SERVICE MANUAL SERVICE MANUAL - Gas Gas

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Part Air filter *Muffler bolts and connections *Valve tolerance Spark plug Injection pump pipes Motor oil and filter oil *Oil motor pipes Coolant Fluid Radiator pipes Clutch Chain *Brakes Brake pipes Brake fluid Tires *Steering play *Front fork *Rear suspension *Nuts and bolts in the frame MAINTENANCE CHART Period Period Period First 5 hours Every 30 hours Every 60 hours Inspect every time the bike has been running and has been checked T T T I - I - I R I I *Check every 4 years I R R R I I I - I Check every 2 years I I I I I I Clean, lubricate and inspect every time it runs I I I I I I *Chec every 4 years I I I *Chec every 2 years I Inspect tire pressure and possible damages caused every time the bike runs I - I I - I I - I T T T NOTE: I = Inspect and clean, adjust, substitute or lubricate if it's necessary; R = Replace, T = Tighten, C = Cleaning EC FSE 2003 -16-
BATTERY This battery is maintenance free and checking the fluid level is not required. It is recommended to check the charge of the battery periodically. To remove the battery, follow these steps : (C) (A) (B) 1. Remove the screws (A) and the seat (B) 2. Pull the rubber (C) and remove the battery EC FSE 2003 -17- WARNING Hydrogen gas produced by the battery may explode if exposed to open flame or sparks. Keep flames and sparks away from the battery. The operating instructions for the battery are as follows: 1. Check the battery tension while the circuit is open. 2. In case the battery’s tension is below 12.60 V, or if the storage period has exceeded 6 months,the battery has to be recharged following the instructions in paragraph. In case the tension is above 12.60 V, the battery can be installed on the vehicle without having to recharge it. 3.1. Charge mode with constant tension. - Constant tension = 14.40 - 14.70V - Initial charging power = 0.1 - 0.5 Cn - Charge duration = 6 hours minimum / 24 hours maximum. 3.2. Charge mode with constant power. - Maximum charge power = 0.1 Cn.
Page 1 and 2: SERVICE MANUAL ENGLISH
Page 3 and 4: Important notice Whenever you see t
Page 5 and 6: SPECIFICATIONS: ENGINE Engine 4 cyc
Page 7 and 8: Location of Components GAS GAS EC F
Page 9 and 10: SIDE STAND To operate the side stan
Page 11 and 12: START THE ENGINE - You have to assu
Page 13: STOPPING THE MOTORCYCLE For maximum
Page 17 and 18: CAUTION Use of incorrect coolant so
Page 19 and 20: - Visually inspect the old coolant.
Page 21 and 22: (D) 5. Remove the tank rubber (D).
Page 23 and 24: - Clean the element in a bath of a
Page 25 and 26: - Remove the inner pipe mounting ri
Page 27 and 28: NOTA: For maximum strech resistance
Page 29 and 30: Front Brake Lever Play Adjust the f
Page 31 and 32: To check the steering adjustment, u
Page 33 and 34: CAUTION The left and right fork tub
Page 35 and 36: (1) REAR SUSPENSION (1). Fork tube
Page 37 and 38: WARINING Improper removal of the sp
Page 39 and 40: Bolt and Nut Tightening Every day b
Page 41 and 42: LUBRICATION Lubricate the points sh
Page 43 and 44: The oil is pumped from the oil rese
Page 45 and 46: WARNING Using a filter with an inco
Page 47 and 48: Troubleshooting Improper Settings L
Page 49 and 50: Front fork doesn´t respond to smal
Page 51 and 52: PREPARATION FOR COMPETITION (1). Ch
Page 53 and 54: To change the time: - Press mode un
Page 55 and 56: 4 5 6 7 8 9 10 TROUBLE CAUSE REMEDY
Page 57 and 58: 17 18 19 20 TROUBLE CAUSE REMEDY Sh
Page 59 and 60: WARRANTY REGULATIONS Manufacturer's

SERVICE MANUAL SERVICE MANUAL - Gas Gas

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