GAS GAS ENDURO 4T EC 2014 Owner'S Manual Download

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Owner´s manual

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Controls and components location XC 4T 250/300/450cc

* Image taken from the XC 4T 450F RACING

Number

Name

Number

Name

Headlamp with position, low beam and high beam lamps

Front fork

Fuel tank

Engine start

Rear shock

Gear shift pedal

Air filter

Carburetor

Side stand

Secondary transmission chain

Front brake disc

Chain guide

Front brake caliper

250/300cc 4T located at the front of the engine..

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Summary of Contents for ENDURO 4T EC 2014

Page 1: ...ProCarManuals com...

Page 2: ...is prohibited wi thout the express authorization of the copyright owner The Company has the right without prior notice to change the technical content of the products The models of the images may app...

Page 3: ...sor and magnet 30 Measure of the wheel circumference 30 HOMOLOGATION 31 OPERATING INSTRUCTIONS 33 STARTING PROCEDURE 34 BREAK IN PROCEDURE 34 DAILY INSPECTION 35 CLEANING 39 STORAGE 40 SERVICE AND MAI...

Page 4: ...justment 59 36 General lubrication 60 37 Steering bearings 60 38 Wheel bearing 60 39 Swingarm and linkage 60 40 Rear suspension 60 41 Chain 63 42 Tires 63 43 Battery charge 64 ADJUSTMENTS 65 INTRODUCT...

Page 5: ...Owner s manual 5 GENERAL INFORMATION ProCarManuals com...

Page 6: ...nd with adequate preparation and corresponding revisions are essential to ensure that your GAS GAS is highly reliable you can enjoy more comfortable and grateful practice the sport motorcycle Thank yo...

Page 7: ...aintaining the warranty Your GAS GAS has been designed for off road use not designed for long travel on highways Such use could lead to engine damages be cause it maintained high revolutions Also tyre...

Page 8: ...start 1 3 Fuel tank 12 Gear shift pedal 4 Rear shock 13 Carburetor 5 Air filter 14 Secondary transmission chain 6 Side stand 15 Chain guide 7 Chain guard 16 License plate holder 8 Front brake disc 17...

Page 9: ...ake caliper 4 Rear shock gas reservoir 13 Rear brake master cylinder 5 Kick starter 14 Suspension linkage 6 Fuel valve 15 Rear brake pedal 7 Manufacturer s identification plate 16 Oil filter 8 Radiato...

Page 10: ...with position low beam and high beam lamps 8 Front fork 2 Fuel tank 9 Engine start 1 3 Rear shock 10 Gear shift pedal 4 Air filter 11 Carburetor 5 Side stand 12 Secondary transmission chain 6 Front b...

Page 11: ...ar shock gas reservoir 12 Rear brake master cylinder 4 Kick starter 13 Suspension linkage 5 Fuel valve 14 Rear brake pedal 6 Manufacturer s identification plate 15 Oil filter 7 Radiator 16 Sump guard...

Page 12: ...nt brake lever 4 Fuel tank cap 10 Turn signals lights horn and engine stop controls 5 Ignition key 11 Steering lock 1 Only XC models Controls and components location EC 4T Number Name Number Name 1 Ho...

Page 13: ...d in the right side of the steering column Your GAS GAS has a steering lock It s found on the right side of the steering column To lock the steering 1 Turn the handlebar fully to the right 2 Insert th...

Page 14: ...8 x 1 4 with O Rings 112 links 5 8 x1 4 with O Rings 114 Clutch type Multi disc wet clutch Clutch trigger Clutch lever Lubrication Mezzo Oil Capacit 1200cc Available rear sprockets 39 40 42 44 46 47 4...

Page 15: ...type Keihin FCR JUM6 37MX Keihin FCR 5TJ 39MX Main jet 168 168 160 Idle jet 45 45 48 Needle jet 68 68 65 Needle NNGU NNGU NNHU Needle position 3 from top Starter jet 115 115 NO Pilot oir jet 70 70 70...

