MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D'ENTRETIEN MANUEL D'ENTRETIEN LIBRETTO D´USO LIBRETTO D´USO USER MANUAL USER MANUAL ENGLISH Foreword GAS GAS thanks you for your confidence. By choosing the new GAS GAS FSE / FSE SM 2005 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. Our FSE / FSE SM 2005 is a bike conceived for highly competitive performance. In fact this bike is the fruit of many years of competition and experimentation in these demanding disciplines; many great trial riders have contributed their expertise and achievements to the essential data we have used to create these high-quality, exclusive motorcycles incorporating key features such as reliability, high performance and stability. Congratulations for making, without a doubt, the right choice. With skill at the controls of this motorbike, an adequate preparation and the corresponding essential servicing this GAS GAS will remain highly reliable and you will be able to enjoy the most comfortable and rewarding motor sport. Thank you for your confidence and welcome to GAS GAS motos SA. -3- 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. All of the instructions to correctly handle and drive this motorcycle are described in detail. Each message will be preceded by a symbol. Inadequate driving skill could cause problems to the environment and conflict with other people. Responsible use of your motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR BIKE LEGALLY, WITH CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE. Motorcycle riding is a fantastic sport, and we hope you will enjoy it to the fullest. WARNING This warning symbol identifies special instructions or procedures that, if not correctly followed, could result in personal injury, or even death. CAUTION This caution symbol identifies special instructions or procedures that, if not strictly observed, could result in damage to or destruction of equipment. OIL RECOMMENDED: NOTE This symbol indicates points of particular interest for more efficient and convenient operation. -4- TABLE OF CONTENTS Foreword.........................................................................................3 Important notice ..............................................................................4 Table of contents ............................................................................5 General information ........................................................................6 Component locations ......................................................................8 Side stand.....................................................................................10 Petrol ....................................................................10 Serial number and the qualification approval plate.......................11 Starting and stopping the engine .....................................12 Cold starting ............................................................13 Gear changes...........................................................13 Stopping the motorcycle...............................................14 Break-in .................................................................14 Maintenance chart .....................................................15 Battery ...................................................................16 Cooling system .........................................................17 Spark plug.....................................................................................20 Air filter ..................................................................23 Accelerator cable.......................................................24 Clutch....................................................................25 Exhaust system ........................................................25 Chain guide .............................................................26 Tension adjustment ....................................................27 Handle bars.............................................................29 Brakes ...................................................................29 Steering .................................................................31 Steering lock ............................................................32 Front forks...............................................................33 Rear suspension .......................................................36 Wheels ..................................................................38 Cleaning.................................................................39 Tighten bolts and nuts .................................................40 Tightening torque table ................................................41 Lubrication ..............................................................42 Engine oil................................................................43 Suspension adjustment................................................47 In competition...........................................................52 Storage ..................................................................53 Multi-function instructions ............................................53 Fault diagnosis .........................................................55 Electrical schemas .....................................................61 Guarantee manual .....................................................63 -5- GENERAL INFORMATION ENGINE Engine Displacement in cubic centimetres Bore and stroke Spark plug Fuel supply TRANSMISSION Transmission type Clutch type Secondary transmission Gear ratio 4 stroke, single-cylinder DOHC 4 valves, liquid cooled 443 cc 95 x 62.6 mm. NGK CR8E or DENSO U24ESR-N Magneti Marelli electronic injection Primary reduction ratio Final reduction ratio Overall drive ratio Transmission oil Capacity Type 6 speed Oil bath, multi-disk hydraulic action By chain 1st 2.071(29/14) 2nd 1.625(26/16) 3rd 1.333(24/18) 4th 1.100(22/20) 5th 0.913(21/23) 6th 0.791(19/24) 2.85(57/20) 3.692 (48/13) 8.149(6th gear) 1200 cc 5W40 API SF or SG CHASSIS Type Tyre sizes Front Rear DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes. Aluminium rocker FSE - 90/90 x 21 FSE SM - 120/60 ZR17 FSE - 140/80 x 18 FSE SM - 150/60 ZR17 -6- Suspension Suspension stroke Front suspension oil Front fork oil level Front Rear Front Rear Öhlins ø 48mm inverted fork. Marzocchi ø 45mm inverted fork. Progressive system with single multi-adjustment ÖHLINS shock absorber. 