Related Manuals for GAS GAS FSE 400 - 2004
Summary of Contents for GAS GAS FSE 400 - 2004
- Page 1 MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D’ENTRETIEN MANUEL D’ENTRETIEN LIBRETTO USO E MANUTENZIONE LIBRETTO USO E MANUTENZIONE Compuesta...
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Page 2: Foreword
GAS GAS thanks you for your confidence By choosing the new GAS GAS EC FSE 400 / 450 you have just entered the great GAS GAS family and, as a user of the number one off-road motorbike manufacturer, you deserve the distinguished treatment that we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this manual. -
Page 3: Important Notice
IMPORTANT NOTICE Whenever you see the symbols shown below, heed their instructions! TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU Always follow safe operating and maintenance practices. USE YOUR BIKE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE. -
Page 4: Table Of Contents
Engine oil.....................106 Manitenance chart ................78 Suspension tuning................109 Battery..................... 79 Preparation for competition..............115 Cooling system ................80 Storage....................116 Spark plug ..................83 Gas Gas speedo instructions..............116 Clogged air..................86 Troubleshooting..................118 Throtlle cable .................. 87 Warranty regulations................123 EC FSE 2004 -... -
Page 5: Specifications
SPECIFICATIONS ENGINE Engine 4 cycle, single cylinder DOHC 4r, crank case induction, liquid cooled Displacement in cubic centimeters 399 / 449 c.c. Bore and stroke 90 x 62,6 mm. / 95 x 62,6 mm. Spark plug NGK CR8E o DENSO U24ESR-N Injection system Magneti Marelli TRANSMISSION... - Page 6 Susmension Front Öhlins inverted fork, 43 mm. ø. WP inverted fork, 43 mm. ø. Mazocchi inverted fork, 45mm. ø. Rear Multi-adjustable, progressive Öhlins shock absorber. Suspension travel Front 295 mm. Rear 320 mm. Front fork oil MARZOCCHI SAE 7.5 WP SAE 5 ÖHLINS SAE 5 - 7.5 Front fork oil level Marzocchi: 110 mm.
- Page 7 LOCATION OF COMPONENTS GAS GAS EC FSE 400cc. / 450cc. 1- Clutch lever 2- Engine Stop Button 3- Fuel Tank Fill Cap 4- Front Brake Fluid Reservoir 5- Front Brake lever 6- Throttle Twist-Grip EC FSE 2004 -...
- Page 8 7- Front Suspension 16- Rear Shock Absorber 8- Radiator 17- Chain Guide 9- Fuel Tank 18- Drive Chain 10- Air Filter 19- Silencer 11- Seat 20- Fuel Tank 12- Brake Disc, front 21- Connecting Rod o'ring and Swingarm 13- Brake Cliper, front 22- Rear Brake Pedal 14- Brake Fluid Reservoir, rear 23- Oil Dipstick...
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Page 9: Side Stand
SIDE STAND FUEL To operate the side stand: The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline Release the security strap (B), the sidestand is held in the down position by the weight of the motorcycle. Thes sidestand automatically Gas Tank Capacity retracts when the motorcycle is placed in the upright position. -
Page 10: Recomended Fuel
RECOMENDED FUEL SERIAL NUMBER Use premium gasoline with an octane rating equal to or higher than This number allows the motorcycle to be registered. The serial that shown in the table. number (or V.I.N.) is located on the steering stem of the frame. Official approval plate OCTANE RATING METHOD MINIUM... -
Page 11: Start The Engine
START THE ENGINE Stopping the Engine - You have to assure the motorcycle to the neutral position. - Change to the neutral position. - Turn the key in the direction clock (position in "ON" (A)), by this - After racing the engine slightly, close the throttle completely and way the electric circuits will be open and then the engine will start. -
Page 12: Choke Button
CHOKE BUTTON SHIFTING GEARS The choke button is a mecanism that opens the throttle, whithout The transmission is a 6 speed, return shift type with neutral halfaway take the twist grip, to favour the engine if it is cold. The engine will between 1st and 2nd gears. -
Page 13: Stopping The Motorcycle
STOPPING THE MOTORCYCLE 1. Start the engine and let it run at idle until the engine is thoroughly warmed up. For maximum deceleration, close the throttle and apply both front 2. Stop and let the engine cool completely. and rear brakes. Disengage the clutch as the motorcycle comes to 3. -
Page 14: Manitenance Chart
MAINTENANCE CHART Part Period Period Period First 5 hours Every 30 hours Every 60 hours Inspect every time the bike has been running and has been checked Air filter *Muffler bolts and connections *Valve tolerance Spark plug Injection pump pipes *Check every 4 years Motor oil and filter oil *Oil motor pipes... -
Page 15: Battery
BATTERY WARNING This battery is maintenance free and checking the fluid level is not Hydrogen gas produced by the battery may explode if exposed to required. It is recommended to check the charge of the battery open flame or sparks. Keep flames and sparks away from the battery. periodically. -
Page 16: Cooling System
- Recommended charging time = 5 - 8 hours. CAUTION - The product of (charging power) x (charging time) has to stay Using high-pressure water, as from a car wash facility, could damage within the range:0,5 - 0,8 Cn. the radiator fins and impair the radiator´s effectiveness. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator. - Page 17 Coolant Level CAUTION Use of incorrect coolant solutions will cause severe engine and - Situate the motorcycle so that it is perpendicular to the ground. cooling system damage. - Remove the radiator cap in two steps. First turn the cap counterclock- Use coolant containing corrosion inhibitors made specifically for wise to the first stop and wait there for a few seconds.
