GAS GAS K2 QUAD 250 - SERVICE, Service Manual

Page 1: ...MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO D USO MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO D USO...

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Page 3: ...SERVICE MANUAL SERVICE MANUAL ENGLISH...

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Page 5: ...UAD funs The correct operation and maintenance are the prerequisites at your safety riding of the QUAD and also can reduce the fault of the QUAD and keep its best performance So please read this manua...

Page 6: ...rom failure to follow WARNING instructions when you are operating inspecting or repairing the QUAD CAUTION A CAUTION indicates special precautions that must be taken to avoiddamage to the QUAD NOTE A...

Page 7: ...e select lever operation and reverse driving 25 Shifting 26 To start out and accelerate 26 To decelerate 26 Engine breakrin 27 Content Safety information 5 Description and machine identification 9 Con...

Page 8: ...g inspection 41 Air filter cleaning 42 Carburetor adjustment 43 Idle speed adjustment 43 Valve clearance adjustment 44 Throttle lever adjustment 44 Front and rear brake shoe inspection 44 Front brake...

Page 9: ...approved motorcycle helment that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before...

Page 10: ...en climbing a hill To avoid stalling use proper gear and maintaina steady speed when climbing a hill If you stall or roll backwards Follow the special procedure for braking described in this manual Al...

Page 11: ...g of gasoline can cause fire and can cause injuries and deaths and other serious accident So do not refuel right after the engine has been running and is still every hot Never refuel while smoking or...

Page 12: ...ng the engine in a closed area will cause the breakdown And exhaust fumes are poisonousus and may cause loss of consciousness and death within a short time Always operate your machine in an area with...

Page 13: ...aillight 9 Rear wheel 10 Rear carrier 11 Spark arrester 12 Seat 13 Fuel tank cap 14 Brake pedal 15 Front carrier 16 Rear brake lever 17 Parking brake 18 Main switch 19 Throttle lever 20 Front brake le...

Page 14: ...our dealer or for reference in case the vehicle is stolen record vehicle identification number in the spaces provided for assistance 1 VEHICLE IDENTIFICATION NUMBER Vehicle identification number The...

Page 15: ...ral indicator light N This indicator light comes on when the transmission is in neutral High beam indicator light This light is yellow in color It comes on when the head light and high beam light is o...

Page 16: ...t To start the engine be sure to set the engine stop switch at Lights swtich LIGHTS Turn the switch to for the low beam and taillight for the hight beam Turn the switch to for the hight beam and taill...

Page 17: ...he machine by changing the throttle position Because the throttle is spring loaded the machine will decelerate and the engine will return to an idle any time the hand is removed from the throttle leve...

Page 18: ...l is located on the right side of the machine and the brake lever is located on the left handlebar Pull the lever toward the handlebar or tread slow the pedal to apply the rear brake 1 Rear brake peda...

Page 19: ...parking brake squeeze the rear brake lever to release the parking brake CAUTION The QUAD could start moving unexpectedly if the parking brake is out of function before starting the engine This could c...

Page 20: ...king brake before starting the engine HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure the parking brake have been released before you begin to ride Shift...

Page 21: ...he seat at the rear you should pay attention to make sure that the seat is securely fitted 1 Seat lock lever Fuel tank cap Remove the fuel tank cap by turning it counter clockwise Fuel cock The fuel c...

Page 22: ...ring preload adjustment To increase the spring preload turn the adjuster in direction A To decrease the spring preload rum the adjuster in direction B Standard position B A Minimum Soft E Maxinum Hard...

Page 23: ...ided in this manual have the QUAD inspected by a our deatler Check for correct free play in the brake levers and brake pedal If the free play is incorrect adjust it see pages Check operation of the le...

Page 24: ...er the engine has been running and is still very hot move smoothly and there shoud be a firm feeling when the brake is applied If not have the machine inspected by a our dealer Test the brakes at slow...

Page 25: ...pring back to idle position when released Repair as necessary for proper operation Fittings and Fastenerns Always check the tightness of chassis fittings and fasteners before a ride Refer to the Servi...

Page 26: ...ccording to the description in the above chart and make sure that the tire pressure is normal 2 The tires should be set to the recommended pressure Front 20KPa 0 20kgf cm22 2 8pai Rear 25KPa 0 25kgf c...

Page 27: ...rst reading to be incorrect Set pressure when tires are in cold and set tire pressures to the condition following specifications 1 Low pressure tire gauge Tire wear limit When the tire groove decrease...

Page 28: ...ne can be started in any gear if the rear brake lever is applier However it is recommended to shift into neutral before starting the engine 5 Use the starter choke in reference to the figure NOTE If t...

Page 29: ...the lock button of the Reverse Handle Bar hard into the socket the you can shift the Reverse Handle Bar After it is moved to the proper position 25 move the Handle Bar and softly to make sure the spri...

Page 30: ...lever CAUTION Always close the throttle while shifting gears Otherwise the engine and drive train may be damaged 2 Shift into first gear and release the shift pedal 3 Open the throttle gradually once...

Page 31: ...te it at one set throttle position 2 10 20 hours Avoid prolonged operation above 2 4throttle revolving the machine can freely through the gears durin running of engine but do not use full throttle any...

Page 32: ...d accessories 165kg Front luggage carrier 30kg Rear luggage carrier 60kg Tool kit 2kg Pulling load total weight of trailer and cargo 330kg Vertical weight on trailer hook 15kg Do not exceed the maximu...

Page 33: ...Dress Always wear a motorcycle helment when riding Also wear the following protective tools eye protection goggles or dust proof shield gloves boots long sleeved shirt or jacket pants 3 Do not operat...

