GAS GAS WILD HP 450 User manual

MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

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.
WILD HP -69-
WARNING
Hydrogen gas produced by the battery may explode if exposed to
open flame or sparks. Keep flames and sparks away from the battery.

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
WILD HP -70-
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

WILD HP -71-
- 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

SPECIFICATIONS
ENGINE
Cylinder size:
Type:
Cooling system:
Bore x Stroke:
Injection system:
Ignition:
Clutch:
Gear box:
Transmission:
Start:
FRAME
Frame:
Front suspension:
Rear suspension:
Front brake:
Rear brake:
Rims:
Front tyre:
Rear tyre:
Kick starter:
Engine, disc and chain ring shield:
DIMENSIONS
Wheelbase:
Total width:
Void weight:
Fuel capacity:
449 c.c.
Single cylinder, four stroke with 4 valves cylinder head.
Líquid cooled.
95 x 62,6 mm.
MAGNETI MARELLI.
Integrated on EFI.
Hydraulic multidisc in oil bath.
6 gears.
Primary with gears, secondary with chain.
Electric starting and aditional kickstarter pedal.
Multi-tube twin-spar frame, Cr-Mo steel made.
Wishbone arms with two ÖHLINS multi-adjustable shock absorbers.
Aluminium allow swing arm with no welding. Progressive system with multi-
adjustment ÖHLINS shock absorber.
Two self-ventilated 180mm discs with floating two-piston BREMBO caliper.
220mm self-ventilated disc with floating twin-piston BREMBO caliper.
Aluminium.
21 x 7,00 – 10”.
20 x 11,00 – 9”.
Forged aluminium.
Forged aluminium.
1.280 mm.
1.300 mm.
175 Kg.
18 litres.
WILD HP -72-

WILD HP -73-
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 obstacle-
free 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.
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

WILD HP -74-
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.

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.
WILD HP -75-
SERIAL NUM.
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.
1
2
3
5. Chain and swing arm axle adjustment
spanner.
5
4
4
1. Chain guard.
2. Swing arm guard.
3. Footrests.
4. Foot protectors.

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.
WILD HP -76-
NOTE
The vehicle's serial number is used for your machine's
identification.
(C)
(D)
(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 ID. N.

WILD HP -77-
1- Clutch lever
2- Light switch
3- Flash beam
4- High beam
5- Emergency stop
6- Contact key
7- Parking brake
8- Starting button and stop engine
11
13
14
15
12
1 2 3 4 79 1065 8
9- Front brake lever
10-Throttle grip
11-Front guard
12-Brake pads
13-Fuel tank cap
14-Footrest grids
15-Rear protection
LOCATION OF COMPONENTS
GAS GAS WILD H.P. 450

WILD HP -78-
1715
18 2419 22
23
21 2520 26
16
15-Headlight fairing
16-Full-throttle body
17-Seat
18-Front shock absorber
19-Engine
20-Gear pedal
21-Swing arm
22-Exhaust pipe
23-Front brake fluid
24-Kick starter pedal
25-Brake pedal
26-Oil tank

LIGHTS
NOTE
The headlight and the rear light can only be switched on when
the engine is on.
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.
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.
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.
WILD HP -79-
Switch (A) slides into three
positions, we will find it in
the "OFF" position.
(A)
(C)
(B)
Short beam
Low beam
Whithout lights
(A) (B)
(D)
(C)
(E)
(A). Light indicator.
(B). High beam.
(C). Blow of high beam.
(D). Indicators.
(E). Horn button.

WILD HP -80-
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.
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.
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.
(G)
(H)
(F)
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.

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.
WILD HP -81-
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.
EMERGENCY STOP
The vehicle features an emergency stop system. This mechanism
prevents the vehicle from running on in case the rider should fall.
One end (C) is attached to the vehicle and the other end (D) is
attached to the rider.
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.
(C)
(D)
(A)
(B)

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.
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.
WILD HP -82-
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.
(F)
(E)

- 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.
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.
WILD HP -83-
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 right-
hand 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.
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
(B)
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 (-).

FOOT PROTECTIONS
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.
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.
WILD HP -84-
The foot protections (F)
are located between
the footrests and the
wheels, and they are
an additional
protection system to
the footrests. By filling
the gap, we have
eliminated the
possibility to damage
our lower limbs with
the wheels.
(F)
(D)
(E)

CHECKINGS TO BE MADE BEFORE RIDING THE VEHICLE
WARNING
Always inspect the quad before every use, to make sure it is in safe
riding conditions.
Always follow the inspection proceedings and programmes described
in this manual. Failure to inspect the machine increases the risk of
accident or breakdown.
FRONT AND REAR BRAKES
WARNING
Always check the brakes before riding. Do not drive the QUAD if
you find a problem in the brakes or if braking capacity may be
reduced, because it might lead to an accident. Should you discover
any problem that cannot be solved using the proceedings described
in this manual, go to a specialised workshop to have the QUAD
inspected.
Disc wear-out is automatically compensated and does not have any
effect on the brake lever or pedal. The only adjustments required
are the brake lever free play, the pedal position and its free play.
Brake lever and pedal
Check the free play in the front brake lever (1). Should it be noticeable,
check the state of the brake pads and look in the "Adjustments and
Maintenance" section of this manual
Make sure the free play of the brake pedal is not excessive (2).
Check the brake pedal position. If you do not find it correct, have it
adjusted at a specialised workshop.
Check the operation of the lever and pedal. They must move smoothly
and when applying the brakes the sensation must be of firm grip in
both of them. Otherwise, have a specialised workshop inspect you
vehicle.
Brake liquid level
Check the brake liquid level. Add liquid if necessary.
(See "Maintenance" section of the manual)
Recommended liquid D.O.T. 3 o D.O.T. 4
NOTE
The vehicle is fitted with D.O.T.4. as standard.
Brake liquid leaks
Check for brake fluid leaks in the pipe joints or fluid reservoirs. Brake
firmly for a minute. In case of a leaking, have a specialised workshop
inspect your vehicle.
WILD HP -85-
1
2