GAS GAS QUAD WILD HP 300 RV - 2005 User 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

PRESENTATION
GAS GAS thank you for the trust you have placed in us.
By choosing the new WILD H.P. 300. RV. you have just entered the great GAS GAS family and, as a user of
the number one off-road motorbike manufacturer, you deserve the distinguished treatment that we wish to offer
to you both in our after-sale relationship and in the explanations that we provide in this manual
Our WILD H.P. 300. RV. is a sports quad designed by and for competition. You will appreciate the high level
of technical perfection and reliability as well as a meticulous design and high performance.
This manual will provide you with a solid basic knowledge of the characteristics and machine handling. It also
contains important safety instructions and provides information about the special skills and techniques required
to drive this machine as well as the basic maintenance and inspection processes.
Thank you for your trust in us, and welcome to GAS GAS motorbikes.
-3-

GENERAL WARNINGS
Read this Manual carefully. It provides all the necessary information
for your safety, and that of others, as guaranteeing the correct
storage and maintenance of the GAS GAS quad you have just
acquired.
READ THIS MANUAL COMPLETELY BEFORE USING THE
MACHINE.
Important information about this manual
The information of special importance is signalled in this manual
with the following notation:
WARNING
The WARNING symbol identifies special instructions or procedures
that, if not correctly followed, could result in personal injury, or even
death for the person using the vehicle, those in the proximity and
those technicians responsible for its inspection and maintenance.
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 damage to the environment and
conflict with other people. Responsible use of your quad will ensure
that these problems and conflicts do not occur.
TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE
YOU USE YOUR QUADRICYCLE LEGALLY, WITH CONCERN
FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF
OTHER PEOPLE.
Quad riding is a fantastic sport, and we hope you will enjoy it to the
fullest.
This manual has been compiled with the data and specifications
available at the time of printing. Any differens there may be regarding
your vehicle will be due to improvements in production and in quality.
GAS GAS Motos S.A. are constantly improving their vehicles so that
you may enjoy them more.
-4-

-5-
- Verifications to be made before starting the
machine ...................................................................................20
Front and rear brakes ..................................................20
Fuel..............................................................................21
Cooling system ............................................................22
Chain ...........................................................................23
Throttle grip..................................................................23
Lights ...........................................................................23
Tyres............................................................................23
- Using the QUAD ...................................................................24
Starting the engine.......................................................24
Changing gears ...........................................................25
Driving the vehicle .......................................................26
Stopping the engine.....................................................26
Running-in the engine..................................................27
Engaging the reverse gear ..........................................27
Parking on slopes ........................................................27
- Driving the QUAD. Practical recommendations ................28
Become familiar with your QUAD ................................28
Drive with care and common sense.............................28
How to turn your QUAD. ..............................................29
Up hills .........................................................................30
Down hills ....................................................................30
Crossing slopes ...........................................................30
Going across shallow water.........................................31
Riding on rough terrain ................................................31
Sliding and skidding.....................................................31
CONTENT
- Presentation............................................................................3
- General warnings ...................................................................4
- Contents..................................................................................5
- Specifications .........................................................................7
- Information about your safety...............................................8
- Important information ..........................................................10
Identification number....................................................10
- Location of components......................................................12
- The main parts of the QUAD................................................14
Ignition key...................................................................14
Starter pedal. ...............................................................14
Lights ...........................................................................14
Emergency lights .........................................................15
Throttle grip..................................................................15
Clutch lever..................................................................15
Front brake lever..........................................................16
Rear brake pedal .........................................................16
Emergency stopping ....................................................16
Reverse gear push button............................................17
Shift pedal....................................................................17
Starter ..........................................................................17
Fuel tank cap ...............................................................17
Fuel tap........................................................................18
Seat..............................................................................18
Front guard ..................................................................18
Rear guard...................................................................19
Footrest assembly........................................................19
Foot protection.............................................................19

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- Tuning ...................................................................................32
Tuning the front suspension ........................................32
Tuning the rear suspension .........................................33
Tuning the fuel supply..................................................33
- Periodic maintenance and adjustment...............................37
Maintenance chart .......................................................37
Clutch lever adjustment ...............................................38
Adjusting the brake lever and pedal ............................38
Checking the brake fluid level......................................39
Checking the brake front and rear pads ......................40
Changing the wheels ...................................................41
Swing arm shaft...........................................................41
Adjusting and lubricating the chain guide ....................41
Checking the coolant level...........................................42
The air filter..................................................................44
Spark plug maintenance..............................................46
Adjusting the idle .........................................................47
Inspecting and lubricating the cables...........................48
Replacing lights ...........................................................48
Tightening torques table ..............................................52
Torque locations diagram ............................................53
- Cleaning, lubrication and storage ......................................54
Cleaning.......................................................................54
Lubrication ...................................................................55
Storage ........................................................................56
- Multifunction speedometer.........................................................57
- Trouble shooting table.................................................................58
- Electrical diagrams......................................................................64
- Warranty manual.......................................................................65

