GAS GAS EC FSE 400 - SERVICE 2002 & 2003 User manual

SERVICE MANUAL
MOTOR FSE400 / 450
2002 / 2003
SERVICE MANUAL
MOTOR FSE400 / 450
2002 / 2003

Contents
Technical Specifications.....................................................84
Engine Removal and Installation.......................................86
Engine Disassembly..................................................…....96
Inspection and Maintenance
of Engine Components......................................................108
Engine Installation................................................................136
Regular Maintenance............................................................156

Technical Specifications
Ec 400 / 450 FSE
Cubic Capacity
399 cc. / 449 cc.
Type 4-stroke with 4-valve cylinder head
Number of Cylinders
One
Cooling System
Water-cooled
Bore and Stroke
90 x 62.6 mm. / 95 x 62.6 mm.
InjectionE.F.I. Magneti Marelli Electronic Fuel
Injection System
Ignition E.F.I. integrated
Clutch Hydraulic-drive disc clutch
Gearbox6 Gears
Type of Frame
Deltabox, made from Cromoly rectangular tubes
Aluminium Rocker
Front Suspension
Inverted WP
43-mm Diameter
295-mm Stroke
Inverted Marzocchi
45-mm Diameter
295-mm Stroke
Inverted Öhlins
46-mm Diameter
295-mm Stroke
Rear Suspension
Progressive System fitted with Ohlins Shock-Absorber
320-mm Stroke
Front Brake
260-mm Disc
Nissin Pump and Nissin single plunger clip
Rear Brake
220-mm Disc
Nissin Pump and Nissin single plunger clip
Wheels Type U D.I.D. Rims fitted with Michelin Comp3 Tyres
Wheelbase
1475 mm
Seat Height
940 mm
Minimum Ground Distance
340 mm
Fuel Tank Capacity
9.5 Litres
ENGINE
FRAME
DIMENSIONS
MODEL
Technical Specifications
84

Engine
Removal
and Installation
86
Engine Removal and Installation

Engine Removal and Installation
88
Engine Removal
Before removing the engine from the frame, wash
it with a steam machine.
The following steps cover the disassembly
sequence.
Remove the saddle and the frame covers.
Drain the oil in the engine. .
Remove the engine plate.
Drain the frame oil reservoir (A).
Drain the engine coolant (B).
Detach the cable (-) from the battery (1) and the
ground coupler from the engine (2).
!
1
2
A
B

Engine Removal and Installation
89
Detach the wire clamp from the alternator (A) and
the sensor cable from the tonewheel.
Detach the spark-plug arm (1), the engine-oil
devaporizing tube (2), the engine-oil reservoir
breather pipe (3).
Loosen the clamp holding the cylinder head injector
conduit (4).
Detach the wire clamp from the water-temperature
sensor (5).
Detach the connecting cable from the starter (6)
and remove the starter.
3
1
2
4
A
5
6

Engine Removal and Installation
90
Remove the water tubes (1).
Remove the lever from the pedal-operated starter.
Remove the exhaust manifold (2).
Detach the radiator tubes.
1
2

Engine Removal and Installation
91
Detach the engine-oil tube (1) in the frame
reservoir.
Remove the gearbox lever.
Remove the engine-pinion cover.
Remove the clutch pump.
Loosen the chain.
Remove the outlet pinion Seeger (1).
1
1

Engine Removal and Installation
92
Remove the engine pinion.
Remove the split pin and the brake pedal.
CAUTION!
Replace the split pins with new ones.
Remove the engine from the frame.
!

Engine Installation
93
Engine Installation
Reverse the above operations to install the engine .
Fit the screws and nuts securing the engine.
NOTE:
At this stage, nuts must only be tightened
provisionally.
The nuts securing the engine are self-locking.
Upon removal, they cease to be self-locking and
become useless.
CAUTION!
Replace the nuts securing the engine with new
ones.
Secure the screwheads with a spanner and tighten
the nuts securing the engine at the specified
torque.
Item Nm Kgf-m
A 66 6,6
B 66 6,6
C 14 1,4
D 66 6,6
Screw length
(A): 108 mm.
(B): 110 mm.
(D): 103 mm.
Tighten the brake-pedal screw at the specified
torque.
Brake-pedal screw: 29 Nm (2,9 Kgf-m)
!
!
!
AB
CD