GAS GAS FSE 450 SM - 2006, 2006 FSE 450, 2006 FSE SM 450 User Manual

MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
BETRIEBSANLEITUNG

ENGLISH

USER MANUAL

USER MANUAL

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Foreword

GAS GAS thanks you for your confidence.

By choosing the new GAS GAS FSE / FSE SM 2006 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 FSE / FSE SM 2006 is a bike conceived for highly competitive performance. In fact this bike is the fruit
of many years of competition and experimentation in these demanding disciplines; many great trial riders have
contributed their expertise and achievements to the essential data we have used to create these high-quality,
exclusive motorcycles incorporating key features such as reliability, high performance and stability.

Congratulations for making, without a doubt, the right choice. With skill at the controls of this motorbike, an
adequate preparation and the corresponding essential servicing this GAS GAS will remain highly reliable and
you will be able to enjoy the most comfortable and rewarding motor sport.

Thank you for your confidence and welcome to GAS GAS motos SA.

-4-

OIL RECOMMENDED:

IMPORTANT NOTICE

Read this manual carefully. This manual covers aspects that will
contribute to your security and to that of others, as well as guaranteeing
a correct conservation and maintenance of this GAS GAS motorcycle
you have just acquired.

All of the instructions to correctly handle and drive this motorcycle
are described in detail. Each message will be preceded by a symbol.

WARNING

This warning symbol identifies special instructions or procedures
that, if not correctly followed, could result in personal injury, or even
death.

CAUTION

This caution symbol identifies special instructions or procedures
that, if not strictly observed, could result in damage to or destruction
of equipment.

NOTE

This symbol indicates points of particular interest for more
efficient and convenient operation.

Inadequate driving skill could cause problems to the environment
and conflict with other people. Responsible use of your 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, WITH CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER
PEOPLE.

Motorcycle riding is a fantastic sport, and we hope you will enjoy it
to the fullest.

-5-

TABLE OF CONTENTS

Foreword.........................................................................................3

Important notice..............................................................................4

Table of contents ............................................................................5

General information ........................................................................6

Component locations......................................................................8

Side stand.....................................................................................10

Petrol ............................................................................................10

Serial number and the qualification approval plate.......................11

Starting and stopping the engine..................................................12

Cold starting..................................................................................13

Gear changes ...............................................................................13

Stopping the motorcycle ...............................................................14

Break-in ........................................................................................14

Maintenance chart ........................................................................15

Battery ..........................................................................................16

Cooling system .............................................................................17

Spark plug.....................................................................................20

Air filter..........................................................................................23

Accelerator cable..........................................................................24

Clutch............................................................................................25

Exhaust system ............................................................................25

Chain guide...................................................................................26

Tension adjustment ......................................................................27

Handle bars ..................................................................................29

Brakes...........................................................................................29

Steering ........................................................................................31

Steering lock.................................................................................32

Front forks.....................................................................................33

Rear suspension...........................................................................36

Wheels..........................................................................................38

Cleaning........................................................................................39

Tighten bolts and nuts ..................................................................40

Tightening torque table.................................................................41

Lubrication ....................................................................................42

Engine oil......................................................................................43

Suspension adjustment ................................................................46

In competition ...............................................................................50

Storage .........................................................................................51

Multi-function instructions ............................................................52

Fault diagnosis..............................................................................58

Guarantee manual........................................................................64

GENERAL INFORMATION

ENGINE

Engine 4 stroke, single-cylinder DOHC 4 valves, liquid cooled
Displacement in cubic centimetres 449 cc
Bore and stroke 97 x 60.76 mm
Spark plug NGK CR8E or DENSO U24ESR-N
Fuel supply Magneti Marelli electronic injection

TRANSMISSION

Transmission type 6 speed
Clutch type Oil bath, multi-disk hydraulic action
Secondary transmission By chain
Gear ratio 1st 2.071(29/14)

2nd 1.625(26/16)
3rd 1.333(24/18)
4th 1.100(22/20)
5th 0.913(21/23)

6th 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 1200 cc

Type 5W40 API SF or SG

CHASSIS

Type DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes.

Aluminium rocker
Tyre sizes Front FSE - 90/90 x 21

FSE SM - 120/60 ZR17

Rear FSE - 140/80 x 18

FSE SM - 150/60 ZR17

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Suspension Front Öhlins ø 48mm inverted fork

Marzocchi ø 45mm inverted fork

Rear Progressive system with single multi-adjustment ÖHLINS shock absorber

Suspension stroke Front 295 mm

Rear 320 mm

Front suspension oil MARZOCCHI SAE 7.5

ÖHLINS SAE 5 - 7.5
Front fork oil level Marzocchi: 100 mm (compressed, without spring)

ÖHLINS: 110 mm (compressed, without spring)

BRAKES

Type Front / rear Disk brakes, NISSIN pump and simple / double callipers
Effective disk diameter Front 260 mm

Rear 220 mm

DIMENSIONS

Overall height 1260 mm
Overall length 2135 mm
Overall width 810 mm
Wheel base 1475 mm
Minimum ground clearance 340 mm
Fuel tank capacity 9.5 litres
Weight 119 Kg

(Specifications subject to change without notification, also possibly not applicable in some countries).

LOCATION OF COMPONENTS

GAS GAS FSE 450

GAS GAS FSE SM 450

-8-

1- Clutch handle
2- Engine start button
3- Fuel tank cap
4- Front brake fluid tank
5- Front brake handle

6- Throttle control

1- Clutch handle
2- Engine start button
3- Fuel tank cap
4- Front brake fluid tank
5- Front brake handle

6- Throttle control

1 3 4 2 65

1 3 4 2 65

-9-

7- Front suspension
8- Radiator
9- Fuel tank
10- Air filter
11- Seat
12- Front brake disk
13- Front brake callipers
14- Rear brake fluid tank
15- Shift pedal

16- Rear shock absorber
17- Chain guide
18- Chain
19- Silencer
20- Rear shock absorber gas tank
21- Tie rod and rocker suspension
22- Rear brake pedal
23- Engine oil cap
24- Exhaust bend

7

8

9

10

1112

13

16

15 17

18

14

19

2021 22

23

24

PETROL

The GAS GAS FSE / SM FSE 450 has a four stroke engine and
requires 98 octane, unleaded petrol.

Fuel Tank Capacity

7.2L

(A). Fuel cap.
(B). Fuel vent hose.

To open the fuel cap (A), release the fuel vent hose (B) from the
handle bar and rotate the fuel cap in an anti-clockwise direction.

To close the fuel cap, rotate it in a clockwise direction.

SIDE STAND

To unfold the side stand (A) the securing strap must be released
(B) then the stand is opened to vertical position.

The stand returns to its original position with the aid of the spring

(B).

(A). Side stand.
(B). Spring.

NOTE

Do not start the engine or ride the motorcycle when the side
stand is down. Always engage the security strap before driving
the motorcycle.

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(B)

(A)

(B)

(A)

SERIAL NUMBER

Printed on the steering tube. Indicates the frame number with which
the motorcycle is registered.

Qualification approval plate

The motorcycle is fitted with its own corresponding qualification
approval plate with the serial number, also printed on the steering
tube and whose data also coincides with that in the documents.

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RECOMMENDED FUEL

Use lead-free petrol with an octane rating equal to or higher than
that shown in the table.

OCTANE RATING METHOD OCTANE

RATING (MIN)

Antiknock Index (RON+MON)/2 90

Research Octane No. (RON) 98

NOTE

If knocking 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.

Stopping the engine

- Change gear to neutral.

- After a slight acceleration, release the throttle completely and rotate
the ignition key anti-clockwise.

- The key should point left (D), this means that all of the electric
circuits are inactive. The engine cannot start.

- The key may be extracted from the ignition.

NOTE

Starting the engine while the key is being turned to the ON
position may cause a loss in battery power.

-12-

STARTING THE ENGINE

- Ensure that the motorcycle is in neutral.

- Rotate the starter key clockwise (ON (A) position), in this way the
electric circuits are active and the engine can start.

- Without using the throttle, press the electric start button (B).

(B)

(D)

(A)

SHIFTING GEARS

The transmission is a 6 speed, return shift type meaning 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 then release the pressure on the shift pedal
and gently release the clutch lever.

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.

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COLD STARTING

The cold start function is responsible for aiding the engine start if
this is cold. (The injection system has a feature which allows high

idling when the engine is cold.)

- There is no need to use the throttle, simply start the engine. Note
that the engine will start after a certain number of revolutions.

