GAS GAS FSE 400 - 2004, FSE 450 - 2004, EC FSE 400, EC FSE 450 Service Manual

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MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

EC FSE 2004 -66-

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 -67-

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.

EC FSE 2004 -68-

TABLE OF CONTENTS

Foreword..............................................................................66

Important notice................................................................................67

Table of contents .......................................................................68

Specifications...................................................................................69

Side stand .......................................................................................73

Recomended fuel..........................................................................73

Serial number.................................................................................. 74

Start the engine .............................................................................. 75

Choke button................................................................................... 76

Shifting gears .................................................................................. 76

Stopping the motorcycle ................................................................. 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 blocade ..............................................................................95

Front Fork ........................................................................................96

Rear suspension ..............................................................................99

Wheels...............................................................................................101

Lubrication...........................................................................................105

Engine oil.............................................................................................106

Suspension tuning..............................................................................109

Preparation for competition..................................................................115

Storage................................................................................................116

Gas Gas speedo instructions..............................................................116

Troubleshooting..................................................................................118

Warranty regulations...........................................................................123

EC FSE 2004 -69-

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 2004 -70-

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 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 65

EC FSE 2004 -72-

7- Front Suspension
8- Radiator
9- Fuel Tank
10- Air Filter
11- Seat
12- Brake Disc, 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 Brake Pedal
23- Oil Dipstick
24- Exhaust

7

8

9

10

1112

13

16

14

15 17

18 19

2021 22 24

23

SIDE STAND

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.

(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.

EC FSE 2004 -73-

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

(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.

(B)

(A)

(C)

(B)

(A)

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.

EC FSE 2004 -74-

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.

EC FSE 2004 -75-

START 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.

- Whithout drive the twist grip, swich the electric start button (C).

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

- 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.

NOTE

Start the engine as soon as the key is turned to the "on" position
or the baattery might lose power.

(B)

(C)

(D)

(A)

EC FSE 2004 -76-

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.

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.

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.

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). Shift Pedal.

(B)

(A)

(A)

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.

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 2004 -77-

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.

(A)

EC FSE 2004 -78-

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

Period

First 5 hours

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

*Chec every 2 years

Inspect tire pressure and possible damages caused every time the bike runs

Period

Every 30 hours

T

­I
I

R

I
I

I
I

I
I

I

-

-

-

T

Period

Every 60 hours

T

I

R

I

R

I
I

I
I

I
I

I

I
I
I

T

MAINTENANCE CHART

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

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 :

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

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

EC FSE 2004 -79-

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.

(A)

(C)

(B)

EC FSE 2004 -80-

- 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.

EC FSE 2004 -81-

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 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.

(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.

(A)

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). Water Pump Cover
(B). Drain Plug

WARNING

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, 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.

(A)

(B)

EC FSE 2004 -83-

- 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

CR7E

CR8E
CR9E

DENSO

U22ESR-N

U24ESR-N
U27ESR-N

COMMENTS

If the standard plug looks

wet or has a dark color,

replace.

Standar
If the standard plug looks
glassy or has a white color,

replace the plug.

EC FSE 2004 -84-

1. Unscrew screws (A)
and (B) (right and left)

2. Remove the seat.

3. Unscrew screws (C)
(right and left).

4. Disconnect the pump
cables (caution: the
tubes contain gasoline).

(A)

(C)

(B)

CAUTION
Incorrect installation of the plug or an incorrect heat range choice
may cause extensive engine 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 your motorcycle.

Extract the spark plug

To remove the spark plug, follow the following steps:

WARNING

When the injection pump pipes are removed, gasoline may be spilled
and cause a fire.
Stop the engine before removing the tank. Keep flames and sparks
away from the gas cap. Do not smoke.

EC FSE 2004 -85-

NOTE

For the correct use of the plug, it is protected by a cap.
Keep the cap clean and dry.

6. Unscrew screw of
fuel tank (E).

5. Remove the tank
rubber (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 between 0.7 and

0.8 mm (0.028 - 0.031 in.).
Before removing the carbon
deposits, check its color; this
color tells us whether the
standard plug is the best for
our use.

- Remove the filter cover (A)

- Remove the wing bolt (B)
and pull out the element (C).

CLOGGED AIR

A clogged air cleaner restricts the engine´s air intake, increasing fuel
consumption, reducing engine power, and causing spark plug fouling.

WARNING

A clogged air cleaner may allow dirt and dust to enter the carburetor
and stick the throttle open. This could cause an accident.

CAUTION
A clogged air cleaner may allow dirt and dust to enter the engine
causing excessive wear and possible engine damage.

Inspect the element, 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 flame anywhere near the working area; this includes
any appliance with a pilot light. Do not use gasoline or a low flash­point solvent to clean the element. A fire or explosion coluld result.

EC FSE 2004 -86-

- Stuff a clean, lint-free towel into the carburetor so no dirt is allowed
to enter the carburetor.

- Wipe out the inside of the air cleaner housing with a clean damp
towel.

CAUTION
Do not spin the filter on its cage. It is possible to tear or damage the
filter.

- Take the support cage
(B) off the frame (A).

(A)

(B)

(C)

- Inspect the element for damage such as tears, hardening, or
shrinkage. If damaged, replace it or it will allow dirt into the carburetor.

- Install the element in the machine, and make sure the sealing
surface of the element is seated properly.

EC FSE 2004 -87-

THROTLLE CABLE

- Inspect the throttle grip for smooth operation in all steering positions.In
accordance with the Periodic Maintenance Chart, check and adjust
the 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 locknut on the upper end of the
throttle cable, and turn the adjuster to obtain the correct amount of
play. Tighten the locknut.

- Squeeze it dry in a
clean towel. Do not
wring the element or
blow it dry; the element
can be damaged.

- Apply grease to all
connections and srew
hole in the air cleaner
housing and intake
tract.

(C) (E) (B)

(A) (D)

- Clean the element in a
bath of a filter cleaning
fluid using a soft bristle
brush.

EC FSE 2004 -88-

CLUTCH

Proper clutch lever play between the clutch lever and the clutch
lever holder is 2-3 mm.

When there is too much lever play, first try adjusting the clutch lever.

Loosen the knurled locknut, turn the adjuster to obtain the proper
amount of lever play, and tighten the locknut.

(A). Clutch Lever.
(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, cracked or rusted, replace
it with a new one. Replace the silencer packing. If the exhaust noise
becomes too loud or the engine performance drops.

