GAS GAS FSE 400 Workshop Manual
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MANUAL DE TALLER /
MANUAL DE TALLER /
WORKSHOP MANUAL
WORKSHOP MANUAL
MOTOR FSE 450
MOTOR FSE 450
2004 / 2005
2004 / 2005

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Table of Contents
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Summary of Contents for GAS GAS FSE 400

  • Page 1 MANUAL DE TALLER / MANUAL DE TALLER / WORKSHOP MANUAL WORKSHOP MANUAL MOTOR FSE 450 MOTOR FSE 450 2004 / 2005 2004 / 2005...
  • Page 3 WORKSHOP MANUAL WORKSHOP MANUAL ENGINE FSE 450 ENGINE FSE 450 2004 / 2005 2004 / 2005...
  • Page 5: Table Of Contents

    Contents Technical specifications..............4 Uninstalling and installing the engine in the chassis....5 Engine dismounting..............15 Engine mounting..............33 Replacement of the standard clutch with the ADLER clutch APTC..................53 Inspection and maintenance of the engine components............59 Periodic maintenance...............91...
  • Page 6: Technical Specifications

    Technical Specifications MODEL FSE 400 / 450 ENGINE Displacement in cubic centimetres 399 cc / 443 cc Type 4 stroke DOHC 4 valves No. of Cylinders Cooling System Water Cooled Bore and stroke 90 x 62,6 mm / 95 x 62,6 mm Injection Fuel injection electronic system Magneti Marelli...
  • Page 7: Uninstalling And Installing The Engine In The Chassis

    Un-installing and installaing the engine in the chassis Un-installing the engine...
  • Page 9 Un-installing the engine in the chassis Before dismounting the engine from the frame, wash it with a steam washer. The dismounting sequence is explained in the following steps. Dismount the seat and the frame covers. Empty the engine oil. Remove the engine plate. Empty the chassis (A) oil tank.
  • Page 10 Disconnect the alternator clamp (E) and the phonic wheel sensor wire. Disconnect the spark plug pipe (F), the engine oil vaporiser tube (G), the engine oil resevoir vent hose (H). Loosen the cylinder head injector tubing clamp (l). Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K).
  • Page 11 Dismount the water tube (L). Remove the pedal starter lever (M). Remove the exhaust collector (N). Disconnect the 2 radiator tubes. Un-installing the engine...
  • Page 12 Disconnect the engine oil tube (O) in the chassis tank. Remove the gearshift lever (P). Remove the engine pinion protector (Q). Remove the clutch cap (R). De-tense the chain. Remove the output pinion clip (S). Un-installing the engine...
  • Page 13 Remove the Engine pinion (T). NOTE: Observe which is the placement direction of the said pinion. Remove the carved bolts and the brake pedal. Remove the motor from the frame. Un-installing the engine...
  • Page 14 Installation of the engine in the chassis Mount the engine in inverse order to de-installation Fix the screws and engine fixing nuts. NOTE: In this phase, temporarily tighten the nuts. The engine fixing nuts are self-locking. Once removed they lose their self-locking capability and are useless.
  • Page 15 Mount the engine pinion. NOTE: Observe which is the placement direction before the said pinion, to be able to achieve the same direction of wear. Place the engine pinion clip. Connect the chassis tank tube. Fix the exhaust collector screw (1), with the specified torque.
  • Page 16 NOTE: Apply LOCTITE 243 to the pedal starter lever screw. Fill 1.2 L of an engine oil classified SF or SG through the API service and with a degree of viscosity SAE 10W-40 through the oil fill mouth in the frame (A) and check the level.
  • Page 17: Engine Dismounting

