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Table of Contents
Related Manuals for GAS GAS EC450 2009
Summary of Contents for GAS GAS EC450 2009
- Page 1 EC450/515´09 EC450/515´09...
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Page 3: Foreword
GAS GAS thanks you for your confidence. By choosing the new GAS GAS EC /EC SM 2009 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 4: Important Notice
Read this manual carefully. This manual covers aspects that will contribute to your security and to that of others, as well as guaranteeing a correct conservation and maintenance of this GAS GAS motorcycle you have just acquired. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE... -
Page 5: Table Of Contents
TABLE OF CONTENTS Chain guide...................26 Foreword..................3 Tension adjustment ..............27 Important notice ................4 Handle bars ..................29 Table of contents ................5 Brakes...................29 General information ................6 Steering ..................31 Component locations ..............8 Steering lock .................32 Side stand..................10 Front forks..................33 Petrol ....................10 Rear suspension................36 Serial number and the qualification approval plate.......11 Wheels..................38 Starting and stopping the engine ..........12 Cleaning..................39... -
Page 6: General Information
GENERAL INFORMATION ENGINE Engine 4 stroke, single-cylinder DOHC 4 valves, liquid cooled Displacement in cubic centimetres 449 cc // 492cc Bore and stroke 97 x 60.80 mm // 100x 62.65mm Fuel supply Electronic injection (Battery Less EFI) TRANSMISSION Transmission type 6 speed Clutch type Oil bath, multi-disk hydraulic action... - Page 7 Suspension Front ø 48 mm inverted fork ø 45 mm inverted fork Rear Progressive system with single multi-adjustment shock absorber Suspension stroke Front 295 mm Rear 320 mm Front suspension oil Between SAE 5 and 7.5 (check manufacturer’s information) Front fork oil level 100 mm (compressed, without spring) 120 mm (compressed, without spring) BRAKES...
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Page 8: Component Locations
2- Engine start button 3- Fuel tank cap 4- Front brake fluid tank 5- Front brake handle 6- Throttle control GAS GAS EC SM 450/515 1- Clutch handle 2- Engine start button 3- Fuel tank cap 4- Front brake fluid tank... - Page 9 7- Front suspension 16- Rear shock absorber 8- Radiator 17- Chain guide 9- Fuel tank 18- Chain 10- Air filter 19- Silencer 11- Seat 20- Rear shock absorber gas tank 12- Front brake disk 21- Tie rod and rocker suspension 13- Front brake callipers 22- Rear brake pedal 14- Rear brake fluid tank...
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Page 10: Side Stand
PETROL SIDE STAND The GAS GAS FSR / SM FSR 450 has a four stroke engine and To unfold the side stand (A) the securing strap must be released requires 98 octane, unleaded petrol. (B) then the stand is opened to vertical position. -
Page 11: Serial Number And The Qualification Approval Plate
RECOMMENDED FUEL SERIAL NUMBER Use lead-free petrol with an octane rating equal to or higher than Printed on the steering tube. Indicates the frame number with which that shown in the table. the motorcycle is registered. Qualification approval plate OCTANE RATING METHOD OCTANE RATING (MIN) The motorcycle is fitted with its own corresponding qualification... -
Page 12: Starting And Stopping The Engine
STARTING THE ENGINE Stopping the engine - Ensure that the motorcycle is in neutral. - Change gear to neutral. - After accelerating lightly, cut the gas completely and press button - Press button (A) to turn on the electrical circuit, so that the motor (C). -
Page 13: Cold Starting
COLD STARTING SHIFTING GEARS The transmission is a 6 speed, return shift type meaning that to go The cold start function is responsible for aiding the engine start if back to first gear from a higher gear, you must shift back through this is cold. -
Page 14: Stopping The Motorcycle
STOPPING THE MOTORCYCLE NOTE The slow speed necessary during the break-in period may cause For maximum deceleration, close the throttle (A) and apply both carbon to build up on the spark plug and soil it. If inspection front and rear brakes. Disengage the clutch as the motorcycle comes of the spark plug shows this to be the case, replace the standard to a stop. -
Page 15: Maintenance Chart
MAINTENANCE CHART Period Period Period Article First 5 hours Every 30 hours Every 60 hours Inspect each time that the motorcycle has run or when necessary Air filter *Exhaust connectors and bolts *Valve tolerances Spark plug Injection pump pipes *Revise every 4 years Engine oil and filter oil *Engine oil pipes Coolant... -
Page 16: Battery
BATTERY 3. Disconnect the terminals ensuring that they do not enter into contact with metal parts then extract the This battery is maintenance free and checking the fluid level is not battery. required. It is advisable to check the charge of the battery periodically WARNING To remove the battery, follow these steps: Hydrogen gas produced by the battery may explode if exposed to... -
Page 17: Cooling System
- Recommended charging duration = 5 - 8 hours. CAUTION Using a high pressure water source could damage the radiator fins - The product (charge current) X (charge duration) must be within and render it ineffective. the range: 0.5 - 0.8 Cn. Do not obstruct or deviate the radiator air intake by installing non- approved accessories. - Page 18 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 stages. First turn the cap anti-clock Use coolant containing corrosion inhibitors made specifically for wise and wait for a few seconds.
