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GAS GAS FSE 400 - 2004, Service Manual

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EC FSE 2004 -

115

-

(2). After first race maintenance

1. Air cleaner element
2. Drive chain slack
3. Rear sprocket nuts
4. Sprockets
5. Front and rear tire air pressure
6. Front and rear axle shaft nuts
7. Pivot shaft nut
8. Muffler, silencer bolts or nuts
9. Front, rear fender mounting bolts or nuts
10. Fuel tank, seat mounting bolts or nuts
11. Front and rear brakes
12. Steering play
13. Fuel tank fill
14. Coolant level check

(3) Maintenance notice for after riding on dusty course

If dirt or dust gets through into the engine, the crankshaft big end
will wear excessively. After riding, inspect the crankshaft big end. If
the crankshaft big end is worn past the service limit, replace the
crankshaft big end with a new one.

(4) Maintenance notice for after riding in rain on muddy course

1. Apply grease to swing arm pivot and rear suspension system
2. Inspect the drive chain and rear sprocket wear
3. Clean the air cleaner element
4. Check the cylinder and crankshaft 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 fork clamp bolt tightness
3. Handlebar clamp bolt tightness
4. Throttle grip screw tightness
5. Throttle grip operation
6. Front and rear brake hose installation
7. Front and rear brake fluid level
8. Front and rear brake disc and caliper installation
9. Front and rear brake function
10. Fuel tank installation
11. Shift pedal bolt tightness
12. Engine mounting bolt tightness
13. Engine sprocket installation
14. Brake pedal bolt tightness
15. Transmission oil level
16. Carburetor clamp screw tightness
17. Carburetor top cap tightness
18. Linkage tie rod mounting bolt tightness
19. Linkage rocker arm mounting bolt tightness
20. Rear shock absorber bolt tightness
21. Swing arm pivot shaft nut tightness
22. Rear axle shaft nut tightness
23. Rear sprocket bolts or nuts tightness
24. Rear brake pedal operation
25. Seat installation
26. Front and rear wheel sproke tightness
27. Front and rear tire air pressure
28. Drive chain slack
29. Coolant level

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Summary of Contents for FSE 400 - 2004

Page 1: ...Compuesta MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO USO E MANUTENZIONE MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO USO E MANUTENZIONE...

Page 2: ...ompetition enduro It is actually the fruit of many years of competition and experimentation in this demanding discipline as well as the many great successes achieved thanks to great trial riders who h...

Page 3: ...ult in damage to or destruction of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation However if improverly conducted the sport has the...

Page 4: ...e 77 Break in 77 Manitenance chart 78 Battery 79 Cooling system 80 Spark plug 83 Clogged air 86 Throtlle cable 87 Clutch 88 Exhaust system 88 Drive chain 89 Handlebar 92 Brakes 92 Steering 94 Steering...

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: ...compressed 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...

Page 7: ...FSE 2004 71 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 Cliper 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 2004 73 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 CAUTION 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 2004 82 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: ...isually 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 2004 93 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: ...m 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: ...bbly 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 th...

Page 38: ...nk 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: ...il 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 r...

Page 44: ...tor 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 i...

Page 45: ...ck 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 properly or the specifications recommended by GA...

Page 46: ...rners adjust the suspension to allow fast cornering Make setting changes in small increments a little bit goes a long way and it is very easy to overadjust a setting The front and rear suspension shou...

Page 47: ...is 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 s...

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 NOTE After any adjustment check front and rear compatibility Adjustment depending on bottoming condition rear shock absorber Bottoms at low speed Increase spr...

Page 50: ...imes after each change In this way the 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 po...

Page 51: ...nkshaft 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 Fron...

Page 52: ...fuel will deteriorate Remove the spark plug and put several drops of SAE 30 oil into the cylinder Kick the engine over slowly a few times to coat the cylinder wall with oil and install the plug Lubri...

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: ...CDI unit the pulse generator 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 b...

Page 55: ...e Incorrect spark plug Connecting rod exhaust system damage Close the starter Clean fuel tank air vent Check the air filter Fill up fuel tank Close the starter Clean fuel tank air vent Check the injec...

Page 56: ...Control 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...

Page 57: ...ing maladjusted TROUBLE CAUSE REMEDY Shock absorption too hard Shock absorption too soft Abnormal train noise Handlebar shakes or excessivery vibrates Motorcycle pull to one side Empty oil from fork a...

Page 58: ...OUBLE CAUSE REMEDY Motorcycle pull to one side Brakes don t hold Las l mparas se funden El sistema de iluminaci n no funciona Change steering stem and go to specialized garage Change front fork Align...

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...

Page 60: ...the 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 exa...

Page 61: ...010438001 C UNICEF n 17 Poligon Industrial Torremirona 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es Web www gasgasmotos es JULI...

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