    Dismounting the engine Dismounting the engine...
  • Page 19 Loosen the 3 screws that hold the starter clutch cover. One of the 3 also holds the alternator cover. Remove the starter clutch cover. Extract the starter clutch. Loosen the 2 screws that hold the starter motor. Extract the starter motor. NOTE: The 2005 starter motor turns in the opposite direction to that of 2004.
  • Page 20 Loosen the 7 retaining screws that hold the alternator cover. One of them is located in the starter clutch cavity. Remove the alternator cover. Loosen the 2 screws that hold the position sensor (Pick-Up) (A). Remove the de-multiplier pinion (B). Loosen and extract the spark plug.
  • Page 21 Loosen the crankshaft nut. NOTE: The nut loosens towards the right. Turn the alternator rotor until placing the 7th tooth (A) of the phonic wheel in the center of the position sensor (Pick-Up) hole. Loosen the 3 screws that hold the cylinder head cover.
  • Page 22 Loosen the 3 screws that hold the oil extractor pump. Remove the oil extractor pump cover. Remove the oil extractor pump. Loosen the 2 screws that hold the distributor chain tensor. Remove the distributor chain tensor. Dismounting the engine...
  • Page 23 Remove the oil distributor. Loosen the 2 lateral screws that hold the cylinder head to the cylinder. Loosen the rear screw that holds the cylinder to the cylinder head. Loosen the front screw that holds the cylinder to the cylinder head. Loosen the 8 screws of the covers of the 2 camshafts and the distribution chain skate.
  • Page 24 Remove the distributor chain upper skate. Remove the intake camshaft cover. Remove the exhaust camshaft cover. Remove the intake camshaft. Remove the exhaust camshaft. Dismounting the engine...
  • Page 25 Loosen and remove cylinder head lateral screw. Loosen the 4 locking screws that hold the cylinder head. Remove the 4 screws. Remove the cylinder head. Remove the cylinder head gasket. Dismounting the engine...
  • Page 26 Remove the distributor chain front skate. Loosen the 2 screws that hold the cylinder to the engine housing. Hold the distributor chain and remove the cylinder. Remove one of the clips that hold the piston casing and push to remove it. Remove the cylinder gasket.
  • Page 27 Loosen the 5 screws that hold the cover of the clutch disks. Remove the cover of the clutch disks. Screw the centering tools into place (supplied together with the tools for the motorbike) and tighten them to 10 Nm. NOTE: This operation is mandatory to ensure the correct dismounting of the clutch.
  • Page 28 Remove the clutch pusher. Open the washer lug. Loosen the fixing bolt, blocking the clutch bell turn with the tool Ref. MFS4504500220. Remove the clutch unit. Loosen the 3 screws that hold the oil filter cover. Dismounting the engine...
  • Page 29 Remove the oil filter cover. Remove the oil filter and the spring. Loosen the screws that hold the clutch casing. Remove the clutch casing. Remove the clutch bell. Dismounting the engine...
  • Page 30 Loosen the screw that holds the distributor chain tensor skate and remove it. Remove the gear selector axle. Remove the gear pedal axle spring. Remove the gear pedal axle unit. Remove the starter intermediate pinion clip. Dismounting the engine...
  • Page 31 Remove the starter intermediate pinion. Remove the oil pump intermediate pinion. Remove the clip and remove the oil pump pinion. Loosen the 2 screws that hold the oil pump cover. Remove the oil pump cover. Dismounting the engine...
  • Page 32 Remove the oil pump gasket. Open the washer lug and loosen the crankshaft axle nut. NOTE: Turn the nut in a clockwise direction. Remove the crankshaft pinion. Remove the distributor chain pinion. Remove the distributor chain through the upper part of the housing. Dismounting the engine...
  • Page 33 Loosen the 10 screws that hold the left housing. One of the 10 screws that hold the left housing is located in the cavity of the oil pump. Loosen the 6 screws that hold the oil pump filter registry cover and remove it. Place the extractor (Ref.
  • Page 34 Remove thehousing gasket. Remove the 2 axles of the gearbox pins. Remove the desmodrome. Remove the gearbox gears unit. Dismounting the engine...
  • Page 35: Engine Mounting

