GAS GAS EC FSE 400 Workshop Manual Download

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Summary of Contents for EC FSE 400

Page 1: ...2004 2005 2004 2005 MOTOR FSE 450 MOTOR FSE 450 MANUAL DE TALLER WORKSHOP MANUAL MANUAL DE TALLER WORKSHOP MANUAL...

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Page 3: ...WORKSHOP MANUAL WORKSHOP MANUAL ENGINE FSE 450 ENGINE FSE 450 2004 2005 2004 2005 ENGLISH...

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Page 5: ...installing 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...

Page 6: ...Type DELTABOX semi double cradle chassis made from rectangular Cromoly tubes Aluminium swing arm Front Suspension Inverted Marzocchi Diameter 45 mm Run 295 mm Inverted hlins Diameter 48 mm Run 295 mm...

Page 7: ...5 Un installing the engine Un installing and installaing the engine in the chassis...

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Page 9: ...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...

Page 10: ...d 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 star...

Page 11: ...Un installing the engine 9 N Dismount the water tube L Remove the pedal starter lever M Remove the exhaust collector N Disconnect the 2 radiator tubes M L...

Page 12: ...e engine 10 S O 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 pini...

Page 13: ...Un installing the engine 11 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 T...

Page 14: ...ing Once removed they lose their self locking capability and are useless PRECAUTION Replace the engine fixing nuts with new ones Hold the screw heads with a spanner and tighten the engine fixing screw...

Page 15: ...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 s...

Page 16: ...e API service and with a degree of viscosity SAE 10W 40 through the oil fill mouth in the frame A and check the level DATA Engine oil capacity Change of oil 1 L Changing the oil and filter 1 2 L Engin...

Page 17: ...Dismounting the engine Dismounting the engine 15...

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Page 19: ...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...

Page 20: ...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 multipl...

Page 21: ...ht 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 Remove the cylind...

Page 22: ...ne 20 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 distr...

Page 23: ...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...

Page 24: ...Dismounting the engine 22 Remove the distributor chain upper skate Remove the intake camshaft cover Remove the exhaust camshaft cover Remove the intake camshaft Remove the exhaust camshaft...

Page 25: ...smounting the engine 23 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 gask...

Page 26: ...ibutor 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 pus...

Page 27: ...tch 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 cl...

Page 28: ...engine 26 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 oi...

Page 29: ...Dismounting the engine 27 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...

Page 30: ...e 28 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 int...

Page 31: ...he engine 29 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 o...

Page 32: ...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 ch...

Page 33: ...f 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 ME25950005 an...

Page 34: ...Dismounting the engine 32 Remove thehousing gasket Remove the 2 axles of the gearbox pins Remove the desmodrome Remove the gearbox gears unit...

Page 35: ...Engine Mounting Engine Mounting 33...

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Page 37: ...the gearbox pins and the pins check that the gears engage normally Place the gears of the transmission in a dead point position The crankshaft pinion and the balance axle pinion have a mark B that ea...

Page 38: ...tact 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 Wash the drain filter with solvent and place...

Page 39: ...using screws check if the crankshaft the intermediate axle and the transmision axle turn smoothly If you detect a great resistance upon turning try to free the axles by tapping them with a plastic ham...

Page 40: ...ing 38 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 s...

Page 41: ...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...

Page 42: ...E 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 w...

Page 43: ...Engine Mounting 41 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...

Page 44: ...rimary 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 produce...

Page 45: ...ashers 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 Pl...

Page 46: ...e Mounting 44 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 seg...

Page 47: ...E 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 NOTE Clean well the surface before placing the gas...

Page 48: ...e 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...

Page 49: ...t the cylinder head to the cylinder Fix via the 4 lateral screws the cylinder to the engine casing Place the lateral screw of the distributor chain NOTE Just before coupling the shaft axle to the cyli...

Page 50: ...t 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 cove...

Page 51: ...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 te...

