User manual GAS GAS K2 QUAD 50

4 STROKE 50 MANUAL DEL USUARIO USER MANUAL MANUEL D'ENTRETIEN LIBRETTO D´USO BETRIEBSANLEITUNG 50 4 STROKE SERVICE MANUAL ENGLISH INTRODUCTION Congratulations on your purchase of QUAD 50 - 4 STROKE it represents the result of many years of our experience in the production of fine machines. You can now appreciate our craftsmanship and reliability of the master piece. This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information. Failure to follow the warnings contained in this manual can result in serious injury or death. It provides information about special techniques and skills necessary to your machine. AN IMPORTANT SAFETY MESSAGE: ­ READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR MACNINE. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ­ PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE. ­ NEVER OPERATE A QUAD WITHOUT PROPER TRAINING OR INSTRUCTION. ­ THIS QUAD SHOULD NOT BE RIDDEN BY ANYONE UNDER 6 YEARS OF AGE FOR 50 cc DISPLACEMENT. -1- -2- CONTENTS 1. LOCATION OF THE "WARNING AND SPECIFICATION LABELS" .................................... 5 2. NOTES FOR SAFEY.......................................... 7 3. DESCRIPTION .................................................. 9 Parts location ......................................................... 9 Identification number record ................................ 10 Parts function ...................................................... 11 Fuel ...................................................................... 13 Engine oil ............................................................. 14 Tires ..................................................................... 15 Inspection ............................................................ 15 Starting procedure ............................................... 17 Run-in ................................................................. 17 Riding .................................................................. 17 Parking ................................................................ 18 Turning .................................................................... 18 Climbing uphill ........................................................ 19 Crossing through shallow water.............................. 19 4. MAINTENANCE .................................................. 20 Maintenance schedule ........................................... 20 Spark plug .............................................................. 21 Air cleaner............................................................... 21 Carburetor and idle speed adjustment .................... 22 Brakes..................................................................... 22 Drive chain .............................................................. 23 Throttle cable .......................................................... 23 Battery .................................................................... 24 5. SPECIFICATIONS .............................................. 25 6. WARRANTY TERMS AND CONDITIONS ............. 26 7. WIRING DIAGRAM ............................................. 29 -3- -4- 1. LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on your machine. They contain important information for safe and proper operation. Never remove any labels from your machine. If a label becomes difficult to read or comes off, a replacement lable is available from your dealer. -5- -6- 2. N0TES FOR SAFETY ­ Read this owner's manual carefully before riding. ­ This vehicle is designed for the riders age 6 and older for 50cc displacement. ­ Both the parents and their children must fully understand everything in this manual be fore riding. ­ This vehicle is for OPERATOR-ONLY. Never carry passenger on an QUAD. ­ Always wear a helmet, face shield ,boots,gloves and protective clothing when riding. ­ Beginners should receive training from a cretified instructor. ­ The practice location must be a level. free of obstacles, off-road area. ­ It is illegal to ride this vehicle on public roads or highways. lf it is necessary to cross a public road, dismount from the vehicle and push it across. ­ Don't allow your child to ride without supervision. ­ Don't take alcohol or drugs when riding.They can affect your judgement and slow down reaction time. ­ Maintain a safe distance between your vehicle and other off-road vehicle. ­ Never ride this vehicle unless it has been properly adjusted and maintained. ­ Never run the engine in close areas.The exhaust gas contains poisonous carbon monoxide. ­ Don't touch any part of the engine or exhaust system during and following operation. ­ Always check for obstacles before operating in a new