- Page 19 NOTE Changing the coolant 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 20: Spark Plug
Examine the used coolant. If white cotton-like patches appear in between electrodes using a gauge and adjust in case that it is not the liquid then this means that the aluminium elements of the cooling correct by bending the outer electrode. If the spark plug electrodes system are corroded. - Page 21 2. Remove the bolts WARNING (C) (left and right). An incorrectly fitted spark plug, or an incorrect temperature can lead to severe damage to the engine, and this damage is not covered by the warranty. Always use the manufacturer's recommended brand of spark plug. Check with your dealer or a qualified mechanic to determine the correct spark plug for your motorbike.
- Page 22 5. Separate the connector (G) from the fuel pump and secure to one side of the tank. 6. Remove the spark plug hood. NOTE WARNING A cap protects the spark plug. Keep this clean and dry. When the injection pump pipes are removed, petrol may be spilled and cause a fire.
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Page 23: Air Filter
- Remove the seat. AIR FILTER - Remove the bracket (A) and remove the filter (B). An obstructed air filter restricts the air intake of the engine, increasing the petrol consumption and reducing the engine power as well as the destruction of the spark plug. WARNING An obstructed air filter may allow dirt to enter into the injector blocking it open;... -
Page 24: Accelerator Cable
- Clean the filter in a THROTTLE CABLE filter bath using a soft - Check that the throttle grip turns smoothly brush. - Check that the throttle grip has 2-3 mm of play. - If the play is incorrect, loosen the locknut on the upper end of the throttle cable, and turn the adjuster to obtain the correct amount of play. -
Page 25: Clutch
CLUTCH THE EXHAUST SYSTEM Proper clutch lever play is 2-3 mm. Play increases with the clutch The exhaust and the silencer reduce noise and carry the gasses wear and thus requires adjustment. away from the driver. When there is too much play, first try to adjust the level of the clutch If the exhaust is damaged, rusted, dented or split then change it. -
Page 26: Chain Guide
Changing the silencer packing WARNING - Remove the cover rivets (A). A chain that breaks or jumps off the sprockets could snag on the - Extract the silencer cover (B). engine sprocket or lock the rear wheel, severely damaging the - Pull out the inner silencer. -
Page 27: Tension Adjustment
NOTE In addition to checking the slack, rotate the rear wheel to inspect Wheel alignment can also be checked using the straightedge the drive chain and sprockets for damaged rollers, loose pins and links, unevenly or excessively worn and damaged teeth. or string method. - Page 28 NOTE Chain guide slide For maximum resistance and safety, a genuine part must be used for replacement. Visually inspect the upper and lower part of the chain slider on the To minimize any chance of the master link coming apart, the swing arm.
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Page 29: Handlebars
Apply oil to the side of the links so that it will penetrate better. Wipe Tighten the bolts securely; first the forward bolts then the rear, to a off any excess oil. torque of 25 Nm. If the handlebar is correctly installed, there will be a minimal gap at the front and rear of the clamp after tightening (A). - Page 30 Front brake lever Adjust brake lever to a comfortable position. To adjust, loosen the nut under the rubber protection (B). Tighten after adjustment. Ensure that the brake responds correctly. (A). Brake pedal. (B). 10 mm of play. (A). Brake lever. WARNING (B).
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Page 31: Steering
If the thickness of either pad is less than 1 mm, replace both pads in the calliper 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... -
Page 32: Steering Lock
To check the steering adjustment, lift the bike off the ground using - Install the upper suspension plate (D). a stand underneath the chassis. Push the handlebar lightly to either - Tighten the steering stem nut (B), the washers and bolts on the side;... -
Page 33: Front Forks
CAUTION - Using a stand underneath the chassis, stabilized the bike. Never leave the key in the lock. If the steering is turned to the left - Put something under the engine so that the front wheel does not with the key in the lock then this will be severely damaged. touch the ground. - Page 34 Adjust the return to the standard measures (rotating anti-clockwise, Standard oil level 12 positions). 100 mm CAUTION The front fork left and right tubes must be at the same level and aligned with the plate. Adjusting the compression - To adjust the compression, rotate the adjustment control on the upper part of the front forks by hand.