SPECIFICATIONS
ENGINE
Displacement:
Type:
Cooling system:
Bore x stroke:
Carburettor:
Ignition:
Clutch:
Gear box:
Transmission:
Power:
CHASSIS
Chassis:
Front suspension:
Rear suspension:
Front brake:
Rear brake:
Rims:
Front tyres:
Rear tyres:
Kick-starter:
Engine, disc and chain sprocket shield:
DIMENSIONS
Wheelbase:
Overall width:
Curb weight:
Fuel tank capacity:
294.7 cc
Single cylinder, two stroke with crankcase and exhaust valve induction
by layers.
Liquid cooled
72 x 72 mm
Keihin PWK 38 mm
Ducati Energia Reverse System
Hydraulic controlled multi-disc
6 speed
Primary by gears, secondary by chain
50.6 HP at 7340 rpm / 5.02 mkg at 6890 rpm
Multi-tube twin-cradle frame, made from Cr-Mo steel (Chromolloy).
Wishbone arms with two ÖHLINS multi-adjustable shock absorbers.
Aluminium alloy swing arm with no welding. Progressive system with single
multi-adjustment ÖHLINS shock absorber.
Two self-ventilated 180mm discs with floating two-piston BREMBO calliper.
Self-ventilated 220 mm disc with floating two-piston BREMBO calliper.
Aluminium
21 x 7.00 – 10”
20 x 11.00 -9”
Forged aluminium
Aluminium alloy, fibre
1.280 mm
1.200 mm
165 Kg
18 litres
-7-

- Always perform the routine checks described in this manual before
using the QUAD, to make sure it is in perfect operating condition.
- Riding a QUAD is not like driving any other vehicle, especially when
cornering. Practise on flat, open ground free from obstacles and
other vehicles.
Read the recommendations made by this manual in the section "Use
of the QUAD".
- The same applies to steep climbs or descents. Start practicing with
minimum slopes and raise the difficulty little by little. Advice about
this is also included in the section mentioned above.
- In case the engine stalls, follow the procedure described in this
manual. If the engine stalls and the vehicle starts rolling backwards,
follow the special braking procedure described in this manual. Get
off the vehicle to the higher on the slope than the vehicle. Remember
that your safety comes before that of the machine, and it is important
to keep this priority in mind.
- When traversing a slope, move your weight to the uphill side; read
the manual regarding this. Avoid excessively slippery slopes or loose
surfaces.
- Never try to overcome big obstacles, like rocks or trunks. This
vehicle has not been designed for this purpose; you may damage
the vehicle and/or cause injury to yourself.
- Do not try to make the vehicle slide sideways if you don't master
this technique; this is a particularly dangerous manoeuvre. Like in
the cases described above, do some testing on flat, wide, obstacle-
free ground beforehand and follow the advice given in this manual.
You must never lose control of the vehicle.
SAFETY INFORMATION
The QUAD is not a toy: driving it can be dangerous.
The QUAD is driven differently form other vehicles such as cars and
motorbikes. Even during routine manoeuvres like turns, driving on
slopes or over obstacles, collisions or tumbles can occur if the correct
precautions are not taken.
WARNING
If these instructions are not followed, serious injury or even death
may result.
- Do not drive the QUAD before reading the following 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 adapt your speed according to your skills, the weather and
ground conditions.
- Pay attention to surface changes and control your speed when
you are not familiar with these conditions.
-8-

- This vehicle has been designed to go through water with maximum
depth of 35 cm. Do not use the vehicle in fast moving water; carefully
read the instructions regarding this type of terrain.
Take into account that braking efficiency is diminished when the
brakes are wet. When coming out of the water, brake several times
so that they dry more quickly by friction.
- Always use the tyre size and type described in this manual.
WARNING
-Always stop the engine before and during 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 is well ventilated and free from any source of
flame or sparks; this includes any appliance with a pilot light.
The fuel might catch fire causing burns. Avoid spilling fuel over the
engine, exhaust or silencer.
- When transporting the QUAD using a trailer, make sure it is upright
and that the fuel tap is in the OFF position (closed). Fuel leaks might
occur in the carburettor or in the fuel tank otherwise.
- Fuel is poisonous. In case of accidental ingestion, abundant vapour
inhalation or contact with eyes, seek medical help immediately. If
fuel comes in contact with your skin, wash it with soap and water.
If fuel is spilled on clothes then change them.
- Always ride your QUAD in well-ventilated areas.
Do not start the engine or keep it running in enclosed areas. The
exhaust vapour is poisonous and may lead to loss of consciousness
or even death in a short time.
-9-