Page 34: ...gh improper installation or use of accessories All parts and accessories added to this vehicle should be genunie our or equivalent components designed for using on this QUAD and should be installed an...

Page 35: ...e of the brakes or shifting can cause the tires slidding to lose the control Must make the engine to slow down fully before engaging a lower gear Turning Must make the turning practice in low speed be...

Page 36: ...e on slippery and loose slope Transfer your body gravity center forward and avoid abrupt acceleration and shift Drive in low speed when climbing the hill WARNING There may be other vehicles and person...

Page 37: ...ning speed should not be too high when making a turn and keep driving straight as far as possible Crossing depression When crossing depression balance your QUAD with body gravity center You should be...

Page 38: ...trol Don t try to ride over big obstacles such as rock and tree on the road Follow the proceduces in operation manual when riding over obstacles Slipping The QUAD may lose control when driving on loos...

Page 39: ...recommended to put this operation manual in the vinyl bag and lay it under the seat as shown Put the tool kit and low pressure tire gauge in the storage case The maintaining information included in t...

Page 40: ...ten in wet or dusty areas Check idle speed Starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for le...

Page 41: ...ge run out Replace if necessary Wheel bearings Check balance assembly for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check opera...

Page 42: ...e checking the oil level 1 Dipstick 2 Maximum level mark 3 Minimum level mark b Wipe the dipstick off with a clean rag Insert the dipstick in the filler hole c Remove the dipstick and inspect the oil...

Page 43: ...ring and drain pulg Then tighten the drain plug and filter cover bolts to the specified torque Tightening torque Drain pulg engine 43Nm 4 3m kg Filer cover bolt 10Nm 1 0m kg e Add oil to the engine w...

Page 44: ...brication oil of gear case Place the machine on a level place Remove the oil filler bolt and check the oil level lt should be up to the brim of the hole If should be up to the brim of the Hole If the...

Page 45: ...dically remove and check the spark plug because heat and deposits will cause slow damage and erosion of the spark plug if electrode erosion is excessive you should replace the spark plug with one of t...

Page 46: ...case 1 Check hose 1 Remove the seat 2 Remove the air filter case cover 1 Air filter element 2 Foam cover 3 Remove the air filter element 4 Remove the foam cover from the air filter element 5 Tap the...

Page 47: ...e air filter element removed This will let unfiltered air enter causing rapid wear and possible damage of engine Additionally operation without the filter element will weak the performance of carburet...

Page 48: ...speed before adjusting the throttle lever 1 lossen the locknut 2 Rotate the adjusting bolt until the throttle lever free play is 3 5mm 0 12 0 20in 3 Tighten the locknut 1 Adjusting bolt 2 Locknut a 3...

Page 49: ...joint of the balancer is straight when applying the brake If not rotate the adjusting nut at the front hubs until the cable joint becomes straight 1 Adjusting nut front hub 3 Retate the adjusting bol...

Page 50: ...the brake rod untill free play is 20 30mm 1 Brake cable adjusting nut 2 Brake rod adjusting nut a 20 30mm 2 Brake lever a Loosen the locknut and fully turn in the adjusting nut on the handlebar b Tur...

Page 51: ...the free play is correct Make sure the brakes do not skid Replacement of brake components requires professional knowledge These procedures should be done by our Group dealer Clutch adjustment 1 Loose...

Page 52: ...hich could cause an accident or injury Inspect cable frequently and replace damaged cables Lubricate the inner cables and the cable joints If the cables do not operate smoothly ask a our Group dealer...

Page 53: ...tation direction of the wheel 2 Tapered wheel nuts are used for both front and rear wheels Install tapered side of the nut towards the wheel 3 Tighten the wheel nut 1 Tapered nut Wheel nut torque Fron...

Page 54: ...ery is stored over the above mentioned time check the voltage at least one month Charge the battery when the voltage is lower than 12 V 1 Battery 1 Main fuse 2 Start relay Fuse replacement 1 The fuse...

Page 55: ...lb If the headlight bulb burns out replace the bulb as following steps 1 Remove the headlight cover 2 Remove the cover and rotate the bulb holder counterclockwise and remove the defective bulb 1 Headl...

Page 56: ...UAD Will improve its runing performance and prolong the service life of many components 1 Before cleaning the QUAD a Block off the exhaust pipe with plastic bag or strong rubber band to prevent water...

Page 57: ...ing protective measures 1 Add fresh fuel into fuel tank 2 Add one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire and run the engine over several times to coat...

Page 58: ...ressure splash MAIN DATA AND SPECIFICATIONS Item specification Engine oil Periodic oil change 1 5L With oil fillter replacement 1 6L Total amount 1 8L Total amout of gear oil 0 27L Main fuel tank capa...

Page 59: ...d operation Rear brake type Drum brake Operation Left hand and right foot operation MAIN DATA AND SPECIFICATIONS Item specification Suspension Supporting rod Front Rotary rod Rear Shock absorber Front...

Page 60: ...h should be done according to the warranty The chart below only acts as maintenance record not as maintenance proof MAINTENACE INTERVAL TIME 1 Month 3Months 6Months 12Months 18Months 24Months 30Months...

Page 61: ...nd light 13 Position light switch 14 Reverse indicator switch 15 Flasher 16 Turning signal switch 17 Emergency light switch 18 Starting motor 19 Ignition switch 20 Horn switch 21 Horn 22 Relay 23 Fan...

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Page 64: ...ona 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es Mayo May Mai Maggio 2005 RECOMIENDA EL USO DE ACEITE RECOMMENDS THE USE OF OIL...