Gas gas FSE 450, FSE400 SERVICE MANUAL

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SERVICE MANUAL

MOTOR FSE400 / 450

2002 / 2003

Contents

Technical Specifications.....................................................84

Engine Removal and Installation.......................................86

Engine Disassembly..................................................…....96

Inspection and Maintenance

of Engine Components......................................................108

Engine Installation................................................................136

Regular Maintenance............................................................156

Technical Specifications

MODEL

Ec 400 / 450 FSE

ENGINE

Cubic Capacity

Type

Number of Cylinders

Cooling System

Bore and Stroke

Injection

Ignition

Clutch

Gearbox

399 cc. / 449 cc.

4-stroke with 4-valve cylinder head

One

Water-cooled

90 x 62.6 mm. / 95 x 62.6 mm.

E.F.I. Magneti Marelli Electronic Fuel Injection System

E.F.I. integrated

Hydraulic-drive disc clutch

6 Gears

FRAME

Type of Frame

Front Suspension

Rear Suspension

Front Brake

Rear Brake

Wheels

Deltabox, made from Cromoly rectangular tubes Aluminium Rocker

Inverted WP

Inverted Marzocchi

Inverted Öhlins

Progressive System fitted with Ohlins Shock-Absorber 320-mm Stroke

260-mm Disc Nissin Pump and Nissin single plunger clip

220-mm Disc Nissin Pump and Nissin single plunger clip

Type U D.I.D. Rims fitted with Michelin Comp3 Tyres

DIMENSIONS

43-mm Diameter 295-mm Stroke

45-mm Diameter 295-mm Stroke

46-mm Diameter 295-mm Stroke

Wheelbase

1475 mm

Seat Height

940 mm

Minimum Ground Distance

340 mm

Fuel Tank Capacity

9.5 Litres

Technical Specifications

Engine Removal and Installation

Engine Removal

Before removing the engine from the frame, wash it with a steam machine. The following steps cover the disassembly sequence.

Remove the saddle and the frame covers.

Drain the oil in the engine. .

Remove the engine plate.

Drain the frame oil reservoir (A). Drain the engine coolant (B).

Detach the cable (-) from the battery (1) and the ground coupler from the engine (2).

Engine Removal and Installation

Detach the wire clamp from the alternator (A) and the sensor cable from the tonewheel.

3 2

Detach the spark-plug arm (1), the engine-oil

devaporizing tube (2), the engine-oil reservoir breather pipe (3).

Loosen the clamp holding the cylinder head injector conduit (4).

Detach the wire clamp from the water-temperature sensor (5). Detach the connecting cable from the starter (6) and remove the starter.

Engine Removal and Installation

Remove the water tubes (1).

Remove the lever from the pedal-operated starter.

Remove the exhaust manifold (2).

Detach the radiator tubes.

Engine Removal and Installation

Detach the engine-oil tube (1) in the frame reservoir.

Remove the gearbox lever.

Remove the engine-pinion cover.

Remove the clutch pump. Loosen the chain.

Remove the outlet pinion Seeger (1).

Engine Removal and Installation

Remove the engine pinion.

Remove the split pin and the brake pedal.

CAUTION! Replace the split pins with new ones.

Remove the engine from the frame.

Engine Removal and Installation

Engine Installation

Reverse the above operations to install the engine

Fit the screws and nuts securing the engine.

NOTE: At this stage, nuts must only be tightened provisionally. The nuts securing the engine are self-locking. Upon removal, they cease to be self-locking and become useless.

CAUTION! Replace the nuts securing the engine with new ones.

Secure the screwheads with a spanner and tighten the nuts securing the engine at the specified torque.

Item Nm Kgf-m A 66 6,6 B 66 6,6 C 14 1,4 D 66 6,6

! !

Screw length

(A): 108 mm. (B): 110 mm. (D): 103 mm.

Tighten the brake-pedal screw at the specified torque.

Brake-pedal screw: 29 Nm (2,9 Kgf-m)

Engine Installation

Attach the engine pinion.

NOTE: The previous CW/ACW direction of this pinion must be duly noted, so that the same wear CW/ACW direction may be preserved.

Attach the engine pinion Seeger.

Attach the tube to the frame reservoir.

Tighten the exhaust manifold screw (1) at the specified torque.

Apply NURAL 29 component to the exhaustsystem joints.

Engine Installation

3 min.

Apply LOCTITE 243 to the screw on the pedaloperated starter lever, then tighten.

For 1.9 litre of API-compliant SF- or SG-grade motor oil and SAE 10W-40-viscosity oil into the oil inlet located in the frame (1) and check the level.