IDENTIFICATION NUMBER
Write down your vehicle's identification number (serial number), the
information on the model label and the key identification number in
the spaces provided, to make paperwork easier should any spares
be required or as a reference in case of vehicle loss.
Serial number
It is located on the front (A) of the vehicle. Indicates the frame
number with which the vehicle is registered.
-10-
SERIAL NUMBER
IMPORTANT INFORMATION
The vehicle leaves the factory with some elements not fitted, in order
to make transportation easier. The dealer will make sure each
element is correctly fitted and you will receive the QUAD ready for
use. Thus, this paragraph is purely for your information.
A carburettor-adjustment kit is included; the adjustments must be
performed by an expert and only when necessary. The carburettor
is already tuned, so setting changes are not initially required.
A tool is also enclosed to adjust the chain and to centre the swing
shaft. Do not lose it; it will be extremely useful.
1
2
3
1. Chain guard.
2. Swing shaft guard.
5. Chain and swing arm
adjustment tool.
6. Idle stop.
7. Full stop.
8. Carburettor needle.
5
6
7
8
4
3. Footrest assembly.
4. Foot protection.
4

Key identification number
The QUAD has two pairs of keys. The first and most important (C)
is the ignition key, and the second (D) is used for the fuel tank and
seat. The identification number is located precisely where the two
keys join as shown in the image. The identification number is stamped
on the ignition key (C). This number is used to order a new set of
keys in case of loss.
HOMOLOGATION PLATE
-11-
QUALITY APPROVAL PLATE
NOTE
The vehicle's serial number is used to identify your machine.
(C)
(D)
(A) (B)
Quality approval plate
The QUAD is fitted with its own corresponding quality approval plate
(B) with the serial number, also printed on the front of the vehicle.
The data coincides with that in the documents. We recommend
noting the data in the following space provided. KEY NUMBER

-12-
LOCATION OF COMPONENTS
GAS GAS WILD H.P. 300. RV.
1- Clutch lever
2- Light switch
3- Flash beam
4- High beam switch
5- Emergency stop
6- Ignition key
7- Parking brake
8- Front brake lever
9- Throttle control
10- Front guard
11- Brake pads
12- Fuel tank cap
13- Footrest grids
14- Rear protection
10
12
13
14
11
178 96
5
4
3
2

-13-
1715
18 2419 22
23
21 2520 26
16
15- Headlight casing
16- Fuel cut-off
17- Seat
18- Front shock absorber
19- Spark plug
20- Shift pedal
21- Swing arm
22- Exhaust pipe
23- Front brake fluid
24- Kick-starter pedal
25- Brake pedal
26- Exhaust

To turn on the low beam lights ( ) push the switch (C) to the position
( ).
To turn on the high beam ( ) push the red button (D).
The high beam indicator on the instrument panel will be turned on
( ).
To turn off the lights push the switch to the position .
LIGHTS
NOTE
The headlight and the rear light can only be switched on when
the engine is on.
THE MAIN PARTS OF THE QUAD
IGNITION KEY
The ignition lock (A) is located on the front part of the handlebars.
To turn the ignition ON, turn the key clockwise to the "ON" position.
To turn the ignition OFF, turn the key anti-clockwise to the "OFF"
position.
KICK STARTER
The kick-start pedal (B) is located on the right hand side of the
QUAD in an initial rest position, pull until it is in operation position.
Operate the kick in order to start the QUAD.
Once the engine is started, fit the starter pedal fastener.
-14-
(C) (D)
(F)
(E)
(G)
(C). Light switch.
(D). High-low beam switch.
(E). Overtaking lights
(F). Indicators.
(G). Horn.
Switch (C) has three
positions, initially in the
"OFF" position.
High beam
Low beam
No lights
(A)
(B)

