GAS GAS WILD HP 300 - SERVICE, Service Manual

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Page 2: ...ILD H P is a sports four wheel vehicle conceived in and for competition It will help you appreciate a high degree of technical perfection and reliability apart from a meticulous design and high perfor...

Page 3: ...hich if not strictly observed may damage or destroy your vehicle NOTE This symbol indicates points of particular interest for higher efficiency and a more convenient operation of the vehicle Inadequat...

Page 4: ...rests 86 Foot protections 86 C h e c k i n g s t o b e m a d e b e f o r e r i d i n g t h e vehicle 87 WILD HP 72 Front and rear brakes 87 Fuel 88 Cooling system 89 Chain 90 Throttle grip 90 Lights 9...

Page 5: ...r 107 Wheel change 108 Swing arm axle 108 Adjustment and lubrication of the chain guide 108 Checking the cooling liquid level 109 Air filter 111 Spark plug maintenance 113 Idle adjustment 114 Inspecti...

Page 6: ...x 72 mm Keihin PWK 38 mm Kokusan digital CDI Multispark Hydraulically operated multidisc 6 speeds Primary gearing secondary chain 50 6 CV A 7 340 rpm 5 02 mkg a 6 890 rpm Multi tube twin spar frame C...

Page 7: ...never lose control of the vehicle This vehicle has been designed to go through a maximum depth of 35 cm of water Do not use the vehicle in fast moving water read the instructions for this type of terr...

Page 8: ...porting the quad using a trailer make sure it is upright ant that the fuel tap is in the OFF position closed Fuel leaks might take place in the carburettor or in the fuel tank otherwise Fuel is poison...

Page 9: ...ortation easier The dealer will make sure each element is correctly fitted and you will receive the quad ready to use This paragraph is purely for your information You will find enclosed a carburettor...

Page 10: ...the picture This number must be mentioned to order a new set of keys in case you lose them WILD HP 78 HOMOLOGATION B NOTE The vehicle s serial number is used for your machine s identification C D B A...

Page 11: ...1 Clutch lever 2 Light switch 3 Flash beam 4 High beam 5 Emergency stop 6 Contact key 7 Parking brake 8 Front brake lever 9 Throttle grip 10 Front guard 11 Brake pads 12 Fuel tank cap 13 Footrest grid...

Page 12: ...18 24 19 22 23 21 25 20 26 16 15 Headlight fairing 16 Fuel tap 17 Seat 18 Front shock absorber 19 Spark plug 20 Change pedal 21 Swing arm 22 Exhaust pipe 23 Front brake fluid 24 Kick starter 25 Brake...

Page 13: ...s located on the front part of the handlebars To turn the contact on turn the key clockwise to the ON position To turn contact off turn the key anti clockwise to the OFF position KICK STARTER The peda...

Page 14: ...ur throttle works smoothly G Make sure it slides back to idle when the grip is released The grip has a spring to return the engine to idle and slow down the vehicle when the hand is taken off the grip...

Page 15: ...en movements and easily released in such cases When released it automatically stops the engine NOTE Make sure you release the parking brake before operating the throttle You are recommended to attach...

Page 16: ...To activate it pull the button and without turning the throttle start the engine You will notice that the engine starts at higher revs than in normal operating conditions After some seconds the engine...

Page 17: ...ara extraer el asiento utilice la misma llave que ha utilizado para abrir el tap n de la gasolina B Introduzca la llave en el cerrojo que est situado en el lateral derecho del QUAD Turn the key clockw...

Page 18: ...lly FOOTRESTS WARNING The footrests and protectors are an essential protection system for the quad s safe riding The quad has very wide wheels and it would easily drag your leg under the wheels causin...

Page 19: ...ree play the pedal position and its free play Brake lever and pedal Check the free play in the front brake lever 1 Should it be noticeable check the state of the brake pads and look in the Adjustments...

Page 20: ...might damage it Be careful not to spill fuel specially on the engine or the exhaust as it may start a fire with risk of serious burns Dry the spilt fuel at once with a cloth Make sure the fuel tank c...

