GAS GAS EC FSE 400 - 2003 SERVICE Service Manual Download Page 7 | Manualshive

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EC FSE 2003 -

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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

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Summary of Contents for EC FSE 400 - 2003 SERVICE

Page 1: ...SERVICE MANUAL SERVICE MANUAL ENGLISH...

Page 2: ...ation 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 p...

Page 3: ...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 inter...

Page 4: ...ycle 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 Steer...

Page 5: ...mission type 6 speed Clutch type Multidisc in oil bath hidraulic actuation Driving system Chain Gear Ratio 1 2 071 29 14 2 1 625 26 16 3 1 333 24 18 4 1 100 22 20 5 0 913 21 23 6 0 791 19 24 Primary r...

Page 6: ...ompressed without spring WP 120 mm compressed without spring hlins 110 mm compressed without spring BRAKES Type Front rear Disc brake Nissin brake pump and Nissin double piston caliper Diameter disc F...

Page 7: ...FSE 2003 9 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 1 3 4 2 6...

Page 8: ...sc 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...

Page 9: ...ring 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 EC FSE 2003 11 FUEL The GAS...

Page 10: ...tane rating equal to or higher than that shown in the table OCTANE RATING METHOD MINIUM RATING Antiknock Index RON MON 2 90 Research Octane No RON 98 NOTE If knocking or pinging occurs try a different...

Page 11: ...osition 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 damag...

Page 12: ...started while in any gear 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 high...

Page 13: ...armed 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 adj...

Page 14: ...T I I R I I I I I I I I I T Inspect every time the bike has been running and has been checked Check every 4 years Check every 2 years Clean lubricate and inspect every time it runs Chec every 4 years...

Page 15: ...attery The operating instructions for the battery are as follows 1 Check the battery tension while the circuit is open 2 In case the battery s tension is below 12 60 V or if the storage period has exc...

Page 16: ...could damage 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 Interfere...

Page 17: ...int of water protect the cooling system against engine and radiator freeze up Use a permanent type of anti freeze soft water and ethylene glycol plus corrossion and rust inhibitor chemicals for alumin...

Page 18: ...Coolant on tires will make them slippery and can cause an accident and injury EC FSE 2003 20 NOTE Check the level when the engine is cold 1 Coolant Level 2 Breather Hose If the coolant level is low ad...

Page 19: ...out periodically to check its gap and ceramic insulator If the plug is oily or has carbon build up on it clean it preferably with a sandblaster and then clean off any abrasive particles The plug may a...

Page 20: ...e 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 yo...

Page 21: ...ber D E 7 Extract the fuel tank 8 Extract the protector cap D 9 Extract de plug and remove the carbon deposits from the spark plug with a small tip or a metallic brush Readjust the gap in the plug bet...

Page 22: ...ement without fail before and after each racing or practice session Clean it if necessary Air cleaner WARNING Clean the element in a well ventilated area and take care that there are no sparks or flam...

Page 23: ...e throttle cable Check that the throttle grip has 2 3 mm of play and turns smoothly A Adjuster B Locknut C Throttle grip D Brake fluid reservoir rear E Choke Button If the play is incorrect loosen the...

Page 24: ...r B Knurled Locknut C Hydraulic fluid tank EXHAUST SYSTEM The muffler and silencer reduce exhaust noise and conduct the exhaust gases back away from the rider If the muffler is badly damaged dented cr...

Page 25: ...break B A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Slack Ins...

Page 26: ...t A B C NOTE Wheel alignment can also be checked using the straightedge or string metod WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Tigh...

Page 27: ...Visually inspect the drive chain guide If the guide is worn excessively or damaged replace it A Chain Slider Wear Visually inspect the upper and lower chain sliders A Chain Slider B Swing Arm Sprocket...

Page 28: ...bout the handlebar holder A and tighten the nuts securely Tighten the clamp bolts front first and then the rear to 25 Nm of torque 18 ft lbs If the handlebar clamp is correctly installed there will be...

Page 29: ...t becomes contaminated with dirt or water EC FSE 2003 31 A B C D 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 adjust...

Page 30: ...r brake hose damage WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled with a type other than the brake fluid already in the...

Page 31: ...the ground Remove the handlebar A Loosen the front fork upper clamp bolts and remove the steering head nut and washer and take off the steering stem head B Turn the steering stem locknut with the ste...

Page 32: ...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 Your GAS GAS forks are designed to work without addi...

Page 33: ...mounting bolts Remove the front fork protectors Remove the handlebar clamp bolts and remove the handlebar Remove the top clamps of the forklegs Let the forks completely compress Raise the fork springs...

Page 34: ...ble 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 s...

