SERVICE MANUAL SERVICE MANUAL ENGLISH Foreword Congratulations for choosing this GAS GAS, wich has been developed through GAS GAS, to produce a light weight, high performance machine with superb handling and stability for racing and sporting use. Your new GAS GAS is a highly tuned production racer for participation in racing events. As with any mechanical device, proper care and maitennance are important for trouble-free operation and top performance. This guide is written to enable you to keep your GAS GAS properly tuned and adjusted. Due to improvents in design and performance during production, in some cases may be minor discrepancies between the actual vehicle and the illustrations and text in this manual. Thanks for your confidence and your welcome from GAS GAS motos, S.A. December 2002 EC FSE 2003 -4- Important notice Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. However, if improverly conducted, the sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of live. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR BIKE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE. CAUTION This caution symbol identifies special instructions or procedures which, if noto strictly observed, could result in damage to or destruction of equipment. IMPORTANT Off-road motorcycle riding is a wonderful sport, and we hope you will enjoy it to the fullest. NOTE This note symbol indicates points of particular interest for more efficient and convenient operation. EC FSE 2003 -5- TABLE OF CONTENTS Foreword..............................................................................4 Important notice................................................................................5 Table of contents .......................................................................6 Specifications.....................................................................................7 Side stand .......................................................................................11 Recomended fuel............................................................ 1 1 Serial number.................................................................................. 12 Start the engine .............................................................................. 13 Choke button................................................................................... 14 Shifting gears .................................................................................. 14 Stopping the motorcycle.................................................................. 15 Break-in ...........................................................................................15 Manitenance chart........................................................................... 16 Battery .............................................................................................17 Cooling system................................................................................ 18 Spark plug ....................................................................................... 21 Clogged air...................................................................................... 24 Throtlle cable................................................................................... 25 Clutch .............................................................................................. 26 . Exhaust system............................................................................... 26 . Drive chain ...................................................................................... 27 . Handlebar........................................................................................ 30 . Brakes ............................................................................................. 30 . Steering........................................................................................... 32 . Steering blocade ............................................................................. 33 . Front Fork........................................................................................ 34 . Rear suspension ............................................................................. 37 . Wheels .............................................................................................39 Lubrication....................................................................................... 43 . Engine oil ........................................................................................ 44 . Suspension tuning........................................................................... 47 . Preparation for competition ............................................................. 53 . Storage............................................................................................ 54 . Gas Gas speedo instructions .......................................................... 54 . Troubleshooting............................................................................... 56 . Warranty regulations ....................................................................... 61 . EC FSE 2003 -6- SPECIFICATIONS: ENGINE Engine Displacement in cubic centimeters Bore and stroke Spark plug Injection system TRANSMISSION Transmission type Clutch type Driving system Gear Ratio 4 cycle, single cylinder DOHC 4r, crank case induction, liquid cooled 399 / 449 c.c. 90 x 62,6 mm. / 95 x 62,6 mm. NGK CR8E o DENSO U24ESR-N Magneti Marelli 6 speed Multidisc in oil bath, hidraulic actuation Chain 1ª 2.071(29/14) 2ª 1.625(26/16) 3ª 1.333(24/18) 4ª 1.100(22/20) 5ª 0.913(21/23) 6ª 0.791(19/24) 2.85 (57/20) 3.692 (48/13) 8.149 (6th gear) 1800 c.c. 5W50 API SF o SG DELTABOX type, made of rectangular-section chromoly tube. Aluminium swingarm. 90/90 x 21" 140/80 x 18" Primary reduction ratio Final reduction ratio Overall drive ratio Transmission oil CHASSIS Frame Tires sizes Capacity Type Front Rear EC FSE 2003 -7- Susmension Front Rear Front Rear Suspension travel Front fork oil Front fork oil level Öhlins inverted fork, 43 mm. ø. WP inverted fork, 43 mm. ø. Mazocchi inverted fork, 45mm. ø. Multi-adjustable, progressive Öhlins shock absorber. 