Page 21: ...f of the gasoline into a container first and stir the mixture throughly Then add the rest of the gasoline and stir the mixture well NOTE At low temperature oil will not easily mix with gasoline Take t...

Page 22: ...e lights to make sure they are in perfect conditions Make any necessary repairs to make them work to perfection if required TYRES Always use the recommended tyres WARNING The use of inadequate tyres o...

Page 23: ...weather make sure that all the cables work smoothly before you go out on your quad If the cables are frozen or do not operate smoothly you could lose control of your QUAD and have an accident 1 To act...

Page 24: ...as to save battery charge GEARBOX This vehicle features a 6 speed gearbox It is a return type change which means that we must go through second gear to change from first into third that is one gear at...

Page 25: ...re to change into higher gears WARNING Too brisk acceleration or releasing the clutch lever too quickly may result in an accident and may cause the vehicle to slide and tumble The throttle must be gra...

Page 26: ...ortant part 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 a...

Page 27: ...earn the basic techniques before attempting more difficult challenges WILD HP 95 WARNING Never carry a passenger The long seat is designed to provide the driver with the necessary room to slide to the...

Page 28: ...place or somewhere far from the reach of pedestrians or children HOW TO TURN WITH YOUR QUAD At low speeds you will have no problem to turn the handlebars On the other hand if speed increases the diff...

Page 29: ...top turn the quad round while you still have some traction and if there is enough room for the turn and go down If the vehicle starts going backwards do not use the rear brake or try to insert a gear...

Page 30: ...ter box Wash it in fresh water if you have driven across salt water or mud RIDING IN ROUGH TERRAIN Riding in rough terrain must be performed very carefully Be always alert to any obstacle that may dam...

Page 31: ...the subsequent risk of accident Compression adjustment For the compression adjustment turn the knob A at the top of the shock absorber with your hand in 2002 models a flat tip screwdriver is required...

Page 32: ...end of the shock absorber with a flat tip screwdriver Turn it anti clockwise to the end which will totally close it WILD HP 100 There are 56 positions available in total The standard setting is 28 cl...

Page 33: ...ition Change in a turn increments If you turn the screw from 1 2 5 turns and the desired result is not obtained change the idle jet C and fine tune using the air screw B WILD HP 101 Carburettor needle...

Page 34: ...carburettor settings afterwards NOTE Make sure the carburettor parts that regulate the flow of fuel and the screw that controls the air flow are well adjusted Correct Poor Rich Dry and clear insulatio...

Page 35: ...ft 3000 m 9600 ft T E M P E R A T U R E C F CORRECTION FACTOR ALTITUDE JET NEEDLE AIR SCREW CHART CORRECTION FACTORS JET NEEDLE SETTING AIR SCREW OPENING 1 06 or ABOVE LOWER CLIP ONE POSITION ONE TUR...

Page 36: ...box Chain guide Cables Radiator pipes and connections Exhaust Wheel bearings 10 outings Check all screws Tightening force chart check chart Brake piston and cover dust guard 2 years Brake pump piston...

Page 37: ...adjustment screw to obtain the optimal free play If the clutch lever adjustment is at its limit it must be adjusted by using the clutch pump piston push rod ADJUSTMENT OF THE BRAKE LEVER AND PEDAL Th...

Page 38: ...l descends then you will be able to control the level decrease WILD HP 106 Air might also have entered the brake system The process to bleed the system is as follows Activate the brake several times Y...

Page 39: ...ubs on the disc and as a consequence is the part that suffers more wear out and requires more control of its thickness When the fluid level is too low add more With a cross tip screwdriver unscrew the...

Page 40: ...with your GAS GAS Quad to tighten the axle ADJUSTMENT AND LUBRICATION OF THE CHAIN GUIDE It must be checked adjusted and lubricated according to the regular maintenance to prevent excessive wear out I...

Page 41: ...on the chain longer and lubricate it better Lubricate on the pin side of the chain so that it filters into them dry out the oil excess CHECKING THE COOLING LIQUID LEVEL The cooling liquid absorbs the...

Page 42: ...bitors in the essence of the cooling liquid Without an anti corrosion liquid in time the radiator would oxidise This would block the cooling ducts inside it CAUTION The use of inadequate liquids may d...