After some minutes, the engine will be at normal operation
temperature. The engine will reach its optimal temperature, in low
time and without causing damage.

NOTE

- If the engine is flooded then start with the throttle fully open.

- The motorcycle may be started in gear if the clutch is
disengaged.

(B)

STOPPING THE MOTORCYCLE

For maximum deceleration, close the throttle (A) 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 clearances in the engine and
transmission that are necessary for smooth engine performance and
reliability, an initial break-in must be completed. For the first hour
or 100 Km of operation, run the engine at low rpm.

-14-

NOTE

The slow speed necessary during the break-in period may cause
carbon to build up on the spark plug and soil it. If inspection
of the spark plug shows this to be the case, replace the standard
spark plug with a higher heat grade spark plug for the duration
of the break-in period.

Break-in following these steps:

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 FULLY.

4. Stop and let the engine cool completely. Check and adjust chain
slack and spoke tightness and make a general inspection.

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

6. Stop and let the engine cool completely. Check and adjust (4).

7. Fit the inspected parts.

8. Fill the radiator up completely with cooling liquid. Before
starting the engine bleed the air from the cooling system.

9. Start the engine and ride for 30 minutes at moderate speed.

10. Stop and let the engine cool completely. Check and adjust (4).

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

CAUTION
In any case, even an imprudent acceleration can cause engine
trouble, take special care and use the proper skills and techniques
required for correct driving of the motorcycle.

NOTE

Following the break-in, fit a new standard spark plug.

(A)

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Article

Air filter
*Exhaust connectors and bolts

*Valve tolerances
Spark plug
Injection pump pipes

Engine oil and filter oil
*Engine oil pipes
Coolant

Radiator hoses
Clutch
Chain
*Brakes
Brake lines

Brake liquid

Tyres
*Steering assembly

*Front forks
*Rear suspension
*Chassis bolts and nuts

Period

First 5 hours

T

I

­I

R

I

-

I
I

I
I

I

I
I
I

T

Inspect each time that the motorcycle has run or when necessary

*Revise every 4 years

Revise every 2 years

Clean, lubricate and inspect each time the motorcycle has run

*Revise every 4 years

*Revise every 2 years

Inspect tyres for damage and check the tyre pressure every time the motorcycle has run

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, replace or lubricate if necessary; R = Replace, T = Tighten, C = Clean

BATTERY

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

To remove the battery, follow these steps:

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

2. Release the rubber (C).

-16-

3. Disconnect the terminals ensuring that they do not
enter into contact with metal parts then extract the
battery.

WARNING

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

The operating instructions for the battery are as follows:

1. Check the battery tension in open circuit status (disconnected).

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 3.

If the battery voltage is above 12.60 V, the battery can be
installed on the vehicle without having to recharge it.

3.1. Constant voltage charge mode.

- Constant voltage = 14.40 - 14.70V

- Initial charge current = 0.1 – 0.5 Cn

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

3.2. Constant power charge mode.

- Maximum charge current = 0.1 Cn

(A)

(C)

(B)

-17-

- Recommended charging duration = 5 - 8 hours.

- The product (charge current) X (charge duration) must be within
the range: 0.5 - 0.8 Cn.

Note

In case that a different mode of charging is used to those
established here, never exceed the maximum allowed currents
nor the maximum charge duration of 24 hours.

CAUTION
Not using the standard manner of charging may seriously shorten
the battery life.
Never exceed the standard charge.

CAUTION
Inverting the polarity of the battery terminals may cause battery
charge problems and cause damage to the battery system.
The red terminal is positive (+) and the black terminal is negative
(-).

THE COOLING SYSTEM

Radiator hose

Check the radiator hoses for cracks or deterioration, and connections
for leaks.

Radiator

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

CAUTION
Using a high pressure water source could damage the radiator fins
and render it ineffective.
Do not obstruct or deviate the radiator air intake by installing non­approved accessories. Interfering with the radiator could cause
overheating and result in engine damage.

Coolant

This 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 for it to cool down.

Anti-freeze liquid information

To protect the cooling system aluminium parts (engine and radiator)
from rust and corrosion, the use of 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
radiator will rust. This will block the cooling hoses.

-18-

(A)

CAUTION
Use of incorrect coolant solutions will cause severe engine and
cooling system damage.
Use coolant containing corrosion inhibitors made specifically for
aluminium 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 in the cooling system.
If normal water is used in the system, it the cooling system tubes
may become blocked.

If the lowest ambient temperature encountered falls below the freezing
point of water, protect the cooling system against freezing.
Use a permanent type of anti-freeze (soft water and ethylene glycol
plus corrosion 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 stages. First turn the cap anti-clock
wise and wait for a few seconds. Then push and turn it further in the
same direction to remove the cap.

(A). Radiator Cap.

CAUTION

Permanent types of antifreeze on the market have anticorrosion and
anti-rust properties. When diluted excessively these lose their
antifreeze and anticorrosion properties. These must be diluted in
accordance with the instructions of manufacturer.

Changing the coolant

- 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). Coolant drain Plug.

WARNING

If coolant gets on the tyres this will make them slippery and could
result in an accident.

-19-

NOTE

Check the level when the engine is cold.

(1). Coolant level.
(2). Filler opening.

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

Recommended liquid

Permanent type of antifreeze (distilled water and ethylene glycol)
with corrosion and rust inhibitor chemicals for aluminium engines
and radiators).

NOTE

Initially a permanent type of antifreeze is installed in the cooling
system by the manufacturer. This is green in colour, containing
50 % ethylene glycol with a freezing point of –35°C.

Total quantity

Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).

(A)

(B)

-Inspection of the coolant. If white cotton-like patches appear in the
liquid then this means that the aluminium elements of the cooling
system are corroded. If the liquid is brown then this means that the
steal or iron parts of the system are oxidized. In either case clean
out the 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 torque shown in the table. Always replace seals with
new ones.

Bolt torques:
Water pump plug: 9 Nm.

- Fill the radiator up to the edge and install the radiator cap.

- Check the cooling system for leaks.

- Start the engine, warm up the engine, and then stop it.

- 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 shown in the table and is tightened to
11 Nm.

Standard spark plug

NGK CR8 E or DENSO U24ESR-N 0.7-0.8 mm.

The spark plug should be taken out periodically to check the electrode
gap. If the plug is oily or has carbon build up on it the clean it with
a sand blaster. Following abrasive particle cleaning, the spark plug
should be cleaned with a wire brush or similar. Measure the distance

-20-

between electrodes using a gauge and adjust in case that it is not
correct by bending the outer electrode. If the spark plug electrodes
are oxidised, damaged or the insulation is broken then replace the
plug.

NOTE

Inspect every 30 hours. Replace every 60 hours.

To find the correct heat grade spark plug is being used, take it out
and examine the insulation around the electrode. If the ceramic is
light brown, the spark plug is correctly matched to engine temperature.
If the ceramic is white, the plug should be replaced with the next
coldest plug. If the ceramic is black, the plug should be replaced
with the next hottest 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 spark plug

is wet then replace it.

Standard
If the standard spark plug
looks glassy or has a white

colour, replace it(

-21-

1. Remove the bolts (A)
(left and right).

2. Remove the seat (B).

3. Remove the bolts (C)
(left and right).

(A)

(C)

(B)

CUIDADO
Un incorrecto montaje de la bujía o grado térmico incorrecto puede
provocar grandes daños en el motor, y estos daños no son cubiertos
por la garantía.

Usar siempre las bujías recomendadas por la marca. Consultar a
los concesionarios o a un mecánico cualificado para saber qué bujía
es la mejor para su motocicleta.

Extracción de la bujía

Para extraer la bujía, seguir los siguientes pasos:

(C)

4. Remove the

rubber attachment

on the tank (D).

(D)

5. Remove the tank
securing bolt (E).

(E)

-22-

NOTE

A cap protects the spark plug.
Keep this clean and dry.

6. Separate the
connectors from the
electronics (F).

8. Remove the spark
plug hood.

9. Take out the spark plug
and clean 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 colour; this
colour tells us whether the
standard plug is the best for
our use.

WARNING

When the injection pump pipes are removed, petrol may be spilled
and cause a fire.

Stop the engine before removing the tank. Keep naked flames and
sparks away from the tank cap. Do not smoke.

7. Separate the
connector (G) from
the fuel pump and
secure to one side of
the tank.

(F)

(G)

-Remove the cap (A).

-Remove the screw (B)
and take the filter out (C).