    Engine Mounting Engine Mounting...
  • Page 37 Introduce the gearbox gears unit. Place the desmodrome. Place the 2 axles and the 2 gearbox pins. One of the pins has a groove (A) for its correct position. NOTE: After mounting the axles of the gearbox pins and the pins, check that the gears engage normally.
  • Page 38 New engine exhaust outlet (De-vaporization model 2005). Eliminate completely the remains of sealant and oil in the contact surface of the left and right housings. Place the new gasket (C) and the 2 guides (D) that facilitate the centering during the assembly of the two housings.
  • Page 39 Place the 10 screws that fix the housing. Apply LOCTITE in the screw that is located in the hole of the oil pump. Housing screw: 11 Nm (1.1 kg) NOTE: After tightening the housing screws, check if the crankshaft, the intermediate axle and the transmision axle turn smoothly.
  • Page 40 Fix the screw that holds the distributor chain tensor skate. Place the washer and tighten the nut with a dynamometric spanner. Place the oil tube. Place the starter intermediate pinion. Place the starter unit. Engine Mounting...
  • Page 41 Place the oil pump axle. Before mounting the oil pump: apply engine oil to the sliding surfaces of the pump casing, the exterior rotor, the interior rotor and the axle. Place the engine oil pump gasket. Place the engine oil pump. Fix, via the 2 screws, the oil pump cover.
  • Page 42 Fix, via the 2 screws, the pump cover. NOTE: Apply a small amount of LOCTITE to the threaded parts of the fixing screws of the oil pump and tighten firmly. Place the pump pinion and fix it with the clip. Fix the intermediate pinion of the pump with the clip.
  • Page 43 Place the bearing. Place the clutch bell. Place the washer. Insert the clutch casing with a new gasket. Fix it via the screws. Place the clutch unit. Engine Mounting...
  • Page 44 In the clutch mounting unit in the gearbox primary cam, make sure it is correctly aligned between the groove present in the interior recipient and the one in the primary camshaft of the gearbox. NOTE: In case of an incorrect assembly the correct lubrication of the clutch unit is not guaranteed and, therefore, damage or malfunctions of the clutch unit may be produced.
  • Page 45 Place the 3 screws, the 3 washers and the 3 springs that hold the clutch unit. Loosen, gradually, the 3 screws that fix the clutch unit. Place the new gasket and the clutch disks cover. Fix, via the 5 screws, the clutch disks cover. Place the new oil filter (See maintenance chart).
  • Page 46 Fix, via the three screws, the oil filter cover. Apply oil in the water pump press. Place the press in its position. Place the water pump turbine and close the cover. Check the wear of the segment. Engine Mounting...
  • Page 47 Place the piston. PRECAUTION: Mount the piston with the mark situated in the head oriented towards the exhaust side. NOTE: Use a new piston plastic ring to prevent it from breaking if it folds. Place the 2 centers in the cylinder. Place the new gasket in the cylinder base.
  • Page 48 Place the distributor chain skate. Place the 2 centers. Place the cylinder head gasket. NOTE: Clean well the surface before placing the gasket. Place the cylinder head. Place the 4 cylinder head interior fixing screws to the cylinder. Engine Mounting...
  • Page 49 Fix, via the 4 interior screws, the cylinder head to the cylinder. Note: Tightening torque of 4.5 Kg. Fix, via the exterior screws located in the front and rear part, the cylinder head to the cylinder. Fix, via the 4 lateral screws, the cylinder to the engine casing.
  • Page 50 Place the exhaust cam shaft. NOTE: The groove of the cam shaft has a position mark. Place the intake camshaft. NOTE: The groove of the camshaft has a position mark. Camshaft position marks (F). Place the exhaust camshaft cover. Place the intake camshaft cover. Engine Mounting...
  • Page 51 Place the distributor chain skate. Fix, via the 6 screws, the 2 covers and the skate. Cam axle stump support screw: 10 Nm (1 kg). Place the oil distributor. Adjust the distributor chain tensor. NOTE: Use a new gasket to avoid possible oil leaks. Distributor chain tensor spring support screw: 8 Nm (0.08 kg).
  • Page 52 Place the cylinder head and the gasket. NOTE: Apply silicon in the indicated zone. silicon Fix, via the 3 screws, the cylinder head cover. Apply a cleaning product as shown in the drawing. Place the alternator rotor and position the 7th tooth of the phonic wheel in the center of the hole of the position sensor (Pick-Up).
  • Page 53 Place the clutch rod. Place the clutch pincer. Place the position sensor (Pick-Up) Check, via a thickness gauge, the distance between the position sensor and the rotor. Place the de-multiplication pinion. Engine Mounting...
  • Page 54 Place the alternator cover. Fix the 7 screws that hold the alternator cover. NOTE: One of them is located in the starter clutch cavity. Place the starter clutch. Place the starter clutch cover and fix with the 3 screws. Introduce the starter motor and place the 2 cases of the starter motor.
  • Page 55: Clutch Aptc