Page 43: ...NOTE There is a check hose on the lower part of the air filter box If dust or water have reached this hose empty it and clean the air filter element and the air filter box WILD HP 111 Coolant Change...

Page 44: ...nd you will see a screw E that can be turned with your fingers 3 Remove the screw and filter Remove the filter package from the air filter box C E NOTE Do not twist the element when you dry it 4 Remov...

Page 45: ...ure all the corners are clean before putting all the parts back in place Grease all the connections screws and inlets to the air filter Place the filter cage back in position and cover the filter lip...

Page 46: ...sed place it back in the cylinder head with your fingers and start to turn it into place with your hands until the bottom CAUTION Always start inserting the plug with your hands which will help you kn...

Page 47: ...worn out or damaged The control operation could be restricted which may result in accidents and injuries Lubricate the inside of the cable hoses and the cable ends If the cables do not slide smoothly...

Page 48: ...st the spring turn it anti clockwise and replace it with a new one Put the lens back in place NOTE Make sure the lens is well tightened F E 6 After freeing the bulb E from the wire part we can remove...

Page 49: ...omotes premature failures Oil level Asegurarnos que el cuadricilo est en una zona llana sin pendentes B Oil level Stand the motorcycle upright and level allow a few minutes for the oil to settle Obser...

Page 50: ...engine and place an oil pan beneath the engine Remove the drain plug and position the vehicle so that it is perpendicular to the ground to allow all the oil to drain out Install the drain plug with it...

Page 51: ...bolt Disc base bolt Rear brake pedal bolt Subframe mount bolt Rear shock absorber bolt Drive chain ring nut Rocker arm bolt Suspension struts bolt bieletas Steering pipe Front wishbones Front hub Rim...

Page 52: ...pedal 1 Set rear wheel 2 Set front shock absorber 3 Set engine 4 Set transmission 5 Set rear wheel 1 7 3 4 8 BOLT AND NUT TIGHTENING Every day before riding check without fail the tighteness of the bo...

Page 53: ...bs 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 wit...

Page 54: ...grease oil or dirt Chain lubrication is necessary after circulating over wet ground or when the chain looks dry It is preferable to use dense oil as it will stay on the chain longer and will provide b...

Page 55: ...chain and all the cables Apply oil on all unpainted metal surfaces to prevent dust avoiding oil on brakes and rubber parts Wrap the exhaust pipe in a plastic bag on the outside to prevent rust Leave...

Page 56: ...WILD HP 124 Work mode This can be activated ON and deactivated OFF Clock Indicates hour and minutes Chronometer Indicates the time passed since the last activation of the work mode Partial distance I...

Page 57: ...for about ten seconds with the indication of zero Km h After this time if the motor is not turned on again the last function previously selected will appear on the screen The screen will turn off comp...

Page 58: ...to specialized garage Is recomended to drain the old fuel from the float chamber Then fill it up with new fuel Clean and dry the spark plug or exchange it respectively In order to pump the engine fre...

Page 59: ...jet higher No clutch lever play maladjusted Check spark plug clean adjust or replace Check spark plug cap if it s damaged change it Go to specialized garage Empty fuel tank and fill it up with new one...

Page 60: ...ect Tire air pressure too high Rebound damping adjustment incorrect Go to specialized garage Go to specialized garage Go to specialized garage Go to specialized garage Go to specialized garage Go to s...

Page 61: ...kes or excessivery vibrates Pull to one side Check tire air pressure Adjust drive chain Change chain and rear engine sprocket Go to specialized garage Change it Go to specialized garage Lubricate with...

Page 62: ...Ilumination fuse is blown Check pad and replace if it is necesary Check and repalce if it is necesary Empty brake fluid and replace with new recomended one Look how purge the fluid brake in Maintenan...

Page 63: ...nd to the extent that a The purchaser has failed to subject the vehicle to any of the inspections and or maintenance work prescribed in the operating manual or has exceeded the date stated for such in...

Page 64: ...he existence of a defect or if a visual inspection or material testing is required GG shall be entitled to demand submission of the parts for which warranty claims are put forward or to order an exami...

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