AIR FILTER

An obstructed air filter restricts the air intake of the engine, increasing
the petrol consumption and reducing the engine power as well as
the destruction of the spark plug.

WARNING

An obstructed air filter may allow dirt to enter into the injector blocking
it open; this could lead to an accident.

CAUTION
An obstructed air filter will allow dirt to enter the engine causing
excess wear and engine damage.

Inspect this without fault, before and after each race or session.
Clean if necessary.

Cleaning the air filter

WARNING

Clean the filter in a well-ventilated zone and ensure that there are
no sources of naked flame or sparks near the work area (including
the focus of a powerful light). Do not use petrol to clean the filter as
this could result in an explosion.

-23-

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

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

Remove the cage (B)
from the air filter (A).

(A)

(B)

(C)

- Clean inside the filter housing using a damp cloth.

- Check the air filter for damage such as scraping, hardening, shrinkage
If it is damaged then replace otherwise dirt will enter the throttle body.

- Grease all of the connections and bolts of the air filter and inlets.

-24-

THROTTLE CABLE

- Check that the throttle grip turns smoothly

- Check that the throttle grip has 2-3 mm of play.

- 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.

(A). Adjustment.
(B). Lock nut.
(C). Throttle grip.
(D). Brake fluid reservoir.

- If the play can not be established by adjusting the cable, remove
the cable protection from the throttle, adjust this using a tensioning
device at the end of the cable, tighten the lock nut and refit the
protection.

- Squeeze it and take it
out with a clean cloth.

– Install the filter in the
cage and cover the filter
lip (A) with a thick layer
of grease to ensure a
seal and to avoid dust
penetration.

- Clean the filter in a
filter bath using a soft
brush.

(C)

(B)

(A)

(D)

- Fit the air filter to the motorcycle and ensure that it is correctly
connected.

THE EXHAUST SYSTEM

The exhaust and the silencer reduce noise and carry the gasses
away from the driver.

If the exhaust is damaged, rusted, dented or split then change it.
Change the silencer packing if the noise begins to be too loud or if
the engine performance drops.

Changing the silencer

1. Remove the right side number carrier cover.

2. Release the exhaust flange.

(A). Silencer.
(B). Silencer attachment bolts.
(C). Flange.

-25-

CLUTCH

Proper clutch lever play is 2-3 mm. Play increases with the clutch
wear and thus requires adjustment.

When there is too much play, first try to adjust the level of the clutch
lever.
Tighten the adjustment bolt to obtain the optimal play.

(A). Clutch Lever.
(B). Clutch cylinder piston rod.
(C). Hydraulic fluid tank.

If the adjustment of the clutch lever has reached its limit, then play
must be adjusted by the clutch cylinder piston rod.

(C)

(B)

(A)

(B)

(A)

(C)

-26-

Changing the silencer packing

- Remove the cover rivets (A).

- Extract the silencer cover (B).

- Pull out the inner silencer.

- Change the silencer packing by wrapping around the inner tube.

- Refit the assembly.

(A). Rivets.
(B). Cover.

CHAIN GUIDE

The drive chain must be checked, adjusted, and lubricated in
accordance with the Periodic Maintenance table in order to prevent
excessive wear. If the chain is worn or badly adjusted (to tight or
loose) then it may jump off the sprockets or break.

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.

Checking tension

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. Adjust the drive chain if it has
too much or too little slack.

NOTE

In muddy or humid conditions, the mud gets inside the chain
increasing tension and may cause the chain to break. To prevent
this, adjust the chain to 30-50 mm of space between the chain
and rocker arm whenever necessary.

(A). 30 - 50 mm.

(A)

(A)

(B)

-27-

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

Tension adjustment

-Loosen the rear axle nut.

- Turn the nuts on the chain adjusting bolts evenly until there is 30­50 mm of space between the chain and the swing arm. To keep the
chain and wheel aligned, the adjustment on the left of the chain
should be equal to that on the right.

(A). Rear axle.
(B). Adjustment nut.
(C). Chain adjustment.

(A)

(B)

(C)

NOTE

Wheel alignment can also be checked using the straightedge
or string method.

WARNING

Misalignment of the wheel will result in abnormal wear and may
result in an unsafe riding condition.

- Tighten the chain adjustment nuts.

- Tighten the axle nut to 98 N-m.

- 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 unsafe riding conditions
may result.

Drive chain, chain guide, chain slide, and rear sprocket

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 pinion and
rear sprocket, and replace them if necessary. Worn teeth will cause
the chain to wear more quickly.

-28-

NOTE

For maximum 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). Chain direction of rotation.

Chain Wear Guide

Visually inspect the drive chain wear guide (A); If the guide is worn
excessively or damaged, replace it.

(A)

Chain guide slide

Visually inspect the upper and lower part of the chain slider on the
swing arm. If this is worn then replace it.

(A). Chain guide slide.
(B). Rocker arm.

Pinion and sprocket teeth wear

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

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 oil because it will stay on the chain longer and provide better
lubrication.

(B)

(A)

-29-

Apply oil to the side of the links so that it will penetrate better. Wipe
off any excess oil.

HANDLEBARS

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

Handlebar position adjustment

Loosen the handlebar holder bolts (B), of the handlebar holder (A)
then rotate bars to desired position.

(A). Apply oil.

(A) (A)

Tighten the bolts securely; first the forward bolts then the rear, to a
torque of 25 Nm. If the handlebar is correctly installed, there will be
a minimal gap at the front and rear of the clamp 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
the brake pedal position and play.

(A)

(B)

(A)

(A). Brake pedal.
(B). 10 mm of play.

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, check
the brakes immediately.

Brake fluid

Regularly check the brake fluid and periodically change it. It should
also be changed if it is contaminated by water or dirt.

-30-

Front brake lever

Adjust brake lever to a comfortable position. To adjust, loosen the
nut under the rubber protection (B). Tighten after adjustment. Ensure
that the brake responds correctly.

(A). Brake lever.
(B). Rubber protection.

Rear brake pedal

When the brake pedal is in rest position, there should be a play of
10 mm. If not, then adjust this.
Ensure that the brake responds correctly and does not rub.
To adjust the pedal play, loosen the locknut, rotate the bolt and
retighten the locknut.

(B)

(A)

(A)

(B)

Recommended liquid

Use D.O.T 3 or 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.

-31-

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 line damage.

WARNING

Do not mix 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

If the thickness of either pad is less than 1 mm, replace both pads
in the calliper 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 without excessive play.

(B)

(A)

To check the steering adjustment, lift the bike off the ground using
a stand underneath the chassis. Push the handlebar lightly to either
side; if it continues moving under its own momentum, the steering
is not too tight. 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 by loosening the handlebar clamp bolts
(A).

- Loosen the steering stem bolt (B).

- Loosen the bolts for the upper suspension plate and remove it (C).

- Rotate the steering adjustment bolt using the special spanner in
order to obtain the appropriate adjustment.

-32-

- Install the upper suspension plate (D).

- Tighten the steering stem nut (B), the washers and bolts on the
front forks to the correct torque.

Steering head nut: 44 Nm (4.5 Kgm)
Suspension plate bolts: 22 Nm (2.25 Kgm)

- Recheck the steering and readjust if necessary.

- Refit all removed parts.

STEERING LOCK

This mechanism allows us to lock the steering. It is located on the
steering tube.

The handlebars must be turned to the right completely, then insert
the key, rotate left, press, rotate right and take the key out.

(A). Steering lock.

(A)

(D) (B) (A)

(C)

- Using a stand underneath the chassis, stabilized the bike.

- Put something under the engine so that the front wheel does not
touch the ground.

- Remove the air purge screw from the upper part of the front forks.

Adjusting the extension

- To adjust the rebound, rotate the adjustment control (A) on the
upper part of the front forks using a screwdriver.

- Adjust the rebound according to your preferences under determined
conditions.

-33-

CAUTION
Never leave the key in the lock. If the steering is turned to the left
with the key in the lock then this will be severely damaged.

FRONT FORKS

The front fork should always be adjusted for the rider's weight and
track conditions. The adjustments are done in 5 stages:

- Air pressure: affects the entire range of fork stroke. The air pressure
increases when the forks heat up, or, as operation time increases.
We don't recommend using air pressure as the forks are designed
to work without adding any air.

- Rebound and compression dampening adjustment: This adjustment
affects the speed of the rebound. The fork rebound dampening
adjustment has 18 positions. The tightened position is completely
hard. The position 12 from the closed position is the standard and
the position 18 is totally soft.

