Home

MANUAL DEL USUARIO USER MANUAL MANUEL D

1. 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
2. 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 CP kc KT 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 between electrodes using a gauge and
3. Ce KC KT 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 sorocket 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 CP KC KT 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 develop
4. 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 Ath 1 100 22 20 5th 0 913 21 23 6th 0 791 19 24 2 85 57 20 3 692 48 13 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 6 Suspension Ohlins 48mm inverted fork Suspension stroke Front suspension oil Front fork oil level Front Rear Front Rear Marzocchi 45mm inverted fork Progressive system with single multi adjustment OHLINS shock absorber 295 mm 320 mm MARZOCCHI SAE 7 5 OHLINS SAE 5 7 5 Marzocchi 100 mm compressed without spring OHLINS 110 mm compressed without spring CM SC II BRAKES Type Effective disk diameter DIMENSIONS Overall height Overall length Overall width Wheel base Minimum ground clearance Fuel tank capacity Weight 119 Kg Front rear Front Rear Disk brakes NISSIN pump and simple double callipers 260 mm 220 mm 1260 mm 2135 mm 810 mm 1475 mm 340 mm 9 5 litres Specifications subject to change without notification also possibly not applicable in some countries COP KC KT LOCATION OF COMPONENTS GAS GAS FSE 450 4 3 4
5. Fill the fuel tank with fuel Check all the points listed in the Daily Pre ride Inspection Section General lubrication Connect the battery Ce KP KT 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 rom 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 Panel 52 Panel description RESET button 2nd row of indicators 1st row of indicators Tachometer with bar graph Tachometer scale Fuel indicator bars optional LED indicator symbols MODE button ONOORWN Description of symbols Left indicator Green Dipped headlights Green 7 Motor oil Red Optional Right indicator Green D Full headlights Blue Neutral Green Optional CP KC KT Technical characteris
6. KF 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 B A Use grease on the inner throttle cable 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 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 ENGINE OIL Ce kc KT 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
7. 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 CP kc KT 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 Ce kc KT 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 pi
8. 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 MAINTENANCE CHART Article Period Period Period First 5 hours Every 30 hours Every 60 hours Air filter Inspect each time that the motorcycle has run or when necessary T T Valve tolerances Sparicp uc CR Injection pump pipes Revise every 4 years Engine oil and filter oil ARANA Engine oil pipes AAA AAA Coolant Revise every 2 years Radiator hoses Ls cq WX qd A Clutch AAA Clean lubricate and inspect each time the motorcycle has run Brakes NN NE ER RE l Brake lines Revise every 4 years Brake liquid Revise every 2 years Steering assembly ASS e Frontforks VV N Rear suspensi n 15 3c _ 0 I NOTE Inspect and clean adjust replace or lubricate if necessary R Replace T Tighten C Clean 15 CP
9. kc KT BATTERY 3 Disconnect the terminals ensuring that they do not enter into contact with metal parts then extract the This battery is maintenance free and checking the fluid level is not battery required It is advisable to check the charge of the battery periodically WARNING To remove the battery follow these steps 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 Incase 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 screws A and remove the seat B 2 Release the rubber C 16 CP kc KT Recommended charging duration 5 8 hours CAUTION The product charge current X charge duration must be within Using a high pressure water source could damage the radiator fins the range 0 5 0 8 Cn
10. Incorrect or poor gasoline or wrong octane rating Drain the petrol and fill with fresh or higher octane petrol Incorrect or non specified spark plug Change spark plug for a new one or recommended one FAULT CAUSE SOLUTION Gears don t engage The spring of the selector is broken Replace the down selector mechanism spring Cylinder change if broken Gear ratchet spring broken Replace the gear drum Replace the ratchet spring of the selector Gear change fork damaged in the gears Change gear fork Gear teeth worn Gear nipple damaged Change Go to a specialist workshop Groove gear drum worn Change Go to a specialist workshop Gear change fork pivot worn Change Gotoa specialist workshop Change shaft Go to a specialist workshop Clutch slipping No play in the clutch handle Go to a specialist workshop Clutch plate worn Replace the clutch plate Go to a specialist workshop Replace the clutch hub Clutch housing worn Adjust the selector position spring or change it Clutch spring broken or weak Change the clutch disks Go to a specialist workshop Clutch plates worn Bike unstable Cable obstructs handlebars Put the cable to one side and release it a little Steering shaft nut too tight Undo the steering shaft nut Steering bearings damaged or worn Replace the steering bearing Steering shaft bent Change the steering shaft Go to a speci