Silencer Packing Change

1. Remove the right side.

2. Remove the silencer mounting bolts and pull the silencer off toward
the rear.

(A). Silencer.
(B). Mounting bolts.

(C)

(B) (A)

(A) (B)

EC FSE 2004 -89-

- Remove the inner pipe mounting rivots (A), and pull out the inner
pipe (B).

- Pull off the old silencer packing, and install the new silencer packing.

- Install the inner pipe into the silencer.

- Install the silencer and right side cover.

(A). Rivots
(B). Inner Pipe

DRIVE CHAIN

The drive chain must be checked, adjusted, and lubricated in
accordance with the Periodic Maintenance table. If the chain becomes
badly worn or maladjusted either too loose or too tight the chain
could jump off the sprockets or 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 Inspection

The space between the chain and the swing arm at the rear of the
chain slider should be 30-50 mm.Rotate the rear wheel to find the
place where the chain is tightest (because it wears unevenly). Adjust
the drive chain if it has too much or too little slack.

NOTE

In wet and muddy conditions, mud sticks to the chain and
sprockets resulting in an overly tight chain, and the chain may
break. To prevent this, adjust the chain to 30-50 mm. of space
between the chain and swing arm whenever necessary.

(A)

EC FSE 2004 -90-

In addition to checking the slack, rotate the rear wheel to inspect
the drive chain and sprockets for damaged rollers, loose pin and
links, unevenly or excessively worn teet, and damaged teeth.

Slack Adjustment

- Loosen the rear axle nut and both chain adjuster locknuts.

- Turn the nuts on the chain adjusting bolts evenly until the drive
chain has 30-50 mm. of space between the chain and the swing
arm. To keep the chain and wheel aligned, the notch on the left chain
adjuster should align with the same swing arm mark that the on the
right chain adjuster aligns with.

(A). Axle.
(B). Adjusting nut.
(C). Adjustment bolt.

(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.

- Tighten the axle nut to 98 N-m. (70ft-lbs).

- Tighten both chain adjuster locknuts.

- Rotate the wheel, measure the chain slack again at the tightest
position, and readjust if necessary.

WARNING

If the axle nut is not securely tightened an unsafe riding
condition may result.

Drive Chain, Chain Guide, Chain Slidder, and Sprockets Wear
Inspection.

When the chain has worn so much that it is more than 2% longer
than when new, it is no longer safe for use and should be replaced.
Whenever the chain is replaced, inspect both the engine and rear
sprockets, and replace them if necessary. Worn sprockets will cause
a new chain to wear quickly.

EC FSE 2004 -91-

NOTE

For maximum strech resistance and safety, a genuine part must
be used for replacement.
To minimize any chance of the master link coming apart, the
master link clip must be installed with the closed end of the
«U» points in the direction of chain rotation.

(A). Clip.
(B). Direction of Chain Rotation.

Chain Guide Wear

Visually 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 Wear

Visually inspect the sprocket teeth. If they are worn or damaged,
replace the sprockets.

Lubrication

Lubrication is necessary after riding through rain or in the mud, or
any time that the chain appears dry. A heavy oil is preferred to a
lighter ol because it will stay on the chain longer and provide better
lubrication.

(A)

(A) (B)

EC FSE 2004 -92-

Apply oil to the side of the rollers so that it will penetrate to the rollers
and bushings. Wipe off any excess oil.

HANDLEBAR

To suit various riding positions, the handlebar position can be adjusted
front to rear.

Handlebar Position Adjustment

Loosen the handlebar holder nuts (B), turn about 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 an even gap at the front and rear after tightening (A).

BRAKES

Disc and disc pad wear is automatically compensated for and has
no effect on the brake lever or pedal action. So there are no parts
that require adjustment on the brakes except brake lever play and
brake pedal position.

(A). Apply oil

(A)

(B)

(A)

(A). Rear Brake pedal
(B). 10 mm play
(C). Adjusting Bolt
(D). Locknut

WARNING

If the brake lever or pedal feels mushy when it is applied, there might
be air in the brake lines or the brake may be defective. Since it is
dangerous to operate the motorcycle under such conditions, have
the brake checked inmediately.

Disc Brake Fluid

In accordance with the Periodic Maintenance Chart, inspect the
brake fluid level in the reservoir and change the brake fluid. The
brake fluid should also be changed if it 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 adjuster (B) to either side. After
adjustment, tighten the locknut securely. Then check the brake for
good braking power and no brake drag.

(A). Brake Lever
(B). Adjuster

Rear Brake Pedal Position

When the brake pedal is in rest position, there should be a play of
10 mm. If not, adjust the pedal position.
The brake pedal has 10-20 mm of play when the pedal is pushed
down lightly by hand.

- To adjust the pedal play, loosen the locknut and turn the adjuster.

- After adjustment, tighten the locknut securely.

(A)

(B)

EC FSE 2004 -94-

Disc Brake Fluid

Use D.O.T.3 o D.O.T.4.

Fluid Level Inspection

The front (A) and rear (B) reservoirs must be kept more than half
full with brake fluid.If the amount of brake fluid is insufficient, add
brake fluid.

CAUTION
Do not spill brake fluid onto any painted surface. Do not use fluid
from a container that has been left open or that has been unsealed
for a long time. Check for fluid leakage around the fittings. Check
for 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 reservoirs.

Brake Wear Inspection

In accordance with the Periodic Maintenance Chart, inspect the
brakes for wear. For each front and rear disc brake caliper. If the
thickness of either pad is less than 1 mm, replace both pads in the
caliper as a set Pad replacement should be done by an authorized
GAS GAS dealer.

STEERING

The steering should always be kept adjusted so that the handlebar
will turn freely but have no excessive play.

(A)

(B)

To check the steering adjustment, using a stand under the frame,
raise the wheel off the ground. Push the handlebar lightly to either
side; if it continues moving under its own momentum, the steering
is not too light. Squatting in front of the motorcycle, grasp the lower
ends of the front fork at the axle, and push and pull the bottom end
of the front fork back and forth; if play is felt, the steering is too loose.

If the steering needs adjustment

- Using the stand under the frame, stabilize the motorcycle.

- Place a stand or block under the engine to raise the front wheel
off 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 stem nut wrench to obtain
the proper adjustment (C).

- Install the stem head (D).

EC FSE 2004 -95-

- Tighten the steering stem head nut, and front fork upper or lower
clamp bolts to the specified torque (A).

Stem Head Nut: 44 N-m (4.5 Kg-m)
Upper Fork Clamp Bolts: 22 N-m (2.25 Kg-m)

- Check the steering again, and readjust if necessary.

