GAS GAS PAMPERA 450 - 2007, Manual

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

Page 2: ......

Page 3: ...petition 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 moto...

Page 4: ...ed 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 equ...

Page 5: ...e 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...

Page 6: ...pe 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 rat...

Page 7: ...ithout 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 wi...

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: ...t 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...

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 ori...

Page 11: ...COMMENDED 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...

Page 12: ...ine 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 th...

Page 13: ...d 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 norm...

Page 14: ...wing 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 spe...

Page 15: ...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 mo...

Page 16: ...ep 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 tens...

Page 17: ...AUTION 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 Interferi...

Page 18: ...lly 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...

Page 19: ...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...

Page 20: ...rk 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...

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 Re...

Page 22: ...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...

Page 23: ...lip 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 c...

Page 24: ...n 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...

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 f...

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...

Page 27: ...ing 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...

Page 28: ...e 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 Rocke...

Page 29: ...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...

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 aft...

Page 31: ...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...

Page 32: ...e 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...

Page 33: ...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 du...

Page 34: ...ks 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...

Page 35: ...r 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 qua...

Page 36: ...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...

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 an...

Page 38: ...linder 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 Ste...

Page 39: ...olts 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 Brak...

Page 40: ...mp 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...

Page 41: ...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...

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...

Page 43: ...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 origina...

Page 44: ...pproximately 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 no...

Page 45: ...nditions 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...

Page 46: ...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 leve...

Page 47: ...endicular 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 s...

Page 48: ...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 Adju...

Page 49: ...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 Tight...

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...

Page 51: ...cator 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 ti...

Page 52: ...m 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 Spee...

Page 53: ...he 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...

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...

Page 55: ...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...

Page 56: ...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 seco...

Page 57: ...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...

Page 58: ...struction 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...

Page 59: ...ver 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...

Page 60: ...hock 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...

Page 61: ...se 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 Veri...

Page 62: ...tly 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 C...

Page 63: ...hat 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 Directiv...

Page 64: ...e 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 ordina...

Page 65: ...red 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 c...

Page 66: ...Notas Notes...