Page 16: ...Owner s manual 16 Electrical diagram ProCarManuals com...

Page 17: ...3 Swingarm bolt M14 80 4 Brake disc bolt M6x14 12 5 Front axle bolt M20 50 6 Brake caliper bolt M8x30 30 7 Engine mount bolt M10x118 40 8 Rear sprocket bolt M8x30 30 GENERAL Size Torque Nm M4 nuts an...

Page 18: ...4 7 Torque Values CHASSIS N Name Size Torque Nm 1 Subframe bolt M8x50 25 2 Brake banjo bolt 6 3 Upper clamp bolt M7x30 15 4 Spokes 1 5 5 Rear axle nut M20 100 6 Linkage bolt M14x110 100 7 Rear brake...

Page 19: ...ual 19 ENGINE N Name Size Torque Nm 1 Gearshift pedal bolt M6 12 2 Kick starter bolt M8 33 3 Kick starter bolt M6x20 12 4 Crankcase bolt M6 10 2 1 4 3 2 Coppie di serraggio Torque Values ENGINE ProCar...

Page 20: ...3 6 Engine drain plug M10x1 25 20 7 Engine drain plug left side M6x1 0 10 8 Water pump drain bolt M6x1 0 10 Clutch cover bolt M6x1 0 10 Sprocket M20x1 0 75 Rotor nut M8x1 25 14 Bolt oil level M6x1 0 1...

Page 21: ...ot leave the device in direct sunlight when the motorcycle is stopped Avoid contact with gasoline degreasers or other cleaning chemical products that could be cause damages in the device Always rememb...

Page 22: ...osen on the previous menu ODO ART SCREENS IN NORMAL MODE Screen 1 DST DST Distance Traveled DST function accumulates the distance data since the last reset while you re riding a motorcycle Press and h...

Page 23: ...SOR AND MAGNET Motorcycles require a magnet placed on a rotating surface such as the front or rear wheel and a sensor in front of the magnet to create a wheel sensor If you have purchased a variety of...

Page 24: ...ce with the motorcycle until the wheel complete one revolution Make a mark on the ground at this point Measure the distance between the marks of the ground and convert to millimeters Use this number a...

Page 25: ...Owner s manual 25 ProCarManuals com...

Page 26: ...Owner s manual 26 This page is intentionally left blank OPERATING INSTRUCTIONS ProCarManuals com...

Page 27: ...re it will be necessary to pull the choke lever It is important to respect the break in procedure with this you will ensure the duration and correct function of your GAS GAS in the long term Intervals...

Page 28: ...to the carburetor the motorcycle engine does not run this position is used only when the engine is stopped If you know that there is litt le fuel in the tank you must start the use with the tap in th...

Page 29: ...al stand and the handlebar at the right side in this position take off the top tank cover with its rubber attention to the dirt is necessary to have a clean space where you leave the disassembled part...

Page 30: ...e any change that you appreciate will make you immediately go to your GAS GAS official service Your GAS GAS official service will be happy to assist you and ensure your safety Does the side stand have...

Page 31: ...go to your official GAS GAS service this affects your safety Is the seat properly fixed This is a point of vital importance for your safety if you have some doubt about this fixation you must go to yo...

Page 32: ...spection Cleaning To clean your GAS GAS follow these steps 1 Put a plug in the exhaust system to prevent water entry 2 Cover with a piece of duct tape the lock anti theft steering lock 3 Remove mud an...

Page 33: ...s Spray oil on all unpainted metal surfaces to prevent oxidation avoid oil on the brakes and rubber parts Tie a plastic bag the exhaust pipe to prevent corrosion Place the motorcycle so that the wheel...

Page 34: ...Owner s manual 34 This page is intentionally left blank SERVICE AND MAINTENANCE ProCarManuals com...

Page 35: ...e and connections 10 hours 40 hours 18 Brakes adjustment 20 hours When necessary 19 Brake wear 30 hours When necessary 20 Brake fluid Every 2 years 21 Brake fluid level 10 hours 20 hours When necessar...