295 mm. 320 mm. MARZOCCHI SAE 7.5 ÖHLINS SAE 5 - 7.5 Marzocchi: 110 mm (compressed, without spring). ÖHLINS: 110 mm (compressed, without spring). BRAKES Type Effective disk diameter Front / rear Front Rear Disk brakes, NISSIN pump and simple / double callipers. 260 mm 220 mm DIMENSIONS Overall height Overall length Overall width Wheel base Minimum ground clearance Fuel tank capacity Weight 1260 mm. 2135 mm. 810 mm. 1475 mm. 340 mm. 9.5 litres 119 Kg. (Specifications subject to change without notification, also possibly not applicable in some countries). -7- LOCATION OF COMPONENTS GAS GAS FSE 450 1 3 42 56 123456- Clutch handle Engine start button Fuel tank cap Front brake fluid tank Front brake handle Throttle control 1 GAS GAS FSE SM 450 3 42 56 123456- Clutch handle Engine start button Fuel tank cap Front brake fluid tank Front brake handle Throttle control -8- 12 7 9 16 11 18 19 14 23 13 8 15 10 17 21 20 22 24 7- Front suspension 8- Radiator 9- Fuel tank 10- Air filter 11- Seat 12- Front brake disk 13- Front brake callipers 14- Rear brake fluid tank 15- Shift pedal -9- 16- Rear shock absorber 17- Chain guide 18- Chain 19- Silencer 20- Rear shock absorber gas tank 21- Tie rod and rocker suspension 22- Rear brake pedal 23- Engine oil rod 24- Exhaust bend SIDE STAND To unfold the side stand (A) the securing strap must be released (B) then the stand is opened to vertical position. The stand returns to its original position with the aid of the spring (B). PETROL The GAS GAS FSE / SM FSE 450 has a four stroke engine and requires 98 octane, unleaded petrol. Fuel Tank Capacity 7.2L (A) (B) (B) (A) (A). Side stand. (B). Spring. NOTE Do not start the engine or ride the motorcycle when the side stand is down. Always engage the security strap before driving the motorcycle. (A). Fuel cap. (B). Fuel vent hose. To open the fuel cap (A), release the fuel vent hose (B) from the handle bar and rotate the fuel cap in an anti-clockwise direction. To close the fuel cap, rotate it in a clockwise direction. -10- RECOMMENDED FUEL Use lead-free petrol 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) OCTANE RATING (MIN) 90 98 SERIAL NUMBER Printed on the steering tube. Indicates the frame number with which the motorcycle is registered. Qualification approval plate The motorcycle is fitted with its own corresponding qualification approval plate with the serial number, also printed on the steering tube and whose data also coincides with that in the documents. NOTE If knocking 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. -11- STARTING THE ENGINE - Ensure that the motorcycle is in neutral. - Rotate the starter key clockwise (ON (A) position), in this way the electric circuits are active and the engine can start. Stopping the engine - Change gear to neutral. - After a slight acceleration, release the throttle completely and rotate the ignition key anti-clockwise. (A) (D) - The key should point left (D), this means that all of the electric circuits are inactive. The engine cannot start. - The key may be extracted from the ignition. NOTE Starting the engine while the key is being turned to the ON position may cause a loss in battery power. (B) - Without using the throttle, press the electric start button (B). -12- COLD STARTING The cold start function is responsible for aiding the engine start if this is cold. - There is no need to use the throttle, simply start the engine. Note that the engine will start after a certain number of revolutions. After some seconds, the engine will be at normal operation temperature. The engine will reach its optimal temperature, in low time and without causing damage. NOTE - If the engine is flooded then start with the throttle fully open. - The motorcycle may be started in gear if the clutch is disengaged. SHIFTING GEARS The transmission is a 6 speed, return shift type meaning 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 then release the pressure on the shift pedal and gently release the clutch lever. 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. (B) (B). Shift pedal. -13- STOPPING THE MOTORCYCLE For maximum deceleration, close the throttle (A) 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. NOTE The slow speed necessary during the break-in period may cause carbon to build up on the spark plug and soil it. If inspection of the spark plug shows this to be the case, replace the standard spark plug with a higher heat grade spark plug for the duration of the break-in period. Break-in following these steps: 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 FULLY. 4. Stop and let the engine cool completely. Check and adjust chain slack and spoke tightness and make a general inspection. 5. Start the engine and ride for 20 minutes at moderate engine speed. NEVER ACCELERATE FULLY. 6. Stop and let the engine cool completely. Check and adjust (4) ...