- Install the removed parts.

STEERING BLOCADE

This mecanism (A) allows us to blokade the steering. Is placed on
pipe steering.

You have to turn right the handlebar, pull in the key, turn left the key,
push, turn right and pull out the key.

(A). Steering blocade

(D)

(B)

(A)

(C)

(A)

- Using the stand under the frame, stabilize the motorcycle.

- Place a stand or block under the engine so that the front wheel is
raised off the ground.

- Remove the screws at the top of the front fork top bolts to let the
air pressure equalize. Then replace them.

Rebound Dampening Adjustment

- To adjust turn the knob located at the top of the fork.

- Adjust to rider preferance.

EC FSE 2004 -96-

CAUTION
Never forget the key in the lock. If you turn left the steering with the
key in, it will be damaged.

FRONT FORK

The front fork should always be adjusted for the rider´s weight and
track conditions by using one or more of the following methods.

- Air pressure: Air pressure acts as a progressive spring and affects
the entire range of fork travel. The air pressure in the fork increases
as the fork heats up, so the 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 adding any air.

- Rebound and compression dampening adjustment: This adjustment
affects how quickly the rebound. The fork rebound dampening
adjuster has 16 clicks. The seated position (fully clockwise until the
adjuster stops) is full hard. From the point 6 - 8 clicks counterclockwise
is the standar setting, and 16 clicks counterclockwise is full soft.

- Oil level adjustment: The effects of higher or lower fork oil level
are only felt during the final 100 mm of fork travel. A higher oil level
will make the fork rebound more slowly.

- Fork springs: Optional springs are available that are softer and
stiffer than standard.

Air Pressure

The standard air pressure in the front fork legs is atmospheric
pressure. The air pressure in the fork legs increases as operation
progresses.

(A). Screw air purge

(A)

(B)

(B). Adjuster knobs

CAUTION
The left and right fork tubes must bealigned (level) at the top clamps.
(see the illustration).

Compression Dampening Adjustment

- To adjust, turn the knob located at the top of the fork. Adjust to
rider preferance.

Oil level Adjustment

- Using the stand under the frame, stabilize the motorcycle.

- Place a stand or block under the engine so that the front wheel is
raised off the ground.

- Remove the front fender and front disc cover.

- Unbolt the brake hose holder 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 from the fork.

- Grasp the top casps and loosen the clck nuts on the caps.

- Remove the caps from the fork legs.

- Remove the fork springs.

- Put the oil level gauge on the top of the fork tube, and measure
the distance from the top of the fork tube to the oil level.

EC FSE 2004 -97-

Stand Oil Level

Marzocchi: 110 mm

WP: 120 mm

(A). Draining Oil
(B). Filling Oil

Adjust the oil level as required within the adjustable range using the
following oil:

MARZOCCHI SAE 7´5

WP. SAE 5

EC FSE 2004 -98-

(A). Push Rod

- Pull up the push rod (A) slowly.

- At this time, the fork oil comes out of the push rod hole, let it
overflow until it stops.

- Put the fork spring (1) into the fork tube.

- Pull down the fork spring and insert the spring holder (5) (special
tool) under the push rod nut or piston holder.

- Install the top cap bolt (3) on the top of the fork tube and tighten
it to 29 N-m. (21 ft.lbs).

- Repeat on other fork.

- Install removed parts.

(1). Spring
(2). Locknut
(3). Suspension cap
(4). Cap Wrench
(5). Lock nut wrench

Fork Springs

Different fork springs are available to achieve suitable 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 slower.

Fork Clamp Position Adjustment

Steering qualities are greatly affected by the fork clamp position (the
amount of the outer tube projecting above the steering stem head).
When the fork tube height is smaller, the front end becomes lighter
due to change in weight bias. Also, it tends to understeer in turns
at «whash out». When the height is greater, the results are opposite.Be
sure the front tire doesn´t rub the fender when the fork tubes compress
fully. Make this adjustment in 5mm increments.

CAUTION

The outer tubes, both right and left, should be adjusted evenly.

EC FSE 2004 -99-

(1). Fork tube height

REAR SUSPENSION

The rear suspension system of this motorcycle is single shock. It
consist of a rear shock absorber, swing arm, tie rods and rocker
arm.

In general the operating characteristics of the single shock are similar
to the front fork. But, in achieving progressive spring characteristics
a linkage system is used.

To suit various riding conditions, the spring preload of the shock
absorber can be adjusted or the spring can be replaced with an
optional 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 dampening
adjuster on the rear shock absorber lower end until you feel a click.

The total number of adjustments is: 60 ¨CLICKS¨.
The standard setting is: 25 ¨CLICKS¨.

(Counterclockwise from fully closed).

Shock compression dampening adjustment

To adjust schock compression dampening, turn the adjuster screw
on the gas reservoir until you feel a (click).

The total number of adjustments is: 60 ¨CLICKS¨.
The standard setting is: 30 ¨CLICKS¨.

(Counterclockwise from fully closed).

(A). Rebound dampening adjuster

(1)

Adjusting the spring

- Remove the seat, right and left side number plates.

- Loosen the air cleaner duct clamp screw.

- Remove the silencer.

- Remove the rear subframe with the air cleaner box.

EC FSE 2004 -

100

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(A). Rear Subframe
(B). Air Cleaner Box

(A). Compression dampening adjuster

Suspension spring

The standard spring is a 4.0.
The standard spring preload length is 258 mm

.

- 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 the standard spring, harder and softer springs are
available. If the standard spring is improper for your purpose, select
a proper one according to the rider´s weight or course conditions.
. Using the harder spring:The spring rate is higher.
. Using the softer spring:The spring rate is lower.

NOTE

Look at page 47.

(B)(A)

(A)

(C)

(B)

(A). Adjusting
(B). Spring
(C). Lock nut (ring)

(A)

EC FSE 2004 -

101

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WARINING

Improper removal of the spring from the rear shock absorber body
may cause the spring and associated parts to be ejected at high
velocity. Always wear eye and face protection. Removal and installation
of spring should be performed by an person or company.

WHEELS

Tires

- Tire pressure affects traction, handling, and tire life.

- Adjust the tire pressure to suit track conditions and rider preference,
but do not stray too far from the recommended pressure.

NOTE

Tire pressure should be checked when the tires are cold before
you ride.

Track condition

- When the track is wet, muddy, sandy or slippery, reduce the tire
pressure.

