Related Manuals for GAS GAS EC FSE 400 - SERVICE MANUAL 2002 & 2003
Summary of Contents for GAS GAS EC FSE 400 - SERVICE MANUAL 2002 & 2003
- Page 1 SERVICE MANUAL SERVICE MANUAL MOTOR FSE400 / 450 MOTOR FSE400 / 450 2002 / 2003 2002 / 2003...
- Page 2 Contents Technical Specifications.............84 Engine Removal and Installation........86 Engine Disassembly..........…..96 Inspection and Maintenance of Engine Components............108 Engine Installation..............136 Regular Maintenance............156...
- Page 3 T echnical Specifications MODEL Ec 400 / 450 FSE ENGINE Cubic Capacity 399 cc. / 449 cc. Type 4-stroke with 4-valve cylinder head Number of Cylinders Cooling System Water-cooled Bore and Stroke 90 x 62.6 mm. / 95 x 62.6 mm. Injection E.F.I.
- Page 4 Engine Removal and Installation Engine Removal and Installation...
- Page 5 Engine Removal Before removing the engine from the frame, wash it with a steam machine. The following steps cover the disassembly sequence. Remove the saddle and the frame covers. Drain the oil in the engine. . Remove the engine plate. Drain the frame oil reservoir (A).
- Page 6 Detach the wire clamp from the alternator (A) and the sensor cable from the tonewheel. Detach the spark-plug arm (1), the engine-oil devaporizing tube (2), the engine-oil reservoir breather pipe (3). Loosen the clamp holding the cylinder head injector conduit (4). Detach the wire clamp from the water-temperature sensor (5).
- Page 7 Remove the water tubes (1). Remove the lever from the pedal-operated starter. Remove the exhaust manifold (2). Detach the radiator tubes. Engine Removal and Installation...
- Page 8 Detach the engine-oil tube (1) in the frame reservoir. Remove the gearbox lever. Remove the engine-pinion cover. Remove the clutch pump. Loosen the chain. Remove the outlet pinion Seeger (1). Engine Removal and Installation...
- Page 9 Remove the engine pinion. Remove the split pin and the brake pedal. CAUTION! Replace the split pins with new ones. Remove the engine from the frame. Engine Removal and Installation...
- Page 10 Engine Installation Reverse the above operations to install the engine . Fit the screws and nuts securing the engine. NOTE: At this stage, nuts must only be tightened provisionally. The nuts securing the engine are self-locking. Upon removal, they cease to be self-locking and become useless.
- Page 11 Attach the engine pinion. NOTE: The previous CW/ACW direction of this pinion must be duly noted, so that the same wear CW/ACW direction may be preserved. Attach the engine pinion Seeger. Attach the tube to the frame reservoir. Tighten the exhaust manifold screw (1) at the specified torque.
- Page 12 Apply LOCTITE 243 to the screw on the pedal- operated starter lever, then tighten. For 1.9 litre of API-compliant SF- or SG-grade motor oil and SAE 10W-40-viscosity oil into the oil inlet located in the frame (1) and check the level.
- Page 13 Engine Disassembly Engine Disassembly...
- Page 14 Detach the alternator cover. Turn the alternator rotor until the 7th tonewheel tooth becomes aligned with the position-sensor hole centre. NOTE: The cylinder-head lid must be removed with the piston in the compression stroke PMS. Remove the cap bolt (1) and the timing-chain idler (2).
- Page 15 Remove the centering devices (1), the input camshaft (2) and the output camshaft (3). NOTE: Prevent the centering devices from falling into the crankcase. Remove the cylinder-head side screw. Remove all four cylinder-head screws in a diagonal sequence. NOTE: Prior to loosening the cylinder-head screws, loosen the cylinder-head screws (6 mm) and the cylinder-base screws.
- Page 16 Remove the cylinder-head gasket (1) and the centering devices (2). Remove the timing-chain guide (3). Remove the cylinder-base screws (4) and then the cylinder. NOTE: In case of difficulty removing the cylinder, tap it with a plastic mallet. Remove the cylinder gasket (5) and the centering devices (6).
- Page 17 Detach the oil-filter lid (1) and the oil filter (2). Remove the starter followers (3), the centering devices (4) and the gasket (5). Remove the pressure-pump lid (1) and the rotor (2). Engine Disassembly...
- Page 18 Remove the coolant-pump cover. Remove the clutch lid. Remove the centering devices (3) and the gasket (4). Loosen the clutch-spring screws in a diagonal sequence (as illustrated) and remove them when they become totally loose. Detach the clutch press and the disc assembly. Remove the clutch rod.
