GasGas EC FSE 2004 Owner's manual

MANUAL DEL USUARIOIO SERVICEI MANUAL MANUEL D’ENTRETIEN’ I

LIBRETTOI TO USOUSO EE MANUTENZIONEANUTENZIONE

Compuesta

Foreword

GAS GAS thanks you for your confidence

By choosing the new GAS GAS EC FSE 400 / 450 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 EC FSE 400 / 450 is a bike conceived for the practice of high-competition 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 have contributed with their expertise to the basic data that have allowed us to create a high-level motorbike.

Congratulations for making the right choice. With your skills at the commands of this motorbike, an adequate preparation and the indispensable servicing for this GAS GAS to be highly reliable, you will be able to enjoy the most comfortable and rewarding enduro practice.

Thanks for your confidence and welcome to GAS GAS Motos.

July 2003

EC FSE 2004 -66-

IMPORTANT NOTICE

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of live.

CAUTION

This caution symbol identifies special instructions or procedures which, if noto strictly observed, could result 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 potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road 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, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.

Off-road motorcycle riding is a wonderful sport, and we hope you will enjoy it to the fullest.

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	TABLE OF CONTENTS
	Foreword..............................................................................	66		Clutch...............................................................................................		88
	Important notice................................................................................	67		Exhaust system................................................................................		88
	Table of contents .......................................................................	68		Drive chain .......................................................................................		89
	Specifications...................................................................................	69		Handlebar ........................................................................................		92
	Side stand .......................................................................................	73		Brakes..............................................................................................		92
	Recomended fuel..........................................................................	73		Steering............................................................................................		94
	Serial number..................................................................................	74		Steering blocade ..............................................................................		95
	Start the engine ..............................................................................	75		Front Fork ........................................................................................		96
	Choke button...................................................................................	76		Rear suspension ..............................................................................		99
	Shifting gears ..................................................................................	76		Wheels		101
			...............................................................................................
	Stopping the motorcycle	77		Lubrication		105
	Break-in...........................................................................................	77		Engine oil.............................................................................................		106
	Manitenance chart ..................................................................	78			109
	..............................................................................	ion tuningSuspens
	Battery..........................................................................	.... 79		Preparation115for competition
	..................................................................
	Cooling system ...............................................................................	80		Storage		116
			................................................................................................
	Spark plug.......................................................................................	83		Gas Gas speedo instructions..............................................................		116
	Clogged air......................................................................................	86		Troubleshooting..................................................................................		118
	Throtlle cable ..................................................................................	87		Warranty regulations...........................................................................		123

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SPECIFICATIONS

		ENGINE
		Engine		4 cycle, single cylinder DOHC 4r, crank case induction, liquid cooled
		Displacement in cubic centimeters		399 / 449 c.c.
		Bore and stroke		90 x 62,6 mm. / 95 x 62,6 mm.
		Spark plug		NGK CR8E o DENSO U24ESR-N
		Injection system		Magneti Marelli
		TRANSMISSION
		Transmission type		6 speed
		Clutch type		Multidisc in oil bath, hidraulic actuation
		Driving system		Chain
		Gear Ratio		1ª 2.071(29/14)
				2ª 1.625(26/16)
				3ª 1.333(24/18)
				4ª 1.100(22/20)
				5ª 0.913(21/23)
				6ª 0.791(19/24)
		Primary reduction ratio		2.85 (57/20)
		Final reduction ratio		3.692 (48/13)
		Overall drive ratio		8.149 (6th gear)
		Transmission oil	Capacity	1800 c.c.
			Type	5W50 API SF o SG
		CHASSIS
		Frame		DELTABOX type, made of rectangular-section chromoly tube.
				Aluminium swingarm.
		Tires sizes	Front	90/90 x 21"
			Rear	140/80 x 18"

