Yes, turning the gains all the way up IS a problem. The gain set how much the signal is amplified, not simply how much power the amp puts out. There is a tutorial for setting gains
here which should help you out, but it is a little bit of work and you will need a voltmeter, which you can get for cheap at radio shack. Spending the few minutes to set your gains right will give your amp and speakers a much longer life.
-Chris
yeah, too high, you'll get thermal overload, too low, you wont hear your sub.
A friend of mine has two Sony X-Plod 12" 1300w subs in his trunk powered by a 175w kenwood 1/2 channel amp and his trunk still vibrates unbelievably. So wattage to the sub isnt much of a problem, however you try to turn the music up too loud with the gain all the way up, the distortion will kill your subs easily.