- When the track is pebbly 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 the rim to warp, hasten nipple and overall spoke fatigue,
and may result in spoke breakage.

(A). Llave tensador radios

Tire bead lock (clamp)

There is a lock (clamp) on the front and rear wheels. The bead lock
(clamp) prevents the tire and tube from slipping on the rim and
damaging the valve stem. Valve stem damage may cause the tube
to leak, necessitating tube replacement. In order that the tire and
tube remain fixed in position on the rim, inspect the bead lock (clamp)
before riding and tighten it if necessary. Tighten the valve stem nut
finger tight only.

NOTE

The weld joint area of the rim may show excessive runout.
Disregard this when measuring runout.

(A). Spoke Wrench

EC FSE 2004 -

102

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Cleaning

1- Preparation for washing

Before washing, precautions must be taken to keep water

off the following places:

Rear opening of: The silencer cover with a plastic bag secured
with rubber bands

Clutch and brake levers, hand grips, engine stop button: Cover
with plastic bags.

Air cleaner intake: Close up the opening with tape or
stuff in rags.

2- Where to be careful

Avoid spraying water with any great force near the following
places:

- Disc brake master cylinders and calipers.

- Under the fuel tank : 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 be wiped dry.

- Front and rear hubs.

- Steering pivots (Steering stem head pipe).

- Suspension linkage system pivots.

- Swing arm pivot.

3- After washing:

- Remove the plastic bags, and clean the air cleaner intake.

- Lubricate the points listed in the lubrication section.

- Start the engine and run for 5 minutes.

- Dry the brakes before operating the motorcycle.

WARNING

Never wax or lubricate the brake disc. Loss of braking and an accident
could result. Clean the disc with an oil-less solvent such as
trichloroethylene or acetone.

Bolt and Nut Tightening

Every day before riding, check without fail the tighteness of the bolts and nuts described here. Also, check to see whether or not each cotter pin
is in place and in good condition.

1- Front / rear rim
2- Front fork
3- Handlebar mounting bolt
4- Clutch lever support bolt
5- Subframe support bolt
6- Air cleaner bolt
7- Seat support bolt
8- Spokes
9- Disc plate screws

18-Rear 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-Connecting rod mounting bolt

10-Front axle clamp nut
11-Brake hose clamp nut
12-Brake hose mounting bolt
13-Radiator mounting nut
14-Engine mounting nuts
15-Shift pedal bolt
16-Chain guide bolts
17-Chain adjuster locknuts

1 1

2

3 4 6 789

10 11 1213 14 15 16 17

27-Rear brake pedal bolt
28-Rocker arm mounting bolt
29-Swingarm shaft nut

18

19 20 21 22 2324 25

26 28 27 29

EC FSE 2004 -

103

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EC FSE 2004 -

104

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Torque Table

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. A bolt or nut if insufficiently tightened may become damaged or
fall out, possibly resulting in damage to the motorcycle and injury to the rider.

E
N
G

I
N
E

C
H
A
S
S

I
S

PART NAME

Engine drain plug
Kick pedal bolt
Kick pedal nut
Shift pedal bolt
Spark plug
Water pump cover drain plug
Caliper mounting bolts
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 nut
Rear disc wheel drive nut
Spokes
Axle clamp nuts
Swingarm pivot bolt
Tornillo bieletas

N-m / FT.LBS.

20 / 15
20 / 15
25 / 18

10 / 7

11 / 7.7

9 / 6.6
25 / 18

10 / 7

36 / 26.5

51 / 38

6 / 4
29 / 21
98 / 72
98 / 72
9 / 6,6
26 / 19
39 / 28
29 / 21

1.5 / 1.1
4 / 3

81 / 60
81 / 60

Kg-m / IN.LBS.

2.0 / 177

2.0 / 177

2.5 / 221

1.0 / 88

1.0 / 88

0.9 / 80

2.5 / 221

1.1 / 96.8

3.6 / 318

5.1 / 451

0.6 / 53

3.0 / 256

10.0 / 866

10.0 / 866

0.9 / 80

2.7 / 230

4.0 / 345

3.0 / 256

0.15 / 13

4.5 / 35

8.3 / 716

8.3 / 716

(D)

(C)

LUBRICATION

Lubricate the points shown here, with either motor oil or regular
grease, in accordance with the Periodic Maintenance Chart or
whenever the vehicle has been operated under wet or rainy conditions,
and especially 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).

- Front brake lever (B).

- Rear brake pedal (C).

- Rear brake rod joints (D).

- Shift pedal (E).

EC FSE 2004 -

105

-

Use an aerosol cable lubricant with a pressure luber:

Apply grease to the
following point
throttle inner
cable upper ends.

(A)

(B)

(E)

Chain lubrication

Lubricate the chain after drive over wet places or when the chain
looks dry. It's better a high viscosity oil than a small viscosity oil
because it will stay a long time in chain.

(A). To grease

EC FSE 2004 -

106

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The recomended viscosity is SAE 10W-50, if a SAE 10W-50 oil is
not posible, use one of the last table.

Checking the oil level and replacing periodicity 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 engine has been stopped for a week.

ENGINE OIL

Ensuring a long engine life depends on using good oil and changing
it periodically. Checking the oil level and making the changes
periodically are two very important things to keep the engine in
perfect shape.

ENGINE OIL

20W-50

15W-40 15W-50

10W-40 10W-50

10W-30

TEMP.

ºC -30 -20 -10 0 10 20 30

ºF -22 -4 -14 32 50 68 86

(A)

(B)

(A)

(B)

(A)

EC FSE 2004 -

107

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6. Remove the dipstick and check the oil level. Oil level must be
between line (L) (LOW) and (F) (FULL). If that is not the case, fill up
the reservoir until the level reaches just the (F) line.

CAUTION
The level of the motor oil has to be between line «L» and line «F»,
engine damage may occur otherwise.

Check the oil level with the dipstick, with the bike in a completely
upright position, every time you are going to use the bike.

NOTE

Motor oil expands and descends when it is hot. Check and
adjust the level when the motor oil is not hot.

Cange of oil and filter

The oil should be changed when the engine is hot, since this helps
the oil 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 reservoir in this motorcycle is located in the top
front part of the frame. The oil level, when the bike is not in use,
decreases. The oil level drips down into the engine case. To check
the oil level, follow these instructions :

1. If the bike has been stopped for a week, we can be sure that all
the oil is within the engine case.

NOTE

When starting the engine, closely follow care and warnings
from the “start the engine” section.