    Replacement of the standard clutch with the clutch ADLER APTC Replacement of the clutch...
  • Page 57 GENERAL WARNINGS Always shut off the engine before starting any work, in particular, when operating in closed environments without gas evacuation facilities. Shut off the engine, remove the contact key and wait until the engine, the exhaust system and the brake unit have cooled enough to avoid burns and risk of fire.
  • Page 58 In the models of 450 cc 4T of enduro produced before 2004 are equipped with a conventionsl clutch that may be substituted by the APTC clutch performingthe following operations. Note: the following operations are performed with the engine installed in the vehicle. Dismounting: Place a recipient to collect oil below the engine and remove the sump purge screw.
  • Page 59 Dismount the clutch pressure disk and remove the gearbox primary cam point. Open the security washer lug that locks the gearbox primary cam nut. Remove the clutch disks one by one. Lock the clutch pail using the special tool MFS450450020. Loosen and remove the nut and the safety washer.
  • Page 61: Inspection And Maintenance Of The Engine Components

    Inspection and maintenance of the engine components Cylinder head................61 Cam axle unit / automatic decompressor.......73 Cylinder..................75 Piston and piston ring..............76 Connecting rod..................78 Crankshaft..................79 Starter clutch................79 Oil pump..................80 Clutch..................80 Gears and gearbox pins............82 Transmission................83 Bearings..................84 Retainers..................88 Inspection and maintenance...
  • Page 63: Cylinder Head

    WARNING Identify the position of each one of the parts. Group the parts (exhaust, intake) to be able to again mount them in their original positions. CYLINDER HEAD Dismounting Dismount the intake tube. Dismount the support of the engine coolant tubes. Remove the tacks (1) and the adjustment pads (2), manually or with a magnet.
  • Page 64 Compress the valve springs and next remove the semi-icons of the valve rod with the special tools. Ref.: Valve spring compressor Ref.: Adapter Ref.: Tongs Remove the valve spring plate (1) and the valve springs (2). Inspection and maintenance...
  • Page 65 Remove the valves through the cylinder head lower side. Remove the valve retainers with some long nosed pliers. Dismount the valve spring washers. NOTE: The normal dismounting work ends with the dismounting of the valves. If the valve guides have not been dismounted for its replacement after checking the associated parts, continue the described procedure in the box related to the maintenance of the guide valves.
  • Page 66 Valve rod de-centering Hold the valve with trapezoidal locks and measure the de-centering of the rod with a quadrant gauge, as shown. If the de-centering surpasses the service limit, replace the valve with a new one. Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support Tool ref.:...
  • Page 67 Valve work surface wear Visually check if the work surface of each valve is worn out or damaged. If abnormal wear is detected, replace the respective valve with a new one. Measure the thickness (T) of the valve work surface. If the thickness is not found within the specified value replace the valve with a new one.
  • Page 68 Valve rod wear Measure the wear exterior diameter with a micrometer. If the exterior diameter is not found within the specified value, replace the valve with a new one. If the rod exterior diameter is found within the specified value but not the deflection, replace the valve guide with a new one.
  • Page 69 Apply oil to the rod hole of each one of the valve guides and introduce the guide in the hole with the valve guide extractor/mounter and the adapter. Tool ref.: Extractor/valve guide mounter Tool ref.: Valve guide mounter adapter WARNING If the valve guide hole is not lubricated before introducing the new guide, this or the cylinder head may be damaged.
  • Page 70 Valve seating maintenance Intake The intake and exhaust valve seatings are mechanised in three different angles. The contact surface of the seating is cut at 45º. Intake Exhaust Exhaust 45º N-128 N-128 15º N-121 30º N-128 60º N-114 N-114 Tool (United States) Vlave seating knife: N-114, N-121 and N-128 Tools (Rest of the world)
  • Page 71 Place the solid centerer (1) and turn it lightly. Place well the centering tool. Place the 45º knife (2), the adapter (3) and the handle in T (4). Initial cut of the seating De-encrust and clean the seating with the 45º knife.
  • Page 72 Upper width cut If the contact surface is too high in the valve or if it is too narrow, use the 30º knife (intake side) and the 15º knife (exhaust side) to lower it and make it narrow. Contact surface too low and too narrow in the valve work surface.
  • Page 73 Valve seating hermetic status check With the valve and the spring mounted, pour a small amount of gasoline through the leading tube of the intake or exhaust. Check that no gasoline comes out of the valve seating. If a leak is observed, correct the lock surface.
  • Page 74 CYLINDER HEAD Mounting Mount the seatings of the valve springs. Apply a molybdenum oil solution to all the valve retainers and introduce them under pressure in its position. WARNING Do not re-use the valve retainers. Apply a molybdenum oil solution, as shown, and then introduce them in the guides.
  • Page 75: Cam Axle Unit / Automatic Decompressor

