User manual GAS GAS WILD HP 50

MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D'ENTRETIEN MANUEL D'ENTRETIEN LIBRETTO D´USO LIBRETTO D´USO USER MANUAL ENGLISH PRESENTATION GAS GAS thank you for the trust you have placed in us. By choosing the new WILD H.P. 50 you have just joined the great GAS GAS family and, as a user of the number one off-road Quad, you deserve the distinguished treatment we would like to offer you both in our after sales service as well as in the explanations given in this manual. Get to know your new machine well. This Quad incorporates our accumulated competition experience and that which we have gained from the achievement of many important titles. You are now in possession of a machine with which, as well as being entirely satisfied, you are offered the infinite possibilities of driving at the highest level of your skill while maintaining a maximum of security. This manual provides you with a good basic knowledge of the features and machine handling. It also contains important indications regarding safety and provides information about the special techniques and skills required for driving this machine, as well as the basic maintenance and inspection processes. Thank you for your trust in us, and welcome to GAS GAS motorcycles. -3- GENERAL ADVICE Read this Manual carefully. It contains all the necessary information for your safety, and that of others, as well as guaranteeing the correct conservation and maintenance of the GAS GAS Quad you have just acquired. PLEASE READ ALL THE MANUAL BEFORE USING THE MACHINE. Important information about this manual Information of special importance is marked in the manual by the following notations: WARNING Ignoring the WARNING instructions could result in serious injuries or even death for the machine user, people in the proximity and for the technicians responsible for its inspection and repair. Inadequate driving 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 MACHINE 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 assembled with the up to date data and the specifications available at the time of edition. Whatever differences you may notice on your vehicle would be due to improvements in production and quality of the model. GAS GAS Motos S.A. is constantly improving its vehicles so that you may better enjoy them. CAUTION This 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. -4- CONTENTS - Presentation .............................................................................. 3 - Common warnings .....................................................................4 - Content ..................................................................................... 5 - Specifications ........................................................................... 7 - Information about your safety ................................................ 8 - Important information ............................................................ 10 Identification number .................................................... 11 - Location of components ......................................................... 12 - The main parts of the QUAD ................................................. 14 Ignition key .................................................................. 14 Kick start pedal .............................................................14 Lights .......................................................................... 14 Emergency Lights ........................................................ 15 Throttle grip ................................................................ 15 Oil reserve indicator ..................................................... 15 Front brake lever .......................................................... 16 Rear brake pedal ........................................................ 16 Emergency stop ........................................................... 16 Starter ......................................................................... 17 Fuel tank cap .............................................................. 17 Fuel tap ...................................................................... 17 Seat ............................................................................. 18 Front guard .................................................................. 18 Rear guard ................................................................... 19 Foot rest assembly ...................................................... 19 Foot protection ........................................................... 19 - Verifications to be made before starting the machine .......... 20 Front and rear tanks ................................................... 20 Fuel ............................................................................. 21 Oil Tank ....................................................................... 22 Cooling system ............................................................ 22 Chain ........................................................................... 23 Throttle grip ................................................................. 23 Lights ........................................................................... 23 Tyres............................................................................ 23 - Using the QUAD ....................................................................... 24 Starting the engine ...................................................... 24 Starting the vehicle ....................................................... 25 Stopping the engine .................................................... 25 Running-in the engine ................................................. 26 Parking on slopes ...................................................... 26 - Driving your QUAD. Practical recommendations ................ 27 Become familiar with your QUAD ................................. 27 Drive carefully using common sense ............................ 27 How to turn your QUAD................................................ 28 Uphill ....................................................................... 29 Downhill .................................................................... 29 Traversing slopes ...................................................... 29 Crossing shallow waters ........................................... 30 Driving on rough ground .............................................. 30 Sliding and skidding ...................................................... 30 -5- - Periodic maintenance and adjustment ................................. 31 Maintenance chart ................................................ 31 Brake lever and pedal adjustment ................................ 32 Checking the brake liquid level .................................... 33 Checking the front and rear brake pads ...................... 34 Changing the wheels ........................................... 35 Swing arm shaft .............................................. 35 Adjusting and lubricating the chain .............................. 35 Checking the coolant level ......................................... 36 Air filter ......................................................................... 38 Spark plug maintenance .............................................. 40 Adjusting the engine idle ............................................. 