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	Susmension	Front	Öhlins inverted fork, 43 mm. ø.
			WP inverted fork, 43 mm. ø.
			Mazocchi inverted fork, 45mm. ø.
		Rear	Multi-adjustable, progressive Öhlins shock absorber.
	Suspension travel	Front	295 mm.
		Rear	320 mm.
	Front fork oil		MARZOCCHI SAE 7.5
			WP SAE 5
			ÖHLINS SAE 5 - 7.5
	Front fork oil level		Marzocchi: 110 mm. (compressed without spring).
			WP: 120 mm. (compressed without spring).
			Öhlins: 110 mm. (compressed without spring).
	BRAKES
	Type	Front & rear	Disc brake, Nissin brake pump and Nissin double - piston caliper.
	Diameter disc	Front	260 mm.
		Rear	220 mm.
	DIMENSIONS
	Overall length		2135 mm.
	Overall width		810 mm.
	Overall height		1260 mm.
	Wheell base		1475 mm.
	Ground clearance		340 mm.
	Fuel tank capacity		9,5 litre (2,4 gallons U.S.)
	Height seat		119 Kg.

(Specifications subject to change without notice, which may not be applicable in every country).

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LOCATION OF COMPONENTS

GAS GAS EC FSE 400cc. / 450cc.

1

3

4 2

5

6

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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12		7		9			16		11		18		19			23

13 8 15 14 10 17 21 20 22 24

7-	Front Suspension	16Rear Shock Absorber
8-	Radiator	17Chain Guide
9-	Fuel Tank	18Drive Chain
10Air Filter		19Silencer
11Seat		20Fuel Tank
12Brake Disc, front		21Connecting Rod o'ring and Swingarm
13Brake Cliper, front		22Rear Brake Pedal
14Brake Fluid Reservoir, rear		23Oil Dipstick
15Shift Pedal		24Exhaust

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SIDE STAND

To operate the side stand:

Release the security strap,the(B)sidestand is held in the down position by the weight of the motorcycle. Thes sidestand automatically retracts when the motorcycle is placed in the upright position.

FUEL

The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline

Gas Tank Capacity

ENDUCROSS FSE

9,5L

(B)

(A)

(C)

(A). Side Stand

(B). Sidestand spring

(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.

(B)

(A)

(A). Fuel Cap.

(B). Fuel Vent hose.

Position the vent hose clip in a position which prevents spillage on the steering bearings and the clock.

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RECOMENDED FUEL

Use premium gasoline with an octane 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 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.

SERIAL NUMBER

This number allows the motorcycle to be registered. The serial number (or V.I.N.) is located on the steering stem of the frame.

Official approval plate

This motorcycle has an official approval plate. It shows the serial number.

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START THE ENGINE

-You have to assure the motorcycle to the neutral position.

-Turn the key in the direction clock (position in "ON"),by(A)this

way the electric circuits will be open and then the engine will start. The key will be locked into the contact.

(A)

Stopping the Engine

-Change to the neutral position.

-After racing the engine slightly, close the throttle completely and push the engine stop button(B).

CAUTION

Stop the engine by the stop button.Don't(B) use the key for stop the engine! it can damage the injection system.

(D)

			(B)	- Swich of the key in the opposite clock direction. The key will be
				located to the left hand side,where(D) all the electric circuits will be
			(C)	closed. The engine will not start. The key can be pulled out of the
				contact.
				- The key can be extract.
				NOTE
- Whithout drive the twist grip, swich the electric start button				Start the engine as soon as the key is turned to the "on" position
				or the baattery might lose power.

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	CHOKE BUTTON
	The choke button is a mecanism that opens the throttle, whithout
	take the twist grip, to favour the engine if it is cold. The engine will
	get a good temperature in a short time and it won't damage.
, and(A)without turn the twist grip,	For use, pull up the choke knob
	start the engine. Look the engine that starts with high revolutions.
	Waiting few seconds, the engine will be a good temperature.
	For pull down the choke button, only drive the twist grip.
	NOTE
	- If the engine is flooded, kick with the throttle fully open.
	- If the clutch lever is pulled, the motorcycle can be started
	while in any gear.

(A)

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 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, gently release the clutch lever, then release the shift pedal.

To shift to the next higher gear; pull in the clutch lever, lift the shift pedal with your toe, gently release the clutch lever, and then release the shift pedal.

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.

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STOPPING THE MOTORCYCLE

For maximum deceleration, close the throttle 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.

(A)

BREAK-IN

To obtain the proper operating clerances in the engine and transmission that are necessary for smooth engine performance and reliability, a brief hour or 20 km of operation, run the engine at low and moderate rpm.

