GAS GAS 2007 PAMPERA 450, Manual

Page 1: ...PAMPERA 450 07 ...

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Page 3: ...mpetition 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 th...

Page 4: ...wed could result in personal injury or even death CAUTION This caution symbol identifies special instructions or procedures that if not strictly observed could result in damage to or destruction of equipment NOTE This symbol indicates points of particular interest for more efficient and convenient operation Inadequate driving skill could cause problems to the environment and conflict with other pe...

Page 5: ...le 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 ...

Page 6: ...ype Oil bath multi disk hydraulic action Secondary transmission By chain Gear ratio 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 Primary reduction ratio 2 85 57 20 Final reduction ratio 3 231 42 13 Overall drive ratio 7 289 6th gear Transmission oil Capacity 1000 cc Type 10W50 API SF or SG CHASSIS Type Manufactured with chromoly tubes Swing arm ma...

Page 7: ... without spring BRAKES Type Front rear Disk brakes pump and simple double callipers Effective disk diameter Front 260 mm Rear 220 mm DIMENSIONS Overall height 1 120 mm Overall length 2 135 mm Overall width 820 mm Wheel base 1 450 mm Minimum ground clearance 300 mm Fuel tank capacity 7 4 litres Weight 119 Kg Specifications subject to change without notification also possibly not applicable in some ...

Page 8: ... 8 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 ...

Page 9: ...at 12 Front brake disk 13 Front brake callipers 14 Rear brake fluid tank 15 Shift pedal 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 ...

Page 10: ... and rotate the fuel cap in an anti clockwise direction To close the fuel cap rotate it in a clockwise direction 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 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 m...

Page 11: ...ECOMMENDED FUEL Use lead free petrol with an octane rating equal to or higher than that shown in the table OCTANE RATING METHOD MINIMUM OCTANE RATING Antiknock Index RON MON 2 95 Research Octane No RON 98 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 d...

Page 12: ...gine cannot start The key may be extracted from the ignition NOTE Starting the engine while the key is being turned to the ON position may cause a loss in battery power 12 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 Without using the throttle press the electric star...

Page 13: ...nd lead to engine damage B Shift pedal 13 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 ...

Page 14: ...owing 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 inspection 5 Start the engine and ride for 20 minutes at moderate spe...

Page 15: ...s Period First 5 hours T I I R I I I I I I I I I T Inspect each time that the motorcycle has run or when necessary Change every 4 years Change every 2 years Clean lubricate and inspect each time the motorcycle has been ridden Revise every 4 years Change every 2 years Inspect tyres for damage and check the tyre pressure every time the motorcycle has run Period Every 60 hours T I R I R I I I I I I I...

Page 16: ...eep the area ventilated and free from naked flames The operating instructions for the battery are as follows 1 Check the battery voltage in open circuit status disconnected 2 In case the battery s tension is below 12 60 V or if the storage period has exceeded 6 months the battery has to be recharged following the instructions in paragraph 3 If the battery voltage is above 12 60 V the battery can b...

Page 17: ...CAUTION Using a high pressure water source could damage the radiator fins and render them 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 l...

Page 18: ...ally 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 CAUTION Soft or distilled water must be used with the inhibitor chemicals and the antifreeze in the cooling system If normal water is used in the system it the cooling system tu...

Page 19: ...n Plug WARNING Coolant on tires will make them slippery and can cause an accident and injury 19 NOTE Check the level when the engine is cold 1 Coolant level 2 Filler opening If the coolant level is low add the correct amount of coolant through the filler opening Recommended liquid Permanent type of antifreeze distilled water and ethylene glycol with corrosion and rust inhibitor chemicals for alumi...

Page 20: ...ark plug should be taken out periodically to check the electrode gap If the spark plug is oily or has carbon build up on it clean it with a wire brush or similar Measure the distance between electrodes using a gauge and adjust in case that it is not correct by bending 20 CR9E CR8E CR7E U22ESR N U24ESR N U27ESR N COMMENTS If the standard spark plug appears to be crystallised or is a white colour it...

Page 21: ... serious engine damage that is not covered by the guarantee Always use spark plugs recommended by GAS GAS Consult the dealers or a qualified mechanic to know which spark plug is better for your bike Removing the spark plug To remove the spark plug follow the following steps 1 Remove the bolts A right and left 2 Remove the seat B A B C C E D 3 Remove the bolts C right and left ...

Page 22: ...k plug and clean the carbon build up with a wire brush Readjust the gap between the electrodes to between 0 7 and 0 8 mm 0 028 0 031 in Before removing the carbon deposits check its colour this colour tells us whether the standard plug is the best for our use WARNING Fuel may be spilled when removing the tube from the tap Stop the engine before removing the tank Keep naked flames and sparks away f...