11. Radiator support bolts 21 Rear shock bolts 29 Rocker arm bolt 6 Air filter housing bolts 14 Nuts and bolts of the engine 22 Exhaust flange bolt 7 Seat support bolts mounting 23 Upper suspension plate bolts 8 Spokes 15 Shift pedal bolts 24 Steering head nut 9 Disk plate screws 16 Chain guide bolts 25 Brake lever support bolt 17 Chain adjust bolt 26 Rod support bolt CP kc 4 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 PART NAME PAPA EU 4 oes Kick pedal nut nut O A Sparkplug jp 1 10 Waterpumpcoverdrainplug 1 9 oo Calliper mounting bolts 23 25 Disc plate mounting screws 10 11 Enginemountingbolts 36 36 Frontaxlebolt n vm 51 Frontbrakeleversupportbolt 6 06 Forkflangebot 1 53 30 Steeringnut 98 100 Rearaxlenut 1 0 X 98 100 Rearbrakepedalbolt O 9 09 Subframesupportbot 55 27 Rearshockabsorberbolt 39 40 Reardiscwheeldrivebolt 29 830 Spkes ZJSZ 15 015 Steeringaxlebot o 4 45 Rockerarmbolt 81 B Rodbot o o 81 83 Ce kc
12. 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 PR REN N If the standard spark plug is wet then replace it E ue N Standard CR9E U27ESR N If the standard spark plug looks glassy or has a white colour replace it Ce kc KT CUIDADO 3 Remove the bolts C Un incorrecto montaje de la buj a o grado t rmico incorrecto puede EZ L left and right provocar grandes da os en el motor y estos da os no son cubiertos por la garant a Usar siempre las buj as recomendadas por la marca Consultar a los concesionarios o a un mec nico cualificado para saber qu buj a es la mejor para su motocicleta Extracci n de la buj a Para extraer la buj a seguir los siguientes pasos A 4 Remove the rubber attachment on the tank D 1 Remove t
13. cap y P A Radiator Cap 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 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 5096 antifreeze 50 CP kc KT 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
14. 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 CP kc KT 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
15. 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 CP kc KT 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 b
16. 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 CP kc KT 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 4 Remove the three screws next to the filter cover C 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 NOTE Put used motor oil in an appropriate container for recycling 5 Remove the filter cover extract the filter element D and the seal E Always replace both elements at the same time WARNING Always use original GAS GAS parts 3 Drain the engine oil by If the filter is incorrectly positioned the engine oil will not flow removing the cap B keep provoking a malfunction in the engine the motorcycle vertical 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
17. kc KT 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 pedal B 10 mm of play A B A Brake lever WARNING B Rubber protection 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 Rear brake pedal dangerous to operate the motorcycle under such conditions check the brakes immediately 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 Brake fluid retighten the locknut Regularly check the brake fluid and periodically change it It should also be changed if it is contaminated by water or dirt 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 Ce KC KT 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
18. 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 lt 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 Front forks The fork oil level is adjustable A change in the oil level will not affect the lower part of the s
19. 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 repa
20. to readjust the gear change according to RPM 55 CP KC KT 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 1 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 2 The screen shows 12 or 24 h and the symbols XX XX XX and AM PM if the 12h option has been selected 3 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 4 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 5 Press the MODE button to switch to the adjustment screen of the gear change according to rpm onc
21. 1 Clutch handle 2 Engine start button 3 Fuel tank cap 4 Front brake fluid tank 5 Front brake handle 6 Throttle control GAS GAS FSE SM 450 1 Clutch handle 2 Engine start button 3 Fuel tank cap 4 Front brake fluid tank 5 Front brake handle 6 Throttle control 12 7 9 16 11 18 13 8 23 15 10 17 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 2120 22 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 Ce kc KT CP kc KT 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 PETROL The GAS GAS FSE SM FSE 450 has a four stroke engine and requires 98 octane unleaded petrol Fuel Tank Capacity 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 f
22. 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 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 30 50 mm of spa
23. Ir pL aU MANUAL DEL USUARIO oP y f eF Yf USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG E SESGO USER MANUAL Ce KP KT 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 CP kc KT IMPORTANT NOTICE Read this manual carefully This manual covers aspects that will contribute to your security and to that of o
24. ON The fuse for the starter relay is blown Battery discharged The starter motor does not work Low temperature Crankshaft locked Cylinder piston crankpin journal seizure Transmission assembly seizure The engine does not rotate Engine rotates but does not Fuel supply incorrect start The motorcycle has been out of operation for a longer period of time Spark plug soiled or humid Engine flooded 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 kick start 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 FAULT CAUSE SOLUTION Engine rotates but does not start The engine starts but does not stop The engine overheats The engine does not run s