- Page 19 Holding the clutch hub with the special tool supplied, remove the clutch-hub nut. Tool Part No.: Clutch-hub fastener Remove the clutch hub and the washer. CAUTION! The clutch hub has a specific fitting position in respect of the input shaft. Mark the position with an indelible marker on the lubrication groove.
- Page 20 Remove the Seeger ring (3) and the pedal-operated starter intermediate gear (4). Detach the foot-operated starter assembly. Detach the pedal-operated starting pawl plate (6). Detach the pedal-operated starter intermediate pinion shaft. Detach the oil-pump intermediate gear (1) and the oil-pump follower (2). Engine Disassembly...
- Page 21 Remove the oil-pump assembly. Remove the selector-shaft assembly. Detach the gear-centering device plate (3) Remove the crankshaft pinion bolt, the washer, the gear, the timing chain and the timing-chain gear. CAUTION! The crankshaft pinion bolt has a left-hand thread. Remove the alternator-rotor bolt and washer. Holding the puller with a spanner, loosen the rotor.
- Page 22 Use the special tool supplied to detach the alternator rotor. CAUTION! Tapping the alternator rotor with a hammer might damage it. Remove the lower oil-reservoir lid. Remove the crankcase left-hand set screws. Detach the crankcase using the special tool supplied. Tool Part No.: ME2595000: crankcase-detachment tool NOTE:...
- Page 23 Remove the shafts of the shifter forks (1) and the forks (2). Detach the gearbox input-shaft assembly (3) and the gearbox output-shaft assembly (4). Detach the crankshaft (5) and the rocker shaft (6). NOTE: Should this detachment operation prove difficult, tap both shafts with a plastic mallet in an alternating pattern.
- Page 24 Inspection and Maintenance of Engine Components Cylinder head.................110 Camshaft / Automatic decompression assembly.....120 Piston and piston ring..............122 Connecting rod................125 Crankshaft..................126 Starter clutch ................126 Oil pump..................127 Clutch...................127 Shifter forks and gear..............128 Transmission................129 Bearings..................130 Seals..................133 Inspection and Maintenance...
- Page 25 CAUTION! Identify the position of each part. Set them in groups (exhaust, admission) so that they may be assembled in their original positions. CYLINDER HEAD Disassembly Detach the intake pipe. Detach the engine-coolant pipe bracket. Remove the tappets (1) and the adjustment washers (2), by hand or with a magnet.
- Page 26 Compress the valve springs and then use the special tools provided to remove the valve-rod semicones. Tool Part Description.: valve-spring compressor Tool Part Description: Adapter Tool Part Description: Pliers Remove the valve-spring plate (1) and the valve springs (2). Inspection and Maintenance...
- Page 27 Remove the valves from the opposite side. Use long-nosed pliers to remove the valve seals. Detach the valve-spring washer. NOTE: The valve detachment completes the standard disassembly operation. If you had not detached the valve guides for replacement after inspecting their associated parts, follow the instructions given in the valve-guide maintenance section.
- Page 28 Valve-head radial offsetting Using one tapered block to hold the valve, measure the valve-head radial offsetting with the dial gauge, as illustrated. If the offsetting is found to exceed the service limit, replace the valve with a new one. Tool Part Description: Dial gauge (1/100 mm) Tool Part Description: Magnetic support...
- Page 29 Valve rod wear Use a micrometer to measure the rod outside diameter. If the outside diameter is found to exceed the specified value, replace the valve with a new one. If the rod outside diameter is found to be within the specified value, but the deflection is not within the specified value, replace the valve guide with a new one.
- Page 30 Valve-seat width Use Prussian blue to spray the valve seat evenly. Fit the valve and attach a valve burnisher to it. Tap the sprayed seat several times in a circular direction to get a clear imprint of the surface contact. Tool Part Description: Valve-burnisher set The ring-shaped sprayed imprint left on the valve...
- Page 31 When fitting the solid centering device (1), turn it slightly. Settle the centering device properly. Fit the 45º knife (2), the adaptor (3) and the T-shaped shank (4). Initial seat-cutting operation Use the 45° knife to descale and clean the seat. Turn the knife around once or twice.
- Page 32 Upper narrowing cutting operation If the contact surface is too high up the valve, or if it is too wide, use the 30º knife (inlet side) and the 15º knife (exhaust side) to lower and narrow Contact surface is too high and too wide on the valve working area.
- Page 33 Valve-seat tightness check With the valve and spring properly fitted, pour a small amount of petrol through the intake- or exhaust port. Check to see that no petrol is leaking through the valve seat. If a leak is found, tighten the sealing surface.
