GAS GAS EC FSE 400 Instruction manual

2004 / 2005
2004 / 2005
MOTOR FSE 450
MOTOR FSE 450
MANUAL DE TALLER /
WORKSHOP MANUAL
MANUAL DE TALLER /
WORKSHOP MANUAL

WORKSHOP MANUAL
WORKSHOP MANUAL
ENGINE FSE 450
ENGINE FSE 450
2004 / 2005
2004 / 2005
ENGLISH

Contents
Technical specifications................................................................4
Uninstalling and installing the engine in the chassis..................5
Engine dismounting................................................................15
Engine mounting...................................................................33
Replacement of the standard clutch with the ADLER
clutch APTC....................................................................................53
Inspection and maintenance
of the engine components.......................................................59
Periodic maintenance...............................................................91

Technical
Specifications
MODEL FSE 400 / 450
ENGINE
Displacement in cubic centimetres
399 cc / 443 cc
Type 4 stroke DOHC 4 valves
No. of Cylinders
One
Cooling System
Water Cooled
Bore and stroke
90 x 62,6 mm / 95 x 62,6 mm
InjectionFuel injection electronic system
Magneti Marelli
Ignition Integrated in fuel injection electronic system
Clutch Oil bath, multi-disk hydraulic action
Gear Box
6 speed
CHASSIS
Frame Type
DELTABOX, semi double cradle chassis made from rectangular
Cromoly tubes. Aluminium swing arm
Front Suspension
Inverted Marzocchi
Diameter 45 mm
Run 295 mm
Inverted Öhlins
Diameter 48 mm
Run 295 mm
Rear Suspension
Progressive system with Öhlins shock absorber
Run 320 mm
Front brake
Disk of 260 mm
Nissin Pump and simple / double Nissin calliper
Rear brake
Disk of 220 mm
Nissin Pump and simple / double Nissin calliper
Wheels Rims D.I.D. Type U with tyres Michelin Comp3
DIMENSIONS
Wheel base
1.475 mm
Seat Height
940 mm
Minimum ground clearance
340 mm
Fuel Tank Capacity
7.2 litres
Technical
Specifications
4

5
Un-installing the engine
Un-installing and
installaing the engine
in the chassis

Un-installing the engine
7
!
CD
A
B
Un-installing the engine in the chassis
Before dismounting the engine from the frame, wash it
with a steam washer.
The dismounting sequence is explained in the following
steps.
Dismount the seat and the frame covers.
Empty the engine oil.
Remove the engine plate.
Empty the chassis (A) oil tank.
Empty the coolant of the engine (B).
Disconnect the wire (-) of the battery (C) and the engine
earth connection (D).

Un-installing the engine
8
H
F
G
I
E
J
K
Disconnect the alternator clamp (E) and the phonic
wheel sensor wire.
Disconnect the spark plug pipe (F), the engine oil
vaporiser tube (G), the engine oil resevoir vent
hose (H).
Loosen the cylinder head injector tubing clamp (l).
Disconnect the starter motor connection wire (J).
Dismount the starter motor removing the screws
(K).

Un-installing the engine
9
N
Dismount the water tube (L).
Remove the pedal starter lever (M).
Remove the exhaust collector (N).
Disconnect the 2 radiator tubes.
M
L

Un-installing the engine
10
S
O
Disconnect the engine oil tube (O) in the chassis tank.
Remove the gearshift lever (P).
Remove the engine pinion protector (Q).
Remove the clutch cap (R).
De-tense the chain.
Remove the output pinion clip (S).
P
Q
R

Un-installing the engine
11
Remove the Engine pinion (T).
NOTE:
Observe which is the placement direction of the
said pinion.
Remove the carved bolts and the brake pedal.
Remove the motor from the frame.
T

Un-installing the engine
12
!
!
!
B
A
C
Installation of the engine in the chassis
Mount the engine in inverse order to de-installation
Fix the screws and engine fixing nuts.
NOTE:
In this phase, temporarily tighten the nuts.
The engine fixing nuts are self-locking.
Once removed they lose their self-locking
capability and are useless.
PRECAUTION
Replace the engine fixing nuts with new ones.
Hold the screw heads with a spanner and tighten
the engine fixing screws with the specified torque.
Element Nm Kgm
A 66 6,6
B 66 6,6
C 66 6,6
Length of the screws
(A): 108 mm
(B): 110 mm
(D): 103 mm
Fix the brake pedal screw with the specified torque.
Brake pedal screw: 29 Nm (2,9 Kg)
PRECAUTION
Replace the carved bolts with new ones.

Un-installing the engine
13
1
Mount the engine pinion.
NOTE:
Observe which is the placement direction before
the said pinion, to be able to achieve the same
direction of wear.
Place the engine pinion clip.
Connect the chassis tank tube.
Fix the exhaust collector screw (1), with the specified
torque.
NOTE:
Apply component NURAL 29 in the exhaust system
joints.

Un-installing the engine
14
!
3 min
Minimum level
Maximum level
NOTE:
Apply LOCTITE 243 to the pedal starter lever screw.
Fill 1.2 L of an engine oil classified SF or SG through the
API service and with a degree of viscosity SAE 10W-40
through the oil fill mouth in the frame (A) and check the
level.
DATA
Engine oil capacity
Change of oil: 1 L
Changing the oil and filter: 1.2 L
Engine general inspection: 1.2 L
Start the engine and leave it running some three
minutes at idle.
Stop the engine and wait three minutes;
immediately check the oil level via the rod.
A

Dismounting
the engine
Dismounting the engine
15

Dismounting the engine
17
Loosen the 3 screws that hold the starter clutch
cover.
One of the 3 also holds the alternator cover.
Remove the starter clutch cover.
Extract the starter clutch.
Loosen the 2 screws that hold the starter motor.
Extract the starter motor.
NOTE:
The 2005 starter motor turns in the opposite
direction to that of 2004.

Dismounting the engine
18
Loosen the 7 retaining screws that hold the
alternator cover.
One of them is located in the starter clutch cavity.
Remove the alternator cover.
Loosen the 2 screws that hold the position sensor
(Pick-Up) (A).
Remove the de-multiplier pinion (B).
Loosen and extract the spark plug.
A