DETAILS Engine oil capacity Oil replacement: 1.7 l Oil and filter replacement: 1.9 l Overall engine check: 1.9 l

Start the engine and leave it ticking over for about 3 minutes. Stop the engine, wait for 3 minutes, then check the oil level with the dipstick.

Maximum level

Engine Installation

Minimum level

Engine Disassembly

Detach the alternator cover.

Turn the alternator rotor until the 7th tonewheel tooth becomes aligned with the position-sensor hole centre.

NOTE: The cylinder-head lid must be removed with the piston in the compression stroke PMS.

Remove the cap bolt (1) and the timing-chain idler (2).

Remove the spark plug (5). Then, remove the cylinder-head lid screws in a

diagonal sequence and detach the cylinder-head cover.

Remove the chain guide (6) and the brackets of the camshaft journals (7).

Engine Disassembly

2 3

Remove the centering devices (1), the input camshaft (2) and the output camshaft (3).

NOTE: Prevent the centering devices from falling into the crankcase.

Remove the cylinder-head side screw.

Remove all four cylinder-head screws in a diagonal sequence.

NOTE:

Prior to loosening the cylinder-head screws, loosen the cylinder-head screws (6 mm) and the cylinder-base screws.

Remove the cylinder-head screws and then the cylinder head.

NOTE:

In case of difficulty removing the cylinderhead, tap it with a plastic mallet.

Engine Disassembly

Remove the cylinder-head gasket (1) and the centering devices (2).

Remove the timing-chain guide (3).

Remove the cylinder-base screws (4) and then the cylinder.

NOTE:

In case of difficulty removing the cylinder, tap it with a plastic mallet.

Remove the cylinder gasket (5) and the centering devices (6).

Cover the cylinder base with a clean cloth to prevent the piston-bolt spring ring from falling into the crankcase.

Remove the piston-bolt spring ring. (7)

Remove the piston-bolt and the piston.

100

Engine Disassembly

Detach the oil-filter lid (1) and the oil filter (2).

Remove the starter followers (3), the centering devices (4) and the gasket (5).

Remove the pressure-pump lid (1) and the rotor (2).

101

Engine Disassembly

Remove the coolant-pump cover.

Remove the clutch lid.

Remove the centering devices (3) and the gasket (4).

Loosen the clutch-spring screws in a diagonal sequence (as illustrated) and remove them when they become totally loose.

Detach the clutch press and the disc assembly.

Remove the clutch rod. Flatten the clutch-hub washer.

102

Engine Disassembly

Holding the clutch hub with the special tool supplied, remove the clutch-hub nut.

Tool Part No.: Clutch-hub fastener

Remove the clutch hub and the washer.

CAUTION! The clutch hub has a specific fitting position in respect of the input shaft. Mark the position with an indelible marker on the lubrication groove. This mark must be taken into account during the installation process.

Remove the clutch-drum assembly.

Detach the timing-chain guide idler (1).

103

Engine Disassembly

3 4

Remove the Seeger ring (3) and the pedal-operated starter intermediate gear (4).

Detach the foot-operated starter assembly.

Detach the pedal-operated starting pawl plate (6).

Detach the pedal-operated starter intermediate pinion shaft.

Detach the oil-pump intermediate gear (1) and the oil-pump follower (2).

104

Engine Disassembly

Remove the oil-pump assembly.

Remove the selector-shaft assembly.

Detach the gear-centering device plate (3)

Remove the crankshaft pinion bolt, the washer, the gear, the timing chain and the timing-chain gear.

CAUTION! The crankshaft pinion bolt has a left-hand thread.

Remove the alternator-rotor bolt and washer. Holding the puller with a spanner, loosen the rotor.

Tool Part No.: MFS400134045, FSE400 flywheel puller

105

Engine Disassembly

Use the special tool supplied to detach the alternator rotor.

CAUTION! Tapping the alternator rotor with a hammer might damage it.

Remove the lower oil-reservoir lid.

Remove the crankcase left-hand set screws.

Detach the crankcase using the special tool supplied.

Tool Part No.: ME2595000: crankcase-detachment tool

NOTE: Fit the crankcase-detachment tool on the lefthand side, so that its plate becomes parallel with the surface of the crankcase end.

Remove the centering devices.

106

Engine Disassembly

! !

Remove the shafts of the shifter forks (1) and the

forks (2).

Detach the gearbox input-shaft assembly (3) and the gearbox output-shaft assembly (4).

Detach the crankshaft (5) and the rocker shaft (6).

NOTE: Should this detachment operation prove difficult, tap both shafts with a plastic mallet in an alternating pattern.

Remove the oil-intake filter and clean it.

107

Engine Disassembly

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