- Page 34 CYLINDER HEAD Fitting Fit the valve-spring seats. Apply a molybdenum-oil solution to each valve seal and press the valves into position. CAUTION! Do not re-use valve seals. Apply a molybdenum-oil solution to the valves, as illustrated, and then fit them into the guides. CAUTION! Care must be taken not to damage the valve-seal lips when fitting the valves into their guides.
- Page 35 CAMSHAFT - AUTOMA TIC DECOMPRESSOR ASSEMBL Y CAUTION! Do not try to disassemble the camshaft / automatic decompressor assembly. It cannot be repaired. Automatic decompressor Move the automatic-decompressor counterweight by hand to make sure that it works smoothly. If the automatic-decompressor counterweight does not work smoothly, replace it with a new one.
- Page 36 Camshaft-bridge wear With the camshaft fitted, use the plastic gauge to measure the oil clearance. Tools Description:.......plastic gauge DETAILS Camshaft-bridge oil clearance (inlet and exhaust) Service limit: 0.150 mm Tighten the bridge-bracket screws evenly and in a diagonal sequence, at the specified torque. Camshaft-bridge bracket screw: 10 Nm (1 Kgf-m) NOTE:...
- Page 37 CYLINDER Cylinder deformation Using a ruler and a feeler gauge, check the surface of the cylinder-block gasket for signs of deformation. Measure the clearance in several places. If any of the clearance measurements is found to exceed the service limit, replace the cylinder block with a new one.
- Page 38 Clearance between piston ring and groove Using the feeler gauge, measure the side clearances of the rings on pistons 1 and 2. If any of the clearances is found to exceed the service limit, replace the piston and the rings. Fig.1 Tool Description: feeler gauge...
- Page 39 Piston bolt and inside diameter of pin Use a small-calibre gauge to measure the piston- bolt inside diameter. If the diameter is found to exceed the service limit, replace the piston with a new one. Tool Description: Dial gauge (1/1000 mm) Tool Description: small-calibre gauge (18-35 mm) DETAILS...
- Page 40 CONNECTING ROD Connecting-rod foot inside diameter Use the small-calibre gauge to measure the connecting-rod foot inside diameter. If the connecting-rod foot inside diameter is found to exceed the service limit, replace the connecting rod with a new one. Tool Description: Dial caliper DETAILS Connecting-rod foot inside diameter...
- Page 41 CRANKSHAFT Crankshaft offsetting Using tapered blocks to hold the crankshaft, measure the amount of offsetting with the dial gauge, as illustrated. If the offsetting is found to exceed the service limit, replace the crankshaft with a new one. Tool Description: dial gauge (1/100 mm) Tool Description: magnetic support...
- Page 42 OIL PUMP Check all the components. The screws securing the pump to the engine casing must be fitted with LOCTITE and given a specific torque. Oil pump: 10 N.m (1.0 kgf-m) CLUTCH Clutch-driving discs Measure the thickness of the clutch-driving discs with vernier calipers.
- Page 43 SHIFTER FORKS AND GEAR Clearance between fork and fork groove The amount of clearance for each shifter fork plays an outstanding role in the achievement of a smooth, positive operation of the gearbox. Use the feeler gauge to measure the clearance of each fork in the groove of its gear.
- Page 44 TRANSMISSION Disassembly Detach the transmission gears as illustrated. 18X40X0,6 WASHER PRIMARY II PINION DIN 471 CIRCLIP 31,5x(25x22)x1 GROOVING WASHER PRIMARY VI PINION PRIMARY III AND IV PINION 25,2x31,5x1 GEAR WASHER Fitting PRIMARY V PINION K25-29-10 NEEDLES BEARING PRIMARY AXIS Reverse the disassembly operations to fit the SECUNDARY AXIS transmission.
- Page 45 BEARINGS Wash the bearings with a solvent and lubricate them with motor oil before checking them. Check to see that the inner guide ring turns smoothly. Any bearing that does not turn smoothly or noiselessly, or that shows signs of any anomaly, is deffective and must be replaced with a new one as follows.
- Page 46 Gearbox output shaft bearings Remove the RH (3) and LH (4) bearings from the gearbox output shaft using the special tool provided. Tool Description: bearing pulling device set CAUTION! Replace the removed bearings with new ones. Fit the RH and LH bearings on the gearbox output shaft using the special tool provided.
