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GAS GAS FSE 450 Service Manual

GAS GAS FSE 450
71 pages
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MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
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GAS GAS FSE 450 Specifications

General IconGeneral
Compression Ratio12.5:1
Transmission5-speed
CategoryEnduro
Displacement449 cm3
Cooling SystemLiquid-cooled
Fuel SystemElectronic Injection
Rear SuspensionMonoshock
Front BrakeSingle disc
Rear BrakeSingle disc
Engine TypeSingle cylinder, 4-stroke

Summary

Foreword

Important Notices and Symbols

Important Notices and Symbols

Details important notices, warnings, cautions, and notes for safe operation and understanding of the manual.

General Information - Engine and Transmission

Engine Specifications

Provides detailed specifications for the engine, including displacement, bore, stroke, and spark plug type.

Transmission and Chassis Details

Outlines transmission type, gear ratios, clutch, and chassis construction, including tyre sizes.

General Information - Suspension, Brakes, and Dimensions

Suspension and Brake System Details

Details suspension components, stroke, brake type, and effective disk diameter.

Motorcycle Dimensions

Lists the overall height, length, width, wheelbase, ground clearance, and weight.

Component Identification - Handlebar Controls

Handlebar Controls Overview

Identifies key controls on the handlebars for FSE and FSE SM models.

Component Identification - Motorcycle Layout

Motorcycle Component Layout

Illustrates and labels major components of the motorcycle.

Operation and Fuel - Side Stand and Fueling

Side Stand Operation

Instructions for using the side stand.

Fuel Requirements

Details on recommended fuel and tank capacity.

Fuel Octane and Serial Number

Fuel Octane Requirements

Specifies fuel octane requirements.

Serial Number and Approval Plates

Locations for serial and approval plates.

Engine Operation - Starting and Stopping

Starting and Stopping the Engine

Step-by-step procedures for starting and stopping the motorcycle's engine.

Engine Operation - Cold Start and Gears

Cold Starting Procedure

Guidance on starting a cold engine.

Gear Shifting Procedure

Instructions for performing gear changes.

Riding and Break-in

Stopping the Motorcycle

Procedure for safely stopping the motorcycle using throttle and brakes.

Motorcycle Break-in Procedure

Detailed steps for the initial break-in period to ensure engine and transmission longevity.

Maintenance Schedule

Maintenance Chart

Comprehensive chart outlining required maintenance tasks at different service intervals.

Battery Maintenance

Battery Removal and Reinstallation

Steps for safely removing and reinstalling the motorcycle battery.

Battery Charging Procedures

Guidelines for charging the battery using constant voltage or power modes.

Cooling System Care

Radiator and Hose Inspection

Instructions for inspecting radiator hoses for cracks and radiator fins for obstructions.

Coolant and Anti-freeze Information

Explains the function of coolant, anti-freeze, and precautions for handling.

Cooling System Care - Coolant Level

Coolant Level Check Procedure

Detailed steps for checking the coolant level safely, including radiator cap removal.

Cooling System Care - Changing Coolant

Changing the Coolant

Step-by-step guide for draining, replacing, and refilling the motorcycle's coolant.

Ignition System Maintenance - Spark Plug

Spark Plug Inspection and Maintenance

Guidance on inspecting, cleaning, gap adjustment, and replacing spark plugs.

Spark Plug Maintenance Chart

A table correlating spark plug types with maintenance recommendations.

Spark Plug Maintenance - Removal and Cleaning

Spark Plug Removal and Cleaning

Detailed steps for removing the spark plug and cleaning carbon deposits.

Air Filter Maintenance - Function and Cleaning

Air Filter Function and Warnings

Explains the importance of the air filter and potential hazards of a clogged filter.

Air Filter Cleaning Process

Instructions and precautions for cleaning the air filter.

Air Filter Maintenance - Cleaning Steps

Air Filter Cleaning Steps

Detailed steps for cleaning and installing the air filter.

Controls Maintenance - Throttle and Clutch

Throttle Cable Adjustment

Procedure for adjusting throttle cable play for smooth operation.

Clutch Lever Play Adjustment

Steps to adjust the clutch lever play for optimal engagement.

Controls Maintenance - Clutch Limit and Exhaust

Clutch Adjustment Limit

What to do if the clutch lever adjustment is at its limit.

Exhaust System Maintenance

Information on the exhaust system and silencer maintenance.

Chain and Sprocket Maintenance - Guide and Tension

Chain Guide and Tension Checks

Inspecting the chain guide and adjusting chain tension for proper function.

Chain and Sprocket Maintenance - Lubrication and Wear

Chain Lubrication and Wear

Guidance on lubricating the chain and inspecting for wear.

Handlebar Adjustment

Handlebar Position Adjustment

Instructions on how to adjust the handlebar position for rider comfort.

Handlebar Bolt Tightening

Torque specifications for handlebar mounting bolts.

Brake System Maintenance

Front and Rear Brake Adjustments

Adjusting front brake lever and rear brake pedal play.

Brake Fluid and Wear Inspection

Procedures for checking brake fluid level, changing fluid, and inspecting pad wear.

Steering System Maintenance

Steering Adjustment and Play Check

How to check and adjust steering for proper operation and minimal play.

Steering Lock Operation

Instructions on how to use the steering lock mechanism.

Front Suspension System - Principles and Rebound

Front Fork Adjustment Principles

Factors influencing front fork adjustment, including rider weight and conditions.

Front Fork Rebound Adjustment

How to adjust the front fork's rebound damping.

Front Fork Compression Adjustment

How to adjust the front fork's compression damping.