25. aining corrosion for leaks and rust inhibitor chemicals is not used over a period of time the radiator will rust This will block the cooling hoses Radiator Check the radiator fins for obstruction by insects or mud Clean off any obstructions with a stream of low pressure water CP kc KT 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 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
26. alist workshop Shock absorption too hard Front forks excess oil Eliminate the excess oil to an adequate level Front fork oil viscosity too high Empty the fork oil and fill with oil of the recommended Front forks twisted viscosity Change front fork Go to a specialist workshop Excessive tyre pressure Verify tyre pressure SOLUTION ER Shock absorption too hard Rear shock badly adjusted Adjust the rear shock Shock absorption too soft The bike makes unusual noise Handlebar shakes or excessively vibrates 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 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 Ch
27. ance by changing the piston rings FAULT CAUSE SOLUTION High oil consumption There is too much engine oil Correct the engine oil level Drain oil as necessary from the engine The quality or viscosity of the oil is Empty the engine oil and fill with oil of the recommended insufficient viscosity Abnormal engine noise Ignition problems Go to a specialist workshop Valve adjustment play Adjust the valve play Go to a specialist workshop See chapter 5 Over heating Exhaust system joints deteriorated Check if the exhaust system is deteriorated The seals must be in perfect condition if not then they must be changed for new ones White fumes from the exhaust Cylinder head gasket leak Change the cylinder head gasket Go to a specialist water leaking into cylinder workshop Brown fumes from the exhaust Air filter obstruction Clean or change the air filter Go to a specialist workshop The gears do not engage Clutch does not release Go to a specialist workshop Shift fork worn or locked Change the gear fork Gear locked in transmission Go to a specialist workshop Shift lever damaged Change the gear lever Selector position spring broken orloose Adjust the selector position spring or change it Detonations in the exhaust Carbon in combustion chamber Clean the combustion chamber Injection system maladjustment Trim Epprom Go to a specialist workshop
28. and render it ineffective Do not obstruct or deviate the radiator air intake by installing non Note approved accessories Interfering with the radiator could cause In case that a different mode of charging is used to those overheating and result in engine damage established here never exceed the maximum allowed currents nor the maximum charge duration of 24 hours Coolant This absorbs excessive heat from the engine and transfers it to the CAUTION air at the radiator If the coolant level becomes low the engine Not using the standard manner of charging may seriously shorten overheats and may suffer severe damage Check the coolant level the battery life each day before riding the motorcycle Replenish coolant if the level Never exceed the standard charge is low WARNING 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 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 THE COOLING SYSTEM Anti freeze liquid information Radiator hose To protect the cooling system aluminium parts engine and radiator from rust and corrosion the use of corrosion and rust inhibitor Check the radiator hoses for cracks or deterioration and connections chemicals in the coolant is essential If coolant cont
29. ange 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 oylinder 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 FAULT CAUSE SOLUTION Motorcycle pulls to one side Chassis twisted Steering incorrectly adjusted Steering shaft bent Front forks twisted Rear wheel misaligned The brakes do not function Disk worn correctly Loss of brake fluid Brake fluid deteriorated Piston cylinder broken Brakes incorrectly adjusted The lights blow Voltage regulator faulty The lighting system does not Installation fuse is blown 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
30. at water does Check the brakes before driving the bike not penetrate certain areas of the bike The exhaust Once this is cold cover it with a plastic bag attached with rubber Never wax or lubricate the brake disk this could lead to brake failure and could provoke an accident Clean the disk using trichloroethylene Clutch and brake levers grips and stop button cover with a or acetone 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 CP kc KT 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 19 20 21 22 24 23 25 8 10 11 13 14 15 12 16 17 18 26 2827 29 1 Front and rear wheels 10 Front axle bolt 18 Rear axle bolt 27 Rear brake pedal bolt 2 Front forks 11 Brake attachment bolt 19 Silencer support bolts 28 Rod support bolt 3 Handle bars 12 Sub chassis support bolt 20 Sub chassis bolts Rocker 4 Clutch lever support bolt 13
31. ce 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 CP KP KT 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 CP KC KT 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 gui
32. d take the filter out C Inspect this without fault before and after each race or session Stuff a clean lint free towel into the intake manifold so that no dirt Clean if necessary is allowed to enter CAUTION Do not spin the filter on its cage It is possible to tear or damage the Cleaning the air filter filter Clean inside the filter housing using a damp cloth 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 Remove the cage B from the air filter A CP KC KT Clean the filter in a filter bath using a soft brush Squeeze it and take it out with a clean 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 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 Fit the air filter to the motorcycle and ensure that it is correctly connected 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 thr
