
Rear suspension............................................................................. 36
Wheels............................................................................................ 38
Cleaning.......................................................................................... 39
Tightening nuts and bolts ............................................................... 40
Table of tightening torques ............................................................. 41
Lubrication ...................................................................................... 42
Engine oil........................................................................................ 43
Suspension adjustment .................................................................. 46
In competition ................................................................................. 50
Storage ........................................................................................... 51
Multifunction instructions ................................................................ 52
Fault diagnosis................................................................................ 58
Guarantee manual.......................................................................... 64

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GENERAL INFORMATION
ENGINE
Motor 4 stroke, single-cylinder DOHC 4 valves, liquid cooled
Displacement in cubic centimetres 449 cc
Bore and stroke 97 x 60.76 mm
Spark plug NGK CR8E or DENSO U24ESR-N
Fuel supply Dell'Orto PHF 36 Carburettor
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 DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes.
Aluminium rocker
Tyre sizes Front 90/90 x 21
Rear 120/90 x 18

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Suspension Front Marzocchi ø'bf 45mm telescopic fork.
Rear Progressive system with SACHS single shock absorber
Suspension stroke Front 202 mm
Rear 320 mm
Front suspension oil MARZOCCHI SAE 7.5
Front fork oil level Marzocchi: 200 mm (compressed, without spring)
BRAKES
Type Front / rear Disk brakes, AJP 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 7.2 litres
Weight 119 Kg.
(Specifications subject to change without notification, also possibly not applicable in some countries).

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1 3 4 2 65
LOCATION OF COMPONENTS
GAS GAS PAMPERA 400
1- Clutch handle
2- Engine start button
3- Fuel tank cap
4- Front brake fluid tank
5- Front brake handle
6- Throttle control

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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
7
8
9
10
1112
13
16 14
15 17
18 19
2021 22
23 24

PETROL
The GAS GAS PAMPERA 400 has a four stroke engine and requires
98 octane, unleaded petrol.
Fuel Tank Capacity
7.4 L
(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.
SIDE STAND
To unfold side stand (A), open to vertical position.
The stand returns to its original position with the aid of the spring
(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.
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(B)
(A)
(B)
(A)

SERIAL NUMBER
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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RECOMMENDED FUEL
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 90
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.

Stopping the engine
- Change gear to neutral.
- Then release the throttle completely and rotate the ignition key
anti-clockwise.
- 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 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.
- Without using the throttle, press the electric start button (B).
(D)
(A)
(B)

SHIFTING GEARS
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). Shift pedal.
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STARTING WHEN THE ENGINE IS COLD
The cold start function is responsible for aiding the engine start if
this 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.
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.
(B)

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.
Downshift progressively as speed is reduced to ensure good engine
response when you want to accelerate.
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.
NOTE
The slow speed necessary during the break-in period may cause
carbon to build up on the spark plug and soil it. If, on inspecting
the spark plug, this is seen to be the case, replace the standard
spark plug with a higher heat grade spark plug for the duration
of the running-in period.
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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(A)

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Period
Every 30 hours
T
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I
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R
I
I
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I
I
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I
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T
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
Period
First 5 hours
T
I
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R
I
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I
I
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T
Inspect each time that the motorcycle has run or when necessary
*Change every 4 years
Change every 2 years
Clean, lubricate and inspect each time the motorcycle has been ridden
*Revise every 4 years
*Change every 2 years
Inspect tyres for damage and check the tyre pressure every time the motorcycle has run
Period
Every 60 hours
T
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R
I
R
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T
MAINTENANCE CHART
I NOTE: I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace, T = Tighten, C = Clean

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
To remove the battery, follow these steps:
1. Remove the screws (A) and remove the seat (B).
2. Release the rubber (C).
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3. Disconnect the terminals ensuring that they do not
enter into contact with metal parts then extract the battery.
WARNING
Hydrogen gas produced by the battery may explode if exposed to
open flame or sparks.
Keep the area ventilated and free from naked flames.
The operating instructions for the battery are as follows:
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
(A)
(C)
(B)

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- 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
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.
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 non-
approved accessories. Interfering with the radiator could cause
overheating and result in engine damage.
Coolant
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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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). 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.
(A)
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.