area. ­ Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. -7- ­ Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level,smooth terrain.On extremely slippery surfaces such as ice,go slow and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate a QUAD in fast flowing water. Remember that wet brakes may have reduced stopping ability.Test your brakes after leaving water.lf necessary. apply them several times to let friction dry out the linings. ­ Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. ­ Never modify a QUAD through improper installation or use of accessories. When transporting the machine in another vehicle.be sure it is kept upright and that the fuel cock is in the "OFF"position. Otherwise,fuel may leak out of the carburetor or fuel tank. -8- 3. DESCRIPTION PARTS LOCATIONS c 1. Fuel tank. 2. Fuel valve. 3. Throttle lever. 4. Rear brake lever. 5. Engine stop switch. 6. Starter. 7. Lights switch. b d g a e f -9- IDENTIFICATION NUMBER RECORD For ordering spare parts from our dealer or for reference in case the vehicle is stolen, record vehicle identification number and engine number in the spaces provided for assistance. (1) vehicle identification number. The vehicle identification number is stamped on vehicle frame. Use for identificating your vehicle. (2) Engine number Engine number Vehicle number -10- PARTS FUNCTION a. Engine stop switch The engine stop switch is on the left handlebar. When the switch is in the "OFF" position, the engine will not operate. This switch can be used as a safety or emergency switch. Be sure to push the switch to the "ON" position when you start and operate the machine. b. Throttle lever The throttle lever is beside the right handlebar grip to be activated by the right hand thumb. To accelerate the vehicle, simply press lever forward. To decelerate, just release the lever and the throttle will close automaticaly. -11- c. Parking brake When parking, squeeze the left hand brake lever. And at this moment press the parking brake button on the left handlebar brake set. Make sure that the brake lever is locked for more safety. Only squeeze the left hand brake lever once again the parking brake will be released in free motion. Always keep the disc plate clean, refrain from grease. d. Mechanical disc rear brake The mechanical disc rear brake is operated with the lever on the left handlebar. When braking, grasp this lever which applies the brake to the rear wheels. -12- e. Safety switch There is a rider safety device with this vehicle. The safety switch is located behind the body. The cap of the switch tied to a rope is normally connected to the safety switch when riding the vehicle. This rope should never be attached to the rider. The supervisor should hold the safety switch behind the vehicle and pull the rope to activate the safety switch if necessary. The engine will stop automatically when the switch cap is off from the switch. OFF Switch mark " " If the lever is in this position. fuel will not flow, Alaways turn the lever to this position when the engine is not runing. · ON Switch mark " " If the lever is in this position, fuel flows to the carburetor. Normal riding is done with the lever on this position. FUEL a. Fuel valve The three way fuel valve is on the left side of the vehicle. -13- Res Switch mark " " After refueling return the fuel cock lever to the "ON" position. when your QUAD run out of fuel while riding, Turn the fuel cock from "ON" to "Res", you can run your QUAD for a few minutes. b. Fuel tank Fuel tank capacity is 3.2liter (0.87gal). gasoline with octane number of 91 or higher may be used. After refueling,be sure to tighten the tank cap firmly. Do not refuel-right after the engine has been running and still very hot. ENGINE OIL Four-stroke engine oil must be added to the Cramkoorp periodically. check oil indicator every time before operating this vehicle. If oil supply to engine is not enough,the machine will be out of order.it can not work again.you can refill the oil into the cramkcase behind the engine. -14- The pressure should be checked when the tires are "cold" before running the vehicle. Tire wear limit When the tire groove decreases to 3mm (0.1" ) due to wear. replace the tire. Oil hole Light switch The light swith is on the left handbar. when the switch is on the mark " ", it means to turn off light. Be sure to push the switch to the mark "HL" position. the light is turned on. · TIRES Check tire pressure frequently with the air pressure gauge. Tire should be inflated to the recommended pressure. Recommended: FRONT: 20kpa, (0.2 kgf/ cm2), 2.8 psi REAR: 20kPA, (0.2 KGF/CM2), 2.8 psi Minimum: FRONT:17Kpa, (0.17 kgf/cm2), 2.4 psi REAR: 17Kpa, (0.17 kgf/cm2), 2.4 psi OPERATION INSPECTION Inspect your vehicle every day before you run it. It only takes a few minutes to check and might save your live. Check oil level in crankcase The oil level should be between the maximum and mini mum marks. -15- Check brake operation. If any problem cannot be corrected by the adjustment, have the QUAD inspected by leader. Check tires condition and pressure as recommended. Check throttle for smooth opening and closing. lt must return back to idle position when released. Check engine stop switch for good function. Check steering for proper wheels turning. Check nuts,bolts and other fastners. -16- STARTING PROCEDURE 1. Parking the vehicle on a level surface and lock the parking brake. 