33. d 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 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 im E d a 1 Spring k d 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 A Hydraulic rod and the track conditions Hard springs make the forks harder and the rebound faster Light springs make the forks softer and the rebound slower 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 Suspension plate position Put the fork spring 1 into the fork tube Tighten the suspension spring and insert the spanner 5 onto the Ensure that the tyre do
34. de is worn excessively or damaged replace it 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 Apply oil to the side of the links so that it will penetrate better Wipe off any excess oil A Apply 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 CP lt A II 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 CP
35. 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 A Spoke tightening tool 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 CP kc KT Cleaning 3 After cleaning Remove the plastic bags and clean the air filter intake 1 Preparation for cleaning Lubricate the locations listed in the lubrication section Start the engine and let it heat for 5 minutes Before cleaning the motorcycle must be prepared so th
36. e 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 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 high
37. e the clock has been configured 6 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 7 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 8 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 9 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 10 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 56 Ce kc KT 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 mode k mode LE mode 4 5 CP koc KT FAULT DIAGNOSIS 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 SOLUTI
38. e throttle control bolts Verify grease the throttle control Verify the front and rear brake lines Front and rear brake fluid level Front and rear brake disc and calliper installation Front and rear brake operation Fuel tank installation Check cables Engine mounting bolts Engine pinion Shift pedal bolt Transmission oil level Battery charge Throttle housing Rod mounting bolts Rod bolts Rear shock bolts Tighten the swinging arm pivot nut Tighten the rear axle nut Tighten nut and bolt of rear sprocket Operate rear brake pedal Check seat Tighten the spokes Tyre air pressure Tighten chain Coolant Level 2 Following a day of competition Clean the air filter Adjust the chain tension slack Tighten the bolts of the rear sprocket Tighten spokes Check the tyre pressure Tighten the front and rear axle nuts Tighten the swinging arm nut Tighten the nuts and bolts of the exhaust and silencer 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 D epo OO ee NS 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
39. ecome 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 64 COP KC KT Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that
40. ed 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 SAS EE dide Tighten the front axle and disks Tighten the front forks flange bolts Tighten the handlebar clamp bolts Tighten th
41. edal B CP KP KT 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 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
42. er 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 CP kc KT 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 A Purge bolt 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 B Adjustment control CP kc KT 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 anti clockwise 12 positions Adjusting the oil level Using the stan
43. es not touch the mudguard when the forks cap lock 3 counter nut 2 are fully compressed There should be at least 5 mm clearance Fit the suspension cap 3 to the fork tube and tighten to 29 Nm Fit the other fork Refit all removed parts CAUTION The right and left suspension rods must be adjusted equally 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 A Rebound adjustment 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 compl
44. etely closed position Ba A Compression adjustment 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 A Sub chassis B Filter housing CP KTP KT Suspension spring The standard spring is a 5 4 The length of the preloaded spring with the shock in rest position is 258 mm A C A Nut B Spring C Counter nut ato B 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 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
45. 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 CP kc KT 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
46. he bolts A left and right m y p ed 5 Remove the tank securing bolt E 2 Remove the seat B CP KC KT 6 Separate the connectors from the electronics F 8 Remove the spark plug hood 7 Separate the NOTE connector G from A cap protects the spark plug the fuel pump and Keep this clean and dry secure to one side of the tank 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 0 7 0 8 mm 0 028 0 031 in Ce KTP KT 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 Remove the cap A An obstructed air filter will allow dirt to enter the engine causing Remove the screw B excess wear and engine damage an
47. iring 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 66 Notes CP KC KT CASCAS 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 L Global Racing Oil PUO10638001 JUNIO JUNE JUIN GIUGNO JUNI 2006 C UNICEF n 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