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

- Fork springs: Optional springs are available that are softer and
stiffer than standard K=4.5.

Air Pressure

The standard air pressure for the front forks is atmospheric pressure.
The air pressure in the fork legs increases as operation progresses
and therefore the forks become harder.

(A). Purge bolt.

(B). Adjustment
control.

(A)

(B)

Adjust the return to the standard measures (rotating anti-clockwise,
12 positions).

CAUTION
The front fork left and right tubes must be at the same level and
aligned with the plate.

Adjusting the compression

- To adjust the compression, rotate the adjustment control on the
upper part of the front forks by hand.

- Adjust the compression suited to your needs under certain conditions.
Adjust the compression to the standard measures (rotating anti­clockwise, 12 positions).

Adjusting the oil level

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

- Take out the handlebar bolts and take out the handlebars.

- Remove the suspension caps from the rods.

- Slowly compress the front forks all the way.

- Lift the fork springs.

- Holding the suspension rod cap with a spanner, loosen the cap
locking counter nut.

- Remove the suspension rod caps.

- Remove the suspension spring guide.

- Using a spanner, remove the springs from the forks.

- Place the oil level indicator on the upper part of the fork tube and
measure the distance from the upper part to the oil level.

-34-

Standard oil level

Marzocchi: 100 mm

(A). Releasing oil.
(B). Filling oil.

Adjust to the level of oil required in the tables using the following oil:

Recommended oil

MARZOCCHI: SAE 7´5

-35-

(A). Hydraulic rod

- Pull on the hydraulic 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.

- Tighten the suspension spring and insert the spanner (5) onto the
cap lock (3) counter nut (2).

- Fit the suspension cap (3) to the fork tube and tighten to 29 Nm.

- Fit the other fork.

- Refit all removed parts.

(1). Spring.
(2). Counter nut.
(3). Suspension cap.
(4). Cap spanner.
(5). Counter nut spanner.

Suspension rod spring

Different springs can be used depending on the weight of the driver
and the track conditions.

- Hard springs make the forks harder and the rebound faster.

- Light springs make the forks softer and the rebound slower.

Suspension plate position

Ensure that the tyre does not touch the mudguard when the forks
are fully compressed. There should be at least 5 mm clearance.

CAUTION

The right and left suspension rods must be adjusted equally.

-36-

(1). Fork tube
height

REAR SUSPENSION

The rear suspension is made up of a shock absorber, swing arm,
tie rods and rocker arm.

In general the operating characteristics of the single shock are similar
to the front fork however this is characterized as well as by the shock,
the articulated quadrangle composed of the rods and rocker arm.

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.

Extension adjustment

To adjust this, rotate the control on the rear of the shock by hand
until noting a click.

There is a possibility of 50 “Clicks” in total.
The standard rebound is at : 25 “Clicks”.

(Anti-clockwise from the completely closed position).

Compression adjustment

To adjust, rotate the control on the gas reservoir using the point of
a screwdriver until noticing a «click».

There is a possibility of 60 “Clicks” in total.
The standard rebound is at: 30 “Clicks”.

(Anti-clockwise from the completely closed position).

(A). Rebound
adjustment

(1)

Spring adjustment

- Remove the seat and the side covers.

- Loosen the bolt of the air filter conduit clamp.

- Remove the silencer.

- Remove the sub chassis with the air filter housing.

-37-

(A). Sub chassis.
(B). Filter housing.

(A). Compression adjustment.

Suspension spring

The standard spring is a 5,4. The length of the preloaded spring with
the shock in rest position is 258 mm.

- Tighten the counter nut correctly.

- Following the adjustment, move the spring up and down to ensure
that this is correctly in place.

- Refit all removed parts.

Rear shock absorber spring replacement

Stiffer or softer springs are available. If the standard spring is
unsuitable for your purpose, select a proper one according to the
rider's weight and course conditions.

- Use of a stiffer spring: faster rebound.

- Use of a softer spring: slower rebound.

NOTE

See the adjustments page 47.

(A)

(C)

(B)

(A)

(A). Nut
(B). Spring.
(C). Counter nut.

(A)

(B)

-38-

Centring the rim

Put a quadrant gauge next to the rim and rotate the wheel to measure
the axial centring.

Put the dial on the inside of the rim circumference, rotate the wheel
and the difference between the largest and smallest measurement
is the centring measurement.

If the wheel is slightly off-centre then this can be corrected by
loosening certain spokes and tightening others in order to change
the rim position. If the rim is bent or crooked then it must be replaced.

NOTE

A soldered area on the rim may give an excessive reading.
Ignore this while measuring the centring.

(A). Spoke tightening tool

WARNING

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 official distributor.

WHEELS

Tyre

. Tyre pressure affects traction, handling, and tyre life.
. Adjust the tire pressure to suit track conditions and rider preference,
but do not deviate excessively from the recommended pressure.

NOTE

Tyre pressure should be tested when the tyre is cold before
driving.

Track conditions

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

- When the track is stony or hard, increase the tyre pressure.

Spokes and rims

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.

-39-

Cleaning

1- Preparation for cleaning

Before cleaning the motorcycle must be prepared so that water does
not penetrate certain areas of the bike.

The exhaust: Once this is cold, cover it with a plastic bag attached
with rubber.

Clutch and brake levers, grips and stop button: cover with a
plastic bag.

Air filter intake: cover this with insulation tape or a cloth.

2- Where to be careful

Avoid spraying water with any great force near the following
places: Disc brake master cylinders and callipers; 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; the affected
parts must be dried).
Front and rear hubs.
Steering pivots (steering tube).
Rear suspension system.
Swing arm pivots.

3- After cleaning

- Remove the plastic bags and clean the air filter intake.

- Lubricate the locations listed in the lubrication section.

- Start the engine and let it heat for 5 minutes.

- Check the brakes before driving the bike.

WARNING

Never wax or lubricate the brake disk, this could lead to brake failure
and could provoke an accident. Clean the disk using trichloroethylene
or acetone.

18

19 20 21 22 2324 25

26 2827 29

Tighten bolts and nuts

Every day before using the bike, rapidly ensure that all bolts and nuts are tightened. Also make certain that all of the other fastenings are in place
and in good condition.

1- Front and rear wheels
2- Front forks
3- Handle bars
4- Clutch lever support bolt
6- Air filter housing bolts
7- Seat support bolts
8- Spokes

9- Disk plate screws

18- Rear axle bolt

19- Silencer support bolts
20- Sub chassis bolts
21- Rear shock bolts
22- Exhaust flange bolt
23- Upper suspension plate bolts
24- Steering head nut
25- Brake lever support bolt
26- Rod support bolt

10- Front axle bolt
11- Brake attachment bolt
12- Sub chassis support bolt
13- Radiator support bolts
14- Nuts and bolts of the engine

mounting
15- Shift pedal bolts
16- Chain guide bolts
17- Chain adjust bolt

1 1

2

3 4 6 789

10 11 1213 14 15 16 17

27- Rear brake pedal bolt
28- Rod support bolt
Rocker

29- Rocker arm bolt

-40-

-41-

TIGHTENING TORQUE TABLE

Tighten all of the bolts and nuts using the correct spanners. If not correctly tightened then motorcycle damage or even an accident could occur.

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 d

rain plug
Calliper mounting bolts
Disc plate mounting screws
Engine mounting bolts
Front axle bolt
Front brake lever support bolt
Fork flange bolt
Steering nut
Rear axle nut
Rear brake pedal bolt
Sub frame support bolt
Rear shock absorber bolt
Rear disc wh

eel drive bolt
Spokes
Steering axle bolt
Rocker arm bolt
Rod bolt

Nm

20
20
25
10
11

9
25
10
36
51

6
29
98
98

9
26
39
29

1.5
4

81
81

Kgm

2,0
2,0
2,5
1,0
1,0
0,9
2,5
1,1
3,6
5,1
0,6

3,0
10,0
10,0

0,9

2,7

4,0

3,0
0,15

4,5

8,3

8,3

(D)

(C)

LUBRICATION

Lubricate the points shown here, with either motor oil or regular
grease, periodically or whenever the vehicle is wet, 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 bearing (D).

- Shift pedal (E).

-42-

Use an aerosol with a pressure tube to lubricate

Use grease on the
inner throttle cable

(D)

(C)

(A)

(B)

(E)

Chain lubrication

Lubricate the chain after wet terrain or when the chain looks dry. A
high viscosity oil rather than low viscosity oil is better because it will
stay a long time in chain providing lubrication.
Put oil on the sides of the chain rollers (A) so that it penetrates into
these; remove excess oil.