- Page 47 Gearbox desmodromic device LH bearing Remove the LH bearing from the gearbox desmodromic device (8) using the special tool provided. CAUTION! Replace the removed bearing with a new one. Fit the LH cam bearing on the gearbox desmodromic device. Rocker shaft RH bearing Remove the RH bearing from the rocker shaft (9) using the special tool provided.
- Page 48 SEALS A damaged seal lip may cause air/petrol-mixture or engine-oil leaks. Check the seals for signs of wear or damage. If any seal is found to be deffective, replace it with a new one. Fit the seals on the crankcase, the clutch cover. Pay special attention to the following points: CAUTION! Replace the removed seals with new ones.
- Page 49 Gearbox output shaft seal Slowly, remove the seal from the gearbox output- shaft in the LH crankcase (1), using the special tool provided. Tool Description: seal pulling device CAUTION! Replace the removed seal with a new one. Slowly, fit the gearbox output-shaft seal in the LH crankcase, using the special tool provided.
- Page 50 Engine Assembly Crankshaft..................138 Cam and shifter forks..............139 Crankcase..................140 Starter clutch and alternator rotor..........141 Rocker shaft..................141 Input drive gear................142 Oil pump....................142 Starting pawl..................143 Camshaft timing chain..............143 Clutch....................144 Crankcase RH cover.................146 Clutch cover..................146 Alternator rotor cover...............146 Piston ring..................147 Piston and cylinder................148 Cylinder head..................149 Camshaft / Automatic decompression assembly......150 Cylinder-head cover................151 Timing-chain idler................152...
- Page 51 Engine Assembly Assembly again the engine in the opposite order of the disassembly. Pay special attention to the following points: CAUTION: Before to assemble the engine, apply motor oil to all the mobile pieces. CRANKSHAFT 1) Crankshaft (RH) 2) Connecting rod 3) Bearing 4) Pin 5) Crankshaft (LH)
- Page 52 DESMODROMIC DEVICE AND SHIFTER FORKS 1) Shifter-fork shaft 2) No. 1 shifter fork 3) No. 2 shifter fork 4) shifter-fork shaft 5) No. 3 shifter fork 6) Desmodromic device Fit the shifter forks into the shifting grooves, in their correct positions and directions. Fit the shafts of the shifter forks.
- Page 53 CRANKCASE Reverse the above operations to assemble the crankcase. Pay special attention to the following points: Totally remove the sealer and oil stains from the contact surface of both the RH and LH crankcases. Prior to fitting the sump filter, wash it with solvent and then dry it with compressed air.
- Page 54 ST ARTER CLUTCH AND AL TERNA TOR ROTOR Remove the grease from the tapered area of the crankcase and the alternator rotor. Fit the linchpin (1) and the alternator rotor (2). Use a 17-mm spanner to tighten the alternator- rotor nut at the specified torque. Alternator-rotor nut: 100 Nm (10 Kgf-m) ROCKER SHAFT...
- Page 55 INPUT DRIVE GEAR After fitting the linchpin, attach the input drive gear (1) by holding the alternator rotor with the 17-mm spanner and by tightening the nut on the input drive gear at the specified torque. Input drive-gear nut 110 Nm (11 Kgf-m) OIL PUMP Before fitting the oil pump, apply motor oil to the sliding surfaces of the pump housing, the outer...
- Page 56 ST ARTING P AWL 1) Starting-pawl plate 2) 5x15 Allen 3) Spring 4) Starting-pawl plate 5) 20 Seeger 6) Washer 7) Starting pinion 8) Starting shaft 9) Washer 10) Spring 11) Centering bushing 12) Starter-pedal retainer 13) Starter inner pinion 14) Washer 15) Shaft Seeger Fit the pedal-operated starter shaft assembly and...
- Page 57 CLUTCH 1) Crankshaft pinion 2) 20/125 bevelled washer 3) Crankshaft pinion lock nut 4) 22.1x42x2.8 clutch-drum washer 5) Clutch crown-gear washer 6) Drum crown-gear pinion 7) Silentblock rubber 8) Clutch-drum crown gear assembly 9) Clutch-drum bearing 10) Clutch-drum bushing 11) Bushing 12) Clutch hub 13) Clutch-seal washer 14) Clutch-hub lock nut...
- Page 58 Holding the clutch hub with the special tool provided, tighten the clutch-hub nut at the specified torque. Tool Description: Clutch-hub holder Clutch-hub nut: 70 Nm (7 Kgf-m) Bend the washer tongue firmly. Fit the clutch driving discs and driven discs into the clutch hub, one by one and in the prescribed order.