NOTE

The slow riding necessary during the break-in period may cause carbon to build up on the spark plug and foul it. If inspection of the spark plug shows this to be the case, replace the standard spark plug with a hotter spark plug for the duration of the b in period.

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 HARD.

4.Stop and let the engine cool completely. Be sure to check and adjust chain slack and spoke tightness and make a general inspection.

5.Start the engine and ride for 20 minutes at moderate speed. - NEVER ACCELERATE HARD.

6.Stop and let the engine cool completely. Check and adjust as step. Then drain the coolant, remove the cylinder head, cylinder and piston, and inspect these parts.

7.Install the parts removed.

8.Fill the radiator up to the bottom of the radiator filler, bleed the air from the cooling system.

9.Start the engine and ride for 30 minutes at moderate speed - NEVER ACCELERATE HARD.

10.Stop and let the engine cool completely, check and adjust.

11.After the break-in procedure has been properly carried out, the motorcycle is ready for regular operation.

CAUTION

However, since recklessly high r/min (rpm) will lead to engine trouble, take care to use the necessary skill and technique in operating the motorcycle.

NOTE

After break-in, install a new standard spark plug, and change the transmission oil.

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MAINTENANCE CHART

Part	Period		Period		Period
	First 5 hours		Every 30 hours		Every 60 hours
Air filter	Inspect every time the bike has been running and has been checked
*Muffler bolts
and connections	T		T		T
*Valve tolerance	I		-		I
Spark plug	-		I		R
Injection pump pipes	I		I		I
			*Check every 4 years
Motor oil and filter oil	R		R		R
*Oil motor pipes	I		I		I
Coolant Fluid	-		I		I
			Check every 2 years
Radiator pipes	I		I		I
Clutch	I		I		I
Chain		Clean,	lubricate and inspect every time it runs
*Brakes	I		I		I
Brake pipes	I		I		I
			*Chec every 4 years
Brake fluid	I		I		I
			*Chec every 2 years
Tires	Inspect tire pressure and possible damages caused every time the bike runs
*Steering play	I		-		I
*Front fork	I		-		I
*Rear suspension	I		-		I
*Nuts and bolts in the frame	T		T		T

NOTE: I = Inspect and clean, adjust, substitute or lubricate if it's necessary; R = Replace, T = Tighten, C = Cleaning

EC FSE 2004 -78-

BATTERY

This battery is maintenance free and checking the fluid level is not required. It is recommended to check the charge of the battery periodically.

To remove the battery, follow these steps :

(A)

(B)

(C)

1.Remove the screws (A) and the seat (B)

2.Pull the rubber (C) and remove the battery

WARNING

Hydrogen gas produced by the battery may explode if exposed to open flame or sparks. Keep flames and sparks away from the battery.

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 exceeded 6 months,the battery has to be recharged following the instructions in paragraph. In case the tension is above 12.60 V, the battery can be installed on the vehicle without having to recharge it.

3.1.Charge mode with constant tension.

-Constant tension = 14.40 - 14.70V

-Initial charging power = 0.1 - 0.5 Cn

-Charge duration = 6 hours minimum / 24 hours maximum.

3.2.Charge mode with constant power.

-Maximum charge power = 0.1 Cn.

EC FSE 2004 -79-

-Recommended charging time = 5 - 8 hours.

-The product of (charging power) x (charging time) has to stay within the range:0,5 - 0,8 Cn.

NOTE

In case charging modes different than the established ones are used, by no means, may the maximum allowed power or the charging time of 24 hours be surpassed.

CAUTION

Exceeding charge standards may reduce the life cycle of the battery.

Never surpass charge standards.

CAUTION

Inverting the polarity of the battery terminals may cause battery charge problems and cause damage to it.

The red terminal is the positive (+) and the black terminal is the negative (-).

COOLING SYSTEM

Radiator Hoses

Check the radiator hoses for cracks or deterioration, and connections for looseness in acordance with the Periodic Maintenance Chart.

Radiator

Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of lowpressure water.

CAUTION

Using high-pressure water, as from a car wash facility, 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.

Interference with the radiator airflow can lead to overheating and consequent engine damage.

Coolant

Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle. Replenish coolant if the level is low.

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down.