(A). Greasing.

-43-

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)

The recommended viscosity is SAE 10W-50; if an SAE 10W-50 oil
is not possible use an alternative according to the table above.

Checking the oil level and making the changes periodically are two
very important operations to keep the engine in perfect shape.

Initially replace the oil after 5 hours of operation and then every 60
hours.

NOTE

The engine oil expands and thus the level increases when it is
hot.
Check and adjust the level when the motor oil is not hot.

Changing the 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.

WARNING

The engine oil and the exhaust manifold can be very hot and cause
burns.
Wait until the oil and the exhaust manifold are a little cooler.

ENGINE OIL

Use a premium 4-stroke engine oil to lengthen the life of your
motorcycle. Use oil classification SF or SG under the API classification.

NOTE

Put used motor oil in an appropriate container for recycling.

-44-

WARNING

Always use original GAS GAS parts.
If the filter is incorrectly positioned, the engine oil will not flow,
provoking a malfunction in the engine.

WARNING
Engine oil is a health risk. Avoid any contact with this given that this
could provoke irritations and, in the worst cases, skin cancer.

- Keep new or used oil away from the reach of children and animals.

- Clean clothes sleeves and pants.

- Wash yourself with soap if oil has been in contact with your skin.

To change the oil, follow the following steps:

1. Place a recipient underneath the crankcase.

3. Drain the engine oil by
removing the cap (B), keep
the motorcycle vertical.

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

(D)
(E)

(C)

(B)

(F)

5. Remove the filter
cover, extract the
filter element (D) and
the seal (E). Always
replace both
elements at the
same time.

-45-

6. Before replacing the oil filter, make sure that the spring (E) and
the o-ring (F) are in the correct position.

7. Replace the filter cover and put the screws that secure the cover,
but without tightening them too hard (do not exceed the recommended
torque).

8. Check the oil inlet filter. To do so, remove the cover of the oil inlet
filter (G), clean the filter and check the O-rings. Install the filter again
and replace the cover.

9.Replace the cover of the crankcase and tighten it. Add approximately
1,200 ml of new oil through the orifice in the ignition cover (H).

WARNING

The engine may 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 specified in the section on Petrol and Oil
recommendations.

10. Start the engine and allow it to run for a few minutes. Check that
no oil is lost through the filter cover. Stop the engine.

11. Check that the oil level is correct: stand the motorbike on a level
surface and check that the oil covers the observation hole (I).

12. Add more oil through the orifice in the ignition cover (H) if
necessary.

(H)

(G)

(I)

Front forks

The fork oil level is adjustable. A change in the oil level will not affect
the lower part of the stroke, but it will affect the upper part.

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

- When the oil level is lowered:
The spring effect becomes less progressive, and the front fork action
feels softer near the bottom of the stroke.

- Change the fork oil level correctly to make the forks work more at
the end of fork travel.

- If fork bottoming is experienced, raise fork oil level in 10 mm
increments. This increase will cause a change in the upper stroke
of the spring.

Adjusting the oil level

Adjust the oil level of the front forks (see the maintenance chart).

-46-

TUNING THE SUSPENSION

No area of machine adjustment is more critical than proper suspension
tuning; an incorrectly tuned suspension will keep even the best rider
from attaining the full benefit of his machine's ability Check the
suspension according to the pilot and the conditions of the terrain.
When tuning the suspension don’t forget:

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

- The major factors which must be considered in suspension tuning
are: rider weight, rider skill and the track conditions (as well as
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 over adjust a setting.

- The front and rear suspension should be balanced; when one is
changed, the other should be changed similarly.
When evaluating suspension performance the rider must make
every effort to ride consciously and recognize the effects of his
changes;
such things as changes in rider position and increasing fatigue may
lead to incorrect judgments about required 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.

- Lubricate the bearings of the swinging arm, rods, rocker and joints
before making changes and every 5 refills to prevent excess friction
affecting the operation of the suspension.

End of
stroke

Suspension stroke

High

levelStandard
level oil

Low level

Force

-47-

Changing incorrect adjustments

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

The proper settings can be achieved by applying the information in
this chapter in a scientific manner. 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.

Front fork symptoms

- The front forks are too stiff

. Rebound adjustment incorrect.
. The springs are too strong.
. Too much oil.
. Oil too dense.

- The front forks stiffen at the end of the stroke

. The fork oil level is too high.

- The front forks operate but ride is too hard

. Oil too dense.
. Fork oil degraded

- Too soft
The front forks dive excessively during braking and deceleration

1. Front fork oil level low.

2. The springs are too soft.

3. Oil too light.

4. Fork oil degraded.

5. Rebound compression incorrect.

Rear shock absorber symptoms

- Too hard

1. Rigid suspension.
. High compression.
. Hard spring.

2. Hard driving.
. Imbalance between the spring and rebound

(too low).

3. The spring is hard or very preloaded

- Too soft

On landing after a big jump, bottoming occurs.
. Spring too soft or compression damping is too soft
. Shock oil degraded.

Determining the Proper Settings

- Standard adjustments

From the factory, the machine is set up for an intermediate-weight
rider possessing intermediate riding ability. If the rider weigh or ability
is greater or lower than average then some adjustments may be
made to the suspension.

- Readjusting the suspension

Type of surface

Smooth Soft spring
Rough Hard spring

-48-

Experience

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

Weight

Heavy: harder spring.
Light: soft spring

Track type

- Many corners:

Lower the front end slightly (increase the fork tube height 5mm).
This increases agility.

- Fast course with many jumps:

Lift the front (lower the fork tube height to 5mm). This increases
stability.

- Deep pits or sandy ground:

Lift the front for increased stability.

Following the preliminary adjustments, make a trial run on the ground
to evaluate the changes.

Remember:

1- Always make changes in small increments.
2- Make sure the rider is logical in their evaluation.
3- A change in the front suspension requires a change in the rear
suspension and vice-versa.

Front and rear compatibility

Use this procedure to determine if the suspension is balanced
reasonably well: Situate the motorcycle so that it is perpendicular to
the ground. While standing next to the machine, pull on the front
brake and place one foot on the brake firmly. If the bike maintains
its level attitude as the suspension is compressed, the suspensions
are well balanced. Sit astride the bike and take up a riding posture
the check to see if the bike is in a horizontal 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 searching going downhill or accelerating out of a
bend ?
Front forks too soft.

1. Increase the compression damping or rebound damping.

2. Increase the oil level 10 mm.

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

Front end knifes or over-steers in turns (front end tends to turn
inward)?
Front forks too soft.

1. Increase the compression damping or rebound damping.

2. Increase the oil level 10 mm.

Front end pushes out or slides in turns

1. Decrease the compression damping or rebound damping.

2. Release air from the fork.

3. Reduce the oil level 10 - 20 mm.

4. Use a softer spring.

-49-

Front fork doesn’t respond to small potholes in wide turns

- Front fork hard:

1. Decrease the compression damping or rebound damping.

2. Reduce the oil level 10 mm.

3. Use a soft spring.

Rear end kicks when braking on potholes

The shock probably has too little rebound damping.

- Increase the rebound damping.

Rear tire won't "hook up" out of corners

(A loss of traction coming out of turns).

- The shock is too stiff:

1. Reduce rear shock absorber spring.

2. Reduce compression.

3. Use a softer spring.

Landing on front wheel in fast jumps

(could also be a rider position problem).

- Rebound too soft or spring too hard:

1. Increase rebound.

2. Reduce preload of the shock spring.

3. Reduce compression.

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. Front : Increase oil level and/or use harder spring.

2. Rear: Use a stronger spring and / or increase compression.

NOTE

After any adjustment, check front and rear compatibility.

Adjustments depending on the bottoming of the suspension
(rear shock).

- Bottoms at low speed: Increase spring preload to maximum.

- Bottom after successive 3 or 4 successive jumps.

NOTE

The rear shock on this machine, due to its adjustment
possibilities, could confuse some riders.

a) The rear shock does not bottom out when the spring and
damping are correct for the total weight of the machine and rider
(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 while jumping; if it does not approach the limit then
attempt to lower the spring preload.

Gears

Selecting the development. Preconditions.

Track conditions: vary the transmission by changing the rear sprocket.
Fast track: Sprocket with lower number of teeth.
Bends or sandy/soft hills: sprocket with more teeth.

- If the time trial is long then the development may be longer for

increased speed.

- When the time trial of the course has many curves, hills or is wet,

the development is decreased so that gear shifting is possible at low
speeds.