295 mm. 320 mm. MARZOCCHI SAE 7.5 WP SAE 5 ÖHLINS SAE 5 - 7.5 Marzocchi: 110 mm. (compressed without spring). WP: 120 mm. (compressed without spring). Öhlins: 110 mm. (compressed without spring). Disc brake, Nissin brake pump and Nissin double - piston caliper. 260 mm. 220 mm. 2135 mm. 810 mm. 1260 mm. 1475 mm. 340 mm. 9,5 litre (2,4 gallons U.S.) 119 Kg. BRAKES Type Diameter disc DIMENSIONS Overall length Overall width Overall height Wheell base Ground clearance Fuel tank capacity Height seat Front & rear Front Rear (Specifications subject to change without notice, which may not be applicable in every country). EC FSE 2003 -8- Location of Components GAS GAS EC FSE 400cc. / 450cc. 1 3 42 5 6 123456- Clutch lever Engine Stop Button Fuel Tank Fill Cap Front Brake Fluid Reservoir Front Brake lever Throttle Twist-Grip EC FSE 2003 -9- 12 7 9 16 11 18 19 23 13 8 15 14 10 17 21 20 22 24 7- Front Suspension 8- Radiator 9- Fuel Tank 10- Air Filter 11- Seat 12- Brake Disc, front 13- Brake Caliper, front 14- Brake Fluid Reservoir, rear 15- Shift Pedal 16- Rear Shock Absorber 17- Chain Guide 18- Drive Chain 19- Silencer 20- Fuel Tank 21- Connecting Rod o'ring and Swingarm 22- Rear Brake Pedal 23- Oil Dipstick 24- Exhaust EC FSE 2003 -10- SIDE STAND To operate the side stand: Release the security strap (B), the sidestand is held in the down position by the weight of the motorcycle. Thes sidestand automatically retracts when the motorcycle is placed in the upright position. FUEL The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline Gas Tank Capacity ENDUCROSS FSE 9,5L (C) (B) (B) (A) (A) (A). Side Stand (B). Sidestand spring (C). Security strap NOTE Do not start the engine or ride the motorcycle when the side stand is down. Always engage the security strab (B) before operation of the motorcycle. (A). Fuel Cap. (B). Fuel Vent hose. Position the vent hose clip in a position which prevents spillage on the steering bearings and the clock. EC FSE 2003 -11- RECOMENDED FUEL Use premium gasoline with an octane rating equal to or higher than that shown in the table. OCTANE RATING METHOD Antiknock Index Research Octane No. (RON+MON)/2 (RON) MINIUM RATING 90 98 SERIAL NUMBER This number allows the motorcycle to be registered. The serial number (or V.I.N.) is located on the steering stem of the frame. Official approval plate This motorcycle has an official approval plate. It shows the serial number. NOTE If ¨knocking¨ or ¨pinging¨ occurs, try a different brand of gasoline or higher octane grade. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. EC FSE 2003 -12- START THE ENGINE - You have to assure the motorcycle to the neutral position. - Turn the key in the direction clock (position in "ON" (A)), by this way the electric circuits will be open and then the engine will start. The key will be locked into the contact. Stopping the Engine - Change to the neutral position. - After racing the engine slightly, close the throttle completely and push the engine stop button(B). CUIDADO Stop the engine by the stop button (B). Don't use the key for stop the engine! it can damage the injection system. (A) (D) (B) - Swich of the key in the opposite clock direction. The key will be located to the left hand side (D), where all the electric circuits will be closed. The engine will not start. The key can be pulled out of the contact. - The key can be extract. NOTA: Start the engine as soon as the key is turned to the "on" position or the baattery might lose power. (C) - Whithout drive the twist grip, swich the electric start button (C). EC FSE 2003 -13- CHOKE BUTTON The choke button is a mecanism that opens the throttle, whithout take the twist grip, to favour the engine if it is cold. The engine will get a good temperature in a short time and it won't damage. For use, pull up the choke knob (A), and without turn the twist grip, start the engine. Look the engine that starts with high revolutions. Waiting few seconds, the engine will be a good temperature. For pull down the choke button, only drive the twist grip. SHIFTING GEARS The transmission is a 6 speed, return shift type with neutral halfaway between 1st and 2nd gears. A ¨return shift¨means that to go back to first gear from a higher gear, you must shift back through the gears one by one. To engage first gear from neutral, pull in the clutch lever and push down on the shift pedal, gently release the clutch lever, then release the shift pedal. To shift to the next higher gear; pull in the clutch lever, lift the shift pedal with your toe, gently release the clutch lever, and then release the shift pedal. CAUTION When changing gears, press firmly on the shift pedal to ensure complete, positive shifting. Careless, incomplete shifts can cause the transmission to jump out of gear and lead to engine damage. NOTA - If the engine is flooded, kick with the throttle fully open. - If the clutch lever is pulled, the motorcycle can be started while in any gear. (A) (A) (B) (B). Shift Pedal. EC FSE 2003 -14- STOPPING THE MOTORCYCLE For maximum deceleration, close the throttle and apply both front and rear brakes. Disengage the clutch as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous under certain conditions. Downshift progressively as speed is reduced to ensure good engine response when you want to accelerate. (A) 1. Start the engine and let it run at idle until the engine is thoroughly warmed up. 2. Stop and let the engine cool completely. 3. Start the engine and ride for 10 minutes at moderate speed NEVER ACCELERATE HARD. 4. Stop and let the engine cool completely. Be sure to check and adjust chain slack and spoke tightness and make a general inspection. 5. Start the engine and ride for 20 minutes at moderate speed. NEVER ACCELERATE HARD. 6. Stop and let the engine cool completely. Check and adjust as step. Then drain the coolant, remove the cylinder head, cylinder and piston, and inspect these parts. 7. Install the parts removed. 8. Fill the radiator up to the bottom of the radiator filler, bleed the air from the cooling system. 9. Sta ...