Page 36: ...able protector in the carburetor adjust with a tensor tighten lock nut and reinstall protector 4 SPARK PLUG The standard spark plug NGK R CR9E in 250 300cc or NGK R CR8E in 450cc must be tightened to...

Page 37: ...IR FILTER Removing the filter To access the air filter must remove the seat and the battery box 1 Loosen the screw of the seat 2 Remove the seat by pulling it back 3 Remove the filter fixing 4 Remove...

Page 38: ...the sealing and prevent the entry of dirt DANGER A clogged air filter allows the entry of dirt into the engine causing excessive wear and damage Inspect by all means before and after each race or pra...

Page 39: ...orrect this before riding Maintenance 7 ENGINE OIL For properly function of transmission and clutch maintain the optimum oil level and change it periodically A motorbike with insufficient oil damaged...

Page 40: ...Remove the oil filter cover 2 and the filter 3 6 Install the new oil filter and O ring of the filter cover 7 Tighten the filter cover to 10 Nm 8 Tighten the oil drain plug with washer tightening to 20...

Page 41: ...muffler 3 and take out by pulling backwards 3 Disengage the muffler arrow 4 Change the muffler and reassembly all parts 11 MUFFLEER FIBER The Muffler on your GAS GAS is a silencer of absorption The ab...

Page 42: ...are used in the coolant essence If an anticorrosive coolants ir not used after some time the radiator will rust This will block the cooling tubes NOTE Initially from the factory a permanent type anti...

Page 43: ...y DANGER To avoid burns do not remove the radiator cap or try to change the coolant when the engine is hot Wait until it cools DANGER Coolant on tires will make them slippery and can cause an accident...

Page 44: ...damage your engine 18 BRAKES ADJUSTMENT Front brake lever Adjust the brake lever 1 until you feel comfortable To adjust loosen the nut 2 After adjust tight it correctly Check the brake response is co...

Page 45: ...discs Changing the front brake pads To change the front pads follow these steps 1 Loosen the pin 1 and remove it 2 Remove the pads 2 3 Put a paper around the brake fluid reservoir to prevent falls Ope...

Page 46: ...ep the metal plate 4 and the fiber plate 5 if the new pads does not have them 5 Loosen the screws 6 and remove the lid of the brake fluid 6 Put a paper around the brake fluid reservoir to prevent fall...

Page 47: ...ferent types of brake fluid The liquid used to fill or renew your cir cuit must meet the standard specified in the fluid reservoir each circuit Therefore in the rear brake must use DOT 4 No specificat...

Page 48: ...Ignore when measuring the centering WARNING The wheels and spokes interventions require action by a specialist so we re commend that you to consult your GAS GAS official service 27 CHAIN GUIDE Lubrica...

Page 49: ...bike on a stand or support The front fork must be fully extended 2 Remove the axle and the front wheel 3 Remove the handlebar by loosening the handlebar clamps 2 and remo ving the upper flanges 4 Rel...

Page 50: ...00cc 350 ml 450cc Recommended oil HLINS RXF HLINS 01312 Oil volume 300 ml 32 BOLTS NUTS AND FASTENERS Every day before riding the bike you should check that all bolts and nuts are tightened Also check...

Page 51: ...at the steering is not too tight Squatting in front of the bike grasp the bottom of the front fork on axis push and pull the fork 1 If there is play the steering is too loose If you have to adjust the...

Page 52: ...cation It is necessary after driving on wet ground when the chain looks dry The chain is an o ring chain therefore a specific lubricant should be used for this type of chains Your GAS GAS official ser...

Page 53: ...round 3 Loosen the seat clamping screw 1 and remove it by pulling it back 4 Remove the silencer see Silencer change in point 10 5 Disengage the side covers of their hooves on the radiator 2 6 Disengag...

Page 54: ...between the connecting rod and shock 8 11 Loosen and remove the shock top mounting screw 9 12 Turn up the subframe rotating on his top anchor 13 To remove the shock from the frame move it toward the...