2. Stop the engine and wait three minutes.

4. Wipe the dipstick clean with a rag.

5. Turn the cap of the dipstick (A). After removing the cap, remove
the dipstick next.

3. After removing
the cap, remove the
dipstick next. (A).

(A)

NOTE

recycle and dispose of used motor oil in an appropriate
container.

WARNING

The engine oil and the outpour tube can be very hot and cause
burns.
Wait until the oil and the outpour tube are a little colder, by touching
the oil drain with your hand.

WARNING

Using new or used oil may be hazardous. Permanent contact of oil
with the skin has caused skin cancer in many lab animals.
Avoid contact of motor 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 in contact with your skin.

To check the oil level follow these instructions:

1. Special spot for oil drain

EC FSE 2004 -

108

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(D)

(E)

2. drain the motor
oil in the frame by
removing the cap
(A).

(A)

3. Drain the oil from
the engine by
removing the cap
(B), keeping the
bike upright at all
times.

4. Remove the three
screws next to the
filter cover (C).

(B)

5. Turn and remove
the filter (D) and
replace it by
another new one.

(C)

EC FSE 2004 -

109

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WARNING

Using a filter with an incorrect design may cause engine malfunction.
Use the oil filter with the genuine GAS GAS design or equivalent for
your motorcycle.

WARNING

A mistake in the placement of the new element may cause engine
malfunction.
The motor oil will not flow if the new element is placed incorrectly.

8. Before replacing the oil filter, make sure that the spring (E)

and the o-ring (F) are in the correct position.

NOTE

Put a new «o-ring» at the same time the filter is replaced.

9. Replace the filter cover and put the screws that secure the cover,
but without tightening them too hard.

10. Replace the drain caps and screw them back 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 GAS GAS MOTOS are not followed.

Use the type of oil in the section of «recommended gasoline and oil
specifications».

11. Start the engine and let it idle for five minutes. Check that oil is
not leaking anywhere.

12. Check that the oil level is correct.

SUSPENSION TUNING

No area of machine adjustment is more critical than proper suspension
tuning. An improperly tuned suspension will keep even the best rider
from attaining the full benefit of his machine´s ability. Match the
suspension to the rider and the course conditions.

- If the machine is new, break-in the suspension with at least one
hour of riding before making any setting evaluations or changes.

(F)

(E)

- When the oil level is lowered:
The aire spring is less progressive, and the front fork does not
become as ¨hard¨ in the later stage of travel.

- Changing the fork oil level works effectively at the end of fork travel.
If fork bottoming is experienced, raise fork fork oil level in 10 mm
increments. This will change the secondary spring rate.

Oil level adjustment

Adjust the front fork oil level (see the Oil Level Adjustment of the
Front Fork section in the Maintenance and adjustment chapter).

EC FSE 2004 -

110

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- The three major factors which must be considered in suspension
tuning are RIDER WEIGHT, RIDER HABILITY, and TRACK
CONDITIONS. Additional influences include the RIDER´S STYLE
and POSITIONING on the machine.

- If you have a problem, test by changing your riding posture or
position so that the cause of the problem can be deduced.

- It is a wise practice to adjust suspension settings to suit the rider´s
strong points. If you are fast through the corners, 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 should be balanced; when one is
changed, the other might need to be changed similarly.

- When evaluating suspension performance the rider must make
every effort to ride consistently and recognize the effects of his input;
such things as changes in rider position and increasing fatigue may
lead to incorrect judgments about neceessary setting adjustments.

- When the proper settings have been determined for a particular
track, they should be written down for reference when returning to
that track.

Front Fork

The fork oil level in the fork tube is adjustable. A change in the fork
oil level will not affect the spring force much at the top of fork travel,
but it will have a great effect at the bottom:

- When the oil level is raised:
The air spring effect becomes more progressive, and the front fork
action feels ¨harder¨in the later stage of travel, near the bottom.

Later stage
of travel

Fork stroke

Increase level

Standard oil
level

Decrease level

Weight

EC FSE 2004 -

111

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Troubleshooting Improper Settings

Listed below are some symptoms of improper suspension settings
and the most likely means of correcting them.

The proper settings can be achieved by applying the information
in this chapter in a scientific, methodical manner; this does not mean,
however, that you must be a scientist or trained technician to succeed.
Simply take time a think about the changes you believe necessary,
check them against the symptoms and cures described here, make
the changes in small increments, and take notes on the changes
and their effects.

Simptoms of the Front Forks
Too hard

- The front forks are too stiff

. Rebound or compression damping adjustment incorrect.
. The springs are too strong.
. Too much oil.
. Too heavy oil.

- The front forks stiffens up the end of stroke

. The fork oil level 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 soft.
. Oil too light.
. Fork oil is worn out.

. Rebound or compression damping adjusting incorrect.

Symptoms of the rear shok:
Too hard

- The suspension is too stiff

. Compression damping is too high.
. Spring is too hard.

Too soft

- On landing after a big jump, bottoming occurs (normally O.K.).

. Spring preload is too soft or compression damping is too soft.
. Spring is too soft.
. Shock oil is worn.

Determining the Proper Settings:

- Standard Settings

From the factory, the machine is set up for an intermediate-weight
rider possessing intermediate riding ability. Hence, if the actual rider
weight is considerably more or less than this, or if his riding experience
and ability are much greater or lesser than the intermediate made
to put the suspension "in the ballpark".

- Readjustment of the suspension

Smooth Softer spring
Rough Harder spring

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Riding experience

Beginner Softer: spring with more rebound damping.
Experienced: Harder spring.

Rider's weight

Heavy: Harder spring.
Light: Softer spring.

Type of course

- Many corners:

Lower the front end slightly (increase the fork tube height 5mm).This
quickes steering and turning ability.

- Fast course with many jumps:

Raise the fornt end slightly (decrease the front tube height 5 mm).

- Deep whoops, or sandy ground:

Raise the front end slightly to gain stability.

fter making such preliminary adjustments, begin the actual on-track
testing and evaluation.

Remember:

1- Always make changes in small increments.
2-Make sure the rider is consistent in this evaluation of improper
suspension performance.
3- A change in the front suspension might require a change in the
rear, and vise versa.

Front and rear compability:

Use this procedure to determine if the suspension is balanced
reasonably well: Hold the bike upright (retract the side stand). While
standing next to the machine, lightly pull on the 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 bike and take a
riding posture. Next check to see that the bike is in a horitzontal
position. If one end drops noticeably more than the other, the front
and rear are not compatible and must be readjusted to achieve a
better balance.
This is one of the most effective adjustment procedures but suspension
settings will vary depending on the conditions at the track and the
rider´s preferences.