2. Turn the fuel valve to "ON". 3. Move the engine stop switch to "ON". 4. Grasp the lever on the right handbar or left. 5. Push the start button on the left handlebar. 6. Push the throttle lever slightly. RIDING Begin by finding a safe area free of obstacles with a level surface. Always keep your feet on the footrest during operation. Under normal riding conditions it is not necessary to touch the ground for balance. Then: 1.Start the engine. 2. After the engine has been warmed up, release the parking brake The vehicle is ready for riding. 3. Increase engine speed by opening the throttle gradually. RUN-IN During the first two weeks of riding.run your new vehicle tenderly. Don't run as fast as to approach maximum rpm. This run-in process will greatly enhance the long term power and the life of the engine. -17- PARKING 1. Parking at a level surface. 2. After stopping the vehicle,turn the engine stop switch to OFF position. 3. Lock the parking brake at the left handlebar. TURNING It is essential that this skill shall be learned at first at low speed. The rider must learn to move his weight and control the throttle to allow the rear tires to get the turn. When turning, the wheel on the outside of the turn must travel a wider radius and thus a greater distance than the inside wheel. As the rear axle does not permit a differing rate of wheel rotation. It is not enough to merely steer this vehicle into a turn. To turn steer in the direction of the turn, leaning your body to the inside of the trun. While supporting your weight on the outer footrest. Use the throttle to maintain power throughout the turn. Incorrect turning may cause the front wheels to slide straight ahead. If this should occur.close the throttle and stop. Avoid braking or accelerating until you have regained directional control. Be careful to avoid skids while traveling on slippery terrain. -18- Climbing uphill Practice riding at first on gentle slopes. Try more difficult climbs only after you have developed your skill. Avoid excessive steep hills or slopes. With slippery or loose surface in rough terrain. Keep both feet on the footrests. When climbing a hill, shift your weight forward, proceed at a steady rate of speed and throttle opening. If you are unable to continue up the hill, dismount vehicle on the uphill side Phypsically turn the vehicle around and then descend the hill. Crossing through shallow water. QUAD 50 can be used to cross slow moving, shallow water of up to a maximum of 16 cm (6.3") in depth. Entering the water where there is no sharp drop off, rocks or other. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water until you have regained proper braking ability. -19- 4. MAINTENANCE MAINTENANCE SCHEDULE The maintenance intervals in the following table are based upon average riding and conditions. Riding in unusual dusty areas require more frequent servicing. Item Fuel line Throttle opertion Air cleaner Spark plup Carburetor adjustment Idle speed adjustment Drive chain Throttle cable Brake shoe wear Brake system Nut, Bolt, Fastener Wheel Steering system Suspension system Buttery Air filter INITIAL SERVICE (First week) H REGULAR SERVICE (every 30 operating days) H C H H H H, L H H H H H H H H C EVERY YEAR H H H H, L H H H H H H Note: H: Hinspect and clean. Adjust. Lubricate or replace, if necessary. C: Clean. L: Lubricate. -20- SPARK PLUG Standard spark plug; TORCH LDE6T 1. Disconnect the spark plug cap. 2. Clean up dirt from around the spark plug base. 3. Remove the spark plug. 4. Inspect the plug electrodes for wear.lf the electrodes and insulator tip appear unusually fouled or burned. change a new one. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. 5. The spark plug gap shall be kept in 0.6-0.7mm (0.24"0.28"). lf adjustment is necessary,bend the side electrode carefully. 6. Install the spark plug, screw it in finger tight and then tighten with the plug wrench another 1/2 turn to compress the washer. AIR CLEANER The air cleaner will accumulate dust and must be cleaned periodically. lf riding in very dusty area. The filter must be cleaned more frequently. To clean the filter: 1. Remove the air cleaner cover. 