41 Inspection and lubrication of cables ............................. 42 Replacing the lights ...................................................... 42 Transmission ............................................................... 44 - Cleaning, lubrication and storage .......................................... 45 Cleaning ...................................................................... 45 Lubrication .................................................................... 46 Storage ......................................................................... 47 - The multifunction instrument panel ...................................... 48 - Trouble shooting guide ...................................................... 49 - Warranty manual ................................................................. 53 -6- SPECIFICATIONS ENGINE Type Cylinder size: Cooling system: Bore x stroke: Carburettor: Ignition: Clutch: Gearbox: Transmission: Power: CHASSIS Chassis: Front suspension: Rear suspension: Front brake: Rear brake: Rims: Front tyres: Rear tyres: Kick-start pedal: Engine, disk and sprocket guard: DIMENSIONS Wheelbase: Overall width: Curb weight: Fuel tank capacity: Two-stroke single cylinder, direct crankcase reed valve admission 49 cc Liquid cooled 37.4 x 41 mm Dell'Orto PHVA 12 Electromagnetic flywheel Dry automatic centrifugal clutch Automatic regulator Primary by gears, secondary by chain fitted with retainers 5.8 HP at 7500 rpm / 5.0 mkg at 7000 rpm Multi-tube made from Cr-Mo steel Wishbone arms with two Sachs adjustable spring shock absorbers One-piece aluminium alloy swing arm. Progressive system with Sachs adjustable spring shock absorber Two self-ventilated 180mm discs with floating double-piston BREMBO calliper 220 mm auto ventilated disc brakes with BREMBO floating double-piston calliper. Aluminium 165 x 70 - 10" 215 x 50 - 9" Forged aluminium Aluminium alloy 1280 mm 1300 mm 135 Kg 18 l -7- SAFETY INFORMATION THE QUAD is not a toy: driving it can be dangerous. The QUAD is driven differently form from 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 control 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 the conditions. - 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. - Follow the procedures described in this manual if the engine stalls. If the engine stalls and the vehicle starts rolling backwards, follow the special braking procedure described in this manual. Get off the quad on the uphill of the slope. 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. As stated 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. -8- - This vehicle has been designed to go through water deeper than 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 switch off the engine when 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 petrol could catch fire and cause 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. - Petrol is toxic. 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 drive the machine in a well-ventilated area. Do not start or run the engine in a closed space. The exhaust vapour is poisonous and may lead to loss of consciousness or even death in a short time. -9- 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. 5 6 5 - Chain and swing arm adjustment tool. 6 - Idle jet. 4 IDENTIFICATION NUMBERS 1 2 3 4 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. 1 - Chain guard. 2 - Swing arm guard. 3 - Footrest assembly. 4 - Foot protectors. SERIAL NUMBER -10- NOTE The vehicle's serial number is used to identify your machine. Q. A. PLATE 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 key identification number (C) is stamped on the key itself. This number is used to order a new set of keys in case of loss. (B) (A) (D) (C) Quality approval plate The QUAD is fitted with its own corresponding quality approval plate 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. -11KEY ID. NUMBER LOCATION OF COMPONENTS GAS GAS WILD H.P. 50 10 11 1 234 5 6 7 8 9 12 13 14 1 - Light burst button 2 - Light switch 3 - Full beam button 4 - Starter button 5 - Emergency stop 6 - Ignition key 7 - Parking brake -12- 8 - Front brake lever 9 - Throttle control 10 - Front guard 11 - Brake pads 12 - Fuel tank cap 13 - Footrest grill 14 - Rear guard 15 16 17 22 25 18 19 20 21 24 25 15 - Front headlight casing 16 - Fuel cut-off 17 - Seat 18 - Front shock absorber 19 - Spark plug 20 - Kick-start pedal -13- 21 - Swing arm 22 - Exhaust pipe 23 - Front brake fluid 24 - Brake pedal 25 - Exhaust PRINCIPAL PARTS OF THE QUAD IGNITION KEY The key (A) is located in the front section of the handle bar. 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. LIGHTS NOTE The headlight and the rear light can only be switched on when the engine is on. High beam Position lights No lights (A) Switch (C) has three positions, initially in the "OFF" position. (E) (C) KICK STARTER The kick-start pedal (B) is located on the left 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. (C) Light switch. (D) Full-dipped beam switch. (E) Main beam light burst. (F) Indicators. (G) Horn. (D) (G) (F) (B) 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 . -14- 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. The button for the horn is located in the same area (G). HAZARD LIGHTS The hazard lights are operated by a button (H), located on the front part of the QUAD, in front of the handlebars. This also works when the ignition is switched 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. WARNING (I) 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. (H) OIL RESERVE INDICATOR The indicator (J) will light when the oil level is low, that is, when the reserve level is reached. At this point, there is about 0.75 litres of oil remaining. THROTTLE CONTROL Before starting the engine, check that the throttle works smoothly (I). Make sure it slides 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. (J) -15- FRONT BRAKE LEVER The front brake lever (A) is located on the right side of the handlebars. Use the lever to apply the front wheel brakes. EMERGENCY STOP The QUAD is fitted with an emergency stop system. This prevents the vehicle from continuing out of control in case the rider should fall off. (A) (D) (C) 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. 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. On becoming detached, the engine stops automatically. NOTE Make sure you release the parking brake before operating the throttle. (B) -16- We recommend that the cable is attached to a strong point, so that it is not accidentally released. (E.g. The cable may be attached to trousers, jacket, ... to a wrist... but always to a strong support). WARNING The use of the QUAD is prohibited without attaching the emergency stop system. Disregard for this may result in serious consequences. To use this, pull on the lever (F) upwards, and without operating the throttle control, 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, rotate the throttle control to the limit and release quickly. NOTE If the engine is flooded then start with the throttle fully open. FUEL TANK CAP CHOKE To open the fuel tank, turn the key anti-clockwise. The choke mechanism (F) is a mechanism that opens the throttle a fixed amount in case the engine is cold so that there is no need to operate the throttle grip. The engine will reach its optimal temperature, in low time and without causing damage. FUEL CUTOFF This tap supplies fuel to the carburettor and is located on the right hand side under the fuel tank. The cut-off has three positions. (F) -17- 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. (A) NOTE When putting the seat back in the normal position, ensure it is secured. (B) When the lever (A) is in the centre position (open) then fuel flows to the carburettor. The machine is normally used with the cut-off in this position. C: Closed. With the lever (A) in this position, there is no fuel flow. Always turn the cut-off (A) to this position when the machine is not in use. R: Reserve. 