Front end seaching during down hill or during acceleration out
of corner:

Front fork is too soft.

1. Increase the compression damping or rebound damping.

2. Increase the oil level 10 mm.

3. Use alternate harder sping, or increase spring preload.

Front end ¨knifes¨or oversteers in turns: (front end tends to
turn inward):

Front fork is too soft.

1. Increase the compression damping or rebound damping.

2. Increase the oil level 10 mm.

Front end pushes or ¨washes out¨in turns:

1. Decrease the compression damping or rebound damping.

2. Release the air at the fork tubes.

3. Decrease oil level 10-20 mm.

4. Use softer spring.

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Front fork doesn´t respond to small bumps in sweeping turns:

- Front Fork is too hard:

1. Decrease the compression damping or rebound damping.

2. Decrease oil level 10 mm.

3. Use softer duty spring.

Rear end ¨kicks¨when braking over bumps:

The shock probably has too little rebound damping.

- Increase the rebound damping.

Rear tire won´t "hook up" out of corners:

(A lack of traction coming out of turns)

- The shock may be too stiff:

1. Decrease the rear shock spring preload.

2. Decrease the compression damping.

3. Use softer spring (In case of a lightweight rider).

Front and rear of the bike bottom off high speed jumps:
(If harsh bottoming occurs once or twice per lap of the race)
. Front and rear suspension system are too soft.

1. Delantera: Increase oil lever and/or use harder spring.

2. Rear: Increase spring preload and/or increase 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 spring preload until maximum preload is achieved.

- Bottom after successive 3 or 4 successive jumps.

- Decrease rebound damping.

NOTE

The rear shock on this machine may mislead some riders.

a) The rear shock bottoms when the spring and damping are
overcome by the total weight of the machine and rider (due to full
stroke).

b) A bottoming sensation (even through the machine is not bottoming)
may actually be the inability of rider and machine weight to overcome
an overly stiff spring or excessive damping.

Observe the rear end off jumps; if it doesn´t approach bottoming,
try lowering the sping preload and damping.

Gearing

Preconditions:

- Si la parte recta de la "crono" es larga, el desarrollo puede alargarse
por lo tanto la velocidad aumenta.

Course condition

Fast course
Many courves or hills
Sandy or soft groud

Rear sprocket

Small
Large

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- If the straight portion of a course is longer, the secondary reduction
ratio should be reduced so that the machine speed can be increased.

- When the course has many corners or uphills or is wet, the
secondary reduction rario should be increased so that gear shifting
is possible with smooth acceleration.

- Actually, the speed must be changed depending on the ground
condition on the day of race and therefore, be sure to run through
the racing circuit prior to a race and set the machine suitable for the
entire course.

- If the straight portion of a course on which the machine can be run
at maximum speed is longer, the machine should be set so that the
maximum machine speed can be developed toward the end of the
straight course, but care should be taken not to over-rev the engine.

- It is difficult to set the machine to be best suited for all portions of
the circuit. Therefore, determine which circuit portions will have the
greatest effect on lap time. Set the machine for these portions.
Confirm your settings by recording lap times 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 powdery
dust) special care must be given to keep the air cleaner element
clean.

2. When riding on wet heavy clay the mud adheres to the tires and
other parts of the vehicle. The mud can add significantly to the weight
of the vehicle and therefore reduce performance. Take care to
remove built-up mud from the tires and chassis after each ride,
before drying occurs.

3. The engine works hardest in muddy conditions and the radiator
can become clogged with mud. Take care not to overheat the engine
in these conditions. The engine also works very hard when ridden
in deep sand.

4. In muddy or sandy conditions adjust the chain looser than in other
conditions as the chain and sprockets will pack with mud/sand and
reduce chain slack.

5. Check chain and sprocket wear frequently when riding in mud or
sand since wear is increased in these conditions.

6. In dusty conditions as the air cleaner collects dust, the engine
runs richer. Therefore it may be advisable to run slightly leaner jetting
(main jet) in very dusty conditions.

SPARE PARTS

Look at part list.

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(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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GAS GAS SPEEDO INSTRUCTIONS

The top button is the reset button.
The bottom button is the mode button.

The initial display is the clock.(time) if you press mode (btm. button)
the display goes:

1. Speedometer.

2. Speed (Km or miles).

3. Total distance in kmh or miles (this has a memory even if battery
disconnected).

4. Trip distance.

00:00

Reset

Mode

Speedometer

0

Speed

00:00

STORAGE

When the motorcycle is to be stored for any lenght of time, it should
be prepared for storage as follows:

- Clean the entire vehicle thoroughly.

- Run the engine for about five minutes to warm the oil shut it off
and drain the transmission oil.

- Put in fresh trransmission oil.

- Empty the fuel from the fuel tank, and empty the carburetor float
bowl. (If left in for a long time, the 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.

- Lubricate the drive chain and all the cables.

- Spray oil on all unpainted metal surfaces to prevent rusting. Avoid
getting oil on rubber parts or in the brakes.

- Set the motorcycle on a box or stand so that both wheels are
raised off the ground. (If this cannot be done, put boards under the
front and rear wheels to keep dampness away from the tire rubber).

- Tie a plastic bag over the exhaust pipe to prevent moisture from
entering.

- Put a cover over the motorcycle to keep dust and dirt from collecting
on it.

To put the motorcycle back into use after storage.

- Remove plastic bag from exhaust.

- Make sure the spark plug is tight.

- Fill the fuel tank with fuel.

- Check all the points listed in the Daily Pre-ride Inspection Section.

- Perform the General lubrication procedure.

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To change the time:

- Press mode until time display is shown.

- Press mode again keeping the button pressed the hour will display
only add the hours by pressing the reset (top) button.

- Press mode again to adjust the minutes in the same way.

- Press mode again and the time is now set.

(when you have set the time the seconds automatically start from
zero )

Trip distance:

- From time display press mode 3 times. (l- 0) to zero the trip , keep
the reset button pressed until it zeros.

To change 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 --- for mp/h

- The white plastic block connector on the speedo is for the display
backlight.

- The red wire is positve.

- The black wire is negative.

- Warning; your speedo is set for the diameter of your front wheel

enduro 21"

supermoto 17"

If you get the display to read "a 00" then you are in the rolling radius
changing mode. you can "trim" the speed to run fast or slow.
It ranges from "a-25" to "a 25".