2.Take out the filter from the air cleaner case. 3. Wash the filter element in a non-flammable or high flash-point solvent.Soak the element in clean oil until saturated, then squeeze out the excess oil. -21- 4. Let the filter element dry and reinstall it. Air cleaner CARBURETOR AND IDLE SPEED ADJUSTMENT The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to the leader who has the professional knowledge and experience to do so. BRAKE Check the brake cable for kinks or signs of wear that could cause sticking or failure. Lubricate the brake cable with a available cable lubricant to prevent premature wear or corrosion. Make sure that the brake arm, spring , rod and fasteners are in good condition. Ask your leader to replace the pads when they are almost in contact with the disc plate. -22- 3) Tighten those bolts and nuts. Rear axle housing DRIVE CHAIN Sometimes,it needs to lubricate the chain. The SAE 80 or 90 gear oil is recommended. The chain will loosen with use, how to adjust chain. 1) Release two rear axle housings nuts and bolts (total six nuts and six bolts). 2) Release two Rear axle housings simultaneously, make sure equal degrees rotation of those and keep the chain vertical suitable distance. THROTTLE CABLE Inspect throttle cable condition and operation. Replace the cable if it has become worn or kinked. Lubricate the cable with oil to prevent premature wear or corrosion. Adjustment can be made with the adjuster beside the throttle lever. Loosen the lock nut and turn the adjuster. -23- The free play should be maintained at 5-10mm (0.1970.254). Check the level of battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. The level should be between the upper and lower level marks. BATTERY When reinstalling the battery, be sure to connect the red cable to the positive (+) lead and the black cable to the negative (-) lead. When the battery no longer can hold a charge, replace it. The battery should be replaced every three years as a normal service. -24- Power max Fuel RON 90 # Unlead Engine oil SAE20 Gear oil API GL-5 Torque max Dimension Wheelbase Length SPECIFICATIONS Engine Displacement Cylinder Cooling Type Bore and stroke Lubrication Fuel capacity Oil capacity Transmission Drive Train Starting Compression ratio Quad 50 49CC 1 Air-cooled 4-stroke-horizontal 47 mm x 41.4 mm oil injection 3.2 liter 0.65liter Single speed Chain Electric 8.8:1 Seat Height Width Height Dry weight Seat height Overall Dimension Tires front Tires,rear Max, Load Max.Spead 3.8KW/8000 rpm 4.5N-m/6000 rpm 828 mm 1335 mm 542 mm 730 mm 780 mm 74 ± 2kg 542 mm 1335 x 730 x 780 AT16 x 8-7 AT16 x 8-7 45 kg 35 km/h -25- WARRANTY TERMS AND CONDITIONS (According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales) Warranty terms of the manufacturer GASGAS Motos, S.A. The company GAS GAS MOTOS, S.A. (hereafter referred to as "GG"), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality. Consequently, GG with this document guarantees the consumer (hereafter referred to as the "purchaser"), in accordance with the conditions set out below, the repair, free of charge, of any defect in materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by this Warranty and with no limit on the number of kilometres covered or hours of use. Warranty Period The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer, or in the case of demonstration models, on the date in which the vehicle is used for the first time. The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23/2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999/44/EC for other members of the European Community. For countries outside the European Community, the Warranty Period will be determined by the existing regulations in those countries. Nevertheless, should the fault appear during the first six months after the delivery of the motorcycle, it will be presumed that the said fault existed at the time of delivery; from the end of the sixth month onwards, the purchaser must demonstrate that the unwarranted fault existed at the moment of delivery. During the first six months subsequent to the delivery of the repaired vehicle, the seller will be responsible for any unwarranted faults arising out of the repair. Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period. If the last day of this period is a Sunday or an official holiday, the Warranty period will be extended such that the last day of the period covered will be the first working day after the Sunday or official holiday. Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of the Warranty Period will be excluded. -26- Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that: a) The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users' Manual, or has exceeded the date set for such inspections or maintenance work. Also excluded from guarantee are those faults that appeared prior to the dates established for an inspection or maintenance work where the latter was not carried out, or was carried out later than the date established. b) An inspection, maintenance or repair has been performed on the vehicle by third parties not recognised or authorised by GG. c) Any maintenance or repair has been carried out on the vehicle that violates the technical requirements, specifications and/or instructions indicated by the manufacturer. d) Spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs to the vehicle, or in the event that the vehicle has been used with fuels, lubricants or other liquids (including, amongst others, cleaning products) that have not been expressly mentioned in the specifications set out in the User's Manual. e) The vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle. f) The vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements. g) The vehicle has been used for special purposes other than ordinary use, such as competition, races or record breaking attempts. h) The vehicle has been directly or indirectly damaged as a result of a fall or an accident. Warranty exclusions The following items are not covered by this Warranty: a) Worn parts, including, without any limitation, spark plugs, batteries, petrol filters, oil filter elements, (secondary) chains, engine output pinions, rear sprockets, air filters, brake discs, brake pads, clutch plates and discs, bulbs, fuses, carbon brushes, footrest rubbers, tyres, inner tubes, cables and other rubber components b) Lubricants (for example, oil, grease, etc.) and working fluids (for example, battery liquid, coolant, etc.) c) Inspection, adjustments and other maintenance tasks, as well as all kinds of cleaning work d) Damage to the paint-work and consequent corrosion due to external causes, such as stones, salt, industrial fumes and other environmental impact, or inadequate cleaning with inappropriate products -27- e) Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.) f) Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.) g) Phenomena that are the result of the ageing of the vehicle (for example, discolouring of painted or metallic coated surfaces). Various 1.- GG shall have the prerogative to decide, at its own discretion, whether to repair or replace defective parts. Where parts are replaced, ownership of the parts removed shall pass to GG without any other consideration. The GG authorised dealer, to whom the making good of the defects has been entrusted, is not authorised to make any declarations that are binding on GG. 2.- In case of doubt regarding the existence of a defect, or a visual or material inspection is required, GG reserves the right to demand the return of the parts which are the object of a claim under Warranty, or to arrange an inspection of the defect by an expert from GG. Any additional obligations arising out of guarantees on parts replaced free of charge, or any other service rendered free of charge, are excluded from the effects of this present warranty. The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned. 3.- Should it prove to be the case that a defect can not be repaired, the purchaser guaranteed shall have the right to the cancellation of the contract (payment of compensation) or a partial refund of the purchase price (discount), instead of repairing the motorcycle. 4.- Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised dealer shall not be affected by the terms of this present Warranty. Neither will this present Warranty affect those additional contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer. However, such additional rights may only be exercised through claims against the authorised dealer. 5.- Should the purchaser resell the product within the Warranty Period, the duration and conditions of the present Warranty will remain unaltered, in such a way as that the rights to make claims under the present Warranty in accordance with the terms and conditions set out in this present document shall be transferred to the new owner of the motorcycle. -28- -29- RECOMIENDA EL USO DE ACEITE: RECOMMENDS THE USE OF OIL: RECOMMANDE L'USAGE DE L'HUILE: CONSIGLIA L'USO D'OLIO: EMPFIEHLT DEN GEBRAUCH VON ÖL: JUNIO / JUNE / JUIN / GIUGNO / JUNI 2006 C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: +34 902 47 62 54 Fax: +34 902 47 61 60 E-mail: officegg@gasgasmotos.es / partsgg@gasgasmotos.es PU010538048