Page 23: ...clip B 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 Stuff a clean lint free rag into the intake manifold so no dirt is allowed to enter Clean inside the filter housing using a damp cloth CAUTION Do ...

Page 24: ...rn the adjuster to obtain the correct amount of play Tighten the locknut A Adjustment B Lock nut C Throttle grip D Brake fluid reservoir If the play can not be established by adjusting the cable remove the cable protection from the carburettor adjust this using a tensioning device at the end of the cable tighten the lock nut and refit the protection Squeeze it and take it out with a clean cloth Do...

Page 25: ... Remove the right side carrier cover 2 Loosen the clamp C 3 Remove the screws B A Silencer B Silencer attachment bolts C Clamp 25 CLUTCH Proper clutch lever play is 2 3 mm When there is too much play first try to adjust the level of the clutch lever Tighten the adjustment bolt to obtain the optimal play A Clutch Lever B Clutch cylinder piston rod C Hydraulic fluid tank If the clutch lever adjustme...

Page 26: ... 26 WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Checking tension The space between the chain and the swing arm at the rear of the chain slider should be 30 50 mm Rotate the rear wheel to find the place where the chain is tightest Adjust the drive chain if it has ...

Page 27: ...sing the straightedge or string method WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Tighten the chain adjustment nuts Tighten the axle nut to 98 N m Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary WARNING If the rear axle nut is not securely tightened this may lead to unsafe riding cond...

Page 28: ...de is worn excessively or damaged replace it Chain Guide Slide Visually inspect the upper and lower part of the chain slider on the swing arm If this is worn then replace it A Chain guide slide B Rocker arm Pinion and sprocket teeth wear Visually inspect the pinion and sprocket teeth If they are worn or damaged replace the pinion or sprocket Lubrication Lubrication is necessary after riding throug...

Page 29: ...n the handlebar as desired Tighten the bolts first the front bolts and then the rear bolts to a torque of 25 Nm If the handlebar is correctly installed there will be a minimal gap at the front and rear of the clamp after tightening A BRAKES 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 t...

Page 30: ... changed if it appears to be contaminated with water or dirt 30 Play in front brake lever Adjust brake lever to a comfortable position To adjust loosen the nut under the rubber protection B Tighten after adjustment Ensure that the brake responds correctly A Brake lever B Rubber protection Rear brake pedal When the brake pedal is in rest position there should be a play of 10 mm If not then adjust t...

Page 31: ...g time Check for fluid leakage around the fittings Check for brake line damage WARNING Do not mix brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled with a type other than the brake fluid already in the reservoirs Brake Wear Inspection If the thickness of either pad is less than 1 mm replace both pads in the calliper as a set Pad replacement sho...

Page 32: ...he ground Remove the handlebar by loosening the handlebar clamp bolts A Loosen the steering stem bolt B Loosen the bolts for the upper suspension plate C and remove it D Rotate the steering adjustment bolt using the special spanner in order to obtain the appropriate adjustment 32 Install the upper suspension plate D Tighten the steering stem nut B the washers and bolts on the front forks to the co...

Page 33: ...e front fork should always be adjusted for the rider s weight and track conditions The adjustments are done in 2 stages Adjusting the oil level The effects of higher or lower oil level are only felt during the final 100 mm of fork stroke A higher oil level will make the fork rebound more quickly A lower oil level will make the fork rebound more slowly A B ...

Page 34: ...rks all the way Lift the fork springs Holding the suspension rod cap with a spanner loosen the cap locking counter nut Remove the suspension rod caps Remove the suspension spring guide Using a spanner remove the springs from the forks Place the oil level indicator on the upper part of the fork tube and measure the distance from the upper part to the oil level 34 Standard level of oil A Releasing o...

Page 35: ...er swing arm tie rods and rocker arm In general the operating characteristics of the single shock are similar to the front fork however this is characterized as well as by the shock the articulated quadrangle composed of the rods and rocker arm To suit various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damp...

Page 36: ...n is 258 mm A Nut B Spring C Counter nut Tighten the counter nut correctly After adjusting move the spring up and down to ensure that it is correctly fitted Refit all removed parts Rear shock absorber spring replacement Stiffer or softer springs are available If the standard spring is unsuitable for your purpose select a proper one according to the rider s weight and course conditions Using a hard...

Page 37: ... pressure Spokes and rims The spokes on both wheels must all be tightened securely and evenly and not be allowed to loosen Unevenly tightened or loose spokes will cause the rim to warp hasten nipple and overall spoke fatigue and may result in spoke breakage Centring the rim Put a quadrant gauge next to the rim and rotate the wheel to measure the axial centring Put the dial on the inside of the rim...