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 (A) back into the centre position (open). SEAT To remove the seat, use the same key as for the petrol-tank cap (B). Insert the key into the lock located on the right hand side of the QUAD. -18FRONT GUARD The front guard juts out from the QUAD assembly. 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. (C) REAR GUARD As with the front guard, the rear guard (D) also protrudes from the QUAD. This guard prevents the QUAD from falling over backwards, which might result in serious injuries. protect feet and legs from the wheels in case of a loss of balance or if feet slip from the footrests. Width is provided for freedom of movement. (D) NOTE In case of steep climbs, the rear guard will not prevent the machine from rolling over backwards, so be prudent in climbs and examine the terrain carefully. FOOT PROTECTORS The foot guards (F) are located between the footrests and the wheels, they are an additional protection system to the footrests. By filling this gap, we eliminate any possibility of injury to lower limbs by the wheels. (F) FOOT REST ASSEMBLY WARNING The footrests and foot guards are an essential protection system for safe driving of the QUAD. The quad has large wheels that could easily trap a leg causing serious injuries. The QUAD has two footrests (E), one on the left and one on the right. Both footrests have a protection grill. The whole assembly will -19- CHECKS TO MAKE BEFORE STARTING THE MACHINE WARNING Always inspect the QUAD before use, to ensure it is safe to operate without any danger. Always follow the inspection and maintenance procedures and programs described in this manual. Failure to inspect the machine increases the risk of accident or breakdown. FRONT AND REAR BRAKES WARNING Before driving, always check the brakes. Do not drive the QUAD there is any braking problem or if a loss in braking capacity is possible, this could result in an accident. If there is any problem that cannot be solved using the procedures described in this manual, go to a specialised workshop to have the QUAD checked. 2 1 Check that the height of the brake pedal is correct. If not, have it adjusted at a specialised workshop. Check the working of the lever and the pedal. They must move smoothly and must feel firm when the brakes are applied. Otherwise, have a specialised workshop inspect the vehicle. Brake fluid level Check level of brake fluid. Add liquid if necessary (see the Maintenance section). Recommended fluid D.O.T 3 or D.O.T 4 NOTE The vehicle comes with D.O.T 4. as standard. Brake fluid leaks Check for brake fluid leaks in the brake line joints or fluid reservoirs. Apply the brakes firmly for about one minute. In case of a leaking, have a specialised workshop inspect the vehicle. Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. So there are no parts that require adjustment on the brakes except brake lever play and the brake pedal position and play. Brake lever and pedal Ensure that there is no play in the front brake lever (1). If so, check the condition of the brake pads and consult the "Adjustments and maintenance" section. Ensure that there is no play in the rear brake pedal (2). -20- Ensure that there is sufficient petrol in the tank. (A) NOTE We recommend the tank is not allowed to run dry. If there is dirt at the bottom of the fuel tank, it could enter the engine and may damage it. To open the fuel tank cap, pull upwards on the tab and then insert one of the two red keys. Rotate to the right and pull on the cap with the key still in place, as shown in the above image. Recommended fuel CAUTION Only use unleaded petrol. The use of leaded petrol will seriously damage internal components of the engine. (B) (A) and (B) Front and rear brake fluid reservoirs. Brake operation Test the brakes by riding slowly, to make sure they work to perfection. If the brakes do not provide adequate braking power, check the brake pads for wear. FUEL The GAS GAS WILD H.P. 50 has a 2-stroke engine that requires a mix of petrol and oil. Recommended fuel: Fuel tank capacity: Reserve: Unleaded 95/98 18 litres 1.2 litres 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. -21- Mixing oil in the engine The oil must be mixed with petrol in order to lubricate the piston, cylinder, camshaft, sockets and ball bearings. Recommended oil: THE COOLING SYSTEM Radiator tubes 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. NOTE If the recommended oil is not found then only use 2-stroke synthetic competition oil. The mix is made automatically by a mechanical pump. The only requirement is to check the oil level each time that the machine is refuelled. OIL TANK The QUAD H.P. 50 has an 1.65 litre oil tank (A) located below the seat. This must never be left empty, otherwise the oil pump will have to be purged of air. CAUTION Using a high-pressure water source could damage the radiator fins and render it 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. (A) (A) -22- Check the cooling liquid level in the reservoir (A) with the cold engine (the liquid level will vary with engine temperature). The level is correct when it is between the two marks. If it falls below the lower mark, add antifreeze. Change the coolant every two years. NOTE The liquid must be between the two marks, not above the upper mark or below the lower. WARNING The use of inadequate tyres or riding the vehicle with incorrect or unequal tyre pressures may lead to loss of control, with the subsequent risk of accident. CHAIN Check the overall condition of the chain and its tension before each run. Lubricate and adjust the chain as necessary (See the section on Maintenance). THROTTLE CONTROL Check that the throttle control is working correctly. It must accelerate smoothly and return to the idle position when released. If necessary, service the grip and grease the moving parts so that it works correctly. LIGHTS Check the headlight and the brake lights to make sure they are in perfect condition. If necessary, make any reparations necessary. TYRES Always use the recommended tyres. Front Rear Manufacturer MAXIS MAXIS Size Model 18.5 x 6.00 -10" RAZR 20 x 10.00 -9" RAZR Tyres should be inflated to the recommended pressure. Measure the tyre pressure with a low pressure gauge. CAUTION Check and adjust tyre pressures when the tyres are cold. Pressure should be equal on both sides. Recommended Front Rear 0.45 bar 0.45 bar Minimum 0.25 bar 0.25 bar Maximum 0.50 bar 0.50 bar Tyre wear limit Examine how the tyres wear down. If the tyre is worn out at the centre, this means that the tyre pressure is too high. -23- If the tyre wears out at the edges, the tyre is a little flat. The tyre must be worn out equally over its surface. USE OF YOUR QUAD WARNING Read the User's Manual carefully so as to become familiar with all of the controls. Loss of control may cause accidents or injuries. STARTING THE ENGINE CAUTION Before starting the engine for the first time, consult the section "Running in the engine". WARNING In cold weather, make sure that all the cables work smoothly before using the QUAD. If the cables are frozen or do not work smoothly you may lose control of your QUAD and suffer an accident. 