Page 35: ...al one Also the dampening force can be adjusted easily so changing oil viscosity is unnecessary Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening turn the rebound...

Page 36: ...Tighten the locknut ring securely After adjustment move the spring up and down to make sure that the spring is seated Install the parts removed Rear Shock Absorber Spring Replacement In addigtion to...

Page 37: ...bly or hard increase the tire pressure Spokes and Rim The spokes on both wheels must all be tightened securely and evenly and not be allowed to loosen Unevenly tightened or loose spokes will cause the...

Page 38: ...k If water gets into the ignition coil or into the spark plug cap the spark will jump through the water and be grounded out When this happens the motorcycle will not start and the affected parts must...

Page 39: ...ar axle nut 19 Silencer mounting bolts 20 Subframe bolts 21 Rear shock absorber bolts 22 Exhaust mounting bolts and nuts 23 Fork clampbolts 24 Steering shaft nut 25 Rear brake mounting bolt 26 Connect...

Page 40: ...Disc plate mounting screws Engine mounting bolts Front axle bolt Front brake lever support nut Fork flange nut Steering nut Rear axle nut Rear brake pedal nut Subframe support nut Rear shockabsorber n...

Page 41: ...ecially 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 General lubrication Clutch lever A F...

Page 42: ...icity are two important things for the engine Begining you have to replace 5 hours ago of the start and then every 60 hours Checking the oil level Fig A When the engine has been running Fig B When the...

Page 43: ...l to go out through the drain located in the lowest part of the engine Follow these steps to change the oil The oil is pumped from the oil reservoir to the engine when the latter is running The oil re...

Page 44: ...otor oil with the skin as much as possible to avoid possible skin irritation Keep new or used oil away from the reach of childrren Clean jersey cuffs and pants Wash yourself with soap if oil has been...

Page 45: ...0 Replace the drain caps and screw them back on Pour new oil through the dipstick hole Approximately 1800 ml or else the required amount WARNING The engine can be damaged if the oil is not used proper...

Page 46: ...a problem test by changing your riding posture or position so that the cause of the problem can be deduced It is a wise practice to adjust suspension settings to suit the rider s strong points If you...

Page 47: ...s too high The front forks operate but ride is too hard Oil too heavy Worn out fork oil Too soft The fron fork dive excessively during braking and deceleration Fork oil level is low Springs are too so...

Page 48: ...front brake place one foot on the footpeg closest to you and push down hard If the bike maintains its level attitude as the suspension is compressed the spring rates are well balanced Sit astride the...

Page 49: ...compression damping or use harder spring NOTA After any adjustment check front and rear compatibility Adjustment depending on bottoming condition rear shock absorber Bottoms at low speed Increase spr...

Page 50: ...he machine will deliver best performance for the entire circuit Special Care According to Track Conditions 1 In dry dusty conditions such as volcanic ash or fine powdery dust special care must be give...

Page 51: ...kshaft big end bearing 5 Grease the throttle grip and cable 5 Suggest spare parts Look service manual PREPARATION FOR COMPETITION 1 Check 1 Front axle shaft and nut or axle clamp nut tightness 2 Front...

Page 52: ...e motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep dampness away from the tire rubber Tie a plastic...

Page 53: ...nge to kilometers per hour or miles per hour Disconnect the battery the total distance will be saved Re connect the battery whilst holding down either button and it will read either met for km h mil f...

Page 54: ...rator or the ignition coil has oxydized Fuel air mixture incorrect Dismount the right paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate t...

Page 55: ...ecting rod exhaust system damage Close the starter Clean fuel tank air vent Check the injector mounting Check the air filter Fill up fuel tank Close the starter Clean fuel tank air vent Check the inje...

Page 56: ...ontrol cable routing incorrect Wiring routing incorrect Steering stem locknut too tight Steering stem bent Front fork oil excessive Change cylinder head gasket leaking Go to specialized garage Clean o...

Page 57: ...misaligned Front rear axle runout excessive TROUBLE CAUSE REMEDY Shock absorption too hard Shock absorption too soft Abnormal train noise Handlebar shakes or excessivery vibrates Empty oil from fork...

Page 58: ...rakes don t hold Las l mparas se funden El sistema de iluminaci n no funciona Go to specialized garage Adjust steering Go to specialized garage Change steering stem and go to specialized garage Change...

Page 59: ...and to the extent that a The purchaser has failed to subject the vehicle to any of the inspections and or maintenance work prescribed in the operating manual or has exceeded the date stated for such i...

Page 60: ...he existence of a defect or if a visual inspection or material testing is required GG shall be entitled to demand submission of the parts for which warranty claims are put forward or to order an exami...

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