    AUTOMATIC DECOMPRESSOR CAM AXLE UNIT WARNING Do not try to disarm the automatic decompressor/cam axle unit. It can not be repaired. Automatic decompressor Manually move the automatic decompressor counterweight to check if it works smoothly. If the automatic decompressor counterweight does not function smoothly, replace it with a new one.
  • Page 76 Cam axle bridge wear With the cam axle mounted, measure the width of the oil with the plastic tool. Tools Ref.: Plastic tool DATA Cam axle bridge oil width (intake and exhaust) Service limit: 0.150 mm Tighten the bridge support screws uniformly and in diagonal sequence with the specified torque.
  • Page 77: Cylinder

    Cam axle de-centering Hold the valve with trapezoidal locks and measure the de-centering of the cam axle with the cuadrant gauge. If the de-centering surpasses the service limit, replace the cam axle with a new one. Tools Ref.: Cuadrant gauge (1/100 mm) Ref.: Magnetic support Ref.:...
  • Page 78: Piston And Piston Ring

    PISTON AND PISTON RING Piston diameter Measure the piston diameter with a micrometer at 15 mm of the end of the skirt. If the piston diameter is lower than the service limit, replace the piston with a new one. Tool ref.: Micrometer (75-100 mm) DATA Piston diameter...
  • Page 79 Free piston ring end aperture and Fig.4 piston ring end aperture First measure the piston ring free end aperture with the calliper and then place the piston ring transversally in the cylinder and measure the aperture of the ring end with the thickness gauge. Tool ref.: Thickness gauge DATA...
  • Page 80: Connecting Rod

    CONNECTING ROD Connecting rod foot interior diameter Measure the connecting rod foot interior diameter with the small calliper. If the interior diameter of the connecting rod foot exceeds the service limit, replace the connecting rod with a new one. Tool ref.: Cuadrant calibrator compass DATA Connecting rod foot interior diameter...
  • Page 81: Crankshaft

    CRANKSHAFT Crankshaft de-centering Hold the crankshaft with trapezoidal locks and measure the de-centering with a quadrant gauge, as shown. If the de-centering surpasses the service limit, replace the crankshaft with a new one. Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support Tool ref.: Trapezoidal lock units (100 mm)
  • Page 82: Oil Pump

    OIL PUMP Check all the components. The screws that fix the pump to the engine sump should be placed with LOCTITE and a specified torque. Oil pump: 10 Nm (1.0 kgm) CLUTCH Place the clutch unit in a bench press using protective gags.
  • Page 83 The thickness of the 8 covered conducting disks lower than 21 mm does not guarantee the correct functioning of the clutch unit. The use of non-original GAS GAS components does not guarantee the correct functioning of the clutch unit. Before assemblingthe clutch unit it is necessary to lubricate allthe components using oil for engines conforming to the GAS GAS prescriptions.
  • Page 84: Gears And Gearbox Pins

    Maintain pressed the disk package with the fingers against the exterior pail and over turning it, introduce it in the interior pail taking care in making sure that the reference marks of bothpails coincide. Tighten the interior pail with the clutch disks corresponding to the positions of the opening springs in the exterior pail.
  • Page 85: Transmission

    DATA Gearbox pins groove width Normal: 4.8 -4.9 mm DATA Gearbox pins thickness: Normal: 4.6 -4.7 mm TRANSMISSION Dismounting Dismount the transmission gears as shown. 01) washer 18x31.5x0.7 gearbox 14) secondary pinion V 02) primary pinion II 15) secondary pinion III 03) circlip d.25 din 471 reduced 16) secondary pinion IV 04) washer 31.5x(25x22)x1 striated...
  • Page 86: Bearings