1 - To activate the parking brake, pull the brake lever while using the lock lever. -24- WARNING - Always use the parking brake before you start the engine. The QUAD could move unexpectedly if the brake is not applied. This could lead to a loss of control or to a collision. - Remember to release the parking brake before moving off. The brake will overheat if the QUAD is used without releasing it. The brake will loose efficiency and could cause an accident. It would also suffer from premature wear. 2 - Turn the fuel cut-off tap to the ON position. 3 - Turn the ignition key (A) clockwise to the ON position. 5 - If the engine is cold then pull on the choke button (F). (F) 6 - Without using the throttle control, use the starter pedal. STARTING THE VEHICLE (A) 1 - Operating the throttle control causes the QUAD to move. 2 - To slow down or stop, release the throttle and apply the brakes evenly and gently. STOPPING THE ENGINE (A) 4 - Then the rider should be secured to the emergency stop system (see the recommendations in the section "The main parts of the QUAD / emergency stop"). 1 - Rotate the ignition key anti-clockwise to the OFF position and the engine will stop automatically. -25- (B) 3 - Use the parking brake (B) to park the vehicle. During the subsequent 10 hours (10-20), it is advisable not to use the engine at full throttle during long periods. PARKING ON A SLOPE WARNING Avoid parking on hills or inclined terrain, as the QUAD may move out of control, with a corresponding accident risk. If it is necessary to park on a hill, engage the first gear, apply the parking brake and block the front and rear wheels with rocks or other objects. 4 - The key may be removed from the ignition. RUNNING IN THE ENGINE The running-in process is a very important element in the life of your QUAD, and we recommend you to follow the instructions below carefully. NOTE The running-in period is a time (usually the first 20 hours of use) in which we must take into account several points for engine preparation. During the first 10 hours we recommend not using more than halfthrottle for long periods or in any situation that may cause engine overheating. On the other hand, short accelerations - for 3-4 seconds - are beneficial for the engine and will not be a problem. Each acceleration sequence must be followed by a resting period, so that the engine can release the heat it has generated. During this 10hour period, try not to run at constant speed, vary the speed from time to time. 1 - Stop the machine by applying the brakes. 2 - With both the front and rear brakes pressed, activate the parking brake and slowly release the brake pedal. -26- DRIVING THE QUAD. PRACTICAL ADVICE. GETTING TO KNOW YOUR QUAD This QUAD is destined for experienced riders, to be used in recreational activities. Even if you are an expert with other types of off-road vehicles and motorbikes, riding the QUAD requires special skills which can only be achieved through practice. We recommend that you to familiarize yourself with your vehicle on flat ground with no obstacles, and without the presence of other drivers. Do not try difficult manoeuvres until you are totally familiarised with you QUAD. A QUAD is not designed to jump obstacles, refrain from doing this as the vehicle could be seriously damaged. WARNING Do not drive the QUAD without first reading this manual. Ensure that you understand how to use the controls and pay special attention to the section "Information about your safety". DRIVE CAREFULLY AND USE COMMON SENSE As we have already noted, driving your QUAD requires special skills which can only be achieved through continuous practice over time. Take your time to learn the basic techniques before attempting more difficult manoeuvres. Checks prior to driving WARNING Never carry passengers. The large seat is designed so that the rider may alter their position as required while driving. This is not designed to carry passengers. Transporting a passenger on this QUAD considerably reduces the possibilities to balance and control the machine. This could lead to an accident with the consequent injury risk for the driver and/or passenger. The quad is fitted with an emergency-stop system in case the rider falls off, but it has not been designed to cope with passenger falls. Equipment - Always wear an approved helmet of your size. - In addition, you should wear: eye protection, gloves, boots, longsleeve shirt or jacket and long trousers. WARNING It is essential to wear the full equipment mentioned above, otherwise the risk of serious injuries or even death is increased. For the due safety and care of the QUAD, always do the verifications before riding. They are explained in detail in the section "Verifications to be made before starting the vehicle". While driving Always ride with the footrests and protections secured, they will protect you from serious injuries in the legs and feet. Always keep -27- feet on the foot rests while driving and both hands on the handlebars. WARNING As we have explained in this manual, the use of the footrests and guards is essential for your physical integrity. is required to turn, and it is important to learn the skill on flat terrain, with no obstacles and at a moderate speed. The speed may be increased as your skills increase. When approaching the corner, slow down and start to turn the handlebars in the desired direction. Lean your body to the inside of the corner to compensate the inertia produced by speed. Use the throttle to keep a uniform speed all through the corner. This manoeuvre may be used to take the corner correctly. The picture demonstrates the technique. Modifications Do not modify this QUAD by fitting or using inadequate accessories. The parts and accessories added to this vehicle must be original GAS GAS parts or equivalent parts designed for use on this QUAD, and must be fitted and used according to the instructions. Fitting inadequate accessories or modifying the vehicle may provoke changes in the machine's handling, which, under certain conditions, might lead to an accident. In case of doubt, consult an authorised dealer. Exhaust system The temperature of the QUAD's exhaust system increases with use. To prevent burns, do not touch it. Park the QUAD in a especially reserved place or somewhere away from pedestrians or children. 1 1 - Turning to the right. 