- Page 18 Coolant Change NOTE Check the level when the engine is cold. - The coolant should be changed periodically to ensure long engine life. - Wait for the engine to cool completely. - Situate the motorcycle so that it is perpendicular to the ground. - - Remove the radiator cap.
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Page 19: Spark Plug
- Visually inspect the old coolant. If whitish cotton-like wafts are it, clean it (preferably with a (sandblaster) and then clean off any observed, aluminum parts in the cooling system are corroded. If the abrasive particles. The plug may also be cleaned using a high flash- coolant is brown, iron or steel parts are rusting. - Page 20 3. Unscrew screws (C) CAUTION (right and left). Incorrect installation of the plug or an incorrect heat range choice may cause extensive engine damage, and such damage would not be covered by the warranty. Use always manufacturer-recommended spark plugs. Consult your dealer or a qualified mechanic in order to know which is the best plug for your motorcycle.
- Page 21 5. Remove the tank rubber (D). 8. Extract the protector cap. NOTE For the correct use of the plug, it is protected by a cap. Keep the cap clean and dry. 9. Extract de plug and r e m o v e t h e c a r b o n deposits from the spark plug...
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Page 22: Clogged Air
CLOGGED AIR A clogged air cleaner restricts the engine´s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident. - Remove the filter cover (A) - Remove the wing bolt (B) CAUTION... -
Page 23: Throtlle Cable
- Clean the element in a THROTLLE CABLE bath of a filter cleaning fluid using a soft bristle - Inspect the throttle grip for smooth operation in all steering positions.In brush. accordance with the Periodic Maintenance Chart, check and adjust the throttle cable. -
Page 24: Clutch
CLUTCH EXHAUST SYSTEM Proper clutch lever play between the clutch lever and the clutch The muffler and silencer reduce exhaust noise and conduct the lever holder is 2-3 mm. exhaust gases back away from the rider. When there is too much lever play, first try adjusting the clutch lever. If the muffler is badly damaged, dented, cracked or rusted, replace it with a new one. -
Page 25: Drive Chain
WARNING - Remove the inner pipe mounting rivots (A), and pull out the inner pipe (B). A chain that breaks or jumps off the sprockets could snag on the - Pull off the old silencer packing, and install the new silencer packing. engine sprocket or lock the rear wheel, severely damaging the - Install the inner pipe into the silencer. - Page 26 In addition to checking the slack, rotate the rear wheel to inspect NOTE the drive chain and sprockets for damaged rollers, loose pin and Wheel alignment can also be checked using the straightedge links, unevenly or excessively worn teet, and damaged teeth. or string metod.
- Page 27 NOTE Chain Slider Wear For maximum strech resistance and safety, a genuine part must be used for replacement. Visually inspect the upper and lower chain sliders. To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the «U»...
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Page 28: Handlebar
Apply oil to the side of the rollers so that it will penetrate to the rollers Tighten the clamp bolts, front first and then the rear, to 25 Nm of and bushings. Wipe off any excess oil. torque (18 ft.lbs). If the handlebar clamp is correctly installed, there will be an even gap at the front and rear after tightening (A). - Page 29 Front Brake Lever Play Adjust the front brake lever (A) to suit you. To adjust the brake lever play, loosen the locknut and turn the adjuster (B) to either side. After adjustment, tighten the locknut securely. Then check the brake for good braking power and no brake drag.