Page 38: ...ylinder and callipers below the petrol tank If water enters the electronic coil or inside the spark plug cap the engine will not start and the affected parts will require drying Front and rear hubs Steering pivots steering tube Rear suspension system Swing arm pivots 3 After cleaning Remove the plastic bags and clean the air filter intake Lubricate the locations listed in the lubrication section S...

Page 39: ...bolts 7 Spokes 8 Drag plate bolts 17 Rear axle bolt 18 Silencer support bolts 19 Sub chassis bolts 20 Rear shock bolts 21 Exhaust clamp bolt 22 Upper suspension plate bolts 23 Steering head nut 24 Brake lever support bolt 25 Rod support bolt 9 Front axle bolt 10 Brake attachment bolt 11 Subchassis support bolt 12 Radiator support bolts 13 Nuts and bolts of the engine mounting 14 Shift pedal bolts ...

Page 40: ...ump cover drain plug Calliper mounting bolts Disc plate mounting screws Engine mounting bolts Front axle bolt Front brake lever support bolt Fork flange bolt Steering nut Rear axle nut Rear brake pedal bolt Subframe support bolt Rear shock absorber bolt Rear disc wheel drive bolt Spokes Steering axle bolt Rocker arm bolt Rod bolts Nm 20 20 25 10 11 9 25 10 36 51 6 29 98 98 9 26 39 29 1 5 4 81 81 K...

Page 41: ...g 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 General lubrication Clutch lever A Front brake lever B Rear brake pedal C Rear brake bearing D Shift pedal E 41 Use aerosol with pipe to pressure lubricate Use grease on the end of the throttle cable E A B D C ...

Page 42: ...a guide 42 A Checking oil level NOTE To maintain the engine in perfect conditions check the oil level and change it regularly Oil increases in volume when it is hot Check and adjust the oil level when the oil has cooled Initially replace the oil after 5 hours of operation and then every 60 hours See the maintenance table Changing the oil DANGER The engine oil and the exhaust manifold can be very h...

Page 43: ...r for future recycling according to the legislation in effect NOTE Change the oil when the engine is hot to facilitate its drainage through the drain on the lowest part of the engine Always use original GAS GAS parts To change the oil follow the following steps 1 Place a recipient underneath the crankcase NOTE Put used motor oil in an appropriate container for recycling 2 Drain the engine oil from...

Page 44: ...approximately 1 000 ml of new oil through the opening in the ignition cover H WARNING The engine may be damaged if the oil is not used properly or the specifications recommended by GAS GAS MOTOS are not followed Use the type of oil specified in the section on Petrol and Oil recommendations 9 Start the engine and allow it to run some minutes Check for oil leaking from the filter cover Stop the engi...

Page 45: ...onditions as well as the rider s style and positioning on the machine If you have a problem test by changing your riding posture or position so that the cause of the problem can be deduced It is a wise practice to adjust suspension settings to suit the rider s strong points If you are fast through the corners adjust the suspension to allow fast cornering Make setting changes in small increments a ...

Page 46: ...e fork oil level is too high The front forks operate but ride is too hard Oil too dense Fork oil degraded Too soft The front forks dive excessively during braking and deceleration 1 Front fork oil level low 2 The springs are too soft 3 Oil too light 4 Fork oil degraded Rear shock absorber symptoms Too hard Rigid suspension Hard spring Spring preload exceeded Too soft On landing after a big jump bo...

Page 47: ...pendicular to the ground While standing next to the machine pull on the front brake and place one foot on the brake firmly If the bike maintains its level attitude as the suspension is compressed the suspensions are well balanced Sit astride the bike and take up a riding posture the check to see if the bike is in a horizontal position If one end drops noticeably more than the other the front and r...

Page 48: ...n systems are too soft 1 Front Increase oil level and or use harder spring 2 Rear Use a stronger spring and or increase preload NOTE After any adjustments always check front and rear compatibility Adjustments according to bottoming conditions rear shock absorber Bottoms at low speed Increase spring preload to maximum a The rear shock does not bottom out when the spring and damping are correct for ...

Page 49: ...s as the air cleaner collects dust the engine runs richer AVAILABILITY OF SPARE PARTS Your Gas Gas dealer will provide any information you may require about spare parts PER MONTH OF USE 1 Check 1 Tighten the front axle and disks 2 Tighten the front forks flange bolts 3 Tighten the handlebar clamp bolts 4 Tighten the throttle control bolts 5 Verify grease the throttle control 6 Verify the front and...

Page 50: ... 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 Tie a plastic bag over the exhaust pipe to prevent moisture from entering Put a cover over the motorcycle to keep dust and dirt from collecting on it To put the motorcycle back into use after storage Remove plastic bag from exhaust Make sure the spark plug is tigh...