2 - Turning to the left. 2 HOW TO TURN YOUR QUAD At low speeds you will have no problem to turn with the handlebars. On the other hand, if speed increases the difficulty to turn will also increase. The back wheels are rigidly mounted on the same axle and turn at the same speed, so the QUAD will resist turning into corners unless the inside wheel loses some traction. A technique -28- If the technique used is not correct, the QUAD will probably continue in a straight line. If it does not turn, stop and practise the procedure again. If the vehicle starts to turn over towards the outside of the corner, reduce speed, compensate with the steering or lean even more to the inside. It could also be necessary to reduce your speed gradually and to turn the steering to the outside of the corner to avoid tumbling over. UPHILLS We recommend starting gradually on gradual slopes and increase the inclination as your skill improves. In any case, avoid loose or slippery surfaces or obstacles at any time, as we have already mentioned, the QUAD has not been designed to jump obstacles so it is advisable to avoid doing this. While climbing a slope you discover that you have not correctly calculated your ability to reach the top, turn the QUAD while you still have some traction (if there is enough room) and descend. If the vehicle starts rolling backwards, do not use the rear brake or try to insert a gear, the QUAD might easily tumble over backwards. Get off the vehicle immediately on the ascending side of the slope. Always remember that your safety comes first. DOWNHILLS When descending a slope with the QUAD, transfer your weight to the back, to the uphill side of the slope. Move to the back of the seat and remain seated their with your arms straight. 4 3 It is important to transfer your weight to the front part of the QUAD during climbs. This can be done by leaning forward and moving the seating position back and, if slope is very steep, standing on the footrests and leaning forward a little. Use the front and rear brakes accordingly in order to avoid slides or tumbling over. WARNING TRAVERSING SLOPES Do not accelerate suddenly. The QUAD may flip over backwards. In this case the rear guard would not help, as the inertia would be considerable. Never go over the top of a climb at full speed. On the other side, there could be an obstacle, a steep descent, another vehicle or even a person. To cross a slope with your QUAD you must place your weight correctly to maintain correct balance. Before attempting to cross a slope make sure you have learned the basic skills on flat ground -29- on flat ground. Avoid slippery sections and rough terrain that may cause you to lose balance. When crossing the slope, keep your body inclined uphill. It might be necessary to correct direction on loose surfaces by turning the steering slightly uphill. When crossing slopes, do not perform tight turns up or downhill. If the QUAD begins to turn over, gradually turn downhill if there is no obstacle in the way when stability is regained, turn once more in the required direction. CROSSING SHALLOW WATERS With the QUAD you can, at slow speed, cross shallow water up to 35 mm in depth. Before entering the water, choose carefully a path to cross. Choose a place with no sudden descents and avoid rocks and other obstacles that may make affect the stability of the QUAD or cause it to slip. Drive slowly and carefully. WARNING Do not cross fast waters or waters deeper than specified in this manual. Remember that the brakes will get wet and lose braking efficiency. Check the brakes after leaving the water. If necessary, operate the brakes a few times in order to dry them by friction. DRIVING ON ROUGH GROUND Take precautions when riding on rough terrain. Beware of any obstacle that may damage or destabilise the QUAD or even cause an accident. Keep your feet firmly placed on the footrests at all times. Avoid jumping over obstacles with the vehicle as this could lead to loss of control and damage to the machine. SLIDING AND SKIDDING When riding over slippery or loose surface, use caution. An uncorrected unexpected slide could result in a serious accident. To reduce the tendency of the front wheels to slide on slippery surfaces, sometimes it is useful to put your body weight over them. If the rear wheels start to slide sideways, control can usually be regained by turning the handlebars towards the slide, if there is enough space available. It is not recommended to accelerate or brake until a skid has been corrected. With practice, after some time you can dominate the controlledsliding technique. Before attempting to do so you must choose the ground carefully, as both stability and control are reduced. Note that it is best to avoid skidding manoeuvres on extremely slippery surfaces such as ice given that this could result in a total loss of control. NOTE Learn to control your slides safely by practising at low speed on flat ground with no inclination. -30- REGULAR MAINTENANCE AND ADJUSTMENTS MAINTENANCE CHART Lubricate The first revision must be performed by a specialised workshop at 500 km or after two fuel tanks. Successive services should be made every 2,000 km or every three months. Check Fill If necessary Change BEFORE USING THE QUAD AFTER AN OUTING EVERY... Fuel level Brake fluid reservoir levels (front and back). Brake lever and pedal play Brake pads Coolant Level Tyre wear General condition of the chain Throttle grip Lights Switches Quad Brake pedal and lever Air filter Air filter casing Chain guide Cables Radiator hose and connections Exhaust Wheel bearings (10 trips) Brake piston and dust guard (2 years) Brake piston pump and dust guard (2 years) Brake line (2 years) -31- Tighten Adjust Clean Regular inspections, adjustments and regular lubrication keep the machine in the best possible conditions of safety and efficiency. Safety is the responsibility of the owner of the machine. The most important points related to inspections, adjustments and lubrication are described in the following pages. WARNING Do not perform any maintenance operation with the engine on. Moving elements might catch clothes or on a part of your body and cause injuries. The electric parts might produce sparks, provoke electric shocks or even fire. Before performing any maintenance operation, stop the engine, unless indicated otherwise. If you are not familiar with the maintenance of the vehicle it is better to go to a specialised workshop. ADJUSTMENT OF THE BRAKE LEVER AND PEDAL Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. So there are no parts that require adjustment on the brakes except brake lever play and the brake pedal position and play. Front brake lever The lever free play will initially be directly related to the brake pad wear, that is, if some play is noticed before the adjustment, it would be a good idea to check the brake pads to see if they must be replaced. (C) (D) (C) Brake lever. (D) Adjustment bolt. Once this observation has been performed adjust the lever to suit comfort. Tighten the screw (D) shown in the picture; it is covered by silicone protection, pull this off to uncover the groove by which a screwdriver may be inserted. Tightening the screw reduces play and loosening increases play. -32- It is possible that air might have entered the brake system. Purge the system in the following way: - Remove the brake fluid reservoir cap (E) to check the level. (E) When the brake pedal is in rest position, there should be a play of 10 mm. If not, then adjust this. 10mm WARNING If the brake pedal has a spongy feel when activated, it may be due to air in the pump or to a fault. It is dangerous to ride under these conditions, check the brakes immediately. - Remove the brake calliper cap (F) (wheel interior) and attach a transparent tube to the end. (F) CHECKING THE BRAKE FLUID LEVEL NOTE Regularly check the brake fluid and periodically change it. It should also be changed if it is contaminated by water or dirt. - Operate the brake lever several times. Fluid starts coming out of the system through the tube. The transparent tube can be