48. 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 CP kc KT 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 gt Y 7 E D B 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 Install the upper suspension plat
49. moothly 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 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 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 toler
50. n 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 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
51. n the second row The digital tachometer displays up to 19 900 rom 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 rom level The tachometer bar flashes when the rom reaches the specific level and stops flashing when the gear is changed MAX RPM Maximum tachometer value It appears in the 2 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 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 I
52. ns 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 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 Ce kc KT 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 i B Shift p
53. 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 65 CP kc KT 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
54. ottle cable and turn the adjuster to obtain the correct amount of play Tighten the locknut C B A D A Adjustment B Lock nut C Throttle grip D Brake fluid reservoir f 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 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 Ce kc KT 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 B C eoo Wm i A x EEE 3 A Silencer B Silencer attachment bolts C Flange CP KC KT Changing the silencer packing Remove the cover rivets A
55. t 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 N 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 CP IICT II 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 detects a signal Ce A MODE MODE MODE 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 HESET 2 Return the data in TRIP 1 AVG and RT at the same time The data of the ODO y 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
56. thers 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 Ce ce II OIL RECOMMENDED Global Racing Oil TABLE OF CONTENTS FOS ie 10 M _ RET RIEN 3 important NOCE RTI USO PE 4 Table of COMMONS PRODIT 5 General MGM MAU ON iaa 6 Component IO CANONS Y FF FN 8 o To EN TO FN AN NN WW 10 Ga o FU A MIA CO CERNIMUS 10 Serial number and the q
57. tics FUNCTIONS Symbol TECHNICAL CHARACTERISTICS INCREMENTS PRECISION Bar Tachometer 500 11 000 rom 500 rpm Digital Tachometer 100 19 900 rom 100 rom Gear change indicator 100 19 900 rom 100 rpm Maximum Tachometer Value 100 19 900 rpm 100 rpm AX RPM MAX m o 2o Speedometer 2 3 300 km h 187 5 m h 0 1 km h o m h H AH z Speedometer 2 3 300 km h 187 5 m h 0 1 km h o m h I as ze TS o Ja 34 Solo I O 1 km h m t 0 1 96 0 1 Average Speed AVG 2 3 300 km h 187 5 m h 0 1 km h o m h Distance counter 1 amp 2 TRIP 1 amp 2 0 999 9 km or O 624 9 miles 0 1 km or miles Mileometer 0 999 999 km or O 624 999 miles 0 1 km or miles Time in use 0 00 00 99 59 59 1 second 50 ppm 50 ppm Total time 0 00 9999 59 1 minute Clock 0 00 00 23 59 59 1 second 1 minute 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 C 80 C engine casing interior Fuel sensor resistance 100 O only in models with fuel level indicator 53 CP kc KT 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 i
58. troke 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 High levelStandard level oil Low level End of stroke Suspension stroke 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
59. ts 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 tur
60. ualification approval plate 11 Starting and stopping the engine ccccccconccccnncccononccnnccnnonancnnnnos 12 ree rp NEN oo o o m 13 E A 13 Stopping the motorcycle amaste 14 EEE E PPP PO A A 14 Maintenance chaft asiatico 15 EEUE qe EETA T A TA E A A NF ETE 16 A 17 A 20 A 23 Accelerator cable circo 24 Gui 25 EXHausEs SIS FN FE NAF E 25 CP kc IEI amp uu A e E A NN CN RY RA RR YO PF 26 Tension AUSTEN M Er 27 Handle DS escoria RF RENT a FUAN 29 EA SS eos _ RM MEINE MEE EI IDEE MEME 29 scio Y FY YN 31 xii oe SN NET 32 o A e o EE EIU FN HUE 33 Rear SUS DENS ION sra 36 e ee FR IONA T 38 A ae eee ee NF A NR 39 Tighten bolts and nuts rcm 40 Tightening torque table t cicl n 41 LIRICA OMY iuair an anA EnA ONE T TT 42 glo qdo MERE 43 Suspension adjustment cc dii 46 Mi competi qM 50 e En Ue E HEN NE E E NM 51 Multi function instructions cir 52 Fak diaghoS TY THE uo 58 Guarantee Manual einstein 64 CP KC KT GENERAL INFORMATION ENGINE Engine Displacement in cubic centimetres Bore and stroke 4 stroke single cylinder DOHC 4 valves liquid cooled 449 cc 97 x 60 76 mm Primary reduction ratio Final reduction ratio Overall drive ratio Spark plug NGK CR8E or DENSO U24ESR N Fuel supply Magneti Marelli electronic injection TRANSMISSION Transmission type 6 speed
61. uel cap rotate it in a clockwise direction 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 MU Research Octane No RON 8 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 11 CP KP wi 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 2 3 ve Mc Uo uh il COP kc KT 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 A Stopping the engine Change gear to neutral After a slight acceleration release the throttle completely and rotate the ignition key anti clockwise D The key should point left D this mea

MANUAL DEL USUARIO USER MANUAL MANUEL D

Contents

Download Pdf Manuals

Related Search

Related Contents