-As a result gears can be changed depending on the terrain on the

day of the race. Ensure to correctly adjust the machine in order to
run the entire race.

- 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 speed can be developed all the way to the end of the
straight course, but care should be taken not to over-rev the engine

- It is difficult to adapt the machine to the entire circuit, for this reason
it is necessary to determine the sections that have more effect on
time and to adapt the motorcycle to these parts. This strategy means
that the machine will gain overall track performance.

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. Wet heavy clay or mud sticking to the tyres and other parts of the
vehicle. The mud can add significantly to the weight if the vehicle
obstructing the radiator and therefore reduce performance. Take care
not to overheat the engine. The same applies to deep sand.

3. 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.

4. Check chain and pinion/sprocket wear frequently when riding in
mud or sand since wear is increase d in these conditions

5. In dusty conditions as the air cleaner collects dust, the engine
runs richer.

SPARE PARTS AVAILIBLE

Your Gas Gas dealer will provide any information you may require
about spare parts.

DURING COMPETITION

(1). Check

1. Tighten the front axle and disks

2. Tighten the front forks flange bolts

3. Tighten the handlebar clamp bolts

4. Tighten the throttle control bolts

5. Verify, grease the throttle control

6. Verify the front and rear brake lines

7. Front and rear brake fluid level

8. Front and rear brake disc and calliper installation

9. Front and rear brake operation

10. Fuel tank installation

11. Check cables

12. Engine mounting bolts

13. Engine pinion

14. Shift pedal bolt

15. Transmission oil level

16. Battery charge

17. Throttle housing

18. Rod mounting bolts

19. Rod bolts

20. Rear shock bolts

21. Tighten the swinging arm pivot nut

22. Tighten the rear axle nut

23. Tighten nut and bolt of rear sprocket

24. Operate rear brake pedal

25. Check seat

26. Tighten the spokes

27. Tyre air pressure

28. Tighten chain

29. Coolant Level

-51-

STORAGE

When the motorcycle is to be stored for any length 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 transmission oil.

Empty the fuel from the fuel tank, and empty the carburettor float
bowl. (If left in for a long time, the fuel will deteriorate).

- Disconnect the battery.

- 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.

- General lubrication

- Connect the battery.

(2). Following a day of competition

1. Clean the air filter

2. Adjust the chain tension / slack

3. Tighten the bolts of the rear sprocket

4. Tighten spokes

5. Check the tyre pressure

6. Tighten the front and rear axle nuts

7. Tighten the swinging arm nut

8. Tighten the nuts and bolts of the exhaust and silencer

9. Tighten the nuts and bolts of the mudguard support

10. Tighten the nuts and bolts of the tank seat

11. Check the brakes

12. Check steering play

13. Fill the tank

14. Check the coolant level

(3) After racing on dusty terrain

If dirt or dust gets through into the engine, the crankshaft will wear
excessively. After riding, inspect the crankshaft. If the crankshaft is
worn past the service limit, replace the crankshaft 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 for wear.

3. Clean the pinion and rear sprocket.

4. Check the piston-cylinder and crankshaft bearing.

5. Grease the throttle control and cable.

(5) Suggested spare parts

Consult the parts manual.

Panel description

1. RESET button

2. 2nd row of indicators

3. 1st row of indicators

4. Tachometer with bar graph

5. Tachometer scale

6. Fuel indicator bars (optional)

7. LED indicator symbols

8. MODE button

Description of symbols

-52-

GAS GAS MULTIFUNCTION INSTRUCTIONS

The multifunction apparatus, which is waterproof, has 4-8 LED
indicators on both sides of a central indicator screen
This central indicator screen, made of liquid crystal and with
illumination, gives information about the rpm, speed, journey,
kilometres travelled, time, average speed, maximum speed,
length of time with motor running and total time, and fuel level.
The data relative to the distance travelled and total time of use
is stored in the memory, even when the apparatus is switched
off. When the multifunction apparatus is not activated, it displays
a clock.
The wheel circumference value is adaptable, as is the measuring
system (metric or imperial).
The number and distribution of the LED indicators, and the
amount of information on screen may vary according to model.

4
3

2

1

5

6

7

8

Panel

Left indicator / Green

Dipped headlights / Green

Motor oil / Red (Optional)

Right indicator / Green

Full headlights / Blue

Neutral / Green (Optional)

N

-53-

Technical characteristics

FUNCTIONS Symbol

TECHNICAL CHARACTERISTICS INCREMENTS

PRECISION

Bar Tachometer

500 - 11.000 rpm 500 rpm

Digital Tachometer

RPM 100 - 19.900 rpm 100 rpm

Gear change indicator

RPM 100 - 19.900 rpm 100 rpm

Maximum Tachometer Value

100 - 19.900 rpm 100 rpm

Speedometer

2,3 - 300 km/h (187,5 m/h) 0,1 km/h o m/h

Speedometer

MAX 2,3 - 300 km/h (187,5 m/h) 0,1 km/h o m/h

Average Speed

AVG 2,3 - 300 km/h (187,5 m/h) 0,1 km/h o m/h

Distance counter 1&2

TRIP 1&2

0 – 999.9 km or 0 - 624.9 miles 0.1 km or miles

Mileometer

ODO

0 – 999,999 km or 0 - 624,999 miles 0.1 km or miles

Time in use

RT 0:00'00" - 99:59' 59"

1 second

Total time

TT 0:00' - 9999:59'

1 minute

Clock

0:00'00" - 23:59' 59"

1 second/1 minute

± 1% o ± 0,1
km/h / m/h

± 1% o ± 0,1
km/h / m/h

± 1% o ± 0,1
km/h / m/h

± 0,1 %

± 0,1%

± 50 ppm

± 50 ppm

± 50 ppm

Initial voltage: 12v CC.
Speed sensor Non-contact magnetic sensor.
Tachometer entry CDI (capacitor discharge ignition) or ignition coil signal.
Wheel circumference adjustment 1 mm – 3.999 mm (1 mm increments).
Working temperature: -10 ºC - + 80 ºC (engine casing interior).
Fuel sensor resistance 100 (only in models with fuel level indicator).

MAX
RPM

ODO: Mileometer

It shows the total mileage accumulated by the vehicle.
The data is stored in the memory, even when the device is not
running.

RT: Time of use controller

It calculates the total time in use since the last RESET operation. It
starts counting from the moment that movement begins.

TT: Total time of use controller

It calculates the vehicle’s total time in use. It starts counting from the
moment that movement begins. The data is stored in the memory,
even when the device is not running.

12/24 hour clock

It shows the time in either 12 or 24 hour formats.

Fuel level indicator (only vehicles with this function)

It has 7 bars showing the amount of fuel remaining in the fuel tank.
The last bar flashes to indicate that the fuel level is too low.

Functions

RPM: Bar

Tachometer with bar graph The bar graph of the tachometer displays
up to 11,000 rpm.

RPM: Digital Tachometer

The rpm is shown in the second row The digital tachometer displays
up to 19,900 rpm The tachometer signal can be read from the CDI
(Capacitator Discharge Ignition) or the ignition coil.

Gear change indicator according to rpm

This function permits setting an indicator for changing gear at a
specific rpm level The tachometer bar flashes when the rpm reaches
the specific level and stops flashing when the gear is changed.

MAX RPM: Maximum tachometer value

It appears in the 2nd row. It shows the highest level reached by the
tachometer since the last resetting of the data.

SPD: Speedometer

The speedometer information appears in the first line of the screen
It shows up to 300 km/h or 187.5 mph.

MAX: Maximum speed gauge

The MAX value appears in the 1st line. It shows the highest speed
reached since the last resetting of the data.

AVG: Average driving speed

The AVG value appears in the 1st line. It calculates the average
speed since the last RESET operation.

TRIP: Journey counter

This appears in the second line of the screen. The TRIP function
contains the vehicle’s accumulated mileage since the last RESET
operation.

-54-

-55-

Operation of the buttons

MODE BUTTON

1. Press the MODE button to switch from one function screen to another when the speed sensor detects no signal.

2. Press the MODE button to switch from one partial screen to another when the speed
sensor detects a signal.

RESET BUTTON

1. Press the MODE button to reach the appropriate screen, and then press RESET
for 2 seconds to return the data stored in TRIP 2, MAX and MAX RPM to zero
separately.

2. Return the data in TRIP 1, AVG and RT at the same time. The data of the ODO,
CLOCK and TT. cannot be returned to zero.