NOTE

Standard setting is "a 00", we recommend you keep it at that.

0.0

Trip distance

0000

Total distance

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TROUBLESHOOTING

NOTE

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the

troubleshooting for some of the more common difficulties.

TROUBLE

CAUSE

REMEDY

Starter engine doesn't crank

Engine doesn't crank

Engine cranks but doesn't start

- Blown fuse in the starter relay.

- Discharged battery.

- Low outside temperatur.

- Crankshaft seizure.

- Cylinder-piston, connecting rod big end
seizure.

- Transmission set seizure.

- Fuel supply interrupted.

- The motorcycle has been out of operation
for a longer period of time. Therefore old
fuel has accumulated in the float chamber.

- Scooty or wet spark plug.

- Flooded engine.

- The plug connection of the 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 battery and investigate the causes for
discharging; contact a dealer.

- Start engine with start pedal.

- Go to specialized garage.

- Go to specialized garage.

- Go to specialized garage.

- Check fuel pump relay, extract air filter cover, check fuel
pump isn't glogged.

- Is recomended to drain the old fuel from the float chamber.

- Clean and dry the spark plug or exchange it, respectively.

- In order to "pump the engine free", pull de starter pedal 5
or 10 times. Then, start the engine as described above. If
the engine fails to start, unscrew the spark pulug and dry it.

- Remove the seat and teh fuel tank. Clean teh plug
connection and treat it with contact spray.

- Clean tank cap air vent. Check by-pass throttle body. Check
the air filter.

1

2

3

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TROUBLE CAUSE REMEDY

Engine start but stops few
seconds ago.

Engine gets to hot

Engine flooded

Engine does not rev high, will
not reach full power

High oil consumption

Abnormal engine noise

Spark knock

- Incorrect air supply.

- There isn't fuel.

- Insufficient cooling liquid.

- Radiators very dirty.

- Injection system maladjustment.

- Incorrect valve gap.

- Fuel supply partically interrupted or
carburettor dirty.

- Dirty air filter.

- Hose of engine ventilation is bent.

- Valve gap to small.

- Loss of compression.

- Cylinder-piston diameter tolerance higest.

- Engine oil level higest.

- Oil quality and viscosity incorrect.

- Starter problem.

- Carbon buit up in combustion chamber.

- Over heating.

- Carbon in combustion chamber.

- Injection system maladjustment.

- Incorrect or poor gasoline.

- 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
injector mounting. Check the air filter.

- Clean radiators.

- Adjust injection system. Go to specialized garage.

- Adjust valve gap. Go to specialized garage.

- Clean and check fuel system as well as carburettor.

- Clean and change the air filter.

- Replace non-buckling ventilation hose.

- Adjust valve gap. Go to specialized garage.

- Check the good system work.

- Adjust tolerance changing piston ring.

- Check level oil engine.

- Empty oil engine, and fill up with a recomended viscosity
oil.

- Go to specialized garage.

- Adjust valve gap. Go to specialized garage.

- Look number 5.

- Clean combustion chamber.

- Go to specialized garage.

- Empty, and fill up with good gasoline.

- Check spark plug.

- Check if the exhaust system is damaged. Connecting rods
have to be perfect, if they aren't, change them.

4

5

6

7

8

9

10

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TROUBLE CAUSE REMEDY

Exhaust pipe get out white
smoke.

Exhaust pipe get out brown
smoke.

Clutch not disengaging properly

Jumps out of gear

Clutch slipping

Stability Unsatisfactory

Shock absorption too hard

- Cylinder head gasket leaking.

- Air filter is bloked.

- No clutch lever play maladjusted.

- Friction plate worn or warped.

- Steel plate worn or warped.

- Gear lever damaged.

- Clutch spring broken or weak.

- Clutch release mechanism trouble.

- Clutch hub or housing unevenly worn.

- Shift fork worn, gear worn.

- Gear dogs and/or dog holes worn.

- Shift drum groove worn.

- Gear positioning.

- Lever spring weak or broken.

- No clutch lever play, maladjusted.

- Friction plate worn or warped.

- Steel plate worn or warped.

- Clutch spring broken or weak.

- Clutch disc unevenly worn.

- 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 or change the air filter. Go to specialized garage.

- Go to specialized garage.

- Change friction plate.

- Go to specialized garage.

- Change gear lever.

- Check or change clutch spring.

- Check clutch release mechanism.

- Change clutch hub.

- Change it and go to specialized garage.

- Change it and go to specialized garage.

- Change it and go to specialized garage.

- Change it and go to specialized garage.

- Change it and go to specialized garage.

- Go to specialized garage.

- Change friction plate and go to specialized garage.

- Change steel plate.

- Check or change clutch spring.

- Change clutch disc. Go to specialized garage.

- Move control cable or unscrew.

- Unscrew wiring routing.

- Change steering stem locknut.

- Change and go to specialized garage.

- Empty and review level oil.

11

12

13

14

15

16

17

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17

18

19

20

21

- Front fork oil viscosity too hight.

- Front fork leg bent.

- Tire air pressure too high.

- Rear shock absorber maladjusted.

- Front fork oil insufficient and/ or leaking.

- Front fork oil viscosity too low.

- Front fork leg bent.

- Tire air pressure too small.

- Rear shock absorber maladjusted.

- Drive chain adjusted improperly.

- Chain worn.

- Rear and/or engine sprocket worn.

- Chain lubrication insufficient.

- Rear wheel misaligned.

- Oil front fork insufficient or too thin.

- Spring weak or broken.

- Disc brake worn.

- Pad installed incorrectly or surface glazed.

- Cylinder damaged.

- Bracket, nut, bolt, etc. not properly
mounted or tightened.

- Tire, swing arm sleeve or needle bearin
damaged.

- Rim warped.

- Wheel misaligned.

- Front/ rear axle runout excessive.

- Frame bent.

- Steering 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 and go to specialized garage.

- Change it. Go to a specialized garage.

- Check tire air pressure.

- Check rear shock absorber.

- Fill up until correct level.

- Empty oil from fork and fill up with suitable viscosity oil.

- Change front fork. Go to specialized garage.

- Check tire air pressure.

- Check rear shock absorber.

- Adjust chain.

- Change chain and rear engine sprocket.

- Change it.

- Lubricate with apropiate chain oil.

- Align rear wheel.

- Add oil until correct level.

- Change spring.

- Change disc brake.

- Replace pad or change.