    Mounting Mount the transmission in inverse order to the dismounting. Take special care in the following points: NOTE: Before mounting the gears, apply engine oil to the internal surface of each bearing and plug. WARNING Never re-use a plastic ring. Once the axle is removed, discard it and place a new one.
  • Page 87 Gearbox primary axle right bearing Remove the gearbox primary axle right bearing (1) with the special tool. Tool ref.: Bearing extractor unit WARNING Replace the extracted bearing with a new one. Mount the gearbox primary axle right bearings with the special tool. Tool ref.: Bearing mounting unit Gearbox primary axle left bearing...
  • Page 88 Gearbox secondary axle bearings Remove the right bearings (3) and the left (4) of the gearbox secondary axle with the special tool. Tool ref.: Bearing extractor unit WARNING Replace the extracted bearings with new ones. Mount the right and left bearings of the gearbox secondary axle with the special tool.
  • Page 89 Desmodrome gearbox left bearing Remove the desmodrome gearbox left bearing (8) with the special tool. Tool ref.: Bearing extractor unit WARNING Replace the extracted bearing with a new one. Mount the left bearing of the desmodrome gearbox. Bearing extractor unit Balance axle right bearing Extract the balance axle right bearing (9) with the special tool.
  • Page 90: Retainers

    RETAINERS If the lip of the retainers are deteriorated engine oil or gasoline/air mix leaks may be produced. Check if the retainers are worn out or damaged. If you observe any imperfection, change the retainer with a new one. Place the retainers in the sump and the clutch cover.
  • Page 91 Selector axle retainer Slowly remove the selector axle retainer of the left sump (1) with the special tool. Tool ref.: Retainer extractor WARNING Replace the extracted retainer with a new one. Slowly place the selector axle retainer in the left sump with the special tool.
  • Page 92 Crankshaft cavity sheet and oil filter cleaning Dismount the oil filter from the right sump interior. Proceed to its cleaning without dismounting the filter sheet. WARNING If the filter is deteriorated, replace it with a new one. Dismount the crankshaft cavity sheet and check its completeness and good condition.
  • Page 93: Periodic Maintenance

    Periodic maintenance Spark plug..................93 Oil filter and engine oil..............94 Engine oil tubes................97 Periodic maintenance...
  • Page 95 SPARK PLUG Inspection after 30 hours of functioning. Replace after 60 hours of functioning. Dismount the fuel tank. Disconnect the spark plug pipe and remove the spark plug. COLD STANDAR CR9E CR8E CR7E DENSO U27ESR-N U24ESR-N U22ESR-N U31ESR-N Soot deposits Check if there is soot in the spark plug.
  • Page 96 Electrode Check the electrode status. If the electrode is extremely worn out or burned replace the spark plug with a new one. Also replace the spark plug if the isolator is broken, the thread damaged, etc. WARNING Check the shape and length of thread when replacing the spark plug.
  • Page 97 Engine oil change The engine oil is found in the tank of the chassis front high part and in the engine sump. To evacuate the oil open the chassis (1) and of the ngine (2) plugs also the fill plug (3). Once the oil comes out screw the screws with the specified torque and then fill the oil again through the fill hole.
  • Page 98 Oil filter change Remove the oil filter cover (1) and the oil filter (2). Change the filter with a new one. NOTE: Before mounting the filter cover make sure of the correct mounting of the spring and replace the filter cover gasket. Makesure that the thoric behind the filter is placed in the correct position.
  • Page 99 ENGINE OIL TUBES Initial inspection after five hours of use and after 30 hours. Check that the engine oil tubes are not damaged and that they have no leaks. If any damage is detected, change the tubes with new ones. Check compression The correct compression of a cylinder indicates that the internal conditions are good.
  • Page 100 Oil pressure testing Check the oil pressure periodically. This will give a good indication of the conditions of the engine moving parts. DATA: Oil pressure: Above 40 Kpa (0.4 Kgf/cm2, 5.7 psi) at 3000 rpm Above 140 Kpa (1.4 Kgf/cm2, 19.9 psi) Oil pressure testing procedure Connect tachometer to high voltage wire.
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