- Page 35 (1). Spring. (2). Counter nut. (3). Suspension cap. (4). Cap spanner. (5). Counter nut spanner. Suspension rod spring Different springs can be used depending on the weight of the driver (A). Hydraulic rod and the track conditions. - Hard springs make the forks harder and the rebound faster. - Light springs make the forks softer and the rebound slower.
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Page 36: Rear Suspension
Extension adjustment To adjust this, rotate the screw on the rear of the shock until noting a click. There is a possibility of 32 “Clicks” in total. The standard rebound is at : 16 “Clicks”. (Anti-clockwise from the completely closed position). (1). - Page 37 Suspension spring The standard spring is k=5,4. (A) Nut. (B) Spring. (C) Counter nut. (A). Low speed compression adjustment. (B). High speed compression adjustment. Spring adjustment - Remove the seat and the side covers. - Loosen the bolt of the air filter conduit clamp. - Remove the silencer.
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Page 38: Wheels
WARNING 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 official distributor. WHEELS Tyre (A). -
Page 39: Cleaning
Cleaning 3- After cleaning - Remove the plastic bags and clean the air filter intake. 1- Preparation for cleaning - Lubricate the locations listed in the lubrication section. - Start the engine and let it heat for 5 minutes. Before cleaning the motorcycle must be prepared so that water does - Check the brakes before driving the bike. -
Page 40: Tighten Bolts And Nuts
Tighten bolts and nuts Every day before using the bike, rapidly ensure that all bolts and nuts are tightened. Also make certain that all of the other fastenings are in place and in good condition. 1- Front and rear wheels 10- Front axle bolt 18- Rear axle bolt 27- Rear brake pedal bolt... -
Page 41: Tightening Torque Table
TIGHTENING TORQUE TABLE Tighten all of the bolts and nuts using the correct spanners. If not correctly tightened then motorcycle damage or even an accident could occur. PART NAME Engine drain plug Kick pedal bolt Kick pedal nut Shift pedal bolt Spark plug Water pump cover drain plug Calliper mounting bolts... -
Page 42: Lubrication
LUBRICATION Lubricate the points shown here, with either motor oil or regular grease, periodically or whenever the vehicle is wet, 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 43: Engine Oil
Chain lubrication The recommended viscosity is SAE 5 W-40; if an SAE 5 W-40 oil is not possible use an alternative according to the table above. Lubricate the chain after wet terrain or when the chain looks dry. A high viscosity oil rather than low viscosity oil is better because it will Checking the oil level and making the changes periodically are two stay a long time in chain providing lubrication. - Page 44 WARNING Always use original GAS GAS parts. If the filter is incorrectly positioned, the engine oil will not flow, 2. With the motorbike parked on a flat provoking a malfunction in the engine.
- Page 45 (F) are in the correct position. The engine may be damaged if the oil is not used properly or the specifications recommended by GAS GAS MOTOS are not followed. 6. Replace the filter cover and put the screws that secure the cover,...
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Page 46: Suspension Adjustment
TUNING THE SUSPENSION Front forks No area of machine adjustment is more critical than proper suspension The fork oil level is adjustable. A change in the oil level will not affect tuning; an incorrectly tuned suspension will keep even the best rider the lower part of the stroke, but it will affect the upper part. - Page 47 Changing incorrect adjustments Rear shock absorber symptoms Listed below are some symptoms of improper suspension settings - Too hard and the most adequate means of correcting them. 1. Rigid suspension. . High compression. The proper settings can be achieved by applying the information in .
- Page 48 Experience Front and rear compatibility Beginner: softer spring with more rebound damping. Use this procedure to determine if the suspension is balanced Experienced: Harder spring. reasonably well: Situate the motorcycle so that it is perpendicular to the ground. While standing next to the machine, pull on the front brake and place one foot on the brake firmly.
- Page 49 Front fork doesn’t respond to small potholes in wide turns - Bottoms at low speed: Increase spring preload to maximum. - Front fork hard: - Bottom after successive 3 or 4 successive jumps. 1. Decrease the compression damping or rebound damping. 2.
