GAS GAS FSE 450 - 2006, User Manual

Page 1: ...MANUAL DEL USUARIO USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG ...

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Page 3: ...ENGLISH USER MANUAL USER MANUAL ...

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Page 5: ...it 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 c...

Page 6: ...sult 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 Respons...

Page 7: ...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 comp...

Page 8: ...sk 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 t...

Page 9: ...rzocchi 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...

Page 10: ...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 6 5 1 3 4 2 6 5 ...

Page 11: ... 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 11 12 13 16 15 17 18 14 19 20 21 22 23 24 ...

Page 12: ... 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 sec...

Page 13: ... 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 ...

Page 14: ...ctive 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 e...

Page 15: ... transmission to jump out of gear and lead to engine damage B Shift pedal 13 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 ...

Page 16: ...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 eng...

Page 17: ... 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...

Page 18: ...eep 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 b...

Page 19: ...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 non approved 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 becom...

Page 20: ...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 ...

Page 21: ...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 ...

Page 22: ...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...

Page 23: ...andes 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 ...

Page 24: ...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 connecto...

Page 25: ...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 ...

Page 26: ...he 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 a...

Page 27: ... 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...

Page 28: ...eak 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 ...

Page 29: ...e 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 ...

Page 30: ...rn 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...

Page 31: ...te 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 requi...

Page 32: ...ld 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 ...

Page 33: ...g 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 sho...

Page 34: ...move 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 S...

Page 35: ...e 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 po...

Page 36: ...he 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 for...

Page 37: ...rk 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...

Page 38: ...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...

Page 39: ...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...

Page 40: ...rber 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 N...

Page 41: ... 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...

Page 42: ...s 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 ...

Page 43: ...ump cover drain 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 wheel 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 K...

Page 44: ...ing 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 ...

Page 45: ... 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...

Page 46: ...he 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 c...

Page 47: ...nkcase 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...

Page 48: ...ding 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 settin...

Page 49: ...oo 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 i...

Page 50: ... 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 o...

Page 51: ... 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 thro...

Page 52: ...n 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...

Page 53: ...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 Tig...

Page 54: ...ourney 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 metri...

Page 55: ...er 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 entr...

Page 56: ...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 MA...

Page 57: ...RIP 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 c...

Page 58: ...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 in...

Page 59: ... 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 ...

Page 60: ...p 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 kick start 5 to 10 times or operate the electric starter 2 times in 5 seconds Then star...

Page 61: ...linder 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 by pass 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 coolin...

Page 62: ...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 insufficie...

Page 63: ...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...

Page 64: ...acket 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 Ali...

Page 65: ...ly 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 cy...

Page 66: ...ts 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 Neverthe...

Page 67: ...n 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 ordi...

Page 68: ... 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...

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Page 72: ... 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 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es JUNIO JUNE JUIN GIUGNO JUNI 2006 PUO10638001 ...