EC FSE 450
SERVICE MANUAL
SERVICE MANUAL
ENGLISH
Foreword
Congratulations for choosing this GAS GAS, wich has been developed through GAS GAS, to produce a light
weight, high performance machine with superb handling and stability for racing and sporting use.
Your new GAS GAS is a highly tuned production racer for participation 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 properly tuned and adjusted.
Due to improvents in design and performance during production, in some cases may be minor discrepancies
between the actual vehicle and the illustrations and text in this manual.
Thanks for your confidence and your welcome from GAS GAS motos, S.A.
December 2002
EC FSE 2003 -4-
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.
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 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.
EC FSE 2003 -5-
TABLE OF CONTENTS
Foreword..............................................................................4
Important notice................................................................................5
Table of contents .......................................................................6
Specifications.....................................................................................7
Side stand .......................................................................................11
Recomended fuel............................................................1 1
Serial number..................................................................................12
Start the engine ..............................................................................13
Choke button...................................................................................14
Shifting gears ..................................................................................14
Stopping the motorcycle..................................................................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
Steering blocade .............................................................................. 33
Front Fork......................................................................................... 34
Rear suspension .............................................................................. 37
Wheels .............................................................................................39
Lubrication........................................................................................ 43
Engine oil ......................................................................................... 44
Suspension tuning............................................................................ 47
Preparation for competition.............................................................. 53
Storage............................................................................................. 54
Gas Gas speedo instructions........................................................... 54
Troubleshooting................................................................................ 56
Warranty regulations........................................................................ 61
EC FSE 2003 -6-
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"
EC FSE 2003 -7-
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).
EC FSE 2003 -8-
Location of Components
GAS GAS EC FSE 400cc. / 450cc.
1 3 4 2 65
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
EC FSE 2003 -9-
7
9
16
1112
18 19
23
13
8
10
1415 17
7- Front Suspension
8- Radiator
9- Fuel Tank
10- Air Filter
11- Seat
12- Brake Disc, front
13- Brake Caliper, front
14- Brake Fluid Reservoir, rear
15- Shift Pedal
2021 22 24
16- Rear Shock Absorber
17- Chain Guide
18- Drive Chain
19- Silencer
20- Fuel Tank
21- Connecting Rod o'ring and Swingarm
22- Rear Brake Pedal
23- Oil Dipstick
24- Exhaust
EC FSE 2003 -10-
SIDE STAND
FUEL
To operate the side stand:
Release the security strap (B), the 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.
(C)
(B)
(A)
(B). Sidestand spring
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.
(A). Side Stand
(C). Security strap
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)
(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.
EC FSE 2003 -11-
RECOMENDED FUEL
SERIAL NUMBER
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.
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.
EC FSE 2003 -12-
START THE ENGINE
(B)
(C)
Stopping the Engine
- You have to assure the motorcycle to the neutral position.
- Turn the key in the direction clock (position in "ON" (A)), by this
way the electric circuits will be open and then the engine will start.
The key will be locked into the contact.
(A)
- Whithout drive the twist grip, swich the electric start button (C).
EC FSE 2003 -13-
- Change to the neutral position.
- 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 damage the injection system.
(D)
- Swich of the key in the opposite clock direction. The key will be
located to the left hand side (D), where all the electric circuits will be
closed. The engine will not start. The key can be pulled out of the
contact.
- The key can be extract.
NOTA:
Start the engine as soon as the key is turned to the "on" position
or the baattery might lose power.
CHOKE BUTTON
SHIFTING GEARS
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.
For use, pull up the choke knob (A), and without turn the twist grip,
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.
- 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)
(A)
NOTA
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)
EC FSE 2003 -14-
(B). Shift Pedal.
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)
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.
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.
EC FSE 2003 -15-
However, since recklessly high r/min (rpm) will lead to engine trouble,
CAUTION
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.
Part
Air filter
*Muffler bolts
and connections
*Valve tolerance
Spark plug
Injection pump pipes
Motor oil and filter oil
*Oil motor pipes
Coolant Fluid
Radiator pipes
Clutch
Chain
*Brakes
Brake pipes
Brake fluid
Tires
*Steering play
*Front fork
*Rear suspension
*Nuts and bolts in the frame
MAINTENANCE CHART
Period
First 5 hours
Period
Every 30 hours
Every 60 hours
Inspect every time the bike has been running and has been checked
T
I
I
T
I
I
*Check every 4 years
R
I
-
R
I
I
Check every 2 years
I
I
I
I
Clean, lubricate and inspect every time it runs
I
I
I
I
*Chec every 4 years
I
I
*Chec every 2 years
Inspect tire pressure and possible damages caused every time the bike runs
I
I
I
T
-
-
-
T
Period
T
I
R
I
R
I
I
I
I
I
I
I
I
I
I
T
NOTE: I = Inspect and clean, adjust, substitute or lubricate if it's necessary; R = Replace, T = Tighten, C = Cleaning
EC FSE 2003 -16-
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)
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.
1. Remove the screws (A) and the seat (B)
2. Pull the rubber (C) and remove the battery
EC FSE 2003 -17-
- 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.
Using high-pressure water, as from a car wash facility, could damage
CAUTION
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.
Exceeding charge standards may reduce the life cycle of the battery.
CAUTION
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.
EC FSE 2003 -18-
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.
Use of incorrect coolant solutions will cause severe engine and
CAUTION
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.
Coolant Level
- Situate the motorcycle so that it is perpendicular to the ground.
- Remove the radiator cap in two steps. First turn the cap counterclock wise 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.
Soft or distilled water must be used with the inhibitor chemicals and
CAUTION
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.
EC FSE 2003 -19-
(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.
Check the level when the engine is cold.
NOTE
(1). Coolant Level
(2). Breather Hose
If the coolant level is low, add the correct amount of coolant through
the filler opening.
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)
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.
EC FSE 2003 -20-
(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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