-15-
Indicators (F) are located in the lower part of the same left hand side
grip. Note that pushing the switch to the right turns on the right
indicator, and to the left to operate the left indicator.
On the same group we will find the horn button (G).
DISTRESS LIGHTS
The button is located on the front part of the vehicle (H), in front of
the handlebars. This works even when the ignition is off.
When on, a light inside the button will also flash.
NOTE
Regarding the use of this lights, follow the legal conditions of
each country.
THROTTLE GRIP
Before starting the engine, check that the throttle works smoothly
(I). Make sure it spins smoothly back to idle when the grip is released.
The grip has a return spring that puts the engine to idle and slows
the QUAD down when the control is released.
CLUTCH LEVER
The clutch lever is located on the left side of the handlebar.
It is used to engage or disengage the clutch (J).
To make the clutch work smoothly, the lever must be pulled quickly
and released slowly.
(H)
WARNING
If the throttle is not working properly, it may be difficult to accelerate
or decelerate as desired. This could result in an accident. Check the
correct operation of the throttle before starting the engine. If the
throttle does not work smoothly then find the cause. Solve the
problem before using the machine, or go to a specialised workshop.
(I)
(J)
(H)

-16-
One end (C) is attached to the vehicle and the other end (D) is
secured to the rider.
The cable is elastic. One end is joined to the rider and the other to
the vehicle so that the end of the cable attached to the vehicle is
sensitive to sudden movements and will release.
When released, the engine stops automatically.
NOTE
Make sure you release the parking brake before operating the
throttle.
We recommend that the cable is attached to a strong point, so that
it is not accidentally released.
(Ex. The cable may be attached to trousers, jacket, ... to a wrist...
but always to a part where it is secure).
WARNING
The use of this vehicle is prohibited without attaching the emergency
stop system. Disregard for this may result in serious consequences.
(D).
FRONT BRAKE LEVER
The front brake lever (A) is located on the right side of the handlebars.
Operate it to apply the front-wheel brakes.
REAR BRAKE PEDAL
The rear brake pedal (B) is located on the right hand side of the
lower chassis. Operate it to apply the brake to the rear wheels.
EMERGENCY STOP
The vehicle features an emergency stop system. This prevents the
vehicle from continuing out of control in case the rider should fall off.
(D)
(C)
(A)
(B)

STARTER
The starter (F) is a mechanism that aids engine operation in case
it is cold. The engine will reach its optimal temperature, in low time
and without causing damage.
To operate, pull up the choke knob without turning the throttle grip,
start the engine. Note that the engine will start after a certain number
of revolutions.
After just a few seconds, the engine will be at a correct operation
temperature. To release the choke just press the button in all the
way.
NOTE
- If the engine is flooded then start with the throttle fully open.
- The QUAD may be started in gear if the clutch is disengaged.
FUEL TANK CAP
To open the fuel tank, turn the key anti-clockwise.
REVERSE GEAR BUTTON
The WILD H.P 300 RV. is fitted with a reverse gear. The reverse
gear button (1) is located in the centre of the handlebars.
WARNING
-The reverse gear button must NEVER be operated when the QUAD
is moving.
-The kick-starter must NEVER be operated when the reverse gear
system is engaged.
For more information, see the chapter “Engaging the reverse gear”,
page 27
GEAR SHIFT PEDAL
This machine is fitted with a 6 - speed gear box. The gear shift pedal
(E) is located on the left side of the engine and is used in combination
with the clutch when changing gears.
-17-
(1)
(E)
(F)

-18-
FUEL CUT-OFF
This tap supplies fuel to the carburettor and is located on the left
hand side under the seat. The cut-off has three positions.
OFF: With the lever in this position, there is no fuel flow. Always
turn the cut-off to this position when the machine is not in use.
ON: With the lever in this position, fuel flows to the carburettor. The
machine is normally used with the cut-off in this position.
RES: This indicates that the fuel reserve is being used. If the machine
runs out of fuel in the ON position then turn the cut-off to this position.
CAUTION
If the RESERVE must be used then fill the tank as soon as possible!
Following refuelling put the lever of the cut-off back into the position
(A) ON.
SEAT
To remove the seat, use the same key for the petrol-tank cap (B).
Insert the key into the lock located on the right hand side of the
QUAD.
Turn the key clockwise, and then insert your hand between the seat
and the chassis at the rear of the seat.
The seat will lift easily.
NOTE
When putting the seat back in the normal position, ensure it is
secured.
FRONT GUARD
The front guard (C) projects from the QUAD. In case of a frontal
collision, the protection, attached directly to the frame, will absorb
the impact and protect the steering and the rest of the vehicle from
significant damage.
ON
Open
OFF
Closed
RES
Reserve
(A)
(B)
(C)