used to see if there is air, i.e. bubbles, in the system. - Once the system has been bled, refill the reservoir to the top. Rear brake pedal Check the brake operation and make sure it does not rub against any part of the QUAD. To adjust the pedal play, loosen the locknut, rotate the bolt, fit the lever in the required position and retighten the locknut. -33- Fluid level inspection Front: A small brake fluid reservoir is located to the left of the throttle grip. If we look at the reservoir carefully, a small transparent bubble is located on one of the flat sides that will allow us to check what is happening inside the brake fluid reservoir. If you have just purchased your quad, nothing can be seen through the bubble because the reservoir is full, the level will be seen when it is going down. When the brake fluid level is very low, top up: - With a cross-tip screwdriver, unscrew the two screws on the recipient. - Next, top up with sufficient fluid. - Put the screws back in place and make sure the reservoir is tightly secured. Rear: The rear brake fluid reservoir is located underneath the seat. - Insert the fuel tank key into the lock on the right side of the QUAD just below the seat. - Next make sure that the fluid container is well closed, put the seat back and lock it in place using the key. Ensure that the seat is secured correctly. Recommended liquid Use D.O.T 3 or D.O.T 4 CHECKING THE FRONT AND REAR BRAKE PADS - Turn the key. - Put your hand between the rear of the seat and the chassis and pull the seat up. There are 3 brake callipers: One on the each of the front wheels (2); and 1 on the drive chain that brakes the rear wheels together. All operate in the same way and are checked in the same way. As we can see in the picture, the brake calliper is formed by different parts. The pad is the part that rubs on the disk, thus, it is this element that wears down and must be checked. (D) (A) (B) (C) - There is a small easy access reservoir (A), There are two marks: "MIN" and "MAX". The fluid level should be closer to the "MAX" mark. If it is significantly below it, add fluid. (B) Pads (C) Callipers (D) Brake disk (C) -34- NOTE Do not skip checking the brake pads, if the thickness is not checked they could cause damage to the brake calliper. When the thickness of the pads are considerably reduced, visit a specialist and have the pads changed. CHANGING THE WHEELS We must change the wheels when they are worn out or after a puncture. Proceed as follows: - Each wheel has four nuts (E) which we will remove with a no.15 wrench. - Unscrew the nuts and remove the wheel from the axle. - To put them back in place, follow the same procedure in reverse order. (F) ADJUSTING AND LUBRICATING THE CHAIN The drive chain must be checked, adjusted, and lubricated in accordance with the Periodic Maintenance table in order to prevent excessive wear. If the chain is worn or badly adjusted (too tight or loose) then it may jump off the sprockets or break. WARNING A chain that breaks or jumps off the sprockets could snag on the engine or the rear wheel, severely damaging the QUAD and causing it to go out of control. Checking tension The gap between the chain and the swing arm at the chain guide must be about a finger width, if it is more or less, adjust to the correct measurement. Follow the procedure explained next: (E) SWING ARM SHAFT It is very important that the rear wheel axle is well centred, otherwise, or if there is play, the bearing could be damaged. - To adjust the axle nut, we will go to the rear end of the QUAD. The bolt is found to the right of the swing arm. - Use the spanner (F), supplied with your vehicle, to adjust the shaft. -35- - Go to the rear of the QUAD. There are four bolts (A) on the swing arm. - Unscrew the 4 screws. Chain lubrication is one of the operations that must be performed frequently. When? - After riding on wet ground. - When the chain appears dry. - After washing the QUAD. -If the QUAD has been immobile for a long time. A high viscosity oil rather than low viscosity oil is better because it will stay on the chain longer providing lubrication. Put oil on the sides of the chain pins so that it penetrates into these; remove excess oil. CHECKING THE COOLANT LEVEL The coolant absorbs excessive heat from the engine and transfers it to the air by the radiator. If the coolant level is low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the QUAD. NOTE The level, in normal conditions should not fall. If liquid must be added often, revise the circuit for leaks and take the QUAD to a specialist. 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. (A) - With the spanner (B), supplied with your QUAD, adjust the chain correctly and then retighten the four bolts. (B) NOTE Ensure that the bolts are tightened and that the chain tension is correct. Inspecting the condition of the chain Inspect the chain for damaged links, lost pins, unequal sprocket teeth or damaged teeth. If the drive chain is damaged, go to a specialised workshop and have it replaced. Chain lubrication Good chain maintenance is essential to ensure the correct operation. -36- 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. 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. Soft or distilled water must be used with the inhibitor chemicals and the antifreeze in the cooling system. 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. Coolant Level In case of a liquid loss we must check the level in two containers. They are located together on the left side of the quad. (D) (C) Normally, if the level in the reservoir (C) is below the mark then the radiator must be checked (D). WARNING Always perform these operations when the engine is cold, the liquids may be hot, and be ejected from the system under pressure, causing serious burns. - Remove the radiator cap and top up fluid. - Remove the container cap and fill up until level is between the two marks. - Start the engine and leave it at idle for 15-20 seconds. - Stop the engine and check the levels in the two containers, most likely it will have gone down because the engine has run out of liquid. - Refill the containers (if necessary). -37- Changing the coolant The coolant should be changed periodically to ensure long engine life. - Wait for the engine to cool completely. - Put the QUAD in a horizontal position. - Remove the radiator cap. Place a container under the coolant drain plug, and drain the coolant from the radiator and engine by removing the drain plug at the bottom of the water pump cover. Immediately wipe or wash off any coolant that spills on the frame, engine, or wheels. - Install the water pump cover drain plug with the specified torque shown in the table. Replace all seals with new ones. Water pump plug: 9 Nm / 0.9 Kgf - Fill the radiator up to the edge and install the radiator cap. - Check the cooling system for leaks. - Start the engine, warm it up and then stop it. - Check the coolant level after the engine cools down. AIR FILTER (A) (A) Water pump cap. (B) Coolant drain plug. CAUTION The air filter must ALWAYS be cleaned after an outing with the Quad. Otherwise, dirt may penetrate the engine and damage it seriously. WARNING WARNING Coolant on tires will make them slippery and can cause an accident and injury. An obstructed air filter restricts the air intake of the engine, increasing the petrol consumption and reducing the engine power. -Inspection of the coolant. If white cotton-like patches appear in the liquid then this means that the aluminium elements of the cooling system are corroded. If the liquid is brown then this means that the steel or iron parts of the system are oxidized. In either case, clean out the system. - Check the cooling system for damage, loose joints, or leaks. -38- (B) An obstructed air filter will allow dirt to enter into the carburettor and may cause the throttle slide valve to seize. This is an accident risk! Cleaning process Use an engine filter cleaning kit. This consists of two components: a grease cleaning liquid and a special oil for impregnating the filter. WARNING Clean the filter in a well-ventilated zone and ensure that there are no sources of naked flame or sparks near the work area (including the focus of a powerful light). Do not use petrol to clean the filter as this could result in an explosion. 