PAMPERA 450-07 Foreword GAS GAS thanks you for the trust you have placed in us. By choosing a new PAMPERA 450 2007 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 450 2007 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. -3- 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. 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. CAUTION This caution symbol identifies special instructions or procedures that, if not strictly observed, could result in damage to or destruction of equipment. USE OF OIL RECOMMENDED: NOTE This symbol indicates points of particular interest for more efficient and convenient operation. -4- 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.............................................................................................. 26 Tension adjustment ........................................................................ 27 Handlebars ..................................................................................... 29 Brakes............................................................................................. 29 Steering .......................................................................................... 31 Steering lock ................................................................................... 32 Front fork ........................................................................................ 33 Rear suspension............................................................................. 35 Wheels ............................................................................................ 37 Cleaning.......................................................................................... 38 Tightening nuts and bolts................................................................ 39 Table of tightening torques ............................................................. 40 Lubrication ...................................................................................... 41 Engine oil ........................................................................................ 42 Suspension adjustment .................................................................. 45 In competition ................................................................................. 49 Storage ........................................................................................... 50 Multifunction instructions ................................................................ 51 Fault diagnosis................................................................................ 57 Guarantee manual .......................................................................... 63 -5- GENERAL INFORMATION ENGINE Motor Displacement in cubic centimetres Bore and stroke Spark plug Fuel supply Ignition TRANSMISIÓN Transmission type Clutch type Secondary transmission Gear ratio 4 stroke, single-cylinder DOHC 4 valves, liquid cooled 443 cc 95 x 62.5 mm CR8 E o U24ESR-N Carburetor Digital CDI Primary reduction ratio Final reduction ratio Overall drive ratio Transmission oil Capacity Type 6 speed Oil bath, multi-disk hydraulic action By chain 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) 2.85(57/20) 3.231 (42/13) 7.289(6th gear) 1000 cc 10W50 API SF or SG CHASSIS Type Tyre sizes Front Rear Manufactured with chromoly tubes. Swing arm made of aluminium, cast in one piece. 90/90 x 21 120/90 x 18 -6- Suspension Suspension stroke Front suspension oil Front fork oil level Front Rear Front Rear ø'bf 45mm telescopic fork. Progressive system with single shock absorber 202 mm 220 mm SAE 7.5 200 mm (compressed, without spring) BRAKES Type Effective disk diameter Front / rear Front Rear Disk brakes, pump and simple / double callipers. 260 mm 220 mm DIMENSIONS Overall height Overall length Overall width Wheel base Minimum ground clearance Fuel tank capacity Weight 1,120 mm 2,135 mm 820 mm 1,450 mm 300 mm 7.4 litres 119 Kg. (Specifications subject to change without notification, also possibly not applicable in some countries). -7- LOCATION OF COMPONENTS GAS GAS PAMPERA 450 1- Clutch handle 2- Engine start button 3- Fuel tank cap 4- Front brake fluid tank 5- Front brake handle 6- Throttle control -8- 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 -9- 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 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). PETROL The GAS GAS PAMPERA 450 has a four stroke engine and requires 98 octane, unleaded petrol. Fuel Tank Capacity 7.4 L (A) (B) (B) (A) (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. (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. -10- RECOMMENDED FUEL Use lead-free petrol with an octane rating equal to or higher than that shown in the table. OCTANE RATING METHOD Antiknock Index Research Octane No. (RON+MON)/2 (RON) MINIMUM OCTANE RATING 95 98 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. 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. -11- 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. Stopping the engine - Change gear to neutral. - Then release the throttle completely and rotate the ignition key anti-clockwise. (A) (D) - 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. (B) NOTE Starting the engine while the key is being turned to the ON position may cause a loss in battery power. - Without using the throttle, press the electric start button (B). -12- STARTING WHEN THE ENGINE IS COLD The cold start function is responsible for aiding the engine start if it 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 or press the clutch. 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. 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) (B). Shift pedal. -13- 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. NOTE The slow speed necessary during the break-in period may cause dirt to build up on the spark plug. If inspection of the spark plug shows this to be the case, replace the standard spark plug with a higher heat grade spark plug for the duration of the break-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 inspe ...