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Page 30: Steering
1 mm, replace both pads in the caliper as a set Pad replacement should be done by an authorized GAS GAS dealer. STEERING The steering should always be kept adjusted so that the handlebar will turn freely but have no excessive play. -
Page 31: Steering Blocade
To check the steering adjustment, using a stand under the frame, - Tighten the steering stem head nut, and front fork upper or lower raise the wheel off the ground. Push the handlebar lightly to either clamp bolts to the specified torque (A). side;... -
Page 32: Front Fork
- Air pressure: Air pressure acts as a progressive spring and affects the entire range of fork travel. The air pressure in the fork increases as the fork heats up, so the fork action on your GAS GAS will get stiffer as the race progresses. Because of this, we don´t recommend using air pressure for additional springing. - Page 33 CAUTION Stand Oil Level The left and right fork tubes must bealigned (level) at the top clamps. (see the illustration). Marzocchi: 110 mm WP: 120 mm Compression Dampening Adjustment - To adjust, turn the knob located at the top of the fork. Adjust to rider preferance.
- Page 34 (1). Spring (2). Locknut (3). Suspension cap (4). Cap Wrench (5). Lock nut wrench Fork Springs Different fork springs are available to achieve suitable front fork action in accordance with the rider´s weight and track conditions. - Harder springs make the fork stiffer, and rebound action quicker. - Softer sprigs make the fork softer, and rebound action slower.
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Page 35: Rear Suspension
Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening, turn the rebound dampening adjuster on the rear shock absorber lower end until you feel a click. The total number of adjustments is: 60 ¨CLICKS¨. The standard setting is: 25 ¨CLICKS¨. (Counterclockwise from fully closed). - Page 36 Suspension spring The standard spring is a 4.0. The standard spring preload length is 258 mm (A). Adjusting (B). Spring (C). Lock nut (ring) (A). Compression dampening adjuster Adjusting the spring - Remove the seat, right and left side number plates. - Loosen the air cleaner duct clamp screw.
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Page 37: Wheels
(A). Llave tensador radios WARINING Improper removal of the spring from the rear shock absorber body may cause the spring and associated parts to be ejected at high velocity. Always wear eye and face protection. Removal and installation of spring should be performed by an person or company. WHEELS Tires (A). - Page 38 Cleaning 3- After washing: - Remove the plastic bags, and clean the air cleaner intake. 1- Preparation for washing - Lubricate the points listed in the lubrication section. - Start the engine and run for 5 minutes. Before washing, precautions must be taken to keep water - Dry the brakes before operating the motorcycle.
- Page 39 Bolt and Nut Tightening Every day before riding, check without fail the tighteness of the bolts and nuts described here. Also, check to see whether or not each cotter pin is in place and in good condition. 20 21 22 13 14 26 28 27 1- Front / rear rim...
- Page 40 Torque Table Tighten all bolts and nuts to the proper torque using an accurate torque wrench. A bolt or nut if insufficiently tightened may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. PART NAME N-m / FT.LBS.
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Page 41: Lubrication
LUBRICATION Lubricate the points shown here, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions, and especially after using 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. -
Page 42: Engine Oil
Chain lubrication The recomended viscosity is SAE 10W-50, if a SAE 10W-50 oil is not posible, use one of the last table. Lubricate the chain after drive over wet places or when the chain looks dry. It's better a high viscosity oil than a small viscosity oil Checking the oil level and replacing periodicity are two important because it will stay a long time in chain. - Page 43 The oil is pumped from the oil reservoir to the engine when the latter 6. Remove the dipstick and check the oil level. Oil level must be is running. The oil reservoir in this motorcycle is located in the top between line (L) (LOW) and (F) (FULL).
- Page 44 NOTE WARNING recycle and dispose of used motor oil in an appropriate container. The engine oil and the outpour tube can be very hot and cause burns. Wait until the oil and the outpour tube are a little colder, by touching the oil drain with your hand.