Page 55: ...a chain is too used stretched more than 2 should be replaced Usually it is the right time to change guide front and rear sprockets It is for practical reasons economic and security A chain in the lim...

Page 56: ...it back slightly 2 Loosen the fixing screws of battery cover 2 and remove it 3 Loosen the battery terminals 3 and remove it Replace the battery by a new one and follow the steps in sequence inverse to...

Page 57: ...Owner s manual 57 ADJUSTMENTS ProCarManuals com...

Page 58: ...mixture screw must rotate from a position of fully closed Make changes by half turn increments If turning the screw 1 to 2 5 turns do not get the desired result change a step in the idle jet 1 and tu...

Page 59: ...n jet when the needle narrows changes from cylindrical 1 to conical 2 its position determines the amount of fuel passing At the top of the needle are five slots 3 which sets the clip This clip positio...

Page 60: ...ample Raise clip 1 position and loosen 1 turn the mixture screw WARNING To make corrections always take as reference the competition carburetion Do not make changes if you are not sure that they are n...

Page 61: ...easily gets wet causing failure The proper mixture varies according to atmospheric conditions pressure and temperature This conditions must be taken into consideration when adjusting the car buretor...

Page 62: ...ated at the top of the fork Spring Preload not externally adjustable Oil Volume 300 ml hlins 01312 WARNING The screw on the right side 8 of the compression adjustment should not be unscrewed It isn t...

Page 63: ...6 clicks from closed 12 clicks from closed 12 clicks from closed 12 clicks from closed Rear Shock REIGER HLINS TTX44 250 300cc 450cc 250 300cc 450cc Spring 65 70kg 48 N mm 50 N mm 50 N mm 54 N mm 70 7...

Page 64: ...52N m ideal rider weight 75 85 kg K spring 450cc 54N m ideal rider weight 75 80 kg WARNING The cap which is housed in the regulation of low speed compression damping 2 and 5 there must not be unscrewe...

Page 65: ...r 3 Get off the bike of the bike stand and position it with both wheels on the ground not supported on the side stand 4 Re measure the vertical distance between the rear axle nut and bolt clam ping th...

Page 66: ...sition and or fatigue may incorrectly view on settings When the proper change for a particular terrain is found it should be writ ten down for reference when returning to a similar terrain Lubricate s...

Page 67: ...5 Retighten the screws to the frame using threadlocker 3 6 While holding the footpeg 7 Place the spring 6 within the window and align with the hole to insert the bolt 2 requires some pressure in the...

Page 68: ...Owner s manual 68 This page is intentionally left blank TROUBLESHOOTING ProCarManuals com...

Page 69: ...spark plug then put a gear and push the bike several feet with the throttle fully open Visually you will know when the pre compression pan is empty Mount the spark plug and start the bike You may have...

Page 70: ...tione Andare al vostro servizio ufficiale GAS GAS Benzina di scarsa qualit o di ottani non specifici Svuotare il deposito e riempire con benzina nuo va o di ottani specificii Candela in cattivo stato...

Page 71: ...otare l olio della forcella e riempirla con olio a viscosit specifica Forcella anteriore storta Andare al vostro servizio ufficiale GAS GAS Troppa pressione nel pneumatico Controllare la pressione dei...

Page 72: ...GAS GAS Sterzo mal regolato Registrare lo sterzo Asse dello sterzo storto Andare al vostro servizio ufficiale GAS GAS Forcella anteriore storta Andare al vostro servizio ufficiale GAS GAS Ruote non a...

Page 73: ...Owner s manual 73 ProCarManuals com...

Page 74: ...Owner s manual 74 This page is intentionally left blank WARRANTY MANUAL ProCarManuals com...

Page 75: ...of the repair Any defects detected in the product must be broughtto the attention of a GG authorised dealer within the Warranty Period If the last day of this period is a Sunday or an official holiday...

Page 76: ...t its own discretion whether to repair or replace defective parts Where parts are replaced ownership of the parts removed shall pass to GG without any other consideration The GG authorised dealer to w...

Page 77: ...ProCarManuals com...

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