Page 51: ...icator screen This central indicator screen made of liquid crystal and with illumination gives information about the rpm speed journey kilometres travelled time average speed maximum speed length of time with motor running and total time The data relative to the distance travelled and total time of use is stored in the memory even when the apparatus is switched off When the multifunction apparatus...

Page 52: ...rpm Digital Tachometer RPM 100 19 900 rpm 100 rpm Gear change indicator RPM 100 19 900 rpm 100 rpm Maximum Tachometer Value 100 19 900 rpm 100 rpm Speedometer 2 3 300 km h 187 5 mph 0 1 km h or m h Speedometer MAX MAX 2 3 300 km h 187 5 mph 0 1 km h or m h Average Speed AVG AVG 2 3 300 km h 187 5 mph 0 1 km h or m h Distance counter 1 and 2 TRIP 1 2 0 999 9 km or 0 624 9 miles 0 01 km or miles Mil...

Page 53: ...the second row The digital tachometer displays up to 19 900 rpm The tachometer signal can be read from the CDI Capacitator Discharge Ignition or the ignition coil Gear change indicator according to rpm This function permits setting an indicator for changing gear at a specific rpm level The tachometer bar flashes when the rpm reaches the specific level and stops flashing when the gear is changed MA...

Page 54: ... 2 MAX and MAX RPM to zero separately 2 Return the data in TRIP 1 AVG and RT at the same time The data of the ODO CLOCK and TT cannot be returned to zero OPERATION OF THE GEAR CHANGE ACCORDING TO RPM 1 Press the MODE button to switch to the RPM screen accelerate to the rpm which is desired for the gear change indicator to be activated 2 Press the RESET button to confirm and establish the gear chan...

Page 55: ...e 12 24h system changes and when MODE is pressed the configuration concludes and the configuration of the clock digits opens 4 Press the RESET button to increase the value of the flashing digit one by one press the MODE button to confirm the configuration and pass on to the following digit 5 Press the MODE button to switch to the adjustment screen of the gear change according to rpm once the clock...

Page 56: ...e and is followed by four digits by default the flashing digit is the one to be changed 11 Press the RESET button to increase the value of the flashing digit one by one press the MODE button for 2 seconds to confirm the digit change and pass on to the following digit ...

Page 57: ...e air filter cover then change the starter motor fuse Recharge the battery and investigate the causes for discharging visit a qualified workshop Start engine with start pedal Crankshaft locked Go to a specialist workshop Go to a specialist workshop Go to a specialist workshop Check fuel tap for breaks or blockages It is advisable to drain the old fuel from the tank When the fuel tank is filled wit...

Page 58: ...bstruction Exhaust deteriorated with leaks Valve set too small Decompression maladjusted Piston cylinder ring diameter tolerance excessive Clean the petrol tank ventilation Close the starter Clean the petrol tank ventilation Fill the fuel tank with fuel Add coolant check the seal of the cooling system Clean the radiator fins or change Adjust the carburation system Visit a specialist workshop Adjus...

Page 59: ...ever damaged Selector position spring broken or loose Correct the level of engine oil Drain oil as necessary from the engine Empty the engine oil and fill with oil of the recommended viscosity Go to a specialist workshop Adjust the valve play Go to a specialist workshop See chapter 5 Clean the combustion chamber Go to a specialist workshop Drain the petrol and fill with fresh or higher octane petr...

Page 60: ...Shock absorption too hard Replace the down selector mechanism spring Replace the gear drum Replace the ratchet spring of the selector Change gear fork Change Go to a specialist workshop Change Go to a specialist workshop Change Go to a specialist workshop Change shaft Go to a specialist workshop Go to a specialist workshop Replace the clutch plate Go to a specialist workshop Replace the clutch hub...

Page 61: ...ose steering shaft bolt loose Adjust the rear shock Change front fork Go to a specialist workshop Add oil to the forks as required Empty the fork oil and fill with oil of the recommended viscosity Verify tyre pressure Adjust the rear shock Adjust the chain Change the chain rear sprocket and secondary transmission pinion Change the rear sprocket Lubricate using a correct chain lubricant Align the r...

Page 62: ...ctly The lights blow The lighting system does not work Change the chassis Go to a specialist workshop Adjust the steering Go to a specialist workshop Change steering shaft Go to a specialist workshop Change front fork Align the wheels Change Disk Check brake circuits Change any that are damaged or broken Drain brake fluid and replace with new as recommended by the manufacturer Replace the pump pis...

Page 63: ...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 Nevertheles...

Page 64: ...he 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...

Page 65: ...ered 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 refu...

Page 66: ...Notas Notes ...