Page 52: ...ly silicon in the indicated zone 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...

Page 53: ...ounting 51 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...

Page 54: ...e 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 start...

Page 55: ...Replacement of the standard clutch with the clutch ADLER APTC Replacement of the clutch 53...

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Page 57: ...mounting not performed in accordance with the instructions lead to the automatic annulment of any existing guarantee over the product All the characteristics described in the present documentation sho...

Page 58: ...ations 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 Loosen and remove the screw that fixes the b...

Page 59: ...unting The mounting procedure is performed as described from page 41 of this manual Warning A moderate use is recommended during the first period of use of the APTC to allow the normal adjustment of t...

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Page 61: ...he engine components 59 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...

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Page 63: ...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...

Page 64: ...enance 62 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 va...

Page 65: ...fter checking the associated parts continue the described procedure in the box related to the maintenance of the guide valves Cylinder head deformation De carbonise the combustion chamber With a ruler...

Page 66: ...port Tool ref Trapezoidal lock units 100 mm DATA Valve rod de centering Service limit 0 05 mm 0 002 in Valve head radial de centering Hold the valve with a trapezoidal lock and measure the radial de c...

Page 67: ...eplace the valve with a new one Tool ref Thickness gauge DATA Valve work surface thickness T Service limit 0 5 mm 0 02 in Valve rod deflection Remove the valve some 10 mm from the seat Measure the rod...

Page 68: ...e or the guide check the deflection Tool ref Micrometer 0 25 mm DATA Valve rod exterior diameter Intake 4 975 4 990 mm 0 1959 0 1965 in Exhaust 4 955 4 970 mm 0 1951 0 1957 in Valve guide maintenance...

Page 69: ...adjusting them Tool ref Valve guide tool 5 mm Tool ref Tool handle Valve seating width Paint uniformly with Prussian blue the valve seating Mount the valve and couple to it a valve polisher Apply lig...

Page 70: ...N 114 Tool United States Vlave seating knife N 114 N 121 and N 128 Tools Rest of the world Ref Valve seating corrector unit Ref Knife N 128 Ref Knife N 114 Ref Knife N 121 NOTE Use the solid centerer...

Page 71: ...he seating De encrust and clean the seating with the 45 knife Turn the knife one or two turns Measure the width of the valve seating W after each cut If the valve seating is bruised or burned use the...

Page 72: ...ing correct widths and position are obtained use the 60 knife very lightly to clean the shavings produced by the previous cutting operations WARNING Do not use a polishing compound after having perfor...

Page 73: ...rce maintains tightened the valve seating With the spring weakened the engine power is reduced and a valve mechanism failure is produced Check the force of the valve springs measuring its free length...

Page 74: ...id damaging the valve retainer lips Mount the valve spring with the smaller pass end towards the cylinder head A Smaller pass B Greater pass C Below Place the spring holder by pressing it with the val...

Page 75: ...automatic decompressor counterweight does not function smoothly replace it with a new one Cam wear The wearing of the cams usually provokes the misalignment of the valve adjustment with the correspond...

Page 76: ...and measure the width of the plastic tool compressed with the surrounding ruler This measurement should be performed in the wider part of the compressed plastic tool If the cam axle bridge oil width s...

Page 77: ...deformation With a ruler and thickness gauge check if the surface of the cylinder block gasket is deformed Measure the looseness in various places If any of the looseness measurements surpass the ser...

Page 78: ...and the groove Measure the side spaces of the 1st and 2nd piston rings with the thickness gauge If any of the spaces exceeds the service limit replace the piston and the rings Tool ref Thickness gaug...

Page 79: ...ing end Fig 5 Service limit 1 0 50 mm 2 0 50 mm Piston bolt holder and bolt interior diameter Measure the piston bolt holder diameter with a small calliper If the diameter surpasses the service limit...