OPERATION OF THE GEAR CHANGE ACCORDING TO RPM

1. Press the MODE button to switch to the RPM screen; accelerate to the rpm which is desired for the gear change indicator to be activated.

2. Press the RESET button to confirm and establish the gear change indicator according to the rpm.

3. The tachometer with bar graph and a LED will flash to indicate the need to change gear.

4. Use the steps 1 and 2 to readjust the gear change according to RPM.

-56-

Multifunction and wheel circumference adjustment

The configuration operations include the 12/24 hour clock, the gear change according to rpm indicator, the number of engine revolutions by
signal, the wheel circumference and the units of measurement The configuration must be carried out step by step. The computer will return
automatically to the main screen if no button is pressed in any adjustment screen for 75 seconds.

Press the MODE and RESET buttons to switch to the adjustment screen. In the adjustment screen, press the RESET button to increase the
value of the flashing digits or to convert units, press the MODE button to confirm the configuration and move on to the next digit or the next
adjustment screen to be configured. Press the MODE button for 2 seconds in any adjustment screen to conclude the configuration and return
to the main screen.

The screen shows 12 or 24 h, and the symbols: XX: XX-XX, and AM/PM if the 12h option has been selected.
When the RESET button is pressed the 12/24h system changes, and when MODE is pressed, the configuration concludes and the configuration
of the clock digits opens.

Press the RESET button to increase the value of the flashing digit one by one; press the MODE button to confirm the configuration and pass
on to the following digit.

Press the MODE button to switch to the adjustment screen of the gear change according to rpm, once the clock has been configured.

The screen will show RPM rXXX00. Press the RESET button to increase the value of the digit one by one; press the MODE button to confirm
the configuration and pass on to the following digit.

Press the MODE button to switch to the adjustment screen for the engine revolution by signal, once the gear change according to rpm
configuration is completed.

The screen will show SPC-X.X RPM, with 1.0 as the default value There are 4 options 1.0, 2.0, 3.0 and 0.5. They correspond to the number
of revolutions for each signal. For example, a value of 2.0 means that the motor turns over twice to produce a signal.

Press the RESET button to move between the four values . Press the MODE button to confirm the configuration and to move on to the wheel
circumference adjustment screen

When cXXXX appears on screen, the “c” stands for “circumference” and is followed by four digits by default; the flashing digit is the one to be changed.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

-57-

11.

Press the RESET button to increase the value of the flashing digit one by one; press the MODE button for 2 seconds to confirm the digit
change and pass on to the following digit.

-58-

NOTE

This is not an exhaustive list, it is meant simply as a rough guide to assist troubleshooting for some of the more common difficulties.

FAULT

CAUSE SOLUTION

1

2

3

FAULT DIAGNOSIS

The starter motor does not work

The engine does not rotate

Engine rotates but does not
start

- Remove the number plate on the right hand side and the
air filter cover then change the starter motor fuse.

- Recharge the battery and investigate the causes for
discharging, visit a qualified workshop.

- Start engine with start pedal.

- Go to a specialist workshop.

- Go to a specialist workshop.

- Go to a specialist workshop.

- Check fuel pump relay; check fuel pump filter, located in
the fuel tank, isn't blocked.

- It is advisable to drain the old fuel from the tank.

- When the fuel tank is filled with new flammable fuel the
engine starts immediately.

- Take the spark plug out and replace it.

- To «unflood» the engine, full throttle, then operate the kick­start 5 to 10 times or operate the electric starter 2 times in
5 seconds. Then start the engine as described below. If the
engine fails to start, unscrew the spark plug and dry it.

- The fuse for the starter relay is blown.

- Battery discharged.

- Low temperature.

- Crankshaft locked.

- Cylinder/ piston/ crankpin journal seizure.

- Transmission assembly seizure.

- Fuel supply incorrect.

- The motorcycle has been out of operation
for a longer period of time.

- Spark plug soiled or humid.

- Engine flooded.

-59-

FAULT CAUSE SOLUTION

Engine rotates but does not start

The engine starts but does not
stop

The engine overheats

The engine does not run
smoothly

The engine is under powerful or
accelerates badly.

High oil consumption

The ECU pin connector, generator or coil
oxidised or in bad condition.

- Petrol / gas mixture incorrect (Trim
Epprom).

- Air supply incorrect.

- Fuel insufficient.

- Insufficient coolant in the circuit.

- The radiator is soiled or partially
obstructed.

- Injection system maladjustment. (Trim
Epprom).

- Valve adjustment incorrect.

- Fuel supply faulty.

- Air filter obstruction.

- Exhaust deteriorated with leaks.

- Valve set too small.

- Decompression maladjusted.

- Piston-cylinder ring diameter tolerance
excessive.

- Remove the seat and the fuel tank, clean the pin connector
and treat it using a contact spray.

- Clean the petrol tank ventilation. Adjust the throttle body by­pass. Adjust the air filter conduit.

- Close the starter. Clean the petrol tank ventilation. Adjust
the injector mounting. Adjust the air filter conduit.

- Fill the fuel tank with fuel.

- Add coolant, verify the cooling system seal.

- Clean the radiator fins or change it.

- Adjust the injection system. Go to a specialist workshop.

- Adjust the valve play. Go to a specialist workshop.

- Clean and check fuel system.

- Clean or change the air filter.

- Check if the exhaust system is damaged, change the glass
fibre in the silencer if necessary.

- Adjust the valve play. Go to a specialist workshop.

- Verify the operation of the system.

- Adjust the tolerance by changing the piston rings.

3

4

5

6

7

8

-60-

FAULT CAUSE SOLUTION

High oil consumption

Abnormal engine noise

Detonations in the exhaust

White fumes from the exhaust

Brown fumes from the exhaust

The gears do not engage

– Correct the engine oil level. Drain oil as necessary from
the engine.

- Empty the engine oil and fill with oil of the recommended
viscosity.

- Go to a specialist workshop.

- Adjust the valve play. Go to a specialist workshop.

- See chapter 5.

- Clean the combustion chamber.

- Go to a specialist workshop.

- Drain the petrol and fill with fresh or higher octane petrol.

- Change spark plug for a new one or recommended one.

- Check if the exhaust system is deteriorated. The seals
must be in perfect condition, if not then they must be changed
for new ones.

- Change the cylinder head gasket. Go to a specialist
workshop.

- Clean or change the air filter. Go to a specialist workshop.

- Go to a specialist workshop.

- Change the gear fork.

- Go to a specialist workshop.

- Change the gear lever.

- Adjust the selector position spring or change it.

8

9

10

11

12

13

- There is too much engine oil.

- The quality or viscosity of the oil is
insufficient.

- Ignition problems.

- Valve adjustment play.

- Over heating.

- Carbon in combustion chamber.

- Injection system maladjustment. (Trim
Epprom).

- Incorrect or poor gasoline or wrong
octane rating.

- Incorrect or non-specified spark plug.

- Exhaust system joints deteriorated.

- Cylinder head gasket leak
(water leaking into cylinder).

- Air filter obstruction.

- Clutch does not release.

- Shift fork worn or locked.

- Gear locked in transmission.

- Shift lever damaged.

- Selector position spring broken or loose.

-61-

13

14

15

16

17

- The spring of the selector is broken.

- Cylinder change if broken.

- Gear ratchet spring broken.

- Gear change fork damaged in the gears.

- Gear teeth worn.

- Gear nipple damaged.

- Groove gear drum worn.

- Gear change fork pivot worn.

- No play in the clutch handle.

- Clutch plate worn.

- Clutch housing worn.

- Clutch spring broken or weak.

- Clutch plates worn.

- Cable obstructs handlebars.

- Steering shaft nut too tight.

- Steering bearings damaged or worn.

- Steering shaft bent.

- Front forks excess oil.

- Front fork oil viscosity too high.

- Front forks twisted.

- Excessive tyre pressure.

FAULT CAUSE SOLUTION

Gears don’t engage

Gears jump

Clutch slipping

Bike unstable

Shock absorption too hard

- Replace the down selector mechanism spring.

- Replace the gear drum.

- Replace the ratchet spring of the selector.

- Change gear fork.

- Change. Go to a specialist workshop.

- Change. Go to a specialist workshop.

- Change. Go to a specialist workshop.

- Change shaft. Go to a specialist workshop.

- Go to a specialist workshop.

- Replace the clutch plate. Go to a specialist workshop.

- Replace the clutch hub.

- Adjust the selector position spring or change it.

- Change the clutch disks. Go to a specialist workshop.

- Put the cable to one side and release it a little.