1 - Lift the seat. 2 - Remove the elastic band (A). (A) (B) 3 - Remove the air filter cover (B). 4 - Remove the filter assembly from the housing. NOTE Do not twist the element when draining. 5 - Put the filter in a container with some de-greasing liquid. This liquid will clean the filter without damaging it. 6 - Then wring the filter gently and allow it to dry for some time. CAUTION Use appropriate gloves to complete air filter cleaning operations. The cleaning liquid may cause skin damage. - Check the air filter for damage such as scraping, hardening, shrinkage... If it is damaged then replace it, otherwise dirt will enter the carburettor. -39- NOTE The element should be damp but not dripping. - Once it has stopped dripping, place it in a bath of the special oil. We may avoid the use of a bath and soak the filter in the same liquid, the result is the same. Apply sponge air filter oil to the element. If there is no air filter oil available then use engine oil. - Also clean the cover with a humid cloth as well as the filter housing. - Make sure all the corners are clean before putting all the parts back in the filter housing. - Grease all of the connections and inlets of the air filter. - Place the filter in the cage and cover the filter lip with a thick layer of grease to ensure the correct seal and to prevent dirt from entering the carburettor. - Fit the air filter correctly to the QUAD. CAUTION Never allow the engine to run without the filter element installed. Otherwise non-filtered air would enter the engine and it may result in wear and possibly breakdown. On the other hand, using the engine without the filter element may cause blockage in the carburettor conduits decreasing the engine performance and probably causing the engine to overheat. SPARK PLUG MAINTENANCE The spark plug is an important part of the engine and it is easy to inspect. The state of the plug may indicate the condition of the engine. - Once the spark plug is loosened then finish removing it by hand. Standard spark plug: NGKBR8EG QN86 0.7 - 0.8 mm The plug must be periodically removed to check the gap and the ceramic insulation. - It is located on the cylinder head. Extract the spark plug hood (A) and loosen the plug (B) a little anti-clockwise. (A) (B) -40- - Remove the spark plug to see if it is full of carbon and dirt. - Use a wire brush to clean off the carbon then use a little petrol to finish cleaning. If the spark plug electrodes are oxidised, damaged or the insulation is broken then replace the plug. To find the correct heat grade spark plug is being used, take it out and examine the insulation around the electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is white, the plug should be replaced with the next coldest plug. If the ceramic insulation is black then replace the spark plug with one of a higher heat grade. NOTE This kind of diagnostics should ideally be done by a specialized workshop. CAUTION The spark plug should be examined regularly, because the heat and carbon accumulation gradually erode and eventually rupture the plug. If the spark plug wear is excessive or if there is excess build up of carbon or other accumulations, replace the spark plug by one of different specifications. - Once the spark plug has been verified, put it back in place by hand as far as possible. CAUTION Always screw the spark plug by hand, thus it is possible to ensure it is correctly inserted, otherwise, the screw thread could be damaged causing the spark to be incorrectly adjusted and eventually leading to engine damage. - Finish the adjustment of the spark plug using the spark plug wrench but without tightening excessively. NOTE The spark plug is not a bolt, it should not be tightened excessively otherwise its operation will be affected. - Finally, fit the spark plug tube on to the end. ADJUSTING THE ENGINE IDLE This adjustment is made using the idle adjustment screw (C). (C) - If the engine seems like it is about to stall when idling, rotate the idle adjustment screw clockwise. Otherwise, if the engine speed seems high, rotate the screw anti-clockwise. - Accelerate and decelerate a couple of times to ensure that the idle doesn't change. Re-adjust if necessary. -41- INSPECTION AND LUBRICATION OF THE CABLES WARNING Inspect the cables regularly and replace them if damaged. When the outside protection is damaged, corrosion may occur. The cables may start to peel or be damaged. Control operation could be restricted, which may result in accidents and injuries. (A) Allen bolts (A) Lubricate the inner cables and the cable ends. If the cables do not slide smoothly, have a specialised workshop replace them. Recommended lubricant: Engine oil REPLACING THE LIGHTS Front headlight 1 - Remove the headlight casing, by removing the 4 Allen screws. NOTE Do not touch the reflective surface (B) with your fingers, not even with a cloth, as it will easily be scratched. If there is dust on it, clean it with a duster. (B) WARNING The bulb is hot when lit and immediately after turning off the lights. Wait for the bulb to cool down before touching or removing it. It can burn or could cause a fire if it comes in contact with flammable material. (C) 2 - Next, disconnect the cable from the speedometer (C). -42- 3 - Unscrew the bolts that hold the light from below, they must be engaged to operate them. Rear lights WARNING The bulb is hot when lit and immediately after turning off the lights. Wait for the bulb to cool down before touching or removing it. It can burn or could cause a fire if it comes in contact with flammable material. - With a cross-tip screwdriver unscrew the two screws (G) and remove the lens. (E) (D) (D) Cap. (E) Bulb. 4 - Unplug the bulb cable and remove the rear cover of the light. 5 - Next, the piece of wire spring holding the bulb in place (D) becomes visible. (G) (F) (E) (F) Wire spring bulb attachment. - To remove the bulb, press it against the spring, turn it anti-clockwise, extract and replace it with a new one. - Put the lens back in place. 