GasGas Halley 450 2009 Owner's manual

HALLEY 450´09

Foreword

GAS GAS thanks you for your confidence.

By choosing the new GAS GAS HALLEY 450 2009 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 HALLEY 450 2009 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.

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

CAUTION

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.

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

NOTE

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

OIL RECOMMENDED:

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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

Electrical schemas........................................................................64

Guarantee manual........................................................................66

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GENERAL INFORMATION

ENGINE

Engine 4 stroke, single-cylinder DOHC 4 valves, liquid cooled Displacement in cubic centimetres 449 cc Bore and stroke 97 x 60.80 mm Fuel supply Electronic injection (Battery Less EFI) Sparkplug NGK CR8E / ND U24ESR-N

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 EH 3,15 (41/13) SM 2,92 (38/13 Overall drive ratio 7,11 6,59 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

Pressure

Tyre sizes Front EH - 90/90 x 21 1-----1,2 Kg Cm2

EH SM - 120/60 ZR17 2,4--2,5 Kg Cm2

Rear EH - 130/80 x 18 0.9--1,3 Kg Cm2

EH SM - 150/60 ZR17 2,4--2,5 Kg Cm2

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Suspension Front Inverted fork

Rear Progressive system with single shock absorber

Suspension stroke Front 230 mm

Rear 220 mm Front suspension oil Between SAE 7.5 (check manufacturer’s information) Front fork oil level 100 mm (compressed, without spring)

120 mm (compressed, without spring)

BRAKES

Type Front / rear Disk brakes, dual- piston caliper floating / singel- piston caliper floating 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 265 mm Fuel tank capacity 7.2 litres Weight 118 Kg

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

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LOCATION OF COMPONENTS

LOCALIZACIÓN DE COMPONENTES

GAS GAS EH 450

4 2 6

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

6- Throttle control

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15 17

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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

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SIDE STAND

PETROL

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)

(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.

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

Fuel Tank Capacity

7.2-7.5L

(A)

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

To open the gas tank cover (A), turn it anti-clockwise.

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

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RECOMMENDED FUEL

SERIAL NUMBER

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.

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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STARTING THE ENGINE

Stopping the engine

- Ensure that the motorcycle is in neutral.

- Turn the key (A) to turn on the electrical circuit, so that the motor may be started.

(A)

(B)

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

- Change gear to neutral.

- After accelerating lightly, cut the gas completely and turn the key

(A). The electrical circuits are disconected.

(A)

NOTE

Start the engine soon after making contact with the ON key (A) or the battery may lose its change.

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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.)

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.

- 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.

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.

(B)

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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.

(A)

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.

The slow speed necessary during the break-in period may cause

NOTE

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.

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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

MAINTENANCE CHART

Period

First 5 hours

Period

Every 30 hours

Period

Every 60 hours

Inspect each time that the motorcycle has run or when necessary

I I

*Revise every 4 years

I I

Revise every 2 years

I I

Clean, lubricate and inspect each time the motorcycle has run

I I

*Revise every 4 years

*Revise every 2 years

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

I I I

NOTE: I = Inspect and clean, adjust, replace or lubricate if necessary; R = Replace, T = Tighten, C = Clean

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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:

(A)

(B)

(C)

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

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

2. Release the rubber (C).

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- 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.

Using a high pressure water source could damage the radiator fins

CAUTION

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.

Inverting the polarity of the battery terminals may cause battery

CAUTION

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.

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.

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Use of incorrect coolant solutions will cause severe engine and

CAUTION

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.

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)

Soft or distilled water must be used with the inhibitor chemicals and

CAUTION

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.

(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.

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Check the level when the engine is cold.

NOTE

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

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 bowl under the water pump cover and remove all the liquid

in the radiator and engine by unscrewing the bolts. Immediately wipe

or wash off any coolant that spills on the frame, engine, or wheels.

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)

(A). Water pump cover.

WARNING

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

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- Examine the used 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.

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.

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

Standard spark plug Gap between electrodes: 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

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

COMMENTS

If the standard spark plug is wet then replace it.

If the standard spark plug looks glassy or has a white

colour, replace it(

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An incorrectly fitted spark plug, or an incorrect temperature can lead

WARNING

to severe damage to the engine, and this damage is not covered by the warranty.

Always use the manufacturer's recommended brand of spark plug. Check with your dealer or a qualified mechanic to determine the correct spark plug for your motorbike.

Removing the spark plug

To remove the spark plug, follow these steps:

(A)

(C)

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

(B)

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

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3. Remove the

rubber attachment

on the tank (D).

(E)

(D)

4. Remove the tank securing bolt (E).

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