Page 80: ...ng the movement of the connecting rod foot This method may be also used to check the degree of wear of the connecting rod head parts Tool ref Magnetic support Tool ref Cuadrant gauge 1 100 mm Tool ref...

Page 81: ...de centering Service limit 0 08 mm STARTER CLUTCH Remove the hexagonal screws 1 Starter clutch screw 26 Nm 2 6 kgm Nount the starter clutch in the correct direction as shown Apply engine oil to the st...

Page 82: ...ied torque Oil pump 10 Nm 1 0 kgm CLUTCH Place the clutch unit in a bench press using protective gags Gradually loosen the 3 assembly screws and unscrew them completely Remove the clutch unit from the...

Page 83: ...t since some of the surfaces of the same components are covered with an anti wear covering with low friction coefficients The conducting and conducting disk package should be replaced when the total p...

Page 84: ...ss with protective gags Tighten lightly to close the screw Screw the three assembly screws and remove the clutch unit from the bench press WARNING Make sure that the conductive disk on the fixed pail...

Page 85: ...04 washer 31 5x 25x22 x1 striated 05 primary pinion VI 06 primary pinion III and IV 07 washer 25 2x31 5x1 gearbox 08 primary pinion V 09 bearing needles k25 29 10 10 primary axle 11 bearing needles k2...

Page 86: ...nd firmly coupled NOTE When again mounting the transmission pay attention to the location and position of the washers and the elastic rings In the sectional view are shown the correct positions of the...

Page 87: ...new one Mount the gearbox primary axle right bearings with the special tool Tool ref Bearing mounting unit Gearbox primary axle left bearing Remove the gearbox primary axle left bearing 2 with the sp...

Page 88: ...nit Crankshaft bearings Remove the right bearings 5 and the left 6 of the crankshaft with the special tool Tool ref Bearing extractor unit WARNING Replace the extracted bearings with new ones Mount th...

Page 89: ...e right bearing Extract the balance axle right bearing 9 with the special tool Tool ref Bearing extractor unit WARNING Replace the extracted bearing with a new one Mount the balance axle right bearing...

Page 90: ...and the clutch cover Pay attention to the following points WARNING Replace the extracted retainers with new ones Apply grease to the retainer lips Gearbox secondary axle retainers Remove the casing 1...

Page 91: ...lace the extracted retainer with a new one Slowly place the selector axle retainer in the left sump with the special tool Tool ref Retainer mounting unit Oil retention valve Remove the cover 2 the oil...

Page 92: ...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 com...

Page 93: ...Periodic maintenance Periodic maintenance 91 Spark plug 93 Oil filter and engine oil 94 Engine oil tubes 97...

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Page 95: ...plug Soot deposits Check if there is soot in the spark plug If there is soot deposited remove it using a wire prong brush Spark plug tolerance Measure the tolerance using a thickness gauge If the spa...

Page 96: ...e soot will be deposited in the space of the glowplug and the engine may be damaged Installation of the spark plug WARNING To avoid damaging the thread of the first cylinder head screw the spark plug...

Page 97: ...es with the standard API classifications SF or SG and that it has a range of viscosity SAE 10W 40 ENGINE OIL DRAINAGE In sump 2 21 Nm 2 1 Kg 6 80 lb ft In chassis 1 18 Nm 1 8 Kg 13 0 lb ft WARNING Scr...

Page 98: ...the correct position Change the oil filter cover and tighten the safety nut Add new oil to the engine and check the oil level just as described in the oil change procedure DATA Engine oil capacity Ch...

Page 99: ...is based on the results that we obtain when measuring the cylinder compression Compression verification should be included in concessionaire inspections DATA Compression Standard 1000 Kpa 10 0 Kgf cm2...

Page 100: ...odically 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 te...

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Page 104: ...C Unicef 17 Pol gon Industrial Torremirona 1719 Salt Girona SPAIN TEL 34 902 47 62 54 FAX 34 902 47 61 60 w w w g a s g a s m o t o s e s PU010538043...

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