- Change cylinder damaged.

- Go to specialized garage.

- Change it for new pieces.

- Centre rim.

- Check wheel rim pressure. Adjust if it is necessary.

- Check rear/ front axle steering. Adjust if it's necessary.

- Go to specialized garage.

- Adjust steering. Go to specialized garage.

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21

22

23

24

- Steering stem bent.

- Front fork bent.

- Wheel misalignment.

- Pad or disc worn.

- Brake fluid leak.

- Brake fluid deteriorated.

- Piston pump damaged.

- Brake maladjustment.

- El regulador de la tensión están
defectuosos.

- El fusible del relé de iluminación está
fundido.

TROUBLE CAUSE REMEDY

Motorcycle pull to one side

Brakes don't hold

Las lámparas se funden

El sistema de iluminación no
funciona

- Change steering stem and go to specialized garage.

- Change front fork.

- Align wheel.

- Change disc.

- Check and replace.

- Empty brake fluid and replace with new recomended one.

- Replace pump piston.

- Adjust brake.

- Dismount seat and fuel tank and chec connections, have
voltage regulator checked and fuse of box fuses.

- Dismount seat and fuse box cover and replace fuse.

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WARRANTY REGULATIONS

Manufacturer's warranty

The Company GAS GAS Motos S.A. hereby warrants to the final
purchaser of a vehicle manufactured by GG that both materials and
workmanship are free from defects according to the corresponding
state of the art. Accordingly, GG hereby warrants to the final purchaser
(hereinafter referred to as the «purchaser»), subject to the conditions
stated below, to remove any defects in material or production detected
in a new motorcycle free of charge within the agreed period of
warranty without any limitation whatsoever in terms of the number
of kilometres travelled or the number of operating hours.

Period of warranty

The period of warranty shall commence on the day of delivery of
the vehicle by a licensed GG dealer to the purchaser, or in the case
of demonstration models, on the date on which the vehicle is put
into operation for the first time.

The length of the warranty period depends on the type of vehicle
and is stated in the document of delivery.

Any defects detected in the product shall be brought to the attention
of a licensed GG dealer within the warranty period. If the last day
of the warranty period is a Sunday or public holiday, the warranty
period shall be extended in such a way that the last day of the
warranty period is the next working day following the respective
Sunday or public holiday. Warranty claims shall be excluded for any
defects not brought to the attention of a licensed GG dealer by the
end of the warranty period.

Obligation of the purchaser

GG shall be entitled to refuse to accept warranty claims if 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 inspections or
maintenance work, also excluding from the warranty defects that
appeared before the prescribed date of such inspection or
maintenance work performed not at all or performed only after the
prescribed date.
b) Inspection, maintenance work and repair work on the vehicle has
been performed by a party neither recognized nor licensed by GG;
c) Any maintenance or repair work has been performed on the
vehicle in violation of the technical requirements, specifications and
instructions indicated by the manufacturer.
d) Spare parts not released for use by GG have been used to perform
maintenance or repair work on the vehicle, or if and to the extent
that the vehicle has been operated using other fuels, lubricants or
operating fluids (including but not limited to cleaning agents) than
those expressly stated in the specifications in the operating manual;
e) The vehicle has been altered or modified in any way or equipped
with other components than those expressly released by GG as
admissible vehicle components.
f) The vehicle has been stored or transported in a way that does
not meet the corresponding technical requirements.
g) The vehicle has been used for competitions, races or attempts
at any record whatsoever.

Exclusion from warranty

The following items shall be excluded from warranty:

a) wear and tear parts including, without limitation, sparks plugs,
batteries, fuel filters, oil filter elements, driving chains, engine
sprockets, rear sprockets, air filters, brake discs, brake pads, clutch
discs, lamps, fuses, carbon brushes, footrest rubbers, tires, tubes,
cables and other rubber components.

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b) Lubricants (e.g. oil, grease, etc.) and operating fluids (e.g. battery
fluid, cooling liquid, etc.).
c) Inspection, adjusting and other periodical maintenance work as
well as all kinds of cleaning work.
d) Damage to paint work and corrosion thereof due to external
influences such as stones, salt, industrial exhaust gases and other
environmental impacts or inadequate cleaning with inadequate
products.
e) Any consequential harms caused by defects as well as incidental
expenses directly or indirectly related to defects (e.g.
telecommunication charges, cost of board and lodging, cost of rental
cars, public transport charges, cost of salvage and towing, overnight
expenses, etc.) as well as other financial disadvantages (e.g. caused
by loss of use of a motor vehicle, loss of earnings, loss of time, etc.).
f) Any aesthetic or acoustic phenomena that does not significantly
affect the serviceable condition of the motorcycle (e.g. hidden or
minor blemishes, normal operating noise or vibrations).
g) Phenomena due to the aging of the vehicle (e.g. fading of painted
or metal-coated surfaces).

Miscellaneous

1.- GG shall be entitled to decide in its sole discretion whether to

repair or to replace defective parts. The ownership of parts replaced,
if any, shall pass to GG, free of any consideration whatsoever. The
licensed GG dealer entrusted wit the removal of defects shall not
be authorized to issue binding declarations on behalf of.

2.- In cases of doubt regarding 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 examination of the defect by a GG expert.
Any additional warranty obligations for parts replaced free of charge
or for any service performed free of charge under the present
warranty shall be excluded. The warranty components replaced
within the warranty period shall end at the date of expiry of the
warranty period agreed for the respective product.

3.- If it turns out that any defect cannot be removed, the warranty
shall be entitled to demand termination of the contract (payment of
a compensation) or partial reimbursement for the purchasing price
(discount) instead of repair of the motorcycle.
The warranty shall in no case be entitled to receive a new motorcycle
as a substitute for the defective product.

4.- The warranty claims of the purchaser under the contract of
purchase and sale concluded with the respective licensed dealer
shall not be affected by the present warranty. Neither shall the present
warranty affect any additional contractual rights of the purchaser
under de General Business Conditions of the licensed dealer.
However, such additional rights can only be claimed against the
licensed dealer.

5.- If the purchaser resells the product within the warranty period,
the terms and conditions of the present warranty shall continue to
exist in their present scope, the right to put forward claims under the
present warranty according to the terms and conditions hereof will
be passed on to the new owner of the motorcycle.

July 2003

Compuesta

PU010438001

C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel : [phone] Fax: [phone]

E-mail: [e-mail] / [e-mail] · Web: www.gasgasmotos.es

JULIO / JULY 2003