Front Suspension System - Oil and Spring Details

Front Fork Oil Level Adjustment

Procedure for adjusting the oil level in the front forks.

Front Fork Spring and Oil Details

Information on recommended fork springs and oil types.

Front Suspension System - Spring Installation

Suspension Rod Spring Installation

Steps for installing the suspension spring and related components.

Rear Suspension System - Extension and Compression

Rear Shock Extension Adjustment

How to adjust the rebound damping of the rear shock absorber.

Rear Shock Compression Adjustment

How to adjust the compression damping of the rear shock absorber.

Rear Suspension System - Spring Adjustment

Rear Suspension Spring Adjustment

Procedure for adjusting the rear shock absorber spring preload.

Wheel Maintenance - Tyre Pressure and Spokes

Tyre Pressure and Track Conditions

Adjusting tyre pressure based on track conditions and rider preference.

Spokes and Rim Centering

Instructions for checking spoke tension and rim centering.

Motorcycle Cleaning

Cleaning Preparation and Precautions

Steps to prepare the motorcycle for cleaning and areas to protect from water.

Post-Cleaning Procedures and Warnings

Steps to follow after cleaning, including lubrication and brake checks.

Bolt and Nut Tightening

Daily Bolt and Nut Checks

Importance of ensuring all bolts and nuts are tightened daily.

Component Tightening Points Diagram

Diagram illustrating key points for checking bolt tightness.

Torque Specifications

Tightening Torque Table

A table listing specific torque values for various bolts and nuts.

Lubrication Procedures - General

General Lubrication Points

Identifies key points for general lubrication with oil or grease.

Lubrication Procedures - Chain

Chain Lubrication

Guidance on lubricating the drive chain, including oil viscosity.

Engine Oil Management - Recommendations

Engine Oil Recommendations

Details on recommended engine oil types, viscosity, and API classification.

Engine Oil Management - Level Check

Engine Oil Level Check

Procedure for checking the engine oil level accurately.

Engine Oil Management - Oil and Filter Change

Engine Oil and Filter Change

Steps for changing the engine oil and filter.

Engine Oil Management - Filter Replacement

Oil Filter Replacement

Specific instructions for replacing the engine oil filter element.

Suspension Tuning Guide - Principles and Front Forks

Principles of Suspension Tuning

General advice and factors to consider when tuning suspension.

Front Fork Adjustment Details

Specific adjustments for front forks, including rebound, compression, and oil levels.

Suspension Tuning Guide - Front Fork Troubleshooting

Front Fork Troubleshooting

Common front fork issues and their solutions.

Suspension Tuning Guide - Rear Shock Troubleshooting

Rear Shock Absorber Troubleshooting

Common rear shock absorber issues and their solutions.

Suspension Tuning Guide - Experience and Compatibility

Suspension Experience and Compatibility

Advice based on rider experience and checking front/rear suspension balance.

Suspension Tuning Guide - Handling Adjustments

Handling Adjustments for Turns and Jumps

Adjustments for handling issues in turns and during jumps.

Suspension Tuning Guide - Gear Selection

Gear Selection for Terrain

Guidance on selecting appropriate gear ratios based on track conditions.

Additional Information and Competition - Parts and Care

Spare Parts and Track Condition Care

Information on obtaining spare parts and special care for different track conditions.

Additional Information and Competition - Checks

Competition Preparation and Checks

Lists of checks required before and after competition riding.

Additional Information and Competition - Post-Race Maintenance

Post-Race Maintenance

Specific maintenance tasks after racing on dusty or muddy terrain.

Motorcycle Storage

Storage Preparation and Re-use

Procedures for preparing the motorcycle for storage and taking it back into use.

Multifunction Display Guide - Overview

Display Overview and Functionality

Explanation of the multifunction display, its modes, and settings.

Multifunction Display Guide - Settings

Trip Distance and Clock Settings

How to set and reset trip distance and adjust the clock.

Troubleshooting Guide - Starter and Rotation

Starter Motor and Engine Rotation Issues

Diagnosing and resolving problems with the starter motor and engine rotation.

Troubleshooting Guide - Engine Start and Run

Engine Starting and Running Problems

Troubleshooting common issues related to engine starting and smooth running.

Troubleshooting Guide - Performance and Overheating

Engine Performance and Overheating Issues

Diagnosing and fixing problems with engine performance and overheating.

Troubleshooting Guide - Noise, Fumes, and Gears

Engine Noise, Fumes, and Gear Issues

Addressing abnormal engine noise, exhaust fumes, and gear engagement problems.

Troubleshooting Guide - Clutch, Stability, and Shock

Clutch, Stability, and Shock Issues

Troubleshooting clutch slipping, bike instability, and shock absorption problems.

Troubleshooting Guide - Handling, Noise, and Brakes

Handling, Noise, and Brake System Issues

Resolving issues with handling, vibrations, noise, and brake system malfunctions.

Troubleshooting Guide - Lighting System

Lighting System Issues

Diagnosing and fixing problems with the motorcycle's lighting system.

Electrical Schematics - Diagram and Color Code

Wiring Diagram Overview

Provides a comprehensive diagram of the motorcycle's electrical system.

Wire Color Code Legend

Explains the meaning of different wire colors used in the schematics.

Warranty Information - Terms and Conditions

Warranty Terms and Conditions

Details the manufacturer's warranty terms, coverage, and duration.

Warranty Information - Purchaser Obligations

Purchaser Obligations and Exclusions

Outlines the purchaser's responsibilities and items excluded from warranty coverage.

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