Coolant information

To protect the cooling system aluminum parts (engine and radiator) from rust and corrosion, the use for corrosion and rust inhibitor chemicals in the coolant is essential. If coolant containing corrosion and rust inhibitor chemicals is not used, over a period of time, the cooling system accumulates rust and scale in the water jacket and radiator. This will clog coolant passages, and reduce the efficiency of the cooling system.

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CAUTION

Use of incorrect coolant solutions will cause severe engine and cooling system damage.

Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instructions of the manufacturer.

WARNING

Coolant chemicals are harmful to the human body. Follow coolant manufacturer warnings and coolant handing instructions.

CAUTION

Soft or distilled water must be used with the inhibitor chemicals and the antifreeze (see below for antifreeze) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

If the lowest ambient temperature encountered falls below the freezing point 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 aluminium engines and radiators) in the cooling system.

For the coolant mixture ratio under extreme conditions, choose the mixture ratio listed on the container for the lowest ambient temperature.

Coolant Level

-Situate the motorcycle so that it is perpendicular to the ground.

-Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push

and turn it further in the same direction and remove the cap.

(A)

(A). Radiator Cap

CAUTION

Permantent types of antifreeze on the market have anticorrosion and anti-rust properties. When it is diluted excessively, it loses its antifreeze and anticorrosion properties. Dilute a permanent type of antifreeze in accordance with the instructions of manufacturer.

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NOTE

Check the level when the engine is cold.

(1). Coolant Level

(2). Breather Hose

If the coolant level is low, add the correct amount of coolant through the filler opening.

Recomended Coolant

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators).

NOTE

A permanent type of antifreeze is installed in the cooling system when shipped. It is colored green, contains a 50% solution of ethylene glycol, and has a freezing point of -35º C. (-32º F )(USA).

Water and coolant mixture ratio

1:1 (Water 50%, Coolant 50%)

Total Amount: 1.1 L.Capacidad: 1.1 L.

Coolant Change

-The coolant should be changed periodically to ensure long engine life.

-Wait for the engine to cool completely.

-Situate the motorcycle so that it is perpendicular to the ground. -

-Remove the radiator cap.

-Place a container under the coolant drain plug, and drain the coolant from the radiator and engine by removing the drain plug at the bottom of the water pump cover. Immediately wipe or wash off any coolant that spills on the frame, engine, or wheels.

(A)

(B)

(A). Water Pump Cover

(B). Drain Plug

WARNING

Coolant on tires will make them slippery and can cause an accident and injury.

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-Visually inspect the old coolant. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

-Check the cooling system for damage, loose joints, or leaks.

-Install the water pump cover drain plug and cylinder drain plug with the specified torques shown in the table. Always replace the gasket with a new one, if it damaged.

Drain Plug Tightening Torque

Water Pump Cover Plug: 9 Nm. (6FT.LBS).

-Fill the radiator up to the bottom of the radiator filler neck with coolant, and install the radiator cap.

-Check the cooling system for leaks.

-Start the engine, warm up the engine throughly, then stop the engine.

-Check the coolant level after the engine cools down. Add coolant up to the bottom of the radiator filler neck.

SPARK PLUG

The standard spark plug is a shown in the table, it should have a specified gap, and be tightened to 27 N-m. (20FT.LBS).

Standard Spark Plug

NGK CR8 E 0.7-0.8 mm.

The spark plug should be taken 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 also be cleaned using a high flashpoint solvent and a wire brush or other suitable tool. Measure the gap with a wire-type thickness gauge, and adjust the gap, if incorrect, by bending the outer electrode. If the spark plug electrodes are corroded or damaged, or if insulator is cracked, replace the plug.

NOTE

Inspect every 30 hours. Replace every 60 hours.

To find out whether the right temperature plug is being used, pull it out and examine the ceramic insulator around the center electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is burned whit, the plug should be replaced with the next colder plug. If the ceramic is black, the plug should be replaced with the next hotter plug.

NOTE

If the engine output decreases, replace the spark plug to regain performance.

Spark Plug maintenance

NGK	DENSO	COMMENTS
CR7E	U22ESR-N	If the standard plug looks
		wet or has a dark color,
		replace.
CR8E	U24ESR-N	Standar
CR9E	U27ESR-N	If the standard plug looks
		glassy or has a white color,
		replace the plug.

EC FSE 2004 -83-