- Undo the steering shaft nut.

- Replace the steering bearing.

- Change the steering shaft. Go to a specialist workshop

- Eliminate the excess oil to an adequate level.

- Empty the fork oil and fill with oil of the recommended
viscosity.

- Change front fork. Go to a specialist workshop.

- Verify tyre pressure.

-62-

FAULT CAUSE SOLUTION

Shock absorption too hard

Shock absorption too soft

The bike makes unusual noise

Handlebar shakes or excessively
vibrates

- Rear shock badly adjusted

- Front forks low oil.

- Front fork oil viscosity too low.

- Front forks twisted.

- Low tyre pressure.

- Rear shock absorber maladjusted.

- Drive chain incorrectly adjusted.

- Chain worn.

- Rear sprocket worn.

- Chain lubrication insufficient.

- Rear wheel misaligned.

- Oil front fork insufficient.

- Front fork spring weak or broken.

- Brake disk worn.

- Brake pads incorrect position or crystallised.

- Cylinder damage.

- Brackets, nuts, bolts not properly
tightened.

- Tyre worn, swing arm or needle bearing
worn.

- Rim off-centre.

- Rear wheel misaligned.

- Steering shaft play.

- Handlebar bracket loose, steering shaft
bolt loose.

- Adjust the rear shock.

- Add oil to the forks as required.

- Empty the fork oil and fill with oil of the recommended
viscosity.

- Change front fork. Go to a specialist workshop.

- Verify tyre pressure.

- Adjust the rear shock.

- Adjust the chain.

- Change the chain, rear sprocket and secondary
transmission pinion.

- Change the rear sprocket.

- Lubricate using a correct chain lubricant.

- Align the rear wheel. Go to a specialist workshop.

- Add oil to the forks as required.

- Replace the front fork spring.

- Replace the brake disk.

- Refit the pads or change them.

- Replace the damaged cylinder.

- Verify and adjust to the correct tightening torques.

- Change worn parts.

- Centre the rim.

- Verify the tension of the wheel spokes. Re-adjust if
necessary.

- Check the distance between steering shafts and adjust if
necessary.

- Tighten the handlebar bracket and the steering shaft bolt
to the correct tightening torques.

17

18

19

20

-63-

21

22

23

24

- Chassis twisted.

- Steering incorrectly adjusted.

- Steering shaft bent.

- Front forks twisted.

- Rear wheel misaligned.

- Disk worn.

- Loss of brake fluid.

- Brake fluid deteriorated.

- Piston cylinder broken.

- Brakes incorrectly adjusted.

- Voltage regulator faulty.

- Installation fuse is blown.

FAULT CAUSE SOLUTION

Motorcycle pulls to one side

The brakes do not function
correctly

The lights blow

The lighting system does not
work

- Change the chassis. Go to a specialist workshop.

- Adjust the steering. Go to a specialist workshop.

- Change steering shaft. Go to a specialist workshop.

- Change front fork.

- Align the wheels.

- Change disk.

- Check the brake circuits. Change those that are damaged
or broken.

- Drain the brake fluid and put a new product, recommended
by the maker.

- Replace the piston cylinder.

- Adjust the brakes.

- Remove the seat and the fuel tank then check connections,
verify, the voltage regulator and the fuses in the fuse box.

- Remove the back light cover.

-64-

WARRANTY TERMS AND CONDITIONS

(According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales)

Warranty terms of the manufacturer GASGAS Motos, S.A.

The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer,
the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in
accordance with the highest standards of quality. Consequently, GG with this document guarantees the consumer (hereafter
referred to as the “purchaser”), in accordance with the conditions set out below, the repair, free of charge, of any defect in
materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by
this Warranty and with no limit on the number of kilometres covered or hours of use.

Warranty Period

The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised
dealer, or in the case of demonstration models, on the date in which the vehicle is used for the first time.
The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law
decree 23/2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance
with the Directive 1999/44/EC for other members of the European Community. For countries outside the European Community,
the Warranty Period will be determined by the existing regulations in those countries. Nevertheless, should the fault appear
during the first six months after the delivery of the motorcycle, it will be presumed that the said fault existed at the time of
delivery; from the end of the sixth month onwards, the purchaser must demonstrate that the unwarranted fault existed at
the moment of delivery. During the first six months subsequent to the delivery of the repaired vehicle, the seller will be
responsible for any unwarranted faults arising out of the repair.
Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period.
If the last day of this period is a Sunday or an official holiday, the Warranty period will be extended such that the last day
of the period covered will be the first working day after the Sunday or official holiday.

Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of
the Warranty Period will be excluded.

-65-

Obligation of the purchaser

GG will have the right to reject any claims under Warranty in the event that:

a) The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’
Manual, or has exceeded the date set for such inspections or maintenance work. Also excluded from guarantee are those
faults that appeared prior to the dates established for an inspection or maintenance work where the latter was not carried
out, or was carried out later than the date established.
b) An inspection, maintenance or repair has been performed on the vehicle by third parties not recognised or authorised
by GG.
c) Any maintenance or repair has been carried out on the vehicle that violates the technical requirements, specifications
and/or instructions indicated by the manufacturer.
d) Spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs
to the vehicle, or in the event that the vehicle has been used with fuels, lubricants or other liquids (including, amongst others,
cleaning products) that have not been expressly mentioned in the specifications set out in the User’s Manual.
e) The vehicle has been altered or modified in any way or fitted with components other than those expressly authorised
by GG as accepted components of the vehicle.
f) The vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements.
g) The vehicle has been used for special purposes other than ordinary use, such as competition, races or record breaking
attempts.
h) The vehicle has been directly or indirectly damaged as a result of a fall or an accident.

Warranty exclusions
The following items are not covered by this Warranty:

a) Worn parts, including, without any limitation, spark plugs, batteries, petrol filters, oil filter elements, (secondary) chains,
engine output pinions, rear sprockets, air filters, brake discs, brake pads, clutch plates and discs, bulbs, fuses, carbon
brushes, footrest rubbers, tyres, inner tubes, cables and other rubber components
b) Lubricants (for example, oil, grease, etc.) and working fluids (for example, battery liquid, coolant, etc.)
c) Inspection, adjustments and other maintenance tasks, as well as all kinds of cleaning work
d) Damage to the paint-work and consequent corrosion due to external causes, such as stones, salt, industrial fumes and
other environmental impact, or inadequate cleaning with inappropriate products

-66-

e) Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a
consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport
costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss
of the use of the vehicle, loss of income, time lost, etc.)
f) Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example,
small or hidden imperfections, noise or vibrations that are normal in use, etc.)
g) Phenomena that are the result of the ageing of the vehicle (for example, discolouring of painted or metallic coated
surfaces).

Various

1.- GG shall have the prerogative to decide, at its own discretion, whether to repair or replace defective parts. Where parts
are replaced, ownership of the parts removed shall pass to GG without any other consideration. The GG authorised dealer,
to whom the making good of the defects has been entrusted, is not authorised to make any declarations that are binding
on GG.

2.- In case of doubt regarding the existence of a defect, or a visual or material inspection is required, GG reserves the right
to demand the return of the parts which are the object of a claim under Warranty, or to arrange an inspection of the defect
by an expert from GG. Any additional obligations arising out of guarantees on parts replaced free of charge, or any other
service rendered free of charge, are excluded from the effects of this present warranty. The Warranty on parts replaced
within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned.

3.- Should it prove to be the case that a defect can not be repaired, the purchaser guaranteed shall have the right to the
cancellation of the contract (payment of compensation) or a partial refund of the purchase price (discount), instead of
repairing the motorcycle.

4.- Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised
dealer shall not be affected by the terms of this present Warranty. Neither will this present Warranty affect those additional
contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer.
However, such additional rights may only be exercised through claims against the authorised dealer.

5.- Should the purchaser resell the product within the Warranty Period, the duration and conditions of the present Warranty
will remain unaltered, in such a way as that the rights to make claims under the present Warranty in accordance with the
terms and conditions set out in this present document shall be transferred to the new owner of the motorcycle.

Notes

Notes

RECOMIENDA EL USO DE ACEITE:

RECOMMENDS THE USE OF OIL:

RECOMMANDE L’USAGE DE L’HUILE:

CONSIGLIA L’USO D’OLIO:

EMPFIEHLT DEN GEBRAUCH VON ÖL:

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

E-mail: [e-mail] / [e-mail]

JUNIO / JUNE / JUIN / GIUGNO / JUNI 2006

PUO10638001