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Page 45: Suspension Tuning
Put a new «o-ring» at the same time the filter is replaced. Using a filter with an incorrect design may cause engine malfunction. Use the oil filter with the genuine GAS GAS design or equivalent for your motorcycle. 9. Replace the filter cover and put the screws that secure the cover, but without tightening them too hard. - Page 46 - The three major factors which must be considered in suspension - When the oil level is lowered: tuning are RIDER WEIGHT, RIDER HABILITY, and TRACK The aire spring is less progressive, and the front fork does not CONDITIONS. Additional influences include the RIDER´S STYLE become as ¨hard¨...
- Page 47 Troubleshooting Improper Settings . Rebound or compression damping adjusting incorrect. Listed below are some symptoms of improper suspension settings and the most likely means of correcting them. Symptoms of the rear shok: Too hard The proper settings can be achieved by applying the information in this chapter in a scientific, methodical manner;...
- Page 48 Riding experience Front and rear compability: Beginner Softer: spring with more rebound damping. Use this procedure to determine if the suspension is balanced Experienced: Harder spring. reasonably well: Hold the bike upright (retract the side stand). While standing next to the machine, lightly pull on the front brake, place one foot on the footpeg closest to you, and push down hard.
- Page 49 Front fork doesn´t respond to small bumps in sweeping turns: Adjustment depending on bottoming condition:(rear shock - Front Fork is too hard: absorber). 1. Decrease the compression damping or rebound damping. 2. Decrease oil level 10 mm. - Bottoms at low speed. 3.
- Page 50 - If the straight portion of a course is longer, the secondary reduction ratio should be reduced so that the machine speed can be increased. 3. The engine works hardest in muddy conditions and the radiator can become clogged with mud. Take care not to overheat the engine - When the course has many corners or uphills or is wet, the in these conditions.
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Page 51: Preparation For Competition
PREPARATION FOR COMPETITION (2). After first race maintenance 1. Air cleaner element (1). Check: 2. Drive chain slack 3. Rear sprocket nuts 1. Front axle shaft and nut, or axle clamp nut tightness 4. Sprockets 2. Front fork clamp bolt tightness 5. -
Page 52: Storage
STORAGE GAS GAS SPEEDO INSTRUCTIONS When the motorcycle is to be stored for any lenght of time, it should The top button is the reset button. be prepared for storage as follows: The bottom button is the mode button. - Clean the entire vehicle thoroughly. - Page 53 met -- for km/h mil --- for mp/h 0000 - The white plastic block connector on the speedo is for the display backlight. - The red wire is positve. - The black wire is negative. Total distance Trip distance - Warning; your speedo is set for the diameter of your front wheel To change the time: enduro 21"...
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Page 54: Troubleshooting
TROUBLESHOOTING NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. CAUSE REMEDY TROUBLE Starter engine doesn't crank - Blown fuse in the starter relay. - Page 55 TROUBLE CAUSE REMEDY Engine start but stops few - Incorrect air supply. - Close the starter. Clean fuel tank air vent. Check the air seconds ago. filter. - There isn't fuel. - Fill up fuel tank. Engine gets to hot - Insufficient cooling liquid.
- Page 56 TROUBLE CAUSE REMEDY Exhaust pipe get out white - Cylinder head gasket leaking. - Change cylinder head gasket leaking. Go to specialized garage. smoke. Exhaust pipe get out brown - Air filter is bloked. - Clean or change the air filter. Go to specialized garage. smoke.
- Page 57 TROUBLE CAUSE REMEDY Shock absorption too hard - Front fork oil viscosity too hight. - Empty oil from fork and go to specialized garage. - Front fork leg bent. - Change it. Go to a specialized garage. - Tire air pressure too high. - Check tire air pressure.
- Page 58 TROUBLE CAUSE REMEDY Motorcycle pull to one side - Steering stem bent. - Change steering stem and go to specialized garage. - Front fork bent. - Change front fork. - Wheel misalignment. - Align wheel. Brakes don't hold - Pad or disc worn. - Change disc.
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Page 59: Warranty Regulations
The Company GAS GAS Motos S.A. hereby warrants to the final appeared before the prescribed date of such inspection or... - Page 60 b) Lubricants (e.g. oil, grease, etc.) and operating fluids (e.g. battery 3.- If it turns out that any defect cannot be removed, the warranty fluid, cooling liquid, etc.). shall be entitled to demand termination of the contract (payment of c) Inspection, adjusting and other periodical maintenance work as a compensation) or partial reimbursement for the purchasing price well as all kinds of cleaning work.
- Page 61 JULIO / JULY 2003 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 Compuesta...
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