6 - Free the bulb (E) from the wire part and remove it from the rear. 7 - Replace it with a new bulb. To insert it, follow the above operations in reverse order. NOTE Make sure that the lens is correctly fitted. -43- Indicators - To remove the bulb, press it against the spring, turn it anti-clockwise, extract and replace it with a new one. - Put the lens back in place and make sure the assembly is well secured. Checking the oil level - If the QUAD has been used, then wait some minutes. - Unscrew the oil rod (A). - The oil level should be between the maximum and the minimum. (A) - Using a crosstipped screwdriver, unscrew the screws (A), located on the rear, then extract the small lens. MAX. MIN. TRANSMISSION So that the transmission operates properly, maintain the transmission oil level at the proper level and change it periodically. A QUAD with an insufficient, deteriorated or contaminated oil level will suffer premature wear and transmission damage. Oil level Put the QUAD on a flat slope-free surface. Oil changes The transmission oil should be changed regularly to ensure a long engine life. Heat the engine so that the oil picks up any sediment. - If the level is low, add the quantity of oil required by the oil rod hole without exceeding the maximum mark. Transmission oil Viscosity SAE 30 Capacity: 900 cc (A) -44- NOTE In order to reach the correct engine oil temperature for measurement of the level, the engine must be allowed to completely cool, then heat it once more during some minutes to the normal operation temperature. - Stop the engine and place a recipient under the engine. - Remove the oil drain plug (D) and put the QUAD in a horizontal position to allow the oil to drain out. CLEANING, LUBRICATION AND STORAGE CLEANING Frequently cleaning your vehicle will not serve only to improve its aspect, but also to improve its overall performance and to preserve the duration of components. Before washing the quad some precautions need to be taken to prevent water from entering some parts: Exhaust Brake lever, handgrips y engine stop button - Cover with a plastic bag secured with rubber bands. Cover with a plastic bag. - Close up the opening with tape or stuff a cloth in it. - Ensure they are correctly secured. (D) Air filter intake Spark plug hood and all filler caps - Clean the drain plug magnet of any metal. - Screw in the oil drain plug along with its seal ring to 20 Nm. - Check the oil level, after using the kick-starter 3 to 4 times. - Screw the oil filler cap. - If the outside of the engine has too much grease on it, apply a degreaser with a brush. Do not apply this product to the chain, sprockets or wheel axles. - Eliminate all dirt and the degreaser by washing them off with a garden hose. Reduce the water pressure to the minimum required for the job. CAUTION Excessive water pressure may penetrate the wheel bearings, brakes, transmission bushings and electric components, with resulting in damage. -45- Where to be most careful. Avoid applying high-pressure water to: Brake callipers and brake pump piston below the fuel tank (if water enters the electric coil or in the spark plug hood, the quad will not start and the wet parts must be dried out), Front and rear hubs, suspension system, swing arm bearings. - Wash all surfaces with hot water and neutral soap. - Rinse the machine with clean water and dry all the surfaces with a soft and absorbing cloth. - Clean the seat with a vinyl-lining cleaner so as to keep it soft and shiny. - Apply automotive wax to all chromed and painted surfaces. Avoid using wax combined with cleaning products. Most of these products contain abrasive elements that might make the paint matt or destroy the finish. When finished, start the engine and leave it idling for some minutes. WARNING Wet brakes may lose efficiency, and represent an accident risk. Check the brakes after washing the quad and apply them several times at low speed, so that friction dries them out. LUBRICATION Lubricate the points shown here, with either engine oil or regular grease, periodically or whenever the vehicle has been exposed to wet conditions, and especially after using a high-pressure spray washer. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. (1) (1) Front brake lever. (2) Rear brake pedal (3) Rear brake pedal bearing (2) (3) After washing the QUAD - Remove the plastic bags and clean the air filter intake. - Lubricate the locations listed in the lubrication section. - Start the engine and let it heat for 5 minutes. -46- Use a spray with a tube to lubricate under pressure: STORAGE If you need to keep the QUAD for a long period of time (we consider that long is 60+ days) you must: - Clean the entire vehicle thoroughly. - Run the engine for about five minutes to warm the oil, shut it off and drain the transmission oil (See the section on transmission). - Put in fresh transmission oil. - Empty the fuel from the fuel tank (If left for a long time, the fuel will deteriorate). - Lubricate the drive chain and all the cables. - Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or on the brakes. - Tie a plastic bag over the exhaust pipe to prevent moisture from entering. - Set the QUAD on a box or stand so that both wheels are raised off the ground. (If this cannot be done, put boards under the front and rear wheels to keep dampness away from the tire rubber). - Put a cover over the QUAD to keep dust and dirt from collecting on it. To put the QUAD back into use after storage: - Remove plastic bag from exhaust. - Make sure the spark plug is tight. - Fill the fuel tank with fuel. - Check all the points listed in the "Daily Pre-ride Inspection Section". - General lubrication. (6) (6) Throttle cable. (7) Chain. (7) Lubricate the chain after wet terrain or when the chain looks dry. A high viscosity oil rather than low viscosity oil is better because it will stay on the chain longer providing lubrication. Put oil on the sides of the chain pins so that it penetrates into these; remove excess oil. -47- THE MULTIFUNCTION INSTRUMENT PANEL The multi-function display has two buttons, a mode button and a reset button for certain functions. Reset Mode can be useful to coordinate times (ex: in competition). Chronometer To use the chronometer, press Reset to put it to zero. Counting begins immediately. The partial distance in Km or Miles can be reset by pressing the Reset button. Trip distance in Km To program the trip distance in Km or Miles. Once the battery is connected the display indicates that the program is active (metric or imperial). To make the change connect the battery while holding in one of the buttons, the change will appear on the screen. This function remains completely in memory even though the battery may not be connected. Clock precision The clock precision can be adjusted if it is fast or slow. Wheel design The design of the wheel may be altered (10" - consult). This affects the precision of the speed and distance measurements. Backlight The internal display back light has an independent circuit that can accept 8 to 18 volts AC (Two stroke engines) or DC (4 stroke engines). The circuit is protected. 00:00 The initial display is the clock (time) screen; if you press mode the display changes in the following order: 1. Clock/timer. 2. Speed (Km/h or Miles/hour according to the program). 3. Total distance in km or miles. This has a memory even if battery disconnected. 4. Trip distance (can be reset). Setting the time To set the time go to the clock screen and hold in the Mode button until the time set screen appears, Reset can be used to change the hours, pressing Mode once more will allow the minutes to be set also using the Reset button. Once the time is set then the button Mode will begin the clock at zero seconds of the minute chosen, this 00:00 0 0000 0.0 Clock/timer Speed Total distance Trip distance (The Mode button is used to change screens.) -48-