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Page 50: In Competition
5. In dusty conditions as the air cleaner collects dust, the engine 26. Tighten the spokes runs richer. 27. Tyre air pressure 28. Tighten chain SPARE PARTS AVAILIBLE 29. Coolant Level Your Gas Gas dealer will provide any information you may require about spare parts. -
Page 51: Storage
(2). Following a day of competition STORAGE 1. Clean the air filter 2. Adjust the chain tension / slack When the motorcycle is to be stored for any length of time, it should 3. Tighten the bolts of the rear sprocket be prepared for storage as follows: 4. -
Page 52: Multi-Function Instructions
GAS GAS MULTIFUNCTION INSTRUCTIONS The multifunction apparatus, which is waterproof, has 2 LED indicators on a central indicator screen. This central indicator screen, made of liquid crystal and with illumination, gives information about the rpm, speed, distance travelled, total kilometres travelled, time, average speed, maximum speed, ambient temperature, length of time with motor running and total time. - Page 53 Technical characteristics FUNCTIONS SYMBOL TECHNICAL INCREMENTS PRECISION CHARACTERISTICS CURRENT SPEED SPD: - 399.9 kmph or mph 0.1 kmph or mph +/- 0,1% TACHOMETER 0 -19999 rpm 10 rpm +/- 0,1% TACHOMETER BAR -12000 rpm. Variable +/- 0,1% MAXIMUM SPEED - 399.9 kmph or mph 0.1 kmph or mph +/- 0,1% DISTANCE TRAVELLED...
- Page 54 Functions ODO: Odometer It shows the total mileage accumulated by the vehicle. The data is stored in the memory, even when the device is not running. RPM: Bar Tachometer with bar graph. The bar graph of the tachometer displays ART: Time of use controller up to 12,000 rpm.
- Page 55 Setting the multifunction display parameters After confirming each value, the display goes from one screen to the next until all have been displayed. If no button is pressed, the display returns to the home screen after 15 seconds. Activating adjustment mode Selecting the speed unit To start setting mode for the To change between kmph and...
- Page 56 Setting the time Setting the pulse per Enter the value for the time by revolution (PPR) pressing button 1 in succession. The gauge receives one To go on to the next digit, press electrical pulse for each button 3. revolution on the engine (PPR). Confirm by pressing button 2.
- Page 57 Selecting the temperature unit Selecting the warning To change the temperature temperature display between ºC and ºF, press Note: button 1. This step can only be taken on Confirm by pressing button 2. vehicles fitted with the optional temperature sensor. When the engine temperature exceeds the set value, the warning LED on the left lights up.
- Page 58 Selecting the danger rpm Total reset of the display When the set rpm is reached, the right-hand warning LED flashes to show that the rpm on Press the RESET button, using a suitable object. The display will the engine are too high. start from zero, except for the data for total accumulated distance and time.
- Page 59 Screen options When the display is powered by the internal battery only, the screen lights up partially for 3 seconds when the button is pressed. If the lighting is connected to the 12V system on the vehicle, it will The multifunction display shows all the information on three different screens.
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Page 60: Fault Diagnosis
FAULT DIAGNOSIS NOTE This is not an exhaustive list, it is meant simply as a rough guide to assist troubleshooting for some of the more common difficulties. CAUSE SOLUTION FAULT - The fuse for the starter relay is The starter motor does not work - Remove the number plate on the right hand side and the blown. - Page 61 FAULT CAUSE SOLUTION - Remove the seat and the fuel tank, clean the pin connector Engine rotates but does not start The ECU pin connector, generator or coil and treat it using a contact spray. oxidised or in bad condition. - Clean the petrol tank ventilation.
- Page 62 FAULT CAUSE SOLUTION - The quality or viscosity of the oil High oil consumption – Correct the engine oil level. Drain oil as necessary from is insufficient. the engine. - Empty the engine oil and fill with oil of the recommended - Ignition problems.
- Page 63 FAULT CAUSE SOLUTION - Replace the down selector mechanism spring. Gears don’t engage - The spring of the selector is broken. - Cylinder change if broken. - Replace the gear drum. - Gear ratchet spring broken. - Replace the ratchet spring of the selector. - Change gear fork.
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Page 64: Electrical Schemas
FAULT CAUSE SOLUTION Shock absorption too hard - Rear shock badly adjusted - Adjust the rear shock. Shock absorption too soft - Front forks low oil. - Add oil to the forks as required. - Front fork oil viscosity too low. - Empty the fork oil and fill with oil of the recommended - Front forks twisted. - Page 65 FAULT CAUSE SOLUTION Motorcycle pulls to one side - Chassis twisted. - Change the chassis. Go to a specialist workshop. - Steering incorrectly adjusted. - Adjust the steering. Go to a specialist workshop. - Steering shaft bent. - Change steering shaft. Go to a specialist workshop. - Front forks twisted.
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Page 66: Guarantee Manual
Warranty terms of the manufacturer GASGAS Motos, S.A. The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality. - Page 67 Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that: a) The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’ Manual, or has exceeded the date set for such inspections or maintenance work.
- Page 68 e) Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.) f) Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.)
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