- Page 59 CLUTCH COVER Fit the centering devices (1) and a new seal. CAUTION! Use a new seal, to prevent oil leaks. Tighten the screws on the clutch cover firmly. CLUTCH-DISC COVER Tighten the screws on the clutch-disc cover firmly. NOTE: Fit the new seal and the screws (A) on the clutch- disc cover, as illustrated.
- Page 60 PISTON RINGS Start by fitting the lubrication ring, followed by the 2nd ring and finally by the 1st ring. NOTE: Piston rings 1 (1) and 2 (2) have different shapes. Piston rings 1 and 2 must be attached with their marks facing upwards.
- Page 61 PISTON AND CYLINDER Reverse the above operations to install the piston and cylinder. NOTE: Fit the piston with the mark on its crown facing the exhaust side. Apply a molybdenum-oil solution to the piston bolt and the connecting-rod foot. Cover the cylinder base with a clean cloth to prevent the piston-bolt spring ring from falling into the crankcase.
- Page 62 CYLINDER HEAD Attach the centering pins (1) and a new cylinder- head gasket (2). CAUTION! Use a new cylinder-head gasket, to prevent petrol leaks. With the cylinder head properly settled on the cylinder, secure the cylinder head by tightening the screws in a diagonal sequence. Tighten the cylinder-head screws at the specified torque.
- Page 63 CAMSHAFT / AUTOMA TIC DECOMPRESSOR ASSEMBL Y Position the crankshaft with the piston at inner dead-centre (P.M.S.). CAUTION! If the crankshaft turns without lifting the camshaft driving chain, the chain will become jammed between the crankcase and the pinion. 1st. pin 15 pin NOTE: Just a moment before attaching the camshaft to...
- Page 64 Fit the centering pins. Place the brackets of the camshaft journals and the chain guide in the correct position. NOTE: Camshaft-journal brackets marked “EX” belong in the exhaust side, and camshaft-journal brackets marked “IN” belong in the inlet side. Tighten the screws on the camshaft-journal brackets at the specified torque.
- Page 65 CAMSHAFT DRIVING CHAIN IDLER Attach the camshaft driving chain idler. Pay special attention to the following points: Apply motor oil to the pushing rod. Using a flat-pointed screwdriver, turn the adjusting screw clockwise until the pushing rod becomes locked. Attach a new seal to the body of the chain idler. CAUTION! Use a new seal, to prevent oil leaks.
- Page 66 Regular Maintenance Spark Plug..................156 Engine Oil and Oil Filter............157 Engine oil pipework..............159 Regular Maintenance...
- Page 67 SP ARK PLUG Inspection after 30 hours’ operation. To be replaced after 60 hours’ operation. Detach the fuel tank. Detach the spark-plug arm and remove the spark plug. COLD STANDARD CR9E CR8E CR7E U27ESR-N U24ESR-N U22ESR-N DENSO U31ESR-N Cinder buildups Check the spark plug for cinder.
- Page 68 Spark-plug fitting CAUTION! In order not to damage the cylinder-head thread, start by screwing in the spark plug by hand, and then use the spark-plug spanner to tighten it at the specified torque. Torque for tightening the spark plug: 11Nm (1.1 Kgf-m, 8.0 lb-ft). ENGINE OIL AND OIL FILTER To be initially replaced after 5 hours’...
- Page 69 Oil-filter replacement Follow the same procedure as for replacing the engine oil. Remove the oil-filter lid (1) and the oil filter (2) Replace the filter with a new one. NOTE: Before fitting the oil-filter lid, make sure that the spring (3) and a new O-ring seal (4) have been attached correctly.
- Page 70 ENGINE OIL PIPEWORK To be initially inspected after 5 hours’ operation and then every 30 hours. Check to see that no engine-oil pipes show signs of damage or leaks. If any kind of damage is found, replace the pipes with new ones. Check compression A cylinder with the proper compression means that conditions inside the cylinder are good.
- Page 71 Oil-pressure check Check the oil pressure regularly. This should provide useful information on the condition of the engine moving parts. DETAILS: Oil pressure: Up 40 Kpa (0.4 Kgf/cm, 5.7 psi) at 3000 rpm Up 140 Kpa (1.4 Kgf/cm, 19.9 psi) Low or high pressure may indicate some of the conditions below: Low oil pressure:...
- Page 72 Notes Notas / Notes...
- Page 73 Notas / Notes...
- Page 74 C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: +34 902 47 62 54 Fax: +34 902 47 61 60 E-mail: officegg @ gasgasmotos